Mitsubishi FR - S500 User Manual

TRANSISTORIZED INVERTER

FR-S

500

IN S T R U C T IO N M A N U A L (D e ta ile d )

W IRING

Chapter 1

FUNCTIONS

PRO TECTIVE

FUNCTIONS

SPECIFICATIONS

Chapter 2

Chapter 3

Chapter 4

Thank you for choosing this Mitsubishi Transistorized inverter.
This instruction manual (detailed) provides instructions for advanced use of the
FR-S500 series inverters.
Incorrect handling might cause an unexpected fault. Before using the inverter, always
read this instruction manual and the instruction manual (basic) [IB-0600026] packed
with the product carefully to use the equipment to its optimum.
This instruction manual uses the International System of Units (SI). The measuring
units in the yard and pound system are indicated in parentheses as reference values.

This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have
read through the instruction manual (basic) and appended documents carefully and
can use the equipment correctly. Do not use the inverter until you have a full
knowledge of the equipment, safety information and instructions.
In this instruction manual, the safety instruction levels are classified into
"WARNING" and "CAUTION".

WARNING

CAUTION

Note that even the CAUTION level may lead to a serious consequence according to
conditions. Please follow the instructions of both levels because they are important
to personnel safety.

1. Electric Shock Prevention

While power is on or when the inverter is running, do not open the front cover.
You may get an electric shock.
Do not run the inverter with the front cover removed. Otherwise, you may access
the exposed high-voltage terminals or the charging part of the circuitry and get
an electric shock.
If power is off, do not remove the front cover except for wiring or periodic
inspection. You may access the charged inverter circuits and get an electric
shock.
Before starting wiring or inspection, check for residual voltages with a meter etc.
more than 10 minutes after power-off.
Earth the inverter.
Any person who is involved in wiring or inspection of this equipment should be
fully competent to do the work.
Always install the inverter before wiring. Otherwise, you may get an electric
shock or be injured.
Perform setting dial and key operations with dry hands to prevent an electric shock.
Do not subject the cables to scratches, excessive stress, heavy loads or
pinching. Otherwise, you may get an electric shock.
Do not change the cooling fan while power is on.
It is dangerous to change the cooling fan while power is on.
When you have removed the front cover, do not touch the connector above the
3-digit monitor LED display. You will get an electric shock.

Assumes that incorrect handling may cause hazardous
conditions, resulting in death or severe injury.

Assumes that incorrect handling may cause hazardous
conditions, resulting in medium or slight injury, or may
cause physical damage only.

WARNING

A-1

2. Fire Prevention

CAUTION

Mount the inverter to incombustible material. Mounting it to or near combustible
material can cause a fire.
If the inverter has become faulty, switch off the inverter power. A continuous flow
of large current could cause a fire.
Do not connect a resistor directly to the DC terminals P(+), N(−). This could
cause a fire.

3. Injury Prevention

Apply only the voltage specified in the instruction manual to each terminal to
prevent damage etc.
Ensure that the cables are connected to the correct terminals. Otherwise,
damage etc. may occur.
Always make sure that polarity is correct to prevent damage etc.
While power is on and for some time after power-off, do not touch the inverter or
brake resistor as they are hot and you may get burnt.

4. Additional instructions
Also note the following points to prevent an accidental failure, injury, electric shock, etc.
(1) Transportation and installation

When carrying products, use correct lifting gear to prevent injury.
Do not stack the inverter boxes higher than the number recommended.
Ensure that installation position and material can withstand the weight of the
inverter. Install according to the information in the Instruction Manual.
Do not operate if the inverter is damaged or has parts missing.
When carrying the inverter, do not hold it by the front cover or setting dia l; it may fall off
or fail.
Do not stand or rest heavy objects on the inverter.
Check the inverter mounting orientation is correct.
Prevent screws, wire fragments, other conductive bodies, oil or other flammable
substances from entering the inverter.
Do not drop the inverter, or subject it to impact.
Use the inverter under the following environmental conditions:

Ambient
temperature
Ambient humidity 90%RH or less (non-condensing)
Storage
temperature

Ambience

Environment

Altitude, vibration

*Temperatures applicable for a short time, e.g. in transit.

-10°C to +50°C (14°F to 122°F) (non-freezing)

-20°C to +65°C * (-4°F to 149°F)
Indoors (free from corrosive gas, flammable gas,

oil mist, dust and dirt)
Maximum 1000m (3280.80feet) above sea level for
standard operation. After that derate by 3% for
every extra 500m (1640.40feet) up to 2500m
(8202.00feet) (91%).

5.9m/s

CAUTION

CAUTION

2

or less (conforming to JIS C 0040)

A-2

(2) Wiring

CAUTION

Do not fit capacitive equipment such as power factor correction capacitor, radio
noise filter or surge suppressor to the output of the inverter.
The connection orientation of the output cables U, V, W to the motor will affect
the direction of rotation of the motor.

(3) Trial run

Check all parameters, and ensure that the machine will not be damaged by a
sudden start-up.
When the load GD2 is small (at the motor GD2 or smaller) for 400V from 1.5K to

3.7K, the output current may vary when the output frequency is in the 20Hz to
30Hz range.
If this is a problem, set the Pr. 72 "PWM frecuency selection" to 6kHz or higher.
When setting the PWM to a higher frequency, check for noise or leakage current
problem and take countermeasures against it.

(4) Operation

CAUTION

WARNING

When you have chosen the retry function, stay away from the equipment as it will
restart suddenly after an alarm stop.
The [STOP] key is valid only when the appropriate function setting has been
made. Prepare an emergency stop switch separately.
Make sure that the start signal is off before resetting the inverter alarm. A failure
to do so may restart the motor suddenly.
The load used should be a three-phase induction motor only. Connection of any
other electrical equipment to the inverter output may damage the equipment.
Do not modify the equipment.

CAUTION

The electronic overcurrent protection does not guarantee protection of the motor
from overheating.
Do not use a magnetic contactor on the inverter input for frequent
starting/stopping of the inverter.
Use a noise filter to reduce the effect of electromagnetic interference. Otherwise
nearby electronic equipment may be affected.
Take measures to suppress harmonics. Otherwise power harmonics from the
inverter may heat/damage the power capacitor and generator.
When a 400V class motor is inverter-driven, it should be insulation-enhanced or
surge voltages suppressed. Surge voltages attributable to the wiring constants
may occur at the motor terminals, deteriorating the insulation of the motor.
When parameter clear or all clear is performed, each parameter returns to the
factory setting. Re-set the required parameters before starting operation.
The inverter can be easily set for high-speed operation. Before changing its
setting, fully examine the performances of the motor and machine.
In addition to the inverter's holding function, install a holding device to ensure
safety.
Before running an inverter which had been stored for a long period, always
perform inspection and test operation.

A-3

(6) Maintenance, inspection and parts replacement

CAUTION

Do not carry out a megger (insulation resistance) test on the control circuit of the
inverter.

(7) Disposing of the inverter

CAUTION

Treat as industrial waste.

(8) General instructions

Many of the diagrams and drawings in this instruction manual show the inverter
without a cover, or partially open. Never operate the inverter like this. Always
replace the cover and follow this instruction manual when operating the inverter.

A-4

CONTENTS

1. WIRING 1

1.1 Japanese Version.....................................................................................2

1.1.1 Terminal connection diagram .................................................................... 2

1.1.2 Layout and wiring of main circuit terminals............................................... 3

1.2 North America Version .............................................................................4

1.2.1 Terminal connection diagram .................................................................... 4

1.2.2 Layout and wiring of main circuit terminals............................................... 5

1.3 European Version.....................................................................................7

1.3.1 Terminal connection diagram .................................................................... 7

1.3.2 Layout and wiring of main circuit terminals............................................... 8

1.4 Description of I/O Terminal Specifications ...............................................9

1.4.1 Main circuit.................................................................................................. 9

1.4.2 Control circuit .............................................................................................. 9

1.5 How to Use the Main Circuit Terminals..................................................11

1.5.1 Cables, wiring lengths, crimping terminals, etc...................................... 11

1.5.2 Wiring instructions .................................................................................... 12

1.5.3 Peripheral devices .................................................................................... 13

1.5.4 Leakage current and installation of earth leakage circuit breaker......15

1.5.5 Power-off and magnetic contactor (MC) ................................................. 17

1.5.6 Regarding the installation of the power factor improving reactor ....... 18

1.5.7 Regarding noise and the installation of a noise filter..............................18

1.5.8 Grounding precautions.............................................................................19

1.5.9 Regarding power harmoni cs..................................................................... 20

1.5.10 Japanese power harmonic suppression guideline............................... 20

1.6 How to Use the Control Circuit Terminals..............................................24

1.6.1 Terminal block layout................................................................................24

1.6.2 Wiring instructions .................................................................................... 24

1.6.3 Changing the cont rol logi c........................................................................25

1.7 Input Terminals.......................................................................................28

1.7.1 Run (start) and stop (STF, STR, STOP)................................................. 28

1.7.2 Connectio n o f fr eq uen cy setting potentio mete r a nd output fr eq uen cy

meter (10, 2, 5, 4, AU)..............................................................................31

1.7.3 External frequency selection (REX, RH, RM, RL).................................. 32

1.7.4 Indicator connection and adjustment...................................................... 34

1.7.5 Control circuit common terminals (SD, 5, SE)........................................ 37

1.7.6 Signal inputs by contactless switches..................................................... 37

1.8 How to Use the Input Signals

(Assigned Terminals RL, RM, RH, STR)................................................38

Multi-speed setting (RL, R M, R H, RE X signals): Se tting "0, 1 , 2, 8"

1.8.1

Remote setting (RL, RM, RH signals): Setting "0, 1, 2"......................... 38

1.8.2 Second function selection (RT signal): Setting "3".................................38

I

Contents

1.8.3 Current input selection "AU signal": Setting "4"......................................38

1.8.4 Start self-holding selection (STOP signal): Setting "5"........................... 38

1.8.5 Output shut-off (MRS signal): Setting "6"................................................ 39

1.8.6 External thermal relay input: Setting "7"..................................................39

1.8.7 Jog operation (JOG signal): Setting "9" .................................................. 40

1.8.8 Reset signal: Setting "10"......................................................................... 40

1.8.9 PID control valid terminal: Setting "14".................................................... 41

1.8.10 PU operation/external operation switching: Setting "16" ..................... 41

1.9 Handling of the RS-485 Connector

(Type with RS-485 Communication Function) .......................................41

1.10 Design Information ............................................................................... 44

2.

FUNCTIONS

2.1 Function (Parameter) List.......................................................................46

2.2 List of Parameters Classified by Purpose of Use...................................56

2.3 Explanation of Functions (Parameters)..................................................58

2.3.1 Torque boost

2.3. 2 Ma ximum an d minimu m f re q u en cy

2.3.3 Base frequency, Base frequency voltage

2.3.4 Multi-speed operation

2.3.5 Acceleration/ decel erati on time

2.3.6 Electronic overcurrent protection

2.3.7 DC injection brake

2.3.8 Starting frequency

2.3.9 Load pattern sel ection

2.3.10 Jog frequen cy

2.3.11

2.3.12 Stall prevention function and current limit function

2.3.13 Stall prevention

2.3.14 Acceleration/deceleration pattern

2.3.15 Extended fun ction displ ay selection

2.3.16 Frequency ju mp

2.3.17 Speed di splay

2.3.18 Biases and gai n s o f th e fr eq uen cy setting voltage (curre nt)

2.3.19 Start-time ground fault detection selection

2.4 Output Terminal Function Parameters...................................................78

2.4.1 Up-to-frequency sensitivity

2.4.2 Output frequen cy dete ction

2.5 Current Detection Function Parameters.................................................80

2.5.1 Output current detection functions

2.5.2 Zero current dete ction

2.6 Display Function Parameters.................................................................82

2.6.1 Monitor display

RUN

key rotation direction sel e ction ............................................. 67

...........................................................................58

....................................... 59

...........................................................................65

.....................................................................66

.......................................................................67

to ...............................................................72

................................................................................73

to .......................................................................... 74

........................................................................82

.........................................................64

............................................................69

..............................................................78

............................................................81

II

to

....................................................64

.................................................71

.............................................72

..................................78

....................................................79

........................................80

....................59

to .......61

...................62

......................68

45

2.6.2 Setting dial function sele ction .........................................................83

2.6.3 Monitoring reference

..............................................................84

2.7 Restart Operation Parameters...............................................................84

2.7.1 Restart setting

.........................................................................84

2.8 Additional Function Parameters.............................................................86

2.8.1 Remote setting function selection

..................................................86

2.9 Terminal Function Selection Parameters...............................................88

2.9.1 Input terminal fun ction sele ction

2.9.2 Output terminal function selection

.........................................90

..........................88

2.10 Operation Selection Function Parameters...........................................91

2.10.1 Retry function

2.10.2 PWM carrier frequency

2.10.3 Applied motor

2.10.4 Voltage i npu t sele ction

.................................................................................93

..................................................................93

2.10.5 Input filte r time con sta nt

2.10.6 Re set se le ct io n /PU st o p se le ct io n

2.10.7 Cooling fan operation selection

2.10.8 Parameter w rite i nhib i t selectio n

2.10.9 Reverse rotati on p rev e nti on sele ctio n

2.10.10 Operation mode sele ction

2.10.11 PID cont rol

to ....................................................................101

.....................................................91

........................................................92

................................................................94

................................................94

....................................................96

..................................................97

..........................................98

...........................................................98

2.11 Auxiliary Function Parameters ...........................................................109

2.11.1 Slip compensation

2.11.2 Automati c to rque b oo st sel e ction

2.11.3 Motor primary resistance

.....................................................109

...............................................109

............................................................111

2.12 Calibration Parameters ...................................................................... 111

2.12.1 Meter (frequency meter) calibration

2.12.2 Meter (frequency meter) calibration

(Japanese version)

(NA and EC version) ...... 113

.........111

2.13 Clear Parameters...............................................................................115

2.13.1 P a rameter clear

2.13.2 Alarm history clear

...........................................................................115

.......................................................................115

2.14 Communication Parameters

(Only for the type having the RS - 48 5 co mmun ication function)...........116

2.14.1 Communi ca tion se tti n g s

2.14.2 Operation and speed command write

2.14.3 Link start mode selectio n

2.14.4 E

2

PROM write selection ..............................................................132

to , ......................................118

...............................130

............................................................131

2.15 Parameter Unit (FR-PU04) Setting ....................................................133

2.15.1 Paramete r uni t d i splay language switching

2.15.2 Buzzer sound cont rol

2.15.3 PU contrast adjust ment

..................................................................133

...............................................................134

2.15.4 PU main display screen data selection

2.15.5 PU disconnection de te ction/PU setti ng lock

...............................133

......................................134

..............................135

Contents

III

3. PROTECTIVE FUNCTIONS 136

3.1 Errors (Alarms).....................................................................................137

3.1.1 Error (alarm) definitions..........................................................................137

3.1.2 To know the operati ng sta tus at the occurren ce of alarm

(Only when FR-PU04 is used)...............................................................145

3.1.3 Correspondence between digital and actual characters......................145

3.1.4 Resetting the inverter .............................................................................145

3.2 Troubleshooting....................................................................................146

3.2.1 Motor remains stopped ..........................................................................146

3.2.2 Motor rotates in opposite direction ........................................................147

3.2.3 Speed greatly differs from the setting....................................................147

3.2.4 Acceleration/deceleration is not smooth...............................................147

3.2.5 Motor current is large..............................................................................147

3.2.6 Speed does not increase.......................................................................147

3.2.7 Speed varies during operation...............................................................147

3.2.8 Operation mode is not changed properly..............................................148

3.2.9 Operation panel di spla y is not operating...............................................148

3.2.10 Parameter write cannot be performed................................................148

3.2.11 Motor produces annoying sound.........................................................148

3.3 Precautions for Maintenance and Inspection.......................................149

3.3.1 Precautions for maintenance and inspection........................................ 149

3.3.2 Check items ............................................................................................ 149

3.3.3 Periodic inspection..................................................................................149

3.3.4 Insulation resistance test using megger................................................150

3.3.5 Pressure test........................................................................................... 150

3.3.6 Daily and periodic inspection................................................................. 150

3.3.7 Replacement of parts ............................................................................. 154

3.3.8 Measurement of main circuit voltages, currents and powers..............157

4. SPECIFICATIONS 160

4.1 Specification List ..................................................................................161

4.1.1 Ratings ....................................................................................................161

4.1.2 Common specifications..........................................................................165

4.2 Outline Drawings..................................................................................167

5.

INSTRUCTIONS

5.1 Selecting Instructions ...........................................................................171

5.2 Peripheral Selecting Instruc tio ns..........................................................171

5.3 Operating Instructions ..........................................................................173

5.4 Inverter-driven 400V class motor.........................................................175

170

APPENDIX 176

APPENDIX 1 PARAMETER DATA CODE LIST........................................177

IV

1. WIRING

This chapter explains the basic "wiring" for use of this
product. Always read the instructions before use.
For description of "installation", refer to the instruction
manual (basic).

1.1 Japanese Version......................................................2

1.2 North America Version...............................................4

1.3 European Version......................................................7

1.4 Descriptio n o f I/O Terminal specification....................9

1.5 How to Use the Main Circuit Terminals....................11

1.6 How to Use the Control Circuit Terminals ................24

1.7 Input Terminals........................................................28

1.8 How to Use the Input Signals

(Assigned Terminals RL, RM, RH, STR)..................38

1.9 Handling of the RS-485 Connector

(Type with RS-485 Communication Function).......... 41

1.10 Design Information.................................................44

<Abbreviations>

PU
Control panel and parameter unit (FR-PU04)
Inverter
Mitsubishi transistorized inverter FR-S
FR-S500
Mitsubishi transistorized inverter FR-S
Pr.
Parameter number

1

500

500

series
series

Chapter 1

1

Chapter 2

Chapter 3

Chapter 4

1

.1 Japanese Version

.1.1 Terminal connection diagram

1

FR-S520-0.1K to 3.7K (-R) (-C)
FR-S540-0.4K to 3.7K (-R)

MC

3-phase AC
power supply

External transistor common

Contact input common (source)

Multi-speed selection

Control input signals
(No voltage input allowe d)

Frequency setting signals (Analog)

Frequency
setting
potentiometer
1/2W1k
(*4)

When using the current input as
the frequency setting signal, set
"4" in any of Pr. 60 to Pr. 63 (input
terminal fu nction selection), assign
AU (current input selection) to any
of terminals RH, RM, RL and STR,
and turn on the AU signal.

NFB

24VDC power supply

Be careful not to short
terminals PC-SD.

Forward rotati on start
Reverse rotation start

High

Middle

Low

Contact input common

3

2

1

Current input (-)

4 to 20mADC (+)

Main circuit terminal Control circuit input t erminal Control circuit out put t erminal

Inverter

R
S
T

PC

STF
STR

*5

RH

*5

RM

*5
*5

RL
SD

(Note)

SINK

SOURCE

10 (+5V)

DC 0 to 5V

2

DC 0 to 10V

5 (Common)

4 (4 to 20mADC)

RS-485 Connector (*1)

*6
*6
*6

*6

(*3)

Selected

RUN

FM

SD

P1

SE

U
V

W

P
N

A
B
C

Power factor improving
DC reactor
(FR-BEL: Option)

Jumper:

jumper when FR-BEL
is connected.

Alarm
output

Running
Open collector

output common

Indicator
1mA full-scale
Analog meter
(Digital indicator)

1mA

Calibration
resistor (*2)

Earth (Ground)

(+) (-)

Motor

IM

Ground

Remove this

Operation status
output

Open
collector
outputs

REMARKS

*1 Only the type with RS-485 communication function.
*2 Not needed when the setting dial is used for calibration. This resistor is used

when calibration must be made near the frequency meter for such a reason as a
remote frequency meter. Note that the needle of the frequency meter may not
deflect to full-scale when the calibration resistor is connected. In this case, use

both the resistor and setting dial for calibration.
*3 You can switch between the sink and source logic positions. Refer to page 25.
*4 When the setting potentiometer is used frequently, use a 2W1kΩ potentiometer.
*5 The terminal functions change with input terminal function selection (Pr. 60 to

Pr. 63). (Refer to page 38, 88) (RES, RL, RM, RH, RT, AU, STOP, MRS, OH,

REX, JOG, X14, X16, (STR) signal selection)
*6 The terminal functions change with output terminal function selection (Pr. 64,

Pr. 65). (Refer to page 90) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL,

LF, ABC signal selection)

2

CAUTION

(

)

)

)

To prevent a malfunct ion due to noise, keep the si gnal cables more than 10cm (3.94i nches)
away from the power cabl es.

FR-S520S-0.1K to 1.5K (-R) (-C)
FR-S510W-0.1K to 0.75K (-R)

NFB

Power supply

MC

R
S

U
V

W

Motor

IM

REMARKS

To ensure safety, connect the power input to the inv erter via a magn etic contactor and earth

•

leakage circuit breaker or no-fuse breaker, and use the magnetic contactor to switch power on-off.

The output is thr ee-phase 200V.

•

.1.2 Layout and wiring of main circuit terminals

1

FR-S520-0.1K, 0.2K, 0.4K, 0.75K (-R) (-C

Jumper

NP

P1

V

U

RST

Power supply Motor

W

IM

FR-S520-1.5K, 2.2K, 3.7K (-R) (-C)
FR-S540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K (-R

NP

Jumper

P1

R S

T

Power supply Motor

U

W

V

IM

FR-S520S-0.1K, 0.2K, 0.4K, 0.75K (-R) FR-S520S-1.5K (-R)

Jumper

NP

P1

RS

Power supply Motor

V W

U

IM

N

Jumper

P

P1

RS

Power supply Motor

U V

W

IM

FR-S510W-0.1K, 0.2K, 0.4K (-R) FR-S510W-0.75K (-R)

Earth

Ground

1

NP

RS

Power supply Motor

V W

U

IM

NP

RS

Power supply

U

V

IM

Motor

W

CAUTION

The power supply cables must be connected to R, S, T. If they are connected to U, V, W,

•

the inverter will be damaged. (Phase sequence need not be mat ched.)

For use with a singl e-phase power supply, the power suppl y cables must be connected to
R and S.

Connect the motor to U, V, W.

•

Turning on the forward rotation switch (signal) at this time rotates the motor
counterclockwise when viewed from the load shaft.

3

1

.2 North America Version

.2.1 Terminal connection diagram

1

FR-S520-0.1K to 3.7K-NA
FR-S540-0.4K to 3.7K-NA (R)

NFB

3-phase A C
power supply

External transistor common

Contact input common (s our ce )

Frequency setting signals (Anal og )

When using the current input as
the frequency setting signal, set
"4" in any of Pr. 60 to Pr. 63 (input
terminal function selection), assign
AU (current input selection) to any
of terminals RH, RM, RL and STR,
and turn on the AU signal.

24VDC power supply

Take care not to short
terminals PC -SD.

Forward rotation start

Reverse rotation start

Multi-speed selection

Contact input common

Control input signals
(No voltage input allowed)

Frequency
setting
potentiometer
1/2W1k
(*3)

4 to 20mADC (+)

Main circuit terminal Control circuit input terminal

MC

3

2

1

Current input (-)

High

Middle

Low

Inverter

R
S
T

PC

STF
STR

*4

RH

*4

RM

*4
*4

RL
SD

SINK

SOURCE

10 (+5V)

DC 0 to 5V

2

DC 0 to 10V

5 (Common)

4 (4 to 20mADC)

RS-485 Connector (*1)

*5
*5
*5

*5

(*2)

Selected

U
V

W

P1

N

A
B
C

RUN

SE

AM

Power factor improving
DC reactor
(FR-BEL: Option)

P

5

Jumper:

jumper when FR-BEL
is connected.

Alarm
output

Running

Open collector
output common

(+)
(-)

Earth (Ground)

Control circuit output terminal

Motor

IM

Earth
(Ground)

Remove this

Operation status
output

Open
collector
outputs

Analog signal
output
(0 to 5VDC)

REMARKS

*1 Only the type with RS-485 communication function.
*2 You can switch between the sink and source logic positions. Refer to page 25.
*3 When the setting potentiometer is used frequently, use a 2W 1kΩ potentiometer.
*4 The terminal functions change with input terminal function selection (Pr. 60 to

Pr. 63). (Refer to page 38, 88) (RES, RL, RM, RH, RT, AU, STOP, MRS, OH,

REX, JOG, X14, X16, (STR) signal selection)
*5 The terminal functions change with output terminal function selection (Pr. 64,

Pr. 65). (Refer to page 90) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL,

LF, ABC signal selection)

4

NOTE

(

)

y

To prevent a malfunction due to noise, keep the signal cables more than 10cm
(3.94inches) away from the power cables.

FR-S510W-0.1K to 0.75K-NA

NFB

Power supply

MC

R
S

U

V

W

Motor

IM

Earth

Ground

REMARKS

• To ensure safety, connect the power input to the inverter via a magnetic contactor
and earth leakage circuit breaker or no-fuse breaker, and use the magnetic
contactor to switch power on-off.

• The output is three-phase 200V.

.2.2 Layout and wiring of main circuit terminals

1

FR-S520-0.1K, 0.2K, 0.4K, 0.75K-NA

Jumper

NP

P1

RST

Power

supply

U V W

IM

Motor

FR-S520-1.5K, 2.2K, 3.7K-NA
FR-S540-0.4K, 0.75 K, 1.5K, 2. 2K, 3.7K -NA (R)

NP

Jumper

P1

R S T U V W

Power
supply

IM

Motor

FR-S510W-0.1K, 0.2K, 0.4K-NA FR-S510W-0.75K-NA

RS

Power
supply

NP

U V W

IM

Motor

NP

RS

Power

suppl

U V W

IM

Motor

CAUTION

• The power supply cables must be connected to R, S, T. If they are connected to
U, V, W, the inverter will be damaged. (Phase sequence need not be matched.)

• Connect the motor to U, V, W.
Turning on the forward rotation switch (signal) at this time rotates the motor
counterclockwise when viewed from the load shaft.

1

5

<When single-phase power input is provided for three-phase power input

inverter (NA version only)>

Reduce the output current.

FR-S520- K-NA inverter
Rated output current (A)
Power supply capacity (kVA)
AC input current (A)

0.1 0.2 0.4 0.75 1.5 2.2 3.7

0.4 0.8 1.5 2.5 4.0 5.0 7.0

0.4 0.8 1.5 2.5 4.5 5.5 9.0

1.1 2.4 4.5 6.4 11.2 12.9 17.4

Set m9 (Pr. 637) "current detection filter".
Setting "801" in the manufacturer setting parameter C8 enables you to set the m9
parameter.

CAUTION

Parameters other than m9 can also be made to be displayed, but never alter these
since they are manufacturer setting parameters.

m9 Setting Description

0 Single-phase pow er input

- - -

(Factory setting)

Three-phase power input

CAUTION

Always return the C8 parameter to 0 (factory setting) after you have finished the
setting of m9.

6

1

.3 European Version

.3.1 Terminal connection diagram

1

FR-S540-0.4K to 3.7K-EC(R)

MC

3-phase AC
power su pp ly

Control input signals
(No voltage input allowed)

Multi-speed selection

External transistor common

Contact input common (sink)

Frequency setting signals (Analog)

Frequency
setting
potentiometer
1/2W1k
(*3)

When using the current input as
the frequency setting signal, set
"4" in any of Pr. 60 to Pr. 63 (input
terminal function selection) , assi gn
AU (current input selection) to any
of terminals RH, RM, RL and STR,
and turn on the AU signal.

NFB

Contact input common

Forward rotation start

Reverse rotation start

High

Middle

Low

24VDC power supply

Take care not to short
terminals PC-SD.

3

2

1

Current input (-)

4 to 20mADC (+)

Main circuit terminal Control circuit input terminal

Inverter

L

1

L

2

L

3

PC

STF

STR

*4
RH *4
RM

*4
RL *4

SD

SINK

SOURCE

10 (+5V)

DC 0 to 5V

2

DC 0 to 10V

5 (Commo n)

4 (4 to 20mA DC)

RS-485 Connector (*1)

*5
*5
*5

*5

(*2)

Selected

U
V

W

P1

A
B

C

RUN

SE

AM

Power factor improving
DC reactor
(FR-BEL: Option)

Jumper

jumper when FR-BEL
is connected.

Alarm
output

Running
Open collector

output common

(+)

5

Earth (Ground)

Control circuit output terminal

(-)

Motor

IM

Earth
(Ground)

: Remove this

Operation status
output

Open
collector
outputs

Analog signal
output
(0 to 5VDC)

REMARKS

*1 Only the type with RS-485 communication function.
*2 You can switch between the sink and source logic positions. Refer to page 25.
*3 When the setting potentiometer is used frequently, use a 2W 1kΩ potentiometer.
*4 The terminal functions change with input terminal function selection (Pr. 60 to

Pr. 63). (Refer to page 38, 88) (RES, RL, RM, RH, RT, AU, STOP, MRS, OH,
REX, JOG, X14, X16, (STR) signal selection)

*5 The terminal functions change with output terminal function selection (Pr. 64,

Pr. 65). (Refer to page 90) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL,
LF, ABC signal selection)

1

7

FR-S520S-0.2K to 1.5K-EC (R)

NFB

Power supply

MC

1

L
N

U
V

W

Motor

IM

REMARKS

• To ensure safety, connect the power input to the inverter via a magnetic
contactor and earth leakage circuit breaker or no-fuse breaker, and use the
magnetic contactor to switch power on-off.

• The output is three-phase 200V.

NOTE

• To prevent a malfunction due to noise, keep the signal cables more than 10cm
(3.94inches) away from the power cables.

.3.2 Layout and wiring of main circuit terminals

1

FR-S540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-EC (R)

Earth
(Ground)

-

Jumper

+

P1

L1 L2 L3 U V W

Power

supply

IM

Motor

FR-S520S-0.2K, 0.4K, 0.75K-EC (R) FR-S520S-1.5K-EC (R)

L1 N

Power
supply

Jumper

P1

-

U V W

IM

Motor

-

+

Jumper

+

P1

L1 N

Power
supply

CAUTION

• Connect the motor to U, V, W.
Turning on the forward rotation switch (signal) at this time rotates the motor
counterclockwise when viewed from the load shaft.

1

• For power input wiring, connect L

to R/L1 of the terminal block and N to S/L2 of

the terminal block.

• Do not connect the power supply to U, V and W.

U V W

IM

Motor

8

1

g

g

(

)

g

y

g

g

.4 Description of I/O Terminal Specifications

.4.1 Main circuit

1

Symbol Terminal Name Description

R, S, T *

1

<L

, L2, L3>

U, V, W Inverter output
N<->

P<+>, P1

* R, S <L1, N> terminals for si ngle-phase power input.

AC power input

DC voltage
common
Power factor
improving DC
reactor connection

Earth (Ground)

Connect to the commer cial power supply.
Connect a three-phase squirrel-cage motor .

DC volta
power supply and inverter output.
Disconnect the jumper from terminals P<+>-P1 and
connect the optional power factor imp rov ing DC reactor
(FR-BEL). (The single-phase 100V powe r inpu t model
cannot be connected.)

For grounding the inv erter chassis. Must be earthed.

e common terminal. Not isolated from the

CAUTION

< >Terminal names in parentheses are those of the EC version.

.4.2 Control circuit

1

Symbol Terminal Name Description

STF

STR

RH

Contact input

RM
RL

SD
(*1)

PC
(*1)

Input signals

10

2

4

Frequency setting

Forward rotation
start

Reverse rotation
start

Multi-speed
selection

Contact input
common (sink)

External
transistor
common
24VDC power
supply
Contact input
common

Frequency setting
power supply

Frequency
setting
(Voltage signal)

Frequency
setting
(Current signal)

source

Turn on the STF si
to start forward rotation
and turn it off t o stop.
Turn on the STR signal
to start reverse rotation
and turn it off t o stop.
Turn on the RH, RM and RL signals
in appropriate combinations to select
multiple speeds.
The priorities of the speed commands
are in order of jog, multi-speed setting
(RH, RM, RL, RE X ) and AU .
Common terminal for contact inputs (terminals STF, STR,
RH, RM, RL) and indicator connection (terminal FM).
Isolated from terminals 5 and SE.
When connecting the transistor output (open collector
output), such as a programmable controller (PLC),
connect the positive e xternal power supply for transistor
output to this terminal to prevent a malfunction caused by
undesirable current.
This terminal can be used as a 24V 0.1A DC power
output across t erminals PC-SD.
When source lo
contact input s ignal common.

5VDC. Permissibl e load current 10mA.

entering 0 to 5VDC (0 to 10VDC), the maximum

B
output frequency is reached at 5V (10V) and I/O are
proportional. Use Pr . 73 "0-5V/0- 10V selec tion" t o swit ch
between 5V and 10V.
Input resistance 10kΩ. Maximum permissible voltage 20V.
Enter 4-20mADC. This si
0Hz at 4mA and 60Hz at 20mA. Maximum permissible
input current 30mA. Input resistance approximately 250Ω.
For current input , turn on the signal AU.
Set the AU si
terminal function selection).

nal

When the STF and STR
signals are turned on
simultaneously, the stop
command
is given.

ic is selected, thi s terminal serves as a

nal is factory-adjusted to reac h

nal in any of Pr. 60 to Pr. 63 (input

Input terminal
function selection
(Pr. 60 to Pr. 63)
changes the
terminal functions.
(*4)

1

9

Symbol Terminal Name Description

y

g

g

g

5

Input signals

A
B
C

RUN Inverter running

Open collector

SE

Output signals

Indicator

Frequency
setting input
common

Alarm output

Open collector
output common

For meter

FM

Pulse

<Japanese>

Analog signal

AM

output

Analog

<NA, EC>

Common terminal for the frequenc
(terminals 2, 4) and indicator connection ( terminal AM).
Isolated from terminals SD and SE. Do not earth.

Change-over contact output indicating
that the output has be en stopped by the
inverter's protective function activated.
230V 0.3A AC, 30V 0.3A DC. Alarm:
discontinuity across B-C (continuity
across A-C), normal : continuity across
B-C (discontinuit y across A-C). (*6)

Switched low when the inverter output
frequency is equal t o or higher than the
starting frequency (factory set to 0.5Hz,
variable). Switched high during stop or
DC injection brake operation. (*2)
Permissible load 24VDC 0.1A DC.

Common terminal for inverter runnin
Isolated from terminals 5 and SD.

Factory setting of output item:

One selected from
output frequency
and motor current is
output.
The output signal i s
proportional to the
magnitude of each
monitoring item.

Frequency
Permissible load current 1mA
1440 pulses/s at 60Hz

Factory setting of output item:

Frequency
Output signal 0 to 5VDC
Permissible load current 1mA

setting signals

Output
terminal
function
selection
(Pr. 64, Pr. 65)
changes the
terminal
functions. (*5)

terminal RUN.

Usin

the parameter unit connec tion c able (FR-CB201 to

−−

−−

−−−−

Communication

RS-485 connector
(*3)

205), the parameter unit (FR-PU04) is connectabl e.
Communication operation can be performed throu
RS-485.

*1. Do not connect terminals SD and PC each other or to the earth.

For sink logic, terminal SD acts as the common terminal of contact input. For
source logic, terminal PC acts as the common terminal of contact input. (Refer
to page 25 for the way to switch between them.)

*2. Low indicates that the open collector outputting transistor is on (conducts).

High indicates that the transistor is off (does not conduct).

*3. Compatible with only the type having RS-485 communication function.

(Refer to page 41.)

*4. RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, RES, X14, X16, (STR)

signal selection (Refer to page 88.)

*5. RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, LF, ABC signal selection

(Refer to page 90.)

*6. To be compatible with the European Directive (Low Voltage Directive), the

operating capacity of relay outputs (A, B, C) should be 30V 0.3A DC.

10

h

1

g

g

g

g

g

g

g

g

.5 How to Use the Main Circuit Terminals

.5.1 Cables, wiring lengths, crimping terminals, etc.

1

The following selection example assumes the wiring length of 20m (65.62feet).

1) FR-S520-0.1K to 3.7K (-R) (-C)
FR-S520-0.1K to 3.7K-NA

Applicable

Inverter

Model

FR-S520-0.1K
to 0.75K
FR-S520-

1.5K, 2.2K

FR-S520-3.7K

mm

Cables

2

AWG

Terminal

Screw

Size

Ti

htenin

Torque

N

Crimping

Terminals

m

R, S, T U, V, W R, S, T U, V, W R, S, T U, V, W R, S, T U, V, W

M3.5 1.2 2-3.5 2-3.5 2 2 14 14 2.5 2.5

M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
M4 1.5 5.5-4 5.5-4 3.5 3.5 12 12 4 2.5

Insulated

Cables

2) FR-S540-0.4K to 3.7K (-R)
FR-S540-0.4K to 3.7K-NA (R)
FR-S540-0.4K to 3.7K-EC (R)

Applicable

Inverter

Model

FR-S540-0.4K
to 3.7K

mm

>

Cables

2

U, V, W

R, S, T

1

, L2,

<L

3

L

>

AWG

U, V, W

Terminal

Screw

Size

Ti

htenin

Torque

N

m

Crimping

Terminals

R, S, T

1

<L

, L2,

3

L

>

U, V, W

R, S, T

1

, L2,

<L

3

L

M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5

Insulated

Cables

R, S, T

1

, L2,

<L

3

L

>

3) FR-S520S-0.1K to 1.5K (-R)
FR-S520S-0.2K to 1.5K-EC (R)

Applicable

Inverter

Model

FR-S520S-

0.1K to 0.75K

FR-S520S-

1.5K

mm

Cables

2

U, V, W

AWG

R, S

<L1, N>

U, V, W

Terminal

Screw

Size

Ti

htenin

Torque

N

m

Crimping

Terminals

R, S

1

<L

, N>

U, V, W

R, S

<L1, N>

M3.5 1.2 2-3.5 2-3.5 2 2 14 14 2.5 2.5

M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5

Insulated

Cables

R, S

<L1, N>

4) FR-S510W-0.1K to 0.75K (-R)
FR-S510W-0.1K to 0.75K-NA

Applicable

Inverter

Model

FR-S510W-

0.1K to 0.4K

FR-S510W-

0.75K

mm

Cables

2

AWG

Terminal

Screw

Size

Ti

htenin

Torque

N

Crimping

Terminals

m

R, S U, V, W R, S U, V, W R, S U, V, W

M3.5 1.2 2-3.5 2-3.5 2 2 14 14 2.5 2.5

M4 1.5 5.5-4 2-4 3.5 2 12 14 4 2.5

Insulated

Cables

R, S

1

, N>

<L

PVC

mm

PVC

mm

PVC

mm

PVC

mm

2

2

U, V, W

2

1

U, V, W

2

U, V, W

11

Wiring length
100m (328.08feet) maximum. (50m (164.04feet) maximum for the FR-S540-0.4K.)

CAUTION

• When the wiring length of the 0.1K or 0.2K is 30m (98.43feet) or more, use the
carrier frequency to 1kHz.

• Use the carrier frequency of 1kHz when the wiring length of the FR-S540-0.4K,

0.75K is 30m (98.43feet) or more.

• The wiring length should be 30m (98.43feet) maximum when automatic torque
boost is selected in Pr. 98 "automatic torque boost selection (motor capacity)".
(Refer to page 109)

.5.2 Wiring instructions

1

1) Use insulation-sleeved crimping terminals for the power supply and motor cables.

2) Application of power to the output terminals (U, V, W) of the inverter will damage
the inverter. Never perform such wiring.

3) After wiring, wire off-cuts must not be left in the inverter.
Wire off-cuts can cause an alarm, failure or malfunction. Always keep the inverter
clean.
When drilling a control box etc., take care not to let wire off-cuts enter the inverter.

4) Use cables of the recommended size to make a voltage drop 2% maximum.
If the wiring distance is long between the inverter and motor, a main circuit cable
voltage drop will cause the motor torque to decrease especially at the output of a
low frequency.

5) For long distance wiring, the fast-response current limit function may be reduced or
the devices connected to the secondary side may malfunction or become faulty
under the influence of a charging current due to the stray capacity of wiring.
Therefore, note the maximum overall wiring length.

6) Electromagnetic wave interference
The input/output (main circuit) of the inverter includes harmonic components, which
may interfere with the communication devices (such as AM radios) used near the
inverter. In this case, install the optional FR-BIF radio noise filter (for use in the
input side only) or FR-BSF01 or FR-BLF line noise filter to minimize interference.

7) Do not install a power capacitor, surge suppressor or radio noise filter (FR-BIF
option) in the output side of the inverter.
This will cause the inverter to trip or the capacitor and surge suppressor to be
damaged. If any of the above devices are connected, remove them. (When using
the FR-BIF radio noise filter with a single-phase power supply, connect it to the
input side of the inverter after isolating the T <L

8) Before starting rewiring or other work after performing operation once, check the
voltage with a meter etc. more than 10 minutes after power-off. For some time after
power-off, there is a dangerous voltage in the capacitor.

12

3

> phase securely.)

.5.3 Peripheral devices

1

(1) Selection of peripheral devices

Check the capacity of the motor applicable to the inverter you purchased. Appropriate
peripheral devices must be selected according to the capacity.
Refer to the following list and prepare appropriate peripheral devices:

1) FR-S520-0.1K to 3.7K (-R) (-C)
FR-S520-0.1K to 3.7K-NA

Motor

Output

(kW

(HP))

0.1

(1/8)

0.2

(1/4)

0.4

(1/2)

0.75
(1)

1.5
(2)

2.2
(3)

3.7
(5)

Inverter

Model

FR-S520-

0.1K
FR-S520-

0.2K
FR-S520-

0.4K
FR-S520-

0.75K
FR-S520-

1.5K
FR-S520-

2.2K
FR-S520-

3.7K

Rated current of

Circuit Breaker

(Refer to
page 15)

(*1)

30AF/5A S-N10
30AF/5A S-N10

30AF/5A S-N10 FR-BAL-0.4K FR-BEL-0.4K 2 2
30AF/10A S-N10
30AF/15A S-N10 FR-BAL-1.5K FR-BEL-1.5K 2 2
30AF/20A
30AF/30A S-N20 FR-BAL- 3.7KFR-BAL-3. 7K 3.5 3.5

Magnetic

Contactor

(MC)
(Refer to
page 17)

S-N11,

S-N12

Power
Factor

Improving

AC Reactor

(Refer to
page 18)

FR-BAL-0.4K

(*3)

FR-BAL-0.4K

(*3)

FR-BAL-

0.75K

FR-BAL-2.2K FR-BEL-2.2K 2 2

Power
Factor

Improving

DC Reactor

(Refer to

page 18)

FR-BEL-0.4K

(*3)

FR-BEL-0.4K

(*3)

FR-BEL-

0.75K

Cables (mm2)

(*2)

R, S, T U, V, W

22
22

22

2) FR-S540-0.4K to 3.7K (-R)
FR-S540-0.4K to 3.7K-NA (R)
FR-S540-0.4K to 3.7K-EC (R)

Motor

Output

(kW

(HP))

0.4

(1/2)

0.75
(1)

1.5
(2)

2.2
(3)

3.7
(5)

Inverter

Model

FR-S540-

0.4K
FR-S540-

0.75K
FR-S540-

1.5K
FR-S540-

2.2K
FR-S540-

3.7K

Rated current of

Circuit Breaker

(Refer to
page 15)

(*1)

30AF/5A S-N10

30AF/5A S-N10
30AF/10A S-N10
30AF/15A S-N20
30AF/20A S-N20

Magnetic

Contactor

(MC)
(Refer to
page 17)

13

Power
Factor

Improving

AC Reactor

(Refer to
page 18)

FR-BAL-

H0.4K

FR-BAL-

H0.75K

FR-BAL-

H1.5K

FR-BAL-

H2.2K

FR-BAL-

H3.7K

Power
Factor

Improving

DC Reactor

(Refer to

page 18)

FR-BEL-

H0.4K

FR-BEL-

H0.75K

FR-BEL-

H1.5K

FR-BEL-

H2.2K

FR-BAL-

H3.7K

Cables (mm2)

(*2)

R, S, T

1

<L

, L2,

U, V, W

3

>

L

22
22
22
22
22

1

3) FR-S520S-0.1K to 1.5K (-R)
FR-S520S-0.2K to 1.5K-EC (R)

Power
Factor

Improving

DC Reactor

(Refer to
page 18)

(*3)

FR-BEL-

0.75K

Cables (mm2)

R, S

1

<L

22

Motor

Output

(kW

(HP))

0.1

(1/8)

0.2

(1/4)

0.4

(1/2)

0.75
(1)

1.5
(2)

Inverter

Model

FR-S520S-

0.1K
FR-S520S-

0.2K
FR-S520S-

0.4K
FR-S520S-

0.75K
FR-S520S-

1.5K

Power

Rated current of

Circuit Breaker

(Refer to
page 15)

(*1)

30AF/5A S-N10 FR-BAL-0.4K FR-BEL-0.4K 2 2
30AF/10A S-N10 FR-BAL-0.4K FR-BEL-0.4K 2 2
30AF/10A S-N20
30AF/15A S-N20 FR-BAL-1.5K FR-BEL-1.5K 2 2
30AF/20A S-N21 FR-BAL-2.2K FR-BEL-2.2K 2 2

Magnetic

Contactor

(MC)
(Refer to
page 17)

Factor

Improving

AC Reactor

(Refer to
page 18)

(*3)

FR-BAL-

0.75K

4) FR-S510W-0.1K to 0.75K (-R)
FR-S510W-0.1K to 0.75K-NA

Power
Factor

Improving

DC Reactor

(Refer to
page 18)

(*4)

−−

−−

−−−−

−−

−−

−−−−

−−

−−

−−−−

−−

−−

−−−−

Cables (mm2)

R, S

1

<L

22
22
22

3.5 2

Motor

Output

(kW

(HP))

0.1

(1/8)

0.2

(1/4)

0.4

(1/2)

0.75
(1)

Inverter

Model

FR-S510W-

0.1K
FR-S510W-

0.2K
FR-S510W-

0.4K
FR-S510W-

0.75K

Power

Rated current of

Circuit Breaker

(Refer to
page 15)

(*1)

30AF/10A S-N10
30AF/15A S-N10 FR-BAL- 1.5K
30AF/20A S-N20 FR-BAL- 2.2K
30AF/30A S-N20 FR-BAL- 3.7K

Magnetic

Contactor

(MC)
(Refer to
page 17)

Factor

Improving

AC Reactor

(Refer to
page 18)

FR-BAL-

(*3)

0.75K

*1 For installations in the United States or Canada, the circuit breaker must be

inverse time or instantaneous trip type.
*2 The size of the cables assume that the wiring length is 20m (65.62feet).
*3 The power factor may be slightly less.
*4 The single-phase 100V power input model does not allow the power factor

improving DC reactor to be fitted.

, N>

, N>

(*2)

U, V, W

(*2)

U, V, W

14

.5.4 Leakage current and installation of eart h leakag e ci r cui t br eaker

1

Due to static capacitances existing in the inverter I/O wiring and motor, leakage
currents flow through them. Since their values depend on the static capacitances,
carrier frequency, etc., take the following counter measures.

(1) To-ground leakage currents

Leakage currents may flow not only into the inverter's own line but also into the
other line through the ground cable, etc.
These leakage currents may operate earth leakage circuit breakers and earth
leakage relays unnecessarily.

Counter measures

If the carrier frequency setting is high, decrease the carrier frequency (Pr. 72) of
the inverter.
Note that motor noise increases. Selection of Soft-PWM control (Pr. 70) will make
it unoffending. (Factory setting)
By using earth leakage circuit breakers designed for harmonic and surge
suppression (e.g. Mitsubishi's Progressive Super Series) in the inverter's own line
and other line, operation can be performed with the carrier frequency kept high
(with low noise).

(2) Line-to-line leakage currents

Harmonics of leakage
currents flowing in static
capacities between the
inverter output cables
may operate the external
thermal relay
unnecessarily.

Counter measures

Use the electronic overcurrent protection of the inverter.
Decrease the carrier frequency. Note that motor noise increases. Selection of
Soft-PWM (Pr. 70) makes it unoffending.
To ensure that the motor is protected against line-to-line leakage currents, it is
recommended to use a temperature sensor to directly detect motor temperature.

Installation and selection of no-fuse breaker

On the power receiving side, install a no-fuse breaker (NFB) to protect the primary
wiring of the inverter. Which NFB to choose depends on the power supply side
power factor (which changes with the power supply voltage, output frequency and
load) of the inverter. Especially as the completely electromagnetic type NFB
changes in operational characteristic with harmonic currents, you need to choose
the one of a little larger capacity. (Check the data of the corresponding breaker.)
For the earth leakage circuit breaker, use our product designed for harmonic and
surge suppression (Progressive Super Series). (Refer to page 13 for the
recommended models.)

Power
supply

NFB

Inverter

Line-to-Line Leakage Current Path

Thermal relay

Line static
capacitances

Motor

IM

1

CAUTION

Choose the NFB type according to the power supply capacity.

15

(3) Selecting the rated sensitivity current for the earth leakage circuit

)

(

)

)

(

)

breaker

When using the earth leakage circuit breaker with the inverter circuit, select its rated
sensitivity current as follows, independently of the PWM carrier frequency:

Progressive Super Series
(Type SP, CF, SF, CP)
Rated sensitivity current:
I∆n ≥ 10 × (lg1+Ign+lg2+lgm)
Conventional NV series (Type CA,
CS, SS produced prior to '91)
Rated sensitivity current:
I∆n ≥ 10 × {lg1+lgn+3 × (lg2+lgm)}
lg1, lg2 : Leakage currents of cable

path during commercial
power supply operation

lgn* : Leakage current of noise

filter on inverter input side

lgm : Leakage current of motor

during commercial power
supply operation

<Example>

2mm ×5m
(16.40feet)

NV

Ig1 Ign Ig2 Igm

CAUTION

• The earth leakage circuit breaker should be installed to the primary (power
supply) side of the inverter.

• In the

connection neutral point grounded system, the sensitivity current
becomes worse for ground faults in the inverter secondary side. Hence, the
protective grounding of the load equipment should be 10Ω or less.

• When the breaker is installed in the secondary side of the inverter, it may be
unnecessar ily oper at ed by har m onics if the effe ct ive v alu e i s le ss than the rat ing. In th is
case, do not insta ll the brea ker since th e eddy curre nt and hy steresis loss in crease and
the temperature rises.

* Note the leakage current value of the noise filter installed on the inverter input

side.

Progressive Super Series

Leakage current (Ig1) (mA)
Leakage current (Ign) (mA
Leakage current (Ig2) (mA)
Motor leakage

current (Igm) (mA)
Total leakage current (mA)
Rated sensitivity current

≥≥≥≥

(mA) (

Ig

××××

10)

Example of leakage
current per 1km in cable
path during commercial
power supply operation
when the CV cable is
routed in metal conduit
(200V 60Hz)

120
100

80
60
40
20

0

23.5 814223880

Leakage current (mA)

22

2mm ×70m

5.5 30 60100

Cable size (mm )

(229.66feet)

Noise

filter

Inver­ter

IM

3
200V

1.5kW
(2HP)

(Type SP, CF, SF,CP)

20

5m (16.40feet)

×

1000m

3280.80feet

0 (without noise filter)

70m (229.66feet)

20

×

1000m

3280.80feet

0.14

1.66 4.78
30 100

Leakage current
example of 3-phase
induction motor
during commercial
power supply
operation
(200V 60Hz)

2.0

1.0

0.7

0.5

0.3

0.2

150

2

0.1

Leakage current (mA)

Motor capacity (kW

Conventional NV

(Type CA, CS, SS)

1.5

2.2

= 0.10

= 1.40

7.515221137

3.7

5.5 18.5

55

45

30

16

.5.5 Power-off and magnetic contactor (MC)

r

1

CAUTION

Do not use the inverter power supply side magnetic contactor to start or stop the
inverter.

As shown on the right,
always use the start signal
(ON or OFF across
terminals STF or STR-SD)
to make a start or stop.
(Refer to page 28)

NFB

Power
supply

F

OFF

MC

OFF

ON

MC

ON

RA

MC

MC

RA

RA

R<L

>

1

S<N>
T

B

OFF

C

Inverter

STF (STR)
SD

W

U

To

V

moto

Inverter Start/Stop Circuit Example

(1) Inverter's primary side magnetic contactor (MC)

On the inverter's primary side, it is recommended to provide an MC for the following
purposes (Refer to page 13 for selection.):

1) To release the inverter from the power supply when the inverter's protective
function is activated or when the drive is not functioning (e.g. emergency stop
operation).

2) To prevent an accident caused by an automatic restart made at power restoration
after an inverter stop due to a power failure.

3) To rest the inverter for a long time.
The control power supply for inverter is always running and consumes a little
power. When stopping the inverter for a long time, switching inverter power off
saves power slightly.

4) To separate the inverter from the power supply to ensure safety of
maintenance/inspection work.
As the inverter's primary MC is used for the above purposes, it is equivalent to the
standard duty and select the one of class JEM1038-AC3 for the inverter input side
current.

1

17

5.6 Regarding the installation of the power factor improvi ng reactor

1.

When the inverter is installed near a large-capacity power transformer (500kVA or
more at the wiring length of 10m (32.81feet) or less) or the power capacitor is to be
switched, an excessive peak current will flow in the power supply input circuit,
damaging the converter circuit. In such a case, always install the power factor
improving reactor (FR-BEL or FR-BAL).

Power
supply

FR-BAL

NFB

R
S

TZ

X
Y

Inverter
R<L

>

1

U

S<N>

V

W

T

P<+>P1

FR-BEL(*)

Power supply equipment

1500
1000

500

capacity (kVA)

Power factor
improving reactor
installation range

010

Wiring length (m)

REMARKS

* When connecting the FR-BEL, remove the jumper across terminals P<+>-P1.

The wiring length between FR-BEL and inverter should be 5m (16.40feet)
maximum and as short as possible.
Use the cables which are equal in size to those of the main circuit. (Refer to page

11)

.5.7 Regarding noise and the installation of a noise filter

1

Some noise enters the inverter causing it to malfunction and others are generated by
the inverter causing the malfunction of peripheral devices. Though the inverter is
designed to be insusceptible to noise, it handles low-level signals, so it requires the
following general counter measures to be taken.

General counter measures

Do not run the power cables (I/O cables) and signal cables of the inverter in
parallel with each other and do not bundle them.
Use twisted shield cables for the detector connecting and control signal cables
and connect the sheathes of the shield cables to terminal SD.
Ground the inverter, motor, etc. at one point.
Capacitances exist between the inverter's I/O wiring, other cables, earth and
motor, through which leakage currents flow to cause the earth leakage circuit
breaker, earth leakage relay and external thermal relay to operate unnecessarily.
To prevent this, take appropriate measures, e.g. set the carrier frequency in Pr. 72
to a low value, use an earth leakage circuit breaker designed for suppression of
harmonics and surges, and use the electronic overcurrent protection built in the
inverter.

18

Noise reduction examples

Install filter
on inverter's input side.

Inverter
power su pply

Separate inverte r and power
line more than 30cm (3.94inches)
(at least 10cm (11.81inches))
from sensor circuit.

Control
power su pply

.5.8 Grounding precautions

1

FR-BLF

FR-BSF01

Install filter FR - BIF
on inverter's input side.

Do not earth control
box directly.

Do not earth
control cable.

Control

box

FR-

BLF

FR­BIF

Power
supply
for sensor

Reduce carrier
frequency.

Inverter

FR­BLF

Use twisted pair shielded cable.

Do not earth shield but connect
it to signal common cable.

Install filter
on inv erter's output si d e.

Use 4-core cable for motor
power cable and use one
cable as earth cable.

Sensor

FR-BLF

FR-BSF01

MotorIM

Leakage currents flow in the inverter. To prevent an electric shock, the inverter and

motor must be grounded.

Use the dedicated ground terminal to ground the inverter. (Do not use the screw in

the casing, chassis, etc.)
Use a tinned* crimping terminal to connect the earth cable. When tightening the
screw, be careful not to break the threads.
*Plating should not include zinc.

Use the thickest possible ground cable. Use the cable whose size is equal to or

greater than that indicated in the following table, and minimize the cable length.
The grounding point should be as near as possible to the inverter.

(Unit: mm2)

Motor Capacity

2.2kW (3HP) or less 2 (2.5) 2 (2.5)

3.7kW (5HP) 3.5 (4) 2 (4)

200V, 100V class 400V class

Ground Cable Size

For use as a product compliant with the Low Voltage Directive, use PVC cable
whose size is indicated within parentheses.

Ground the motor on the inverter side using one cable of the 4-core cable.

19

1

.5.9 Reg ardi ng pow er har mon ics

y

g

(

g

1

The inverter may generate power harmonics from its converter circuit to affect the
power generator, power capacitor etc. Power harmonics are different from noise and
leakage currents in source, frequency band and transmission path. Take the following
counter measure suppression techniques.

The following table indicates differences between harmonics and noise:

Item Harmonics Noise

Frequency
Environment

Quantitative
understanding

Generated amount
Affected equipment

immunity
Suppression example

Suppression technique
Harmonic currents produced
on the power supply side by
the inverter change with such
conditions as whether there
are wiring impedances and a

Normall
less (up to 3kHz or l ess)
To-electric c hannel, power
impedance

Theoretical cal culation possible
Nearly proporti onal to load

capacity
Specified in st andard per

equipment
Provide reactor. Increase distance.

40th to 50th degrees or

NFB

High frequency (several 10kHz
to MHz order)

To-space, distance, wiring path
Random occurrence, quantitative

grasping difficult

e with current variation

Chan

larger as switching speed

ratio
increases)
Different dependin
equipment specifications

Power factor

improving DC reactor

Inverter

on maker's

Motor

IM

power factor improving
reactor and the magnitudes of
output frequency and output
current on the load side.

Power factor

improving AC reactor

Do not provide power factor
improving capacitor.

For the output frequency and output current, we understand that they should be
calculated in the conditions under the rated load at the maximum operating frequency.

CAUTION

The power factor improving capacitor and surge suppressor on the inverter output
side may be overheated or damaged by the harmonic components of the inverter
output. Also, since an excessive current flows in the inverter to activate overcurrent
protection, do not provide a capacitor and surge suppressor on the inverter output
side when the motor is driven by the inverter. To improve the power factor, insert a
power factor improving reactor in the inverter's primary side or DC circuit. For full
information, refer to page 18.

.5.10 Japanese power harmonic suppression guideline

1

Harmonic currents flow from the inverter to a power receiving point via a power
transformer. The harmonic suppression guideline was established to protect other
consumers from these outgoing harmonics.

1) [Harmonic suppression guideline for household appliances and general-purpose
products]
The "harmonic suppression guideline for household appliances and general-purpose
products" issued by ex-Ministry of International Trade and Industry (present Ministry
of Economy, Trade and Industry) in September, 1994 applies to the FR-S500 series
other than the three-phase 400V class. By installing the FR-BEL or FR-BAL power
factor improving reactor, this product complies with the "harmonic suppression
techniques for transistorized inverters (input current 20A or less)" established by the
Japan Electrical Manufacturers' Association.

20

2) "Harmonic suppression guideline for specific consumers"
This guideline sets forth the maximum values of harmonic currents outgoing from a
high-voltage or specially high-voltage consumer who will install, add or renew
harmonic generating equipment. If any of the maximum values is exceeded, this
guideline requires that consumer to take certain suppression measures.

Table 1 Maximum Values of Outgoing Harmonic Currents per 1kW Contract Power

Received Power Voltage 5th 7th 11th 13th 17th 19th 23rd

6.6kV 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70
22 kV 1.8 1.3 0.82 0.69 0.53 0.47 0.39 0.36
33 kV 1.2 0.86 0.55 0.46 0.35 0.32 0.26 0.24

Over

23rd

(1) Application of the harmonic suppression guideline for specific

consumers

New installation/addition/
renewal of equipment

Calculation of equivalent
capacity sum

Not more tha n
reference capacity

Sum of equivalent
capacities

Over reference
capacity

Calculation of outgoing
harmonic current

Is outgoing harmonic
current equal to or lower
than maximum value?

Not more than
maximum value

Harmonic suppression
technique is not required.

1

Over maximum value

Harmonic suppression
technique is required.

21