Mitsubishi FR-S520E-0.1K-NA, FR-S520E-0.75K-NA, FR-S520E-0.2K-NA, FR-S520E-0.4K-NA, FR-S520E-1.5K-NA Instruction Manual

FR-S520E-0.1K to 3.7K-NA
FR-S540E-0.4K to 3.7K-NA
FR-S510WE-0.1K to 0.75K-NA

1

2

3

FR-S500E-NA

TRANSISTORIZED INVERTER INSTRUCTION MANUAL (BASIC)

TRANSISTORIZED INVERTER

FR-S500

INSTRUCTION MANUAL (BASIC)

CONTENTS

CONNECTION OF PERIPHERAL DEVICES ............................................. 2

1.1 Basic configuration ...................................................................................... 2

INSTALLATION METHOD.......................................................................... 5

2.1 Installation of the inverter............................................................................. 5

SPECIFICATIONS OF WIRING AND TERMINALS ................................... 6

3.1 Terminal connection diagram ...................................................................... 6

3.2 Main circuit................................................................................................... 7

3.3 Control circuit............................................................................................. 11

DRIVE THE MOTOR ................................................................................. 18

4.1 Step of operation ....................................................................................... 18

4.2 Run and operation ..................................................................................... 19

4.3 Operation by the start command from the operation panel (PU operation

mode)........................................................................................................ 21

Thank you for choosing this Mitsubishi transistorized inverter.
If this is the first time for you to use the FR-S500 series, please read through this instruction manual (basic)
carefully and use the inverter safely.
If you are going to use the inverter for higher-level applications, the FR-S500 instruction manual (detailed)
[IB(NA)-0600209ENG] is separately available from where you purchased the inverter or a Mitsubishi sales
representative.

1
2
3

4

This instruction manual (basic) provides handling information and precautions for use
of the equipment.
Please forward this instruction manual (basic) to the end user.

This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have read
through this 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 (basic), the safety instruction levels are classified into

"WARNING" and "CAUTION".

WARNING

CAUTION

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

important to personnel safety.

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.

CAUTION

1. Electric Shock Prevention

WARNING

z While power is on or when the inverter is running, do not open the front cover. You

may get an electric shock.

z Do not run the inverter with the front cover or wiring cover removed. Otherwise,

you may access the exposed high-voltage terminals or the charging part of the
circuitry and get an electric shock. Also, the inverter's ability to withstand
earthquakes will deteriorate.

z Even 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.

z Before starting wiring or inspection, check to make sure that the 3-digit LED inverter

monitor is off, wait for at least 10 minutes after the power supply has been switched
off, and check to make sure that there are no residual voltage using a tester or the
like.

z This inverter must be grounded. Grounding must conform to the requirements of

national and local safety regulations and electrical codes. (JIS, NEC section 250,
IEC 536 class 1 and other applicable standards)

z Any person who is involved in the wiring or inspection of this equipment should be

fully competent to do the work.

z Always install the inverter before wiring. Otherwise, you may get an electric shock

or be injured.

z Perform setting dial and key operations with dry hands to prevent an electric

shock.

z Do not subject the cables to scratches, excessive stress, heavy loads or pinching.

Otherwise, you may get an electric shock.

z Do not change the cooling fan while power is on. It is dangerous to change the

cooling fan while power is on.

z When you have removed the front cover, do not touch the connector above the 3-

digit monitor LED display. Otherwise, you get an electrick shock.

A-1

2. Fire Prevention

CAUTION

z Install the inverter on an incombustible wall without holes, etc. Installing the inverter

directly on or near a combustible surface could lead to a fire.

z If the inverter has become faulty, switch off the inverter power. A continuous flow of

large current could cause a fire.

z Do not connect a resistor directly to the DC terminals P, N. This could cause a fire.

3. Injury Prevention

CAUTION

z Apply only the voltage specified in the instruction manual to each terminal to

prevent damage, etc.

z Always connect to the correct terminal to prevent damage, etc.
z Always make sure that polarity is correct to prevent damage, etc.
z While power is on or for some time after power-off, do not touch the inverter as it is

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

CAUTION

z When carrying products, use correct lifting gear to prevent injury.
z Do not stack the inverter boxes higher than the number recommended.
z Ensure that installation position and material can withstand the weight of the

inverter. Install according to the information in the instruction manual.

z Do not install or operate if the inverter is damaged or has parts missing.
z When carrying the inverter, do not hold it by the front cover or setting dial; it may

fall off or fail.

z Do not stand or rest heavy objects on the inverter.
z Check the inverter mounting orientation is correct.
z Prevent other conductive bodies as screws and metal fragments or other

flammable substance as oil from entering the inverter.

z As the inverter is a precision instrument, do not drop or subject it to impact.
z Use the inverter under the following environmental conditions: This could cause

the inverter damage.

Ambient
Temperature

Ambient humidity 90%RH maximum (non-condensing)
Storage

temperature

Atmosphere

Environment

Altitude/
vibration

-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)

2

Max.1000m (3280.80 feet) above sea level 5.9m/s
(conforming to JIS C 60068-2-6)

or less

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

A-2

(2) Wiring

CAUTION

z Do not fit capacitive equipment such as power factor correction capacitor, radio

noise filter (option FR-BIF(-H)) or surge suppressor to the output of the inverter.

z 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

CAUTION

z Check all parameters, and ensure that the machine will not be damaged by a

sudden start-up.

2

z When the load GD

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 frequency 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

is small (at the motor GD or smaller) for 400V from 1.5K to 3.7K, the

WARNING

z When you have chosen the retry function, stay away from the equipment as it will

restart suddenly after an alarm stop.

z Since the [STOP] key is valid only when functions are set (refer to page 55),

provide a circuit and switch to make an emergency stop (power off, mechanical
brake operation for emergency stop, etc) separately.

z Make sure that the start signal is off before resetting the inverter alarm. A failure to

do so may restart the motor suddenly.

z 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.

z Do not modify the equipment.
z Do not perform parts removal which is not instructed in this manual. Doing so may

lead to fault or damage of the inverter.

A-3

CAUTION

z The electronic thermal relay function does not guarantee protection of the motor

from overheating.

z Do not use a magnetic contactor on the inverter input for frequent starting/stopping

of the inverter.

z Use a noise filter to reduce the effect of electromagnetic interference. Otherwise

nearby electronic equipment may be affected.

z Take measures to suppress harmonics. Otherwise power supply harmonics from

the inverter may heat/damage the power capacitor and generator.

z When a 400V class motor is inverter-driven, please use an insulation-enhanced

motor or measures taken to suppress surge voltages. Surge voltages attributable to
the wiring constants may occur at the motor terminals, deteriorating the insulation of
the motor.

z When parameter clear or all clear is performed, reset the required parameters

before starting operations. Each parameter returns to the factory setting.

z The inverter can be easily set for high-speed operation. Before changing its

setting, fully examine the performances of the motor and machine.

z In addition to the inverter's holding function, install a holding device to ensure safety.
z Before running an inverter which had been stored for a long period, always

perform inspection and test operation.

(5) Emergency stop

CAUTION

z Provide a safety backup such as an emergency brake which will prevent the

machine and equipment from hazardous conditions if the inverter fails.

z When the breaker on the inverter primary side trips, check for the wiring fault (short

circuit), damage to internal parts of the inverter, etc. Identify the cause of the trip,
then remove the cause and power on the breaker.

z When any protective function is activated, take the appropriate corrective action,

then reset the inverter, and resume operation.

(6) Maintenance, inspection and parts replacement

CAUTION

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

inverter.

(7) Disposing of the inverter

CAUTION

z Treat as industrial waste.

(8) General instructions

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

A-4

Product Checking and Parts Identification

A
A

Unpack the inverter and check the capacity plate on the front cover and the rating
plate on the inverter side face to ensure that the product agrees with your order and
the inverter is intact.

 Parts and name plate

Operation panel

Front cover

Wiring cover

 Inverter type

Symbol

S520E

S540E
S510WE

FR

Three-phase 200V class

Three-phase 400V class
Single-phase 100V class

S520E

-

Voltage class

0.1

- K - NA

Inverter
capacity
"kW"

z Removal and reinstallation of the

front cover

Remove the front cover by pulling it
toward you in the direction of arrow.
To reinstall, match the cover to the

inverter front and install it straight.

Rating plate

Inverter type

Input rating

Output rating

Serial number

Capacity plate

Inverter type Serial number

FR-S520E-0.1K to 0.75K-NA
FR-S510WE-0.1K to 0.4K-NA

FR-S520E-0.1K-NA XXXXXX

FR-S520E-0.1K-NA

FR-S520E-1.5K to 3.7K-N
FR-S540E-0.4K to 3.7K-N
FR-S510WE-0.75K-NA

z Removal and reinstallation of the wiring cover

The cover can be removed easily by pulling it toward
you.
To reinstall, fit the cover to the inverter along the guides.

z RS-485 communication connector

When using the RS-485 connector to wire the cable, you
can cut off the tab of the wiring cover to wire it. (Cutting off
the tab will provide protective structure IP10.)

CAUTION

The connector above the operation panel is for
manufacturer use. Do not touch it as doing so may
cause an electric shock.

Wiring cover

Tab

1

Basic configuration

1. CONNECTION OF PERIPHERAL DEVICES

1.1 Basic configuration

Power supply

Use within the permissible power supply
specifications of the inverter. (Refer to page 76.)

No-fuse breaker or earth leakage circuit breaker

The breaker must be selected carefully since an in-

(NFB)
or (ELB)

(MC)

AC reactor

(FR-HAL
/FR-BAL)

rush current flows in the inverter at power on.

Magnetic contactor

Install for your safety. Do not use this magnetic
contactor to start and stop the inverter. Doing so will
cause the inverter life to be shorten. (Refer to page

17.)

Installation of a reactor

A reactor must be used when the power harmonics
measure is taken, power factor is to be improved or
the inverter is installed near a large supply system
(500kVA or more and wiring distance within 10 m
(32.8 feet)).
Make the selection carefully.

Inverter
(FR-S500E)

Ground

Motor

Ground

DC reactor

(FR-HEL
/FR-BEL)

Inverter

The life of the inverter is influenced by ambient
temperature. Check the ambient temperature.
Epecially when mounting the inverter inside an
enclosure, take cautions of the ambient
temperature. (Refer to page 80.)

Wrong wiring might lead to damage of the inverter.
The control signal wires must be kept fully away
from the main circuit to protect them from noise.
(Refer to page 6.)

Devices connected to the output

Do not install a power factor correction capacitor,
surge suppressor or radio noise filter on the output
side of the inverter.
When installing a no-fuse breaker on the output side
of the inverter, contact each manufacturer for
selection of the no-fuse breaker.

Ground

To prevent an electric shock, always ground the
motor and inverter.
For reduction of induction noise from the power line
of the inverter, it is recommended to wire the ground
cable by returning it to the ground terminal of the
inverter.
(For details of noise reduction techniques, refer to
the instruction manual (detailed).)

2

Basic configuration

Selection of peripheral devices (selection changes with the power input
specifications of the inverter)

1) Three-phase 200V power input

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)

Applied Inverter

Type

FR-S520E-0.1K-NA

FR-S520E-0.2K-NA

FR-S520E-0.4K-NA

FR-S520E-0.75K-NA

FR-S520E-1.5K-NA

FR-S520E-2.2K-NA

FR-S520E-3.7K-NA

No-fuse Breaker

(NFB *1, 4) or

Earth Leakage

Circuit Breaker

(ELB) (*2, 4)

30AF/5A S-N10 0.4 (*3) 0.4 (*3)

30AF/5A S-N10 0.4 (*3) 0.4 (*3)

30AF/5A S-N10 0.4 0.4

30AF/10A S-N10 0.75 0.75

30AF/15A S-N10 1.5 1.5

30AF/20A S-N10 2.2 2.2

30AF/30A

Magnetic

Contactor

(MC)
(Refer to
page 17)

S-N20,

S-N21

AC Reactor
FR-HAL­FR-BAL-

K
K

3.7 3.7

DC Reactor
FR-HEL­FR-BEL-

K
K

1

2) Three-phase 400V power input

Motor

Output

(kW

(HP))

0.4

(1/2)

0.75
(1)

1.5
(2)

2.2
(3)

3.7
(5)

Applied Inverter

Type

FR-S540E-0.4K-NA

FR-S540E-0.75K-NA

FR-S540E-1.5K-NA

FR-S540E-2.2K-NA

FR-S540E-3.7K-NA

No-fuse Breaker

(NFB *1, 4) or

Earth Leakage

Circuit Breaker

(ELB) (*2, 4)

30AF/5A S-N10 H0.4 H0.4

30AF/5A S-N10 H0.75 H0.75

30AF/10A S-N10 H1.5 H1.5

30AF/15A S-N10 H2.2 H2.2

30AF/20A

Magnetic

Contactor

(MC)
(Refer to
page 17)

S-N20,

S-N21

AC Reactor

FR-HAL-K
FR-BAL-K

H3.7 H3.7

DC Reactor

FR-HEL-K
FR-BEL-K

CONNECTION OF PERIPHERAL DEVICES

3

Basic configuration

3) Single-phase 100V power input

Motor

Output

(kW

(HP))

Applied Inverter

Type

(NFB *1, 4) or

Earth Leakage

Circuit Breaker

(ELB) (*2, 4)

No-fuse Breaker

0.1

(1/8)

0.2

(1/4)

0.4

(1/2)

0.75
(1)

FR-S510WE-0.1K-NA

FR-S510WE-0.2K-NA

FR-S510WE-0.4K-NA

FR-S510WE-0.75K-NA

30AF/10A S-N10 0.75 

30AF/15A S-N10 1.5 

30AF/20A

30AF/30A

*1. •Select the NFB according to the inverter power supply

capacity.

• Install one NFB per inverter.

Magnetic

Contactor

(MC)
(Refer to
page 17)

S-N20,

S-N21

S-N20,

S-N21

AC Reactor(*3)

FR-HAL­FR-BAL-

K
K

2.2 

3.7 

NFB

NFB INV

DC Reactor (*5)

FR-HEL­FR-BEL-

K
K

INV

*2. For installations in the United States or Canada, the circuit breaker must be inverse

time or instantaneous trip type.
*3. The power factor may be slightly lower.
*4. When the breaker on the inverter primary side trips, check for the wiring fault (short

circuit), damage to internal parts of the inverter, etc. Identify the cause of the trip,

then remove the cause and power on the breaker.
*5. The single-phase 100V power input model does not allow the DC reactor to be fitted.

IM

IM

4

2. INSTALLATION METHOD

g

2.1 Installation of the inverter

Enclosure surface mounting Encasing multiple inverters

Fix the front
cover and wiring
cover after
removing them.

Leave enough clearances
and provide coolin

z Install the inverter under the following conditions.

measures.

Installation of the inverter

Vertical

When containing two or more
inverters, install them in parallel
and provide cooling measures.

Temperature: -10°C to 50°C
(14°F to 122°F)
Humidity: 90%RH maximum

5cm

5cm

(1.97inches)

Ambient temperature
and humidity

Measurement
position

Inverter

Measurement position

5cm

(1.97inches)(1.97inches)

Clearances (front)

1cm
(0.39inch)
or more

10cm
(3.94inches)
or more

These clearances are also
necessary for changing the
cooling fan. (

more is provided with a
cooling fan.

10cm
(3.94inches)
or more

1cm
(0.39inch)
or more

The 1.5K or

)

Clearances (side)

5cm

(1.97inches)

or more

Inverter

z Inverter consists of precision mechanical and electronic parts. Never install or

handle it in any of the following conditions as doing so could cause an operation
fault or failure.

Direct sunlight

Vibration
(5.9m/s

2

or more)

High temperature,
high humidity

Horizontal placement

2

INSTALLATION METHOD

Vertical mounting
(when mounted
inside enclosure)

Transportation
by holding front
cover or dial

Oil mist, flammable
gas, corrosive gas,
fluff, dust, etc.

5

Mounting to
combustible material

Terminal connection diagram

3. SPECIFICATIONS OF WIRING AND TERMINALS

3.1 Terminal connection diagram

z Three-phase 200V power input
z Three-phase 400V power input

NFB MC

Three-phase AC
power supply

External transistor common
24VDC power supply
Contact input common (source)

Take care not to short
terminals PC-SD.

Forward rotation start
Control input
signals
(No voltage
input allowed)

Frequency setting signals (Analog)

Frequency setting
potentiometer

1/2W1kΩ

Reverse rotation start

Multi-speed

selection

Contact input common

3

*4

1

Current input(-)

4 to 20mADC(+)

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.

High speed

Middle speed

Low speed

2

Inverter

R/L1

S/L2
T/L3

PC

STF
STR

*5
*5

RH

*5

RM

RL

*5

SD

10

(+5V)

0 to 5VDC

2

0 to 10VDC

5

(Common)

4

(4 to 20mADC)

SINK

*3

SOURCE

RS-485

Connector

*1

*2
*6

*6

*6

*6

RUN

Selected

U
V

W

P1

P/+

N/-

PR

A

B

C

SE

AM

Running

Open
collector
output
common

5

Motor

IM

Ground

DC reactor

(FR-HEL/BEL: Option)

Jumper:

jumper when DC reactor
is connected.

Alarm output

Remove this

Operation status
output

Open collector
outputs

(+)

Analog signal
output
(0 to 5VDC)

(-)

Ground

REMARKS

*1. The N/- terminal is not provided for the FR-S520E-0.1K to 0.75K-NA.
*2. The PR terminal is provided for the FR-S520E-0.4K to 3.7K-NA. (not used)
*3. You can switch the position of sink and source logic. (Refer to page 15.)
*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 54.)

(RES, RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, X14, X16, (STR) signal selection)

*6. The terminal function changes according to the setting of output terminal function selection (Pr. 64, Pr. 65).

(Refer to page 54.) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, Y93, Y95, LF, ABC signal selection)

CAUTION

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

Control circuit terminalMain circuit terminal

6

z Single-phase 100V power input

Main circuit

NFB

Power
supply

MC

R/L1
S/L

Motor

U

2

V

W

IM

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.

3.2 Main circuit

3.2.1 Explanation of main circuit terminals

Term inal

Symbol

R/L1, S/L2,

T/L3 (*1)

Terminal Name Description

AC power input

Connect to the commercial power supply.

U, V, W Inverter output
PR (*2)

P/+, N/−

P/+, P1

Brake unit

connection

DC reactor

connection

Ground

*1. When using single-phase power input, terminals are R/L1 and S/L2.
*2. The PR terminal is provided for the FR-S520E-0.4K to 3.7K-NA.

Connect a three-phase squirrel-cage motor.

Do not use PR terminal.

Connect the brake unit (BU), power regeneration
common converter (FR-CV) or high power factor
converter (FR-HC). (The N/- terminal is not provided for
the FR-S520E-0.1K to 0.75K-NA.)

Remove the jumper across terminals P - P1 and connect
the optional DC reactor (FR-HEL(-H)/FR-BEL(-H)).
(The single-phase 100V power input model cannot be
connected.)

For grounding the inverter chassis. Must be grounded.

3

SPECIFICATIONS OF WIRING AND TERMINALS

7

Main circuit

r

r

3.2.2 Terminal block layout

1) Three-phase 200V power input

• FR-S520E-0.1K, 0.2K-NA • FR-S520E-1.5K, 2.2K, 3.7K-NA

P/+

P1

R/L1 S/L2 T/L3

Power supply

U V W

IM

Motor

• FR-S520E-0.4K, 0.75K-NA

P1

IM

P/+

R/L1 S/L2

T/L3

Power supply

PR

U V W

Motor

Jumpe

Jumpe

N/-

PR

P/+

P1

Jumper

R/L1 S/L2 T/L3

Power supply

U V W

IM

Motor

<When single-phase power is applied to three-phase power input inverter
(FR-S520E-0.1K to 3.7K-NA only)>

•Reduce the output current.

FR-S520E- K-NA inverter 0.1 0.2 0.4 0.75 1.5 2.2 3.7

Rated output current (A) 0.4 0.8 1.5 2.5 4.0 5.0 7.0
Power supply capacity (kVA) 0.4 0.8 1.5 2.5 4.5 5.5 9.0
AC input current (A) 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 power 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.

8

2) Three-phase 400V power input

Main circuit

• FR-S540E-0.4K, 0.75K, 1.5K, 2.2K, 3.7K

-NA

Jumper

P/+

N/-

P1

R/L1 S/L2 T/L3

Power supply

U V W

IM

Motor

3) Single-phase 100V power input

• FR-S510WE-0.1K, 0.2K, 0.4K-NA • FR-S510WE-0.75K-NA

R/L1 S/L2

Power supply

P/+N/-

U V W

IM

Motor

N/-

P/+

R/L1 S/L2

Power supply

U V W

IM

Motor

CAUTION

•Make sure the power cables are connected to the R/L1, S/L2, T/L3 of the inverter.

Never connect the power cable to the U, V, W of the inverter. (Phase need not be
matched)

•Connect the motor to U, V, W. At this time, turning on the forward rotation switch

(signal) rotates the motor in the counterclockwise direction when viewed from the
motor shaft.

3

SPECIFICATIONS OF WIRING AND TERMINALS

9

Main circuit

3.2.3 Cables, wiring length, and crimping terminals

The following table indicates a selection example for the wiring length of 20m (65.62
feet).

1) Three-phase 200V power input

Cable Size

AWG

R, S, T

U, V, W

Cable Size

AWG

PVC cable

(mm

R, S, T

U, V, W

PVC cable

(mm

2

)

2

)

Applied Inverter

FR-S520E-0.1K
to 0.75K-NA

FR-S520E-

1.5K, 2.2K-NA
FR-S520E-

3.7K-NA

Ter-

minal

Screw

size

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

Tight­ening

Torque

⋅

m

N

Crimping

R, S, T U, V, W

2) Three-phase 400V power input

Applied Inverter

FR-S540E-0.4K

to 3.7K-NA

Ter-

minal

Screw

size

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

Tight­ening

Torque

⋅

m

N

Crimping

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

Termi nal

Termi nal

HIV cable

(mm

R, S, T

HIV cable

(mm2)

2

)

U, V, W

3) Single-phase 100V power input

Cable Size

AWG

PVC cable

2

(mm

)

Applied Inverter

FR-S510WE-

0.1K
to 0.4K-NA
FR-S510WE-0.75K­NA

Termi -

nal

Screw

size

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

Tight­ening

Torqu e

⋅

m

N

Crimping

Terminal

HIV cable

2

(mm

)

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

z Wiring length

100m (328.08 feet) maximum. (50m (164.04 feet) maximum for the FR-S540E-

0.4K-NA.)

CAUTION

•When the wiring length of the 0.1K and 0.2K of the three-phase 200V and
single-phase 100V class and the 0.4K and 0.75K of the three-phase 400V class
is 30m (98.43 feet) or more, set the carrier frequency to 1kHz.

•When automatic torque boost is selected in Pr. 98 "automatic torque boost
selection (motor capacity)", the wiring length should be 30m (98.43 feet)
maximum. (Refer to page 57.)

10

3.3 Control circuit

3.3.1 Explanation of control circuit terminals

Symbol Terminal Name Definition

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

Input signals

STF

STR

RH

Contact input

RM

RL

SD

(*1)

PC

(*1)

10

Frequency setting

5

Forward rotation
start

Reverse rotation
start

Multi-speed
selection

Contact input
common (sink)

External
transistor
common, 24VDC
power supply,
contact input
common (source)

Frequency setting
power supply

Frequency setting

2

(voltage signal)

Frequency setting

4

(current signal)

Frequency setting
input common

Turn on the STF signal to
start forward rotation and
turn it off to stop.

Turn on the STR signal to
start reverse rotation and
turn it off to 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, REX) and AU.

Common to the contact input terminals (STF, STR, RH, RM,
RL). (*6)
When connecting the transistor output (open collector output),
such as a programmable controller (PLC), connect the positive
external power supply for transistor output to this terminal to
prevent a malfunction caused by undesirable currents.
This terminal can be used as a 24VDC, 0.1A power output
across terminals PC-SD.
When source logic has been selected, this terminal serves
as a contact input common.

5VDC, Permissible load current 10mA.

Inputting 0 to 5VDC (or 0 to 10V) provides the maximum output
frequency at 5V (10V) and makes input and output proportional.
Switch between 5V and 10V using Pr. 73 "0-5V, 0-10V selection".
Input resistance 10kΩ. Maximum permissible input voltage 20V
Input 4 to 20mADC. It is factory set at 0Hz for 4mA and at
60Hz for 20mA.
Maximum permissible input current 30mA. Input resistance
approximately 250Ω.
Turn ON signal AU for current input.
Turning the AU signal on makes voltage input invalid. Use any of
Pr. 60 to Pr. 63 (input terminal function selection) to set the AU
signal.
Common terminal for the frequency setting signals
(terminal 2, 4) and indicator connection (terminal AM). (*6)

Control circuit

The terminal
functions change
with input terminal
function selection
(Pr. 60 to Pr.63).
(*3)

3

SPECIFICATIONS OF WIRING AND TERMINALS

11

Control circuit

Symbol Terminal Name Definition

Changeover contact output indicates
that the inverter protective function has

Output signals

A
B
C

RUN

Open collector

SE

AM

Indicator

Alarm output

Inverter
running

Open collector
common

Analog signal
output

activated and the output stopped.
230VAC 0.3A, 30VDC 0.3A. Alarm:
discontinuity across B-C (continuity
across A-C), Normal: continuity across
B-C (discontinuity across A-C).(*5)
Switched low when the inverter output
frequency is equal to 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 (a
voltage drop is 3.4V maximum when
the signal is on)

Common terminal for inverter running terminal RUN.

The output signal across terminals AM-5 is factory set to about
5VDC at 60Hz and is proportional to the corresponding output
frequency.
Frequency permissible load current 1mA
Output signal 0 to 5VDC

The function of the
terminals changes
according to the
output terminal
function selection
(Pr. 64, Pr.65).
(*4)

(*6)

Using the parameter unit connection cable (FR-CB201 to

205), the parameter unit (FR-PU04) can be connected.
Communication operation can be performed using RS-485.
For details of RS-485 communication, refer to the
separately available instruction manual (detailed).

——

RS-485
connector

Communication

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

For sink logic (factory setting), 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 the
separately available instruction manual (detailed) for switching method.)

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

that the transistor is off (does not conduct).

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

selection (Refer to page 54.)

*4. RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, Y93, Y95, LF, ABC signal selection

(Refer to page 54.)

*5. To be compliant with the European Directive (Low Voltage Directive), the operating

capacity of relay outputs (A, B, C) should be 30VDC 0.3A.

*6. Terminals SD, SE and 5 are isolated from each other. Do not ground.

12

Control circuit

3.3.2 Arrangement and wiring of control circuit terminals

PC

SE RUN 10 2 5 4

SD

AB

SD STF STR RM RH

C

RL AM

Loosen the terminal screw and insert the cable into the
terminal.

Cable stripping size

Screw size: M3 (A, B, C terminals),

M2 (other than the above)

Tightening torque: 0.5N•m to 0.6N•m (A, B, C terminals)

0.22N•m to 0.25N•m (other than the
above)

CAUTION

Wire the stripped cable after
twisting it to prevent it from
becoming loose.
In addition, do not solder it. *

Undertightening can cause cable
disconnection or malfunction. Overtightening
can cause a short circuit or malfunction due
to damage to the screw or unit.

Cable size: 0.3mm
Screwdriver: Small flat-blade screwdriver

Control circuit terminal block

2

to 0.75mm

2

ABC
terminals

Other than
the above

Tip thickness: 0.4mm (0.02 inch)
Tip width: 2.5mm (0.10 inch)

*Information on bar terminals
Introduced products (as of August, 2005): Phoenix Contact Co.,Ltd.

Terminal Screw Size

M3 (A, B, C terminal)

M2 (Other than the above) Al 0.5-6WH A 0.5-6 0.3 to 0.5

Bar Terminal Model

(With Insulation Sleeve)

Al 0.5-6WH A 0.5-6 0.3 to 0.5

Al 0.75-6GY A 0.75-6 0.5 to 0.75

Bar Terminal Model

(Without Insulation Sleeve)

6mm

(0.24 inch)

5mm

(0.20 inch)

Wire Size (mm2)

3

Bar terminal crimping tool: CRIMPFOX ZA3 (Phoenix Contact Co., Ltd.)

CAUTION

When using the bar terminal (without insulation sleeve), use care so that the
twisted wires do not come out.

SPECIFICATIONS OF WIRING AND TERMINALS

13

Control circuit

3.3.3 Connection to RS-485 connector

(1) When connecting the parameter unit

Use the optional FR-CB2 . When the parameter unit (FR-PU04) is used,
operation from the operation panel is not accepted. ( is valid)

(2) RS-485 communication

Using the RS-485 connector, you can perform communication operation from a
personal computer etc. By connecting the RS-485 connector to computers such
as personal computer and FA with a communication cable, you can run/monitor
the inverter and read/write parameter values using a user program. For further
details, refer to the instruction manual (detailed).

· Conforming standard: EIA-485 (RS-485)

· Transmission format: Multi-drop link

· Communication speed: Maximum 19200 bps

· Overall extension: 500m (1640.42 feet)

CAUTION

Do not plug the connector to a computer LAN board, fax modem socket, tele­phone modular connector etc. As they are different in electrical specifications,
the inverter may be damaged.

STOP

RESET

14

Control circuit

3.3.4 Changing the control logic

The input signals are set to sink
logic.
To change the control logic, the
jumper connector under the setting
dial must be moved to the other
position.

Change the jumper connector
position using tweezers, a pair of
long-nose pliers etc.
Change the jumper connector
position before switching power on.

CAUTION

•Make sure that the front cover is installed securely.

•The front cover is fitted with the capacity plate and the inverter unit with the

rating plate. Since these plates have the same serial numbers, always replace
the removed cover onto the original inverter.

•The sink-source logic change-over jumper connector must be fitted in only
one of those positions. If it is fitted in both positions at the same time, the
inverter may be damaged.

1) Sink logic type

• In this logic, a signal switches on when a current flows from the corresponding signal
input terminal.
Terminal SD is common to the contact input signals. Terminal SE is common to the
open collector output signals.

Power supply

STF

STR

SD

• Connecting a positive terminal of the

R

R

external power supply for transistor
output to terminal PC prevents a
malfunction caused by an undesirable
current. (Do not connect terminal SD

AY40
transistor
output module

1

2

RUN

SE

STF

STR

AX40Inverter

1

R

R

9

24VDC

Inverter

24VDC
(SD)

of the inverter with terminal 0V of the
external power supply. When using
terminals PC-SD as a 24VDC power
supply, do not install an external
power supply in parallel with the
inverter. Doing so may cause a

9

9

10

24VDC SD

PC

malfunction in the inverter due to an
undesirable current.)

Current flow

3

SPECIFICATIONS OF WIRING AND TERMINALS

15

Control circuit

2) Source logic type

• In this logic, a signal switches on when a current flows into the corresponding signal
input terminal.
Terminal PC is common to the contact input signals. For the open collector output
signals, terminal SE is a positive external power supply terminal.

PC

Power

supply

STF

STR

R

R

• Connecting the 0V terminal of the
external power supply for transistor
output to terminal SD prevents a
malfunction caused by an undesirable
current.

AY80
transistor
output module

10

Inverter

RUN

SE

24VDC

9

1

2

PC

STF

STR

24VDC

SD

AX80

1

R

R

9

Inverter

24VDC
(SD)

Current flow

16

Control circuit

r

3.3.5 Power-off and magnetic contactor (MC)

(1) Inverter input side magnetic contactor (MC)

On the inverter's input side, it is recommended to provide an MC for the following
purposes. (Refer to page 3 for selection)

1) To release the inverter from the power supply when the inverter protective function
is activated or the drive becomes faulty (e.g. emergency stop operation)

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

3) To rest the inverter for an extended period of time
The control power supply for inverter is always running and consumes a little power.
When stopping the inverter for an extended period of time, powering off the inverter
will save power slightly.

4) To separate the inverter from the power supply to ensure safe maintenance and
inspection work
The inverter's input side MC is used for the above purpose, select class JEM1038­AC3 for the inverter input side current when making an emergency stop during
normal operation.

REMARKS

The MC may be switched on/off to start/stop the inverter. However, since repeated inrush
currents at power on will shorten the life of the converter circuit (switching life is about 100,000
times), frequent starts and stops must be avoided. Turn on/off the inverter start controlling
terminals (STF, STR) to run/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.

*1. When the power supply

is 400V class, install a
step-down transformer.

Power
supply

Operation ready

NFB

OFF

Start/Stop

ON

MC

MC

T (*1)

MC

RA

R/L1
S/L2
T/L3

Inverter

STF(STR)
SD

U

V

W

To
moto

A

B

C

3

(2) Handling of output side magnetic contactor

In principle, do not provide a magnetic contactor between the inverter and motor and
switch it from off to on during operation. If it is switched on during inverter operation, a
large inrush current may flow, stopping the inverter due to overcurrent shut-off. When
an MC is provided for switching to the commercial power supply, for example, switch it
on/off after the inverter and motor have stopped.

MC

Operation

OFF

RA

Inverter Start/Stop Circuit Example

RA

17

SPECIFICATIONS OF WIRING AND TERMINALS

Step of operation

Step of operation

p

4. DRIVE THE MOTOR

4.1 Step of operation

The inverter needs frequency command and start command. Turning the start
command on start the motor rotating and the motor speed is determined by the
frequency command.
Refer to the flow chart below to perform setting.

Step of operation

o

(Hz)

Frequency

Start
command

Start command with

on the operation panel (PU)

Set from the
operation
panel.

Frequency command

Inverter output
frequency

ON

How to

give a frequency

command?

(PU)

Time
(S)

RUN

-+

Change frequency
with ON/OFF switches
connected to terminals
(multi-speed setting)

(External)

Installation/mounting

Wiring of the power

supply and motor

System examination

How

to give a start

command?

Perform frequency
setting by a voltage
output device
(Connection across
terminals 2-5)

(External)

{Refer to page 5}

{Refer to page 8}

Start command using the RS-485
connector of the inverter
(Communication)

Refer to Instruction Manual
(detailed)

Connect a switch, relay, etc.
to the control circuit
terminal block of the inverter
to give a start command. (External)

Perform frequency
setting by a current
output device
(Connection across
terminals 4-5)

(External)

{Refer to page 21} {Refer to page 23} {Refer to page 25} {Refer to page 26}

How to

give a frequency

command?

Set from the
operation panel

(PU)

{Refer to page 28} {Refer to page 30} {Refer to page 32} {Refer to page 34}

CAUTION

Check the following items before powering on the inverter.

•Check that the inverter is installed correctly in a correct place. (Refer to page 5)

•Check that wiring is correct. (Refer to page 6)

•Check that no load is connected to the motor.

Change of frequency
with ON/OFF switches
connected to terminals
(multi-speed setting)

(External)

18

Perform frequency
setting by a voltage
output device
(Connection across
terminals 2-5)

(External)

Perform frequency
setting by a current
output device
(Connection across
Terminals 4-5)

(External)

4.2 Run and operation

4.2.1 Parts of the operation panel

The operation panel cannot be removed from the inverter.

Run and operation

RUN indication

Turns on/flickers* to indicate operation.

PU indication **

Lit to indicate the PU
operation mode.

3-digit monitor LED

Shows the frequency,
parameter number, etc.

EXT indication **

Lit to indicate the external
operation mode.

Setting dial

(Setting dial: Mistubishi inverter's dial)

Used to change the frequency
setting and parameter values.
This dial cannot be removed.

PU/EXT Key

Used to switch between the
PU and external operation
mode.When using the external

RUN

PU

EXT

PU

EXT

RUN

operation mode (operation
using the separately
connected frequency setting
potentiometer and start
signal), press this key to

STOP

RESET

light up the EXT indication.
(Change the Pr. 79 value to

MODE SET

use the combined mode.)
PU: PU operation mode
EXT: External operation mode

RUN Key

Used to give the forward
rotation operation command.
Use Pr. 17 to set reverse
operation.

STOP/RESET Key

Used to stop operation or reset an alarm.

MODE Key

Used to change the setting mode.

SET Key

Used to define each setting.

* RUN indication

On: Indicates that forward rotation operation is being performed.
Slow flickering (1.4s cycle): Indicates reverse rotation
Fast flickering (0.2s cycle): Indicates that operation is not being performed
but the was pressed or the start command was given.

RUN

** PU/EXT indication

Flickers slowly in the computer link operation mode.

REMARKS

•When the parameter unit (FR-PU04) is used, operation from the operation panel is not

accepted. ( is valid)

STOP

RESET

4

DRIVE THE MOTOR

19

Run and operation

4.2.2 Basic operation

The following explains the outline of operation. (factory setting)

<Basic operation> (factory setting)

At powering on

Monitor/frequency setting

Return

Press

MODE

MODE
key.

Parameter setting

[Parameter setting change]

Press

MODE

MODE
key.

Turn the
setting dial
to change
value.

[Operation panel is used for operation]

PU

EXT

Press
PU/EXT
key.

Turn the
setting dial
to match

SET

Press
SET key

frequency.

PU

EXT

Press
PU/EXT
key.

Turn the setting
dial to match
frequency.

SET

After setting is completed,

SET

Press SET key to
show present setting.

press the once to show
Press SET
key to
complete

alarm history, or twice to

show frequency setting screen.

setting.

Frequency setting has
been written and
completed!!

and frequency flickers.

Press to start.

Press to stop.

MODE

RUN

STOP

RESET

[Operation for displaying alarm history]
Four past alarms can be displayed with the setting dial .
(The latest alarm is ended by ".".)

Alarm history

MODE

When no alarm exists, is displayed.

Press MODE key.

20

Operation by the start command from the operation panel

(PU operation mode)

4.3 Operation by the start command from the opera­tion panel (PU operation mode)

4.3.1 Setting the frequency to perform operation

(example: performing operation at 30Hz)

POINT

•Set "0" (setting dial frequency setting mode) in Pr. 53 "frequency setting
operation selection".

Operation

Screen at power-on

1.

The monitor display appears.

2.

Press the
to choose the PU
operation mode.

Turn the to show

3.

the frequency you want to set.
Flickers for about 5s.

While the value is flickering,

4.

press the to set the
frequency.

If you do not press the ,
the value flickers for about 5s and
the display then returns to 0.0
(monitor display). At this time,
return to "step 3" and set the
frequency again.

5.

After the value flickered for about
3s, the display returns to 0.0
(monitor display).

Press the to start operation.

To change the set frequency, perform

6.

the operation in above steps 3 and 4.

(Starting from the previously set frequency.)

Press the to stop.

7.

PU

EXT

SET

RUN

STOP

RESET

SET

PU

EXT

SET

RUN

STOP

RESET

Display

RUN

PU

EXT

RUN

PU indication is lit.

Flickers for about 5s.

Flicker...Frequency setting complete!!

3s later

PU

EXT

RUN

PU

EXT

RUN

PU

EXT

4

Operation cannot be performed at the set frequency ... Why?

Did you carry out step 4 within 5s after step 3?

(Did you press the within 5s after turning the setting dial?)

Setting of higher than 60Hz cannot be made ... Why?

Check to see if the Pr. 1 "maximum frequency" setting is 60Hz.

The frequency does not change by turning the setting dial ... Why?

Check to see if the operation mode selected is the external operation mode.

REMARKS

Pressing the setting dial shows the set frequency.

•The setting dial can also be used like a potentiometer to perform operation. (Refer to page 22.)

DRIVE THE MOTOR

SET

21

Operation by the start command from the operation panel
(PU operation mode)

4.3.2 Using the setting dial like a potentiometer to perform
operation

POINT

•Set "1" (extended function parameter valid) in Pr. 30 "extended function
display selection".

•Set "1" (setting dial potentiometer mode) in Pr. 53 "frequency setting
operation selection".

Operation example Changing the frequency from 0Hz to 60Hz during operation

Operation

Mode/monitor check.

1.

Choose monitor/frequency monitor.



The inverter must be in the



PU operation mode.

Pr. 30 must be set to "1".



Pr. 53 must be set to "1".



Press the to start

2.

RUN

the inverter.

Turn the clockwise

3.

(Press the .)

PU

EXT

( )

RUN

MODE

Display

RUN

PU

EXT

RUN

PU

EXT

until "60.0" appears.
The flickering frequency is

the set frequency.

You need not press the .

SET

Flickers for 3s.

REMARKS

•If flickering "60.0" turns to "0.0", the Pr. 53 "frequency setting operation selection" setting may

not be "1".

•Independently of whether the inverter is running or at a stop, the frequency can be set by

merely turning the dial.

22

Operation by the start command from the operation panel

(PU operation mode)

4.3.3 Use switchs to give a start command and a frequency
command (multi-speed setting)

POINT

•Use to give a start command.

RUN

•Pr. 79 "Operation mode selection" must be set to "4" (external/PU combined
operation mode 2)

•The factory setting of the terminal RH, RM, RL, are 60Hz, 30Hz, and 10Hz.
(Refer to page 44 to change frequency using Pr. 4, Pr. 5 and Pr. 6.)

•Operation at 15-speed can be performed by turning on two (or three) termi­nals simultaneously. (Refer to Instruction Manual (detailed).)

Inverter

Three-phase
AC power supply

High speed

Middle speed
Low speed

R
S
T

RH
RM
RL
SD

Operation

panel

㧗㧙

RUN

､

STOP

RESET

U
V

W

Motor

Operation

Screen at powering on

1.

The monitor display appears.

2.

Press to choose the
parameter setting mode.

Turn until (Pr.79)

3.

appears.

Press to read the currently

4.

set value.

" "(factory setting) appears.

Turn to change it to the

5.

setting value of " ".

Press to set.

6.

MODE

SET

SET

MODE

SET

SET

Display

RUN

PU

EXT

The parameter
number read
previously appears.

4

DRIVE THE MOTOR

Flicker

23

･･･

Parameter setting complete!!