Mitsubishi Electronics FR-V520-1.5K, FR-V540-1.5K User Manual

VECTOR INVERTER

FR-V500

INSTRUCTION MANUAL (Detailed)

HIGH PRECISION & FAST

RESPONSE VECTOR INVERTER

FR-V520-1.5K to 55K FR-V540-1.5K to 55K

WIRING

VECTOR

CONTROL

PARAMETERS

SPECIFICATIONS

Thank you for choosing this Mitsubishi vector inverter. This Instruction Manual (detailed) provides instructions for advanced use of the FR-V500 series inverters. Incorrect handling might cause an unexpected fault. Before using the inverter, always read this Instruction Manual and the Instruction Manual (basic) [IB-0600064] packed with the product carefully to use the equipment to its optimum performance.

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

CAUTION

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.

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.

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 inverter power indicator lamp is off, wait for at least 10 minutes after

the power supply has been switched off, and check that there are no residual voltage using a tester or the like. The capacitor is charged with high voltage for some time after power off and it is dangerous.

z This inverter must be earthed (grounded). Earthing (Grounding) must conform to the requirements of national and local safety

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

z Any person who is involved in 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.

2. Fire Prevention

CAUTION

z Install the inverter on an incombustible wall without holes, etc. Mounting it to or near combustible material can cause 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 When a brake resistor is used, use an alarm signal to switch power off. Otherwise, the brake resistor will overheat abnormally due to

a brake transistor or other fault, resulting in 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 Ensure that the cables are connected to the correct terminals. Otherwise damage etc. may occur. z Always make sure that polarity is correct to prevent damage etc. z 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

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 i

instru

ction manual.

z Do not operate if the inverter is damaged or has parts missing. z When carrying the inverter, do not hold it by the front cover; 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 screws, wire fragments, other conductive bodies, oil or other flammable substances from entering the inverter. z Do not drop the inverter, or subject it to impact z Use the inverter under the following environmental conditions:

Ambient temperature -10°C to +50°C (non-freezing) Ambient humidity 90%RH or less (non-condensing) Storage temperature -20°C to +65°C* Ambience Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)

Environment

Altitude, vibration

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

Maximum 1000m above sea level for standard operation. After that derate by 3% for every extra 500m up to 2500m (91%). 5.9m/s

or less

n the

A-1

2) Wiring

CAUTION

z Do not fit capacitive equipment such as power factor correction capacitor, surge suppressor or radio noise filter (option FR-BIF) to

the inverter output side.

z The connection orientation of the output cables (terminals 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.

4) Operation

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 115) provide a circuit and switch separately to make an

emergency stop (power off, mechanical brake operation for emergency stop, etc).

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.

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, each parameter returns to the factory setting. 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. In addition to the

inverter's holding function, install a holding device to ensure safety.

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 input 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 the 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-2

1 WIRING 1

1.1 Internal block diagram......................................................................................... 2

1.2 Main circuit terminal specifications ...................................................................3

1.3 Connection of stand-alone option units ............................................................4

1.3.1 Connection of the dedicated external brake resistor (FR-ABR) .........................................................4

1.3.2 Connection of the brake unit (FR-BU)................................................................................................5

1.3.3 Connection of the brake unit (BU type) ..............................................................................................6

1.3.4 Connection of the high power factor converter (FR-HC)....................................................................6

1.3.5 Connection of the power regeneration common converter (FR-CV)..................................................7

1.3.6 Connection of the DC reactor (FR-HEL/BEL).....................................................................................7

1.4 Control circuit terminal specifications ..............................................................8

1.4.1 Connecting the control circuit to a power supply separately from the main circuit...........................10

1.5 Precautions for use of the vector inverter....................................................... 11

1.6 Others ................................................................................................................. 12

1.6.1 Leakage currents and countermeasures..........................................................................................12

1.6.2 Power off and magnetic contactor (MC)...........................................................................................14

1.6.3 Installation of reactor........................................................................................................................15

1.6.4 Notes on earthing (grounding)..........................................................................................................16

1.6.5 Inverter-generated noises and their reduction techniques ...............................................................17

1.6.6 Power supply harmonics ..................................................................................................................19

1.6.7 Harmonic suppression guidelines ....................................................................................................20

1.6.8 Inverter-driven 400V class motor .....................................................................................................22

1.6.9 Using the PU connector for computer link........................................................................................23

CONTENTS

1.7 Input terminals ................................................................................................... 26

1.7.1 Run (start) and stop (STF, STR, STOP) ..........................................................................................26

1.7.2 External thermal relay input (OH).....................................................................................................27

1.7.3 Speed setting potentiometer connection (10E, 2 (1), 5)...................................................................27

1.7.4 Torque setting input signal and motor-generated torque (terminals 3, 5) ........................................28

1.7.5 Meter connection method and adjustment (DA1, DA2)....................................................................28

1.7.6 Common terminals (SD, 5, SE)........................................................................................................29

1.7.7 Signal inputs by contact-less switches.............................................................................................29

1.8 How to use the input signals (assigned terminals DI1 to DI4, STR)

(Pr. 180 to Pr. 183, Pr. 187)................................................................................ 30

1.8.1 Multi-speed setting (RL, RM, RH, REX signals): Pr. 180 to Pr. 183, Pr. 187 setting "0, 1, 2, 8"

Remote setting (RL, RM, RH signals): Pr. 180 to Pr. 183, Pr. 187 setting "0, 1, 2" .........................30

1.8.2 Second function selection/second motor switchover (RT signal)

: Pr. 180 to Pr. 183, Pr. 187 setting "3" ............................................................................................30

1.8.3 Jog operation (jog signal): Pr. 180 to Pr. 183, Pr. 187 setting "5" ....................................................30

1.8.4 Third function selection (X9 signal): Pr. 180 to Pr. 183, Pr. 187 setting "9" .....................................31

1.8.5 FR-HC, FR-CV connection (X10 signal): Pr. 180 to Pr. 183, Pr. 187 setting "10"............................31

1.8.6 PU operation external interlock signal (X12 signal): Pr. 180 to Pr. 183, Pr. 187 setting "12"...........31

1.8.7 PID control enable terminal: Pr. 180 to Pr. 183, Pr. 187 setting "14" ...............................................31

1.8.8 Brake sequence opening signal (BRI signal): Pr. 180 to Pr. 183, Pr. 187 setting "15" ....................31

1.8.9 PU operation/external operation switchover: Pr. 180 to Pr. 183, Pr. 187 setting "16"......................31

1.8.10 S-pattern acceleration/deceleration C switchover terminal (X20 signal)

: Pr. 180 to Pr. 183, Pr. 187 setting "20" ..........................................................................................31

1.8.11 Orientation command (X22 signal): Pr. 180 to Pr. 183, Pr. 187 setting "22"....................................32

1.8.12 Pre-excitation/servo on (LX signal): Pr. 180 to Pr. 183, Pr. 187 setting "23" ...................................32

1.8.13 Output stop (MRS signal): Pr. 180 to Pr. 183, Pr. 187 setting "24" ..................................................32

1.8.14 Start self-holding selection (STOP signal): Pr. 180 to Pr. 183, Pr. 187 setting "25".........................32

1.8.15 Control mode changing (MC signal): Pr. 180 to Pr. 183, Pr. 187 setting "26"..................................33

1.8.16 Torque limit selection (TL signal): Pr. 180 to Pr. 183, Pr. 187 setting "27" ......................................33

1.8.17 Start time tuning (X28 signal): Pr. 180 to Pr. 183, Pr. 187 setting "28" ............................................33

1.8.18 Torque bias selection 1 (X42 signal): Pr. 180 to Pr. 183, Pr. 187 setting "42"

Torque bias selection 2 (X43 signal): Pr. 180 to Pr. 183, Pr. 187 setting "43".................................33

1.8.19 P control selection (P/PI control switchover) (X44 signal):

Pr. 180 to Pr. 183, Pr. 187 setting "44" ............................................................................................34

1.9 How to use the output signals (assigned terminals DO1 to DO3, ABC)

(Pr. 190 to Pr. 192, Pr. 195)................................................................................ 35

1.10 Design information to be checked ...................................................................37

1.11 Using the second motor ....................................................................................38

1.11.1 Wiring diagram (second motor)........................................................................................................38

1.11.2 Second motor setting parameters ...................................................................................................38

1.12 Using the conventional motor and other motors............................................ 39

1.12.1 Conventional motor (SF-VR, SF-JR with encoder) ..........................................................................39

1.12.2 Precautions for and wiring of the motor with encoder (SF-JR with encoder) ...................................40

2 VECTOR CONTROL 41

2.1 What is vector control? .....................................................................................42

2.2 Speed control ..................................................................................................... 44

2.2.1 Outline of speed control ...................................................................................................................44

2.2.2 Easy gain tuning function block diagram..........................................................................................44

2.3 Fine adjustment of gains for speed control .................................................... 45

2.3.1 Control block diagram ......................................................................................................................45

2.3.2 Concept of adjustment of manual input speed control gains............................................................46

2.3.3 Speed control gain adjustment procedure (Pr. 820, Pr. 821)...........................................................46

2.3.4 Troubleshooting................................................................................................................................47

2.3.5 Speed feed forward control, model adaptive speed control (Pr. 828, Pr. 877 to Pr. 881)................49

2.4 Torque control.................................................................................................... 51

2.4.1 Outline of torque control...................................................................................................................51

2.5 Fine adjustment for torque control .................................................................. 52

2.5.1 Control block diagram ......................................................................................................................52

2.6 Gain adjustment for torque control.................................................................. 53

2.6.1 Concept of torque control gains .......................................................................................................53

2.6.2 Gain adjustment procedure..............................................................................................................53

2.6.3 Troubleshooting................................................................................................................................54

2.7 Position control (Pr. 419 to Pr. 430, Pr. 464 to Pr. 494) .................................. 55

2.7.1 Connection diagram .........................................................................................................................55

2.7.2 Position control step.........................................................................................................................56

2.7.3 Control block diagram ......................................................................................................................57

2.7.4 Parameter.........................................................................................................................................57

2.7.5 Conditional position feed function by contact input (Pr. 419 = 0).....................................................59

2.7.6 Setting the electronic gear................................................................................................................60

2.7.7 In-position width (Pr. 426) ................................................................................................................62

2.7.8 Excessive level error (Pr. 427) .........................................................................................................62

2.7.9 Pulse monitor selection (Pr. 430) .....................................................................................................62

2.7.10 Concept of position control gains .....................................................................................................62

2.7.11 Troubleshooting................................................................................................................................63

2.7.12 Position control is not exercised normally ........................................................................................64

3 PARAMETERS 65

3.1 Parameter list ..................................................................................................... 66

3.2 At-a-glance guide to functions ......................................................................... 73

3.3 Basic functions (Pr. 0 to Pr. 9).......................................................................... 76

3.3.1 Torque boost (Pr. 0) .........................................................................................................................76

3.3.2 Maximum and minimum speed settings (Pr. 1 , Pr. 2) ....................................................................76

3.3.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19)...................................................................77

3.3.4 Multi-speed operation (Pr. 4 to Pr. 6, Pr. 24 to Pr. 27, Pr. 232 to Pr. 239)......................................77

3.3.5 Acceleration and deceleration time (Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45, Pr. 110, Pr. 111)...78

3.3.6 Motor overheat protection (Pr. 9, Pr. 452, Pr. 876 ) .........................................................................80

3.4 Standard operation functions (Pr. 10 to Pr. 16) .............................................. 82

3.4.1 DC injection brake operation (Pr. 10, Pr.11, Pr. 12, Pr.802) ...........................................................82

3.4.2 Starting speed (Pr. 13) .....................................................................................................................84

3.4.3 Jog operation (Pr. 15, Pr. 16)...........................................................................................................85

3.5 Operation selection functions 1 (Pr. 17 to Pr. 37) ...........................................86

3.5.1 Inverter output stop (MRS) (Pr. 17)..................................................................................................86

3.5.2 Torque limit (Pr. 22, Pr. 803, Pr. 810 to Pr. 817)............................................................................87

3.5.3 RH, RM, RL signal input compensation (Pr. 28) ..............................................................................88

3.5.4 S-pattern acceleration/deceleration curve (Pr. 29, Pr. 140 to Pr. 143, Pr. 380 to Pr. 383) ..............89

3.5.5 Regenerative brake duty (Pr. 30, Pr. 70)..........................................................................................92

3.5.6 Speed jump (Pr. 31 to Pr. 36)...........................................................................................................93

3.5.7 Speed display (Pr. 37, Pr. 144, Pr. 505 )..........................................................................................93

CONTENTS

3.6 Output terminal functions (Pr. 41 to Pr. 50)..................................................... 95

3.6.1 Up-to-speed sensitivity (Pr. 41)........................................................................................................95

3.6.2 Speed detection (Pr. 42, Pr. 43, Pr. 50, Pr. 116)..............................................................................95

3.7 Display functions 1 (Pr. 52 to Pr. 56)................................................................ 97

3.7.1 Monitor display/DA1, DA2 terminal function selection (Pr. 52 to Pr. 54, Pr. 158) ...........................97

3.7.2 Monitoring reference (Pr. 55, Pr. 56, Pr. 866) ................................................................................100

3.8 Automatic restart (Pr. 57, Pr. 58) .................................................................... 101

3.8.1 Automatic restart after instantaneous power failure (Pr. 57, Pr. 58, Pr. 162 to Pr. 165) ................101

3.9 Additional functions (Pr. 59) ...........................................................................103

3.9.1 Remote setting function selection (Pr. 59 ) ....................................................................................103

3.10 Brake sequence (Pr. 60, Pr. 278 to Pr. 285) ................................................... 106

3.10.1 Brake sequence function (Pr. 60, Pr. 278 to Pr. 285).....................................................................106

3.11 Operation selection function 2 (Pr. 65 to Pr. 79) ........................................... 109

3.11.1 Retry function (Pr. 65, Pr. 67 to Pr. 69)..........................................................................................109

3.11.2 Applied motor (Pr. 71, Pr. 450).......................................................................................................111

3.11.3 PWM carrier frequency selection (Pr. 72, Pr. 240).........................................................................112

3.11.4 Speed setting signal on/off selection (Pr. 73).................................................................................113

3.11.5 Reset selection/disconnected PU detection/PU stop selection (Pr. 75) .........................................115

3.11.6 Parameter write disable selection (Pr. 77) .....................................................................................116

III

3.11.7 Reverse rotation prevention selection (Pr. 78 ) ..............................................................................117

3.11.8 Operation mode selection (Pr. 79) .................................................................................................117

3.12 Offline auto tuning (Pr. 80 to Pr. 96)............................................................... 120

3.12.1 Offline auto tuning function

(Pr. 9, Pr. 80, Pr. 81, Pr. 83, Pr. 84, Pr. 71, Pr. 96, Pr. 450, Pr. 452).............................................120

3.12.2 Parameters.....................................................................................................................................120

3.12.3 Execution of offline auto tuning ......................................................................................................121

3.12.4 Utilizing or changing offline auto tuning data for use......................................................................123

3.12.5 Setting the motor constants directly ...............................................................................................124

3.12.6 Direct input + offline auto tuning.....................................................................................................125

3.13 Online auto tuning (Pr. 95) .............................................................................. 126

3.13.1 Online auto tuning selection (Pr. 95, Pr. 9, Pr. 71, Pr. 80, Pr. 81 ).................................................126

3.14 Communication functions (Pr. 117 to Pr. 124, Pr. 342) ................................ 128

3.14.1 Computer link operation (RS-485 communication) (Pr. 117 to Pr. 124)........................................128

3.14.2 E2PROM write selection (Pr. 342) .................................................................................................139

3.15 PID control (Pr. 128 to Pr. 134) ....................................................................... 139

3.15.1 PID control (Pr. 128 to Pr. 134)......................................................................................................139

3.16 Current detection (Pr. 150 to Pr. 153)............................................................. 146

3.16.1 Output current detection function (Pr. 150, Pr. 151).......................................................................146

3.16.2 Zero current detection (Pr. 152, Pr. 153)........................................................................................147

3.17 Auxiliary functions (Pr. 156, Pr. 157).............................................................. 148

3.17.1 Stall prevention operation selection (Pr. 156) ................................................................................148

3.17.2 OL signal output timer (Pr. 157) .....................................................................................................149

3.18 Display function 3 (Pr. 160) .............................................................................150

3.18.1 Extended function display selection (Pr. 160) ................................................................................150

3.19 Initial monitor (Pr. 171) ....................................................................................150

3.19.1 Actual operation hour meter clear (Pr. 171) ...................................................................................150

3.20 Terminal assignment functions (Pr. 180 to Pr. 195) ..................................... 150

3.20.1 Input terminal function selection (Pr. 180 to Pr. 183, Pr. 187).......................................................150

3.20.2 Output terminal function selection (Pr. 190 to Pr. 192, Pr. 195).....................................................152

3.21 Auxiliary function (Pr. 244) ............................................................................. 154

3.21.1 Cooling fan operation selection (Pr. 244).......................................................................................154

3.22 Stop selection function (Pr. 250) .................................................................... 154

3.22.1 Stop selection (Pr. 250)..................................................................................................................154

3.23 Operation selection function (Pr. 251) ........................................................... 155

3.23.1 Output phase failure protection selection (Pr. 251)........................................................................155

3.24 Additional function 2 (Pr. 252, Pr. 253) .......................................................... 156

3.24.1 Override bias, gain (Pr. 252, Pr. 253).............................................................................................156

3.25 Power failure stop functions (Pr. 261 to Pr. 266) ..........................................156

3.25.1 Power-failure deceleration stop function (Pr. 261 to Pr. 266).........................................................156

3.26 Droop (Pr. 286 to Pr. 288) ................................................................................158

3.26.1 Droop control (Pr. 286 to Pr. 288) ..................................................................................................158

3.27 Orientation (Pr. 350 to Pr. 362, Pr. 393 to Pr. 399) ........................................ 159

3.27.1 Orientation control (Pr. 350, Pr. 351, Pr. 356, Pr. 357, Pr. 360 to Pr. 362, Pr. 393,

Pr. 396 to Pr. 399).........................................................................................................................159

3.28 Control system function (Pr. 374) .................................................................. 166

3.28.1 Overspeed detection (Pr. 374) .......................................................................................................166

3.29 Position control (Pr. 419 to Pr. 430, Pr. 464 to Pr. 494) ................................167

3.29.1 Position control (Pr. 419 to Pr. 430, Pr. 464 to Pr. 494).................................................................167

3.30 Remote output (Pr. 495 to Pr.497) .................................................................. 168

3.30.1 Remote output function (Pr. 495 to Pr.497)....................................................................................168

3.31 Operation selection functions 4 (Pr. 800 to Pr. 809) .....................................169

3.31.1 Control selection (Pr. 800, Pr. 451)................................................................................................169

3.31.2 Torque characteristic selection (Pr. 801)........................................................................................169

3.31.3 Torque command source selection (Pr. 804 to Pr. 806).................................................................171

3.31.4 Speed limit (Pr. 807 to Pr. 809)......................................................................................................173

3.32 Control system functions (Pr. 818 to Pr. 837) ............................................... 175

3.32.1 Easy gain tuning selection (Pr. 818, Pr. 819).................................................................................175

3.32.2 Speed loop proportional gain setting (Pr. 820, Pr. 830) .................................................................175

3.32.3 Speed control integral time setting (Pr. 821, Pr. 831) ....................................................................175

3.32.4 Speed setting circuit filter function (Pr. 822, Pr. 832).....................................................................175

3.32.5 Speed detection filter function (Pr. 823, Pr. 833) ...........................................................................176

3.32.6 Current loop proportional gain setting for vector control (Pr. 824, Pr. 834)...................................176

3.32.7 Current control integral time setting for vector control (Pr. 825, Pr. 835)......................................176

3.32.8 Torque setting filter function (Pr. 826, Pr. 836) ..............................................................................176

3.32.9 Torque detection filter function (Pr. 827, Pr. 837) ..........................................................................177

3.32.10 Model speed control gain (Pr. 828) ................................................................................................177

CONTENTS

3.33 Torque biases (Pr. 840 to Pr. 848) .................................................................. 177

3.33.1 Torque bias function (Pr. 840 to Pr. 848) .......................................................................................177

3.34 Additional functions (Pr. 851 to Pr. 865) ........................................................ 180

3.34.1 Selection of number of encoder pulses (Pr. 851)...........................................................................180

3.34.2 Selection of encoder rotation direction (Pr. 852)............................................................................180

3.34.3 Excitation ratio (Pr. 854).................................................................................................................181

3.34.4 Notch filter (Pr. 862, Pr. 863)..........................................................................................................181

3.34.5 Torque detection (Pr. 864) .............................................................................................................182

3.34.6 Low speed detection (Pr. 865) .......................................................................................................182

3.35 Display function (Pr. 867) ................................................................................183

3.35.1 DA1 output response level adjustment (Pr. 867)............................................................................183

3.36 Terminal function assignment (Pr. 868)......................................................... 183

3.36.1 Terminal 1 function assignment (Pr. 868) ......................................................................................183

3.37 Protective functions (Pr. 870 to Pr. 874) ........................................................ 184

3.37.1 Speed deviation excessive (Pr. 870, Pr. 871) ................................................................................184

3.37.2 Speed limit (Pr. 873).......................................................................................................................185

3.37.3 Stop by OLT level prevention (Pr. 874)..........................................................................................185

3.38 Operation selection functions 5 (Pr. 875) ...................................................... 186

3.38.1 Fault definition (Pr. 875).................................................................................................................186

3.39 Control system function 2 (Pr. 877 to Pr. 881) .............................................. 186

3.39.1 Speed feed forward control, model adaptive speed control (Pr. 877 to Pr. 881)...........................186

3.40 Maintenance function (Pr. 890 to Pr. 892)...................................................... 187

3.40.1 Maintenance output function (Pr. 890 to Pr. 892)...........................................................................187

3.41 Calibration functions (Pr. 900 to Pr. 920)....................................................... 188

3.41.1 DA1/DA2 terminal calibration (Pr. 900, Pr. 901).............................................................................188

3.41.2 Biases and gains of speed setting terminals (speed setting terminal 2, torque command terminal 3, multi function terminal 1)

(Pr. 902 to Pr. 905, Pr. 917 to Pr. 920)...........................................................................................190

3.42 Additional function (Pr. 990) ........................................................................... 193

3.42.1 PU buzzer control (Pr. 990)............................................................................................................193

4 SPECIFICATIONS 195

4.1 Model specifications........................................................................................ 196

4.2 Common specifications .................................................................................. 199

4.3 Outline dimension drawings........................................................................... 200

4.3.1 Inverter outline dimension drawings...............................................................................................200

4.3.2 Control panel (FR-DU04-1) outline dimension drawings................................................................203

4.3.3 Parameter unit (FR-PU04V) outline dimension drawings...............................................................203

4.3.4 Dedicated encoder cable outline dimension drawings ...................................................................204

4.3.5 Dedicated motor outline dimension drawings.................................................................................206

APPENDICES 211

Appendix1 Setting a thermistor of a dedicated motor (SF-V5RU*****T)

(when used with the FR-V5AX).......................................................................... 212

Appendix2 Parameter Instruction Code List .............................................................213

Appendix3 SERIAL number check............................................................................ 220

WIRING

This chapter describes the basic "wiring" for use of this product. Always read the instructions and other information before using the equipment.

1.1 Internal block diagram ..........................................2

1.2 Main circuit terminal specifications ....................3

1.3 Connection of stand-alone option units..............4

1.4 Control circuit terminal specifications................8

1.5 Precautions for use of the vector inverter ..........11

1.6 Others.....................................................................12

1.7 Input terminals ......................................................26

1.8 How to use the input signals (assigned terminals

DI1 to DI4, STR) (Pr. 180 to Pr. 183, Pr. 187)...........

1.9 How to use the output signals (assigned terminals

DO1 to DO3, ABC) (Pr. 190 to Pr. 192, Pr. 195)........

1.10 Design information to be checked ......................37

1.11 Using the second motor .......................................38

1.12 Using the conventional motor and other motors .. 39

DU : Control panel (FR-DU04- PU : Control panel (FR-DU04- Inverter : Mitsubishi vector inverter FR-V500 series Pr. : Parameter number PU operation : Operation using the PU (FR-DU04- External operation : Operation using the control circuit signals Combined operation : Operation using both the PU (FR-DU04-

Mitsubishi dedicated motor : SF-V5R Mitsubishi standard motor with encoder : SF-JR Mitsubishi constant-torque motor : SF-HRCA

CC-Link is a registered trademark of CC-Link Partner Association. Ethernet is a registered trademark of XEROX corporation. DeviceNet is a registered trademark of ODVA (Open DeviceNet Vender Association, Inc.) Profibus is a registered trademark of PROFIBUS User Organization. Other company and product names herein are the trademarks or registerd trademarks of

their respective owners.

1) and parameter unit (FR-PU04V)

1/FR-PU04V)

1/FR-PU04V) and external

operation

111

Internal block diagram

1.1 Internal block diagram

Verify the power specification of the motor cooling fan when performing wiring.

Refer to page 196.

Avoid frequent ON-OFF. Repeated inrush current at power on will shorten the converter life. (switching life is about 100,000 times)

MCCB

FR-V500

R S T

Jumper

Control power supply

MCCB MC

Mitsubishi dedicated motor (SF-V5RU)

Jumper: Remove this jumper when connecting the FR-HEL/BEL.

Jumper: Remove this jumper when connecting the FR-ABR. (5.5K or less only)

* R

CHARGE

ASIC

OCR

U V W

FAN

CAUTION

Match the phase sequence. (The fan should have intake rotation.)

U V

Change the jumper connector and parameter according to the encoder specifications.

RS485

-1

DU04

Output speed setting potentiometer

Analog common

0 to 10VDC

10E

External transistor common

Forward rotation

Reverse rotation

Reset Multi-function input 4 Four different signals can be selected using the parameters.

STF

STR

RES

DI1

DI2

DI3

DI4

SINK

SOURCE

10V

CPU

Protective

circuit

ASIC

OPTION

24V5.5V12V EXT

OPTION

CMP

LDV

OPTION

PAR

PBR

PZR

DA1

DA2

Alarm output

Three different

DO1

signals can be selected using the

DO2

parameters.

DO3

(Open collector output)

Encoder

Analog signal output

Thermal protector

* *

CAUTION

1. The 18.5K or more is not equipped with the built-in brake resistor and brake transistor marked *. The brake transistor is provided for the 15K or less and the built-in brake resistor for the 5.5K or less.

2. Always earth (ground) the inverter and motor.

3. **: When using an external thermal relay protection, set "1" (external thermal relay valid) in Pr. 876. (factory setting) (Refer to page 80.)

Main circuit terminal specifications

1.2 Main circuit terminal specifications

Terminal Symbol Terminal Name Description

Connect to the commercial power supply.

R, S, T AC power input

U, V, W Inverter output Connect a three-phase squirrel-cage motor or Mitsubishi dedicated motor.

R1, S1

P, P R

P, N

P, P 1

PR, PX

Power supply for control circuit

Brake resistor connection

Brake unit connection

DC reactor connection

Built-in brake circuit connection

Keep these terminals open when using the high power factor converter (FRHC) or power regeneration common converter (FR-CV).

Connected to the AC power supply terminals R and S. To retain the alarm display and alarm output or when using the high power factor converter (FRHC) or power regeneration common converter (FR-CV), remove the jumpers from terminals R-R1 and S-S1 and apply external power to these terminals. Do not turn off the power supply for control circuit (R1, S1) with the main circuit power (R, S, T) on. Doing so may damage the inverter. The circuit should be configured so that the main circuit power (R, S, T) is also turned off when the power supply for control circuit (R1, S1) is off. 15K or less: 60VA, 18.5K to 55K: 80VA

Disconnect the jumper from terminals PR-PX (5.5K or less) and connect the optional brake resistor (FR-ABR) across terminals P-PR. For the 15K or less, connecting the resistor further provides regenerative braking power.

Connect the optional FR-BU type brake unit, BU type brake unit, power regeneration common converter (FR-CV) or high power factor converter (FR-HC).

Disconnect the jumper from terminals P-P1 and connect the optional DC reactor (FR-HEL/BEL).

When the jumper is connected across terminals PX-PR (factory setting), the built-in brake circuit is valid. (Provided for the 5.5K or less.)

Earth (Ground) For earthing (grounding) the inverter chassis. Must be earthed (grounded).

CAUTION

• The inverter will be damaged if power is applied to the inverter output terminals (U, V, W). Never

perform such wiring.

• When connecting the dedicated external brake resistor (FR-ABR), remove jumpers across terminals

PR-PX (5.5K or less).

• When connecting the brake unit (FR-BU, BU type), remove jumpers across terminals PR-PX (5.5K or

less). Refer to page 5, 6.

WIRING

Connection of stand-alone option units

1.3 Connection of stand-alone option units

The inverter accepts a variety of stand-alone option units as required. Incorrect connection will cause inverter damage or accident. Connect and operate the option unit carefully in

accordance with the corresponding option unit manual.

1.3.1 Connection of the dedicated external brake resistor (FR-ABR)

The built-in brake resistor is connected across terminals P and PR. Fit the external dedicated brake resistor (FRABR) when the built-in brake resistor does not have enough thermal capability for high-duty operation. At this time, remove the jumper from across terminals PR-PX and connect the dedicated brake resistor (FR-ABR) across terminals P-PR. Set "1" in Pr. 30 "regenerative function selection". Set Pr.70 "special regenerative brake duty" as follows: (Refer to page 92.)

7.5K or less. . . . . . .10%

11K or more . . . . . .6%

CAUTION

1. The brake resistor connected should only be the dedicated brake resistor.

2. The jumper across terminals PR-PX (5.5K or less) must be disconnected before connecting the dedicated brake resistor. A failure to do so may damage the inverter.

3. Do not remove a jumper across terminal P and P1 except when connecting a DC reactor.

z Model ..... FR-V520-1.5K, 2.2K, FR-V540-1.5K, 2.2K

1)Remove the screws in terminals PR and PX and remove the jumper.

2)Connect the brake resistor across terminals P and PR. (The jumper should remain disconnected.)

1) Removal of jumper 2) Connection of brake resistor

Terminal P

Terminal PR

Jumpe

Terminal PX

Terminal PR

z Model ..... FR-V520-3.7K to 7.5K, FR-V540-3.7K, 5.5K

1)Remove the screws in terminals PR and PX and remove the jumper.

2)Connect the brake resistor across terminals P and PR. (The jumper should remain disconnected.)

1) Removal of jumper 2) Connection of brake resistor

Terminal P

Terminal PR

Terminal PX

Jumper

Terminal PX

CAUTION

The FR-V520-7.5K does not have the PX terminal. Since it is a free terminal, keep it open.

Connection of stand-alone option units

z Model ..... FR-V520-11K to 15K, FR-V540-7.5K to 15K

1) Connect the brake resistor across terminals P and PR.

Power supply terminal block for control circuit

Dedicated brake resistor

(FR-ABR)

NPRST

1.3.2 Connection of the brake unit (FR-BU)

Connect the optional FR-BU brake unit as shown below to improve the braking capability during deceleration.

T *2

PPR

THS TH2

Resistor unit FR-BR

OFF

TH1

Power supply

Remove jumper.

Inverter

Motor

Brake unit FR-BU

HA HB

*1 Connect the inverter terminals (P, N) and brake unit (FR-BU (H)) terminals so that their terminal signals match with each other.

(Incorrect connection will damage the inverter.) *2 When the power supply is 400V class, install a step-down transformer. *3 Be sure to remove a jumper across terminal PR-PX when using the FR-BU with the inverter of 5.5K or less. *4 The wiring distance between the inverter, brake unit (FR-BU) and resistor unit (FR-BR) should be within 5m. If twisted wires

are used, the distance should be within 10m.

CAUTION

• If the transistors in the brake unit should become faulty, the resistor can be unusually hot, causing a fire. Therefore, install a magnetic contactor on the inverter's input side to configure a circuit so that a current is shut off in case of fault.

• Do not remove a jumper across terminal P and P1 except when connecting a DC reactor.

WIRING

Connection of stand-alone option units

1.3.3 Connection of the brake unit (BU type)

Connect the BU type brake unit correctly as shown on the right. Incorrect connection will

Power supply

MCCB

Inverter

Motor

damage the inverter. Remove the jumpers from terminals HB-PC and TB-HC and fit a jumper across terminals PC-TB of the brake unit.

Fit a jumper.

*1 Connect the inverter terminals (P, N) and brake unit (BU type) terminals so that their terminal signals match with each

other. (Incorrect connection will damage the inverter.) *2 When the power supply is 400V class, install a step-down transformer. *3 For capacity 5.5K or less, remove the jumper across terminals PR-PX.

T*2

OFF

Remove jumpers.

OCR

Remove jumpers.

BU type brake unit

HCHBHA TB P

Discharging resistor

OCR

CAUTION

• The wiring distance between the inverter, brake unit and resistor unit should be within 2m . If twisted wires are used, the distance should be within 5m.

• If the transistors in the brake unit should become faulty, the resistor can be unusually hot, causing a fire. Therefore, install a magnetic contactor on the inverter's power supply side to configure a circuit so that a current is shut off in case of fault.

• Do not remove a jumper across terminal P and P1 except when connecting a DC reactor.

1.3.4 Connection of the high power factor converter (FR-HC)

When connecting the high power factor converter (FR-HC) to suppress power supply harmonics, perform wiring securely as shown below. Incorrect connection will damage the high power factor converter and inverter. After making sure that the wiring is correct, set "2" in Pr. 30 "regenerative function selection".

High power factor converter (FR-HC)

Power supply

RST R4S4T4 N

MCCB

*1 Remove the jumpers across the inverter terminals R-R1, S-S1, and connect the control circuit power supply to the R1

and S1 terminals. Always keep the power input terminals R, S, T open. Incorrect connection will damage the inverter. (E.OPT (option alarm) will occur. (Refer to the Instruction Manual (basic).))

*2 Do not insert the MCCB between terminals P-N (P-P, N-N). Connect the inverter terminals (P, N) and high power factor converter

(FR-HC) terminals so that their terminal signals match with each other. (Incorrect connection will damage the inverter.)

*3 Use Pr. 180 to Pr. 183, Pr. 187 (input terminal function selection) to assign the terminals used for the X10 (X11) signal. (Refer to

page 150.) For communication where the start command is sent only once, e.g. when used with the computer link plug-in option (A5NR), use the X11 signal when making setting to hold the mode at occurrence of an instantaneous power failure. (Refer to page 92.)

MC1MC2

From FR-HCL02

R3 S3 T3

MC2

Outside box

MC1

FR-HCL01

Y1 or Y2 RDY RSO SE

CAUTION

• The voltage phases of terminals R, S, T and terminals R4, S4, T4 must be matched.

• Use sink logic (factory setting) when the FR-HC is connected. The FR-HC cannot be connected when source logic is selected.

• Do not remove a jumper across terminal P and P1 except when connecting a DC reactor.

Inverter

RES

X10 *3

X11 *3

Connection of stand-alone option units

1.3.5 Connection of the power regeneration common converter (FR-CV)

When connecting the FR-CV type power regeneration common converter, connect the inverter terminals (P, N) and FR-CV type power regeneration common converter terminals as shown below so that their symbols match with each other. After making sure that the wiring is correct, set "2" in Pr. 30 "regenerative function selection". Use the FR-CV with capacity one rank greater than the inverter.

Three-phase

C power

supply

R S

Dedicated stand-alone

MCCB

*1 Remove the jumpers across terminals R-R1 and S-S1 of the inverter, and connect the control circuit power supply across

terminals R1-S1. Always keep the power input terminals R, S, T open. Incorrect connection will damage the inverter. (E.OPT (option alarm) will occur. (Refer to the Instruction Manual (basic).))

*2 Do not insert an MCCB between the terminals P − N (between P/L+ − P, between N/L- − N). Connect the inverter terminals

(P, N) and power regeneration common converter (FR-CV) terminals so that their terminal signals match with each other. (Incorrect connection will damage the inverter.).

*3 Assign the terminal for X10 signal using any of Pr. 180 to Pr. 183. Pr.187 (input terminal function selection).

(Refer to page 150)

*4 Be sure to connect the power supply and terminals R/L11, S/L21, T/MC1.

Operating the inverter without connecting them will damage the power regeneration common converter.

reactor (FR-CVL)

R/L S/L T/L

R2/L

S2/L

T2/L

FR-CV power regeneration common converter

R2/L S2/L T2/L

R/L

S/L T/MC1

P/L+

N/L-

P24

RDYA

RDYB

RSO

X10 *3

RES

Inverter

CAUTION

1. The voltage phases of terminals R/L11, S/L21, T/MC1 and terminals R2/L1, S2/L2, T2/L3 must be

matched.

2. Use sink logic (factory setting) when the FR-CV is connected. The FR-CV cannot be connected when

source logic is selected.

3. Do not remove a jumper across terminal P and P1 except when connecting a DC reactor.

1.3.6 Connection of the DC reactor (FR-HEL/BEL)

When using the FR-HEL/BEL DC reactor, connect it between terminals P1-P. In this case, the jumper connected across terminals P1-P must be removed. Otherwise, the reactor will not exhibit its function.

FR-HEL/BEL

Remove the jumper.

CAUTION

1. The wiring distance should be within 5m.

2. The size of the cables used should be equal to or larger than that of the power supply cables (R, S, T).

WIRING

Control circuit terminal specifications

1.4 Control circuit terminal specifications

Type

Input signals

Terminal

Symbol

STF

STR

DI1 to DI4

Contact input

RES Reset

10E

Speed setting

Terminal Name Description Rated Specifications

Forward rotation start

Reverse rotation start

Digital input terminals 1 to 4

Thermal relay protector input

Contact input common (sink)

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

Speed setting power supply

Speed setting (voltage)

Torque setting terminal

Multi-function setting terminal

Speed setting common, Analog signal output 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. The function of the terminals changes according to the output terminal function selection (Pr. 187). Refer to page 150 for details.

The function of the terminals changes according to the output terminal function selection (Pr. 180 to Pr. 183). Refer to page 150 for details.

Temperature sensor terminal input for motor overheat protection. OHT error occurs when terminals OH and SD are open.

Used to reset alarm output provided when protective circuit is activated. Turn on the RES signal for more than

0.1s, then turn it off. Recover about 1s after reset is cancelled.

Contact input common terminal. Common output terminal for 24VDC 0.1A power supply (PC terminal). Isolated from terminals 5 and SE.

When connecting a transistor output (open collector output) such as a programmable controller, connect the external power supply common for transistor output to this terminal to prevent a malfunction caused by a sneak current. PC-SD can be used as a 24VDC and 0.1A power supply. Note that a sneak current may not be prevented in this case. When source logic has been selected, this terminal serves as a contact input common.

Used as power supply when connecting volume for speed setting (torque setting) from outside of the inverter. (terminal 5 is a common terminal)

By entering 0 to 10VDC, the maximum output speed is reached at 10V and I/O are proportional.

Acts as a torque setting signal for torque control or as a torque limit signal for speed control or position control. Acts as an input terminal for the external analog-based torque bias function. 0 to ±10VDC input

Since this is a multi-function selection terminal, its function varies with the Pr.868 "terminal 1 function assignment" setting. Refer to page 183 for details. 0 to ±10VDC input

Common terminal for speed setting signal (terminal 2, 1 or 3) or DA1 and DA2. Isolated from terminals SD and SE. Do not earth (ground).

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

Input resistance 4.7kΩ Voltage at opening 21 to 27VDC Current at short-circuited 4 to 6mADC Control by open collector output or 0V contact signal

Input resistance 150kΩ Voltage at opening 21 to 27VDC Current at short-circuited 140 to 180mADC Isolate by photocoupler

Input resistance 4.7kΩ Voltage at opening 21 to 27VDC Current at short-circuited 4 to 6mADC Control by open collector output or 0V contact signal.

—

Voltage range 18 to 26 VDC Permissible load current

0.1A

10VDC±0.4V Permissible load current 10mA

Input resistance 10kΩ±1kΩ Permissible maximum voltage 20VDC

—

Control circuit terminal specifications

Type

Input signals

Output signals

Communication

Terminal

Symbol

PAR

PBR

Encoder signal

PZR

A, B, C Alarm output

Contact

DO1 to DO3

Open

collector

DA1, DA2

Analog

— PU connector

RS-485

Terminal Name Description Rated Specifications

A-phase signal input terminal

A-phase inverted signal input terminal

B-phase signal input terminal

B-phase inverted signal input terminal

Z-phase signal input terminal

Z-phase inverted signal input terminal

Encoder power supply terminal (Positive side)

Contact input common (sink), Power supply earth (ground) terminal

Digital output terminals 1 to 3

Open collector output common

Analog signal output

Analog signal output common

* Not output during inverter reset.

Differential line receiver input (AM26LS32 equivalent) or complimentary input

Differential line receiver input (AM26LS32 equivalent)

A-, B- and Z-phase signals are input from the encoder. The jumper connector is factory-set to complimentary. Thus, the encoder need not be connected to PAR, PBR and PZR.

Power supply for encoder. You can switch the power supply between 5 (5.5), 12 and 24VDC. Can be switched to the external power supply.

( Refer to the instruction manual (basic) for the switchover method.)

Common terminal for contact input or encoder power supply. Isolated from terminals 5 and SE. Do not earth (ground).

1 changeover contact output indicating that the output has been stopped by the inverter protective function. 230VAC 0.3A, 30VDC 0.3A. Alarm: discontinuity across B-C (continuity across A-C), normal: continuity across B-C (discontinuity across A-C). The terminal function varies with the output terminal function selection (Pr. 195) setting. Refer to page 152 for details.

The terminal functions vary with the output terminal function selection (Pr. 190 to Pr. 192) settings. Refer to page 152 for details.

Common terminal for terminals DO1, DO2 and DO3. Isolated from terminals SD and 5.

One selected from monitoring items, such as the speed, is output.

The output signal is proportional to the magnitude of the corresponding monitoring item.

Common terminal for DA1 and DA2. Isolated from terminals SD and SE. Do not earth (ground).

With the PU connector, communication can be made through RS-485.

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

• Transmission format : Multidrop link

• Communication speed : Maximum. 19200bps

• Overall length : 500m

Differential line receiver input (AM26LS32 equivalent) or complimentary input

Differential line receiver input (AM26LS32 equivalent)

Differential line receiver input (AM26LS32 equivalent) or complimentary input

Differential line receiver input (AM26LS32 equivalent)

5.5VDC 350mA 12VDC 150mA 24VDC 80mA

Power supply common

Contact output Permissible contact 230VAC 0.3A 30VDC 0.3A

Open collector output Permissible load 24VDC

0.1A

—

0 to ±10VDC (DA1), 0 to 10VDC (DA2), Permissible load current 1mA Resolution 12 bit load impedance 10kΩ or more

WIRING

Control circuit terminal specifications

1.4.1 Connecting the control circuit to a power supply separately from the main circuit

If the magnetic contactor (MC) in the inverter power supply is opened when the protective circuit is operated, the inverter control circuit power is lost and the alarm output signal cannot be kept on. To keep the alarm signal on terminals R1 and S1 are available. In this case, connect the power supply terminals R1 and S1 of the control circuit to the primary side of the MC.

• Model FR-V520-1.5K, 2.2K, FR-V540-1.5K, 2.2K <Connection procedure>

Terminal block for main circuit

1) Loosen the upper screws

2) Remove the lower screws.

3) Remove the jumpers.

4) Connect the separate power supply cables for control circuit to the lower terminals (R1, S1). (Note 4)

• Model FR-V520-3.7K to 55K, FR-V540-3.7K to 55K <Connection procedure>

Power supply terminal block for control circuit

RST

Main power supply

CAUTION

1. When the main circuit power (R, S, T) is on, do not switch off the control power (terminals R1, S1).

Otherwise the inverter may be damaged.

2. When using a separate power supply, the jumpers across R-R1 and S-S1 must be removed. Otherwise

the inverter may be damaged.

3. For a different power supply system, which takes the power of the control circuit from other than the

primary side of the MC, the voltage should be equal to the main circuit voltage.

4. For the FR-V520-3.7K to 55K, FR-V540-3.7K to 55K, the power supply cables must not be connected

to the lower terminals. If connected, the inverter may be damaged.

5. Supplying power to only the R1 and S1 terminals and entering the start signal will result in an error

indication (E.OC1).

Power supply terminal block for control circuit

1) Loosen the upper screws.

2) Remove the lower screws.

3) Pull out and remove the jumper.

4) Connect the separate power supply cables for control circuit to the upper terminals (R1, S1). (Note 4)

Precautions for use of the vector inverter

1.5 Precautions for use of the vector inverter

The FR-V500 series is a highly reliable product, but incorrect peripheral circuit making or operation/handling method may shorten the product life or damage the product. Before starting operation, always recheck the following items. (1) Use insulation-sleeved crimping terminals for the power supply and motor cables. (2) The inverter will be damaged if power is applied to the inverter output terminals (U, V, W). (3) After wiring, wire offcuts must not be left in the inverter.

Wire offcuts can cause an alarm, fault or malfunction. Always keep the inverter clean. When drilling mounting holes in an enclosure etc., take care not to allow chips and other foreign matter to enter the inverter.

(4) Wire the cables of the recommended size to make a voltage drop 2% or less.

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 high frequency.

Refer to Instruction Manual (basic) for the recommended wire sizes.

(5) The overall wiring length should be 100m maximum.

Especially for long distance wiring, the fast response current limit function may be reduced or the equipment connected to the secondary side may malfunction or become faulty under the influence of a charging current due to the stray capacity of the wiring. Therefore, note the overall wiring length.

(6) Electromagnetic wave interference

The input/output (main circuit) of the inverter includes high frequency 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 on the input side only) or FR-BSF01 or FR-BLF line noise filter to minimize interference.

(7) Do not install a power factor correction capacitor, surge suppressor or radio noise filter (FR-BIF option) on 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 is installed, immediately remove it. (When the FR-BIF radio noise filter is connected, switching power off during motor operation may result in E. UVT. In this case, connect the radio noise filter in the primary side of the magnetic contactor.)

(8) Before starting wiring or other work after the inverter is operated, wait for at least 10 minutes after the power

supply has been switched off, and check that there are no residual voltage using a tester or the like. The capacitor is charged with high voltage for some time after power off and it is dangerous.

(9) A short circuit or earth (ground) fault in the inverter output side may damage the inverter modules.

• Fully check the insulation resistance of the circuit prior to inverter operation since repeated short circuits caused by peripheral circuit inadequacy or an earth (ground) fault caused by wiring inadequacy or reduced motor insulation resistance may damage the inverter modules.

• Fully check the to-earth (ground) insulation and inter-phase insulation of the inverter secondary side before power on. Especially for an old motor or use in hostile atmosphere, securely check the motor insulation resistance etc.

(10) Do not use the inverter power supply side magnetic contactor to start/stop the inverter.

Always use the start signal (turn on/off terminals STF, STR-SD) to start/stop the inverter. (Refer to page 14.)

(11) Across the P and PR terminals, connect only an external regenerative brake discharge resistor.

Do not connect a mechanical brake.

(12) Do not apply a voltage higher than the permissible voltage to the inverter I/O signal circuits.

Application of a voltage higher than the permissible voltage to the inverter I/O signal circuits or opposite polarity may damage the I/O devices. Especially check the wiring to prevent the speed setting potentiometer from being connected incorrectly to short terminals 10E-5.

(13) Use of single-phase power supply

Do not use single-phase power input.

(14) Precautions for use of any motor other than the vector control dedicated motor (SF-V5RU, SF-VR) and

standard motor with encoder (SF-JR) a)Vector control cannot be exercised without encoder. b)Connect the encoder to the backlash-free motor shaft.

(15) Since the rated voltage differs from the commercial power supply voltage, the Mitsubishi dedicated motor

cannot perform bypass operation.

SF-V5RU

SF-V5RUH

z Capacity (VA) of separate power supply

The capacity is 60VA or more for 15kW or less and 80VA for 18.5kW to 55kW when separate power is supplied from R1, S1.

3.7kW or less 170V

5.5kW or more 160V

3.7kW or less 340V

5.5kW or more 320V

WIRING

Others

1.6 Others

1.6.1 Leakage currents and countermeasures

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

(1) To-earth (ground) leakage currents

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

z Countermeasures

• When the carrier frequency setting is high, decrease the carrier frequency (Pr. 72) of the inverter. Note that motor noise increases. Selection of Soft-PWM (Pr. 240) will make it unoffending.

• By using earth (ground) leakage circuit breakers designed for harmonic and surge suppression 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 capacitances between the inverter output cables may operate the external thermal relay unnecessarily. When the wiring length is long (50m or more) for the 400V class smallcapacity model (7.5kW or less), the external thermal relay is likely to operate unnecessarily because the ratio of the leakage current to the rated motor current increases.

z Line-to-line leakage current data example (200V class)

Motor Capacity

(kW)

1.5 9.0 370 560

2.2 13.0 400 590

Rated Motor

Current(A)

Wiring length 50m Wiring length100m

Leakage Current (mA)

• Motor SF-V5RU 4P

• Carrier frequency: 13.5KHz

• Cable :2mm

• Cab tyre cable

4-core

*The leakage currents of the 400V class are about twice larger.

Power supply

MCCB

Inverter

Line-to-Line Leakage Current Path

Thermal relay

Line static capacitances

Motor

z Measures

• Use the electronic thermal relay function (Pr. 9) of the inverter.

• Decrease the carrier frequency. Note that motor noise increases. Selection of Soft-PWM (Pr. 240) will make it

unoffending. For other than the dedicated motor (SF-V5RU), using a temperature sensor to directly detect the motor temperature is recommended to ensure that the motor is protected against line-to-line leakage currents.

z Installation and selection of moulded case circuit breaker

Install a moulded case circuit breaker (MCCB) on the power receiving side to protect the wiring of the inverter primary side. Select the MCCB according to the power supply side power factor (which depends on the power supply voltage, output frequency and load). Especially for a completely electromagnetic MCCB, one of a slightly large capacity must be selected since its operation characteristic varies with harmonic currents. (Check it in the data of the corresponding breaker.) As an earth (ground) leakage breaker, use the Mitsubishi earth (ground) leakage breaker designed for harmonics and surges.

Others

(3) Selection of rated sensitivity current of earth (ground) leakage breaker

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

• Breaker designed for harmonic and surge Rated sensitivity current IΔn ≥10

× (Ig1 + lgn + Ig2 + Igm)

• Standard breaker Rated sensitivity current IΔn ≥10 × {Ig1 + Ign + 3 × (Ig2 + Igm)} Ig1, Ig2: Leakage currents of cable path during commercial power supply operation Ign *: Leakage current of noise filter on

inverter input side

Igm: Leakage current of motor during

commercial power supply operation

Leakage Current Example of Cable Path per 1km during Commercial Power Supply Operation When CV Cable Is Routed in Metal Conduit (200V 60Hz)

120

100

Leakage current (mA)

23.5

8142230386080

5.5

Cable size (mm

150

100

) Motor capacity (kW)

Leakage Current Example of three-Phase Induction Motor during Commercial Power Supply Operation (200V 60Hz)

2.0

1.0

0.7

0.5

0.3

0.2

Leakage current (mA)

0.1

1.5 3.7

7.5 152211373055

2.2

5.5 18.5

2mm

Noise filter

Inverter

Ig1 Ign Ig2 Igm

2mm

70m

200V1.5kW

CAUTION

• Install the NV on the primary (power supply) side of the inverter.

• In the connection neutral point earthing (grounding) system, the sensitivity current is purified against an earth (ground) fault in the inverter secondary side. Earthing (Grounding) must conform to the requirements of national and local safety regulations and electrical codes. (NEC section 250, IEC 536 class 1 and other applicable standards)

• When the breaker is installed on the secondary side of the inverter, it may be unnecessarily operated by harmonics even if the effective value is less than the rating. In this case, do not install the breaker since the eddy current and hysteresis loss will increase, leading to temperature rise.

• The following models are standard breakers:

BV-C1, BC-V, NVB, NV-L, NV-G2N, NV-G3NA, and NV-2F type leakage current relays (except for NVZHA), NV with AA neutral wire open phase protection

The following models are breakers for harmonic and surge suppression:

NV-C/NV-S/MN series, NV30-FA, NV50-FA, BV-C2, leakage current alarm breaker (NF-Z), NV-ZHA, NV-H

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

Breaker Designed for Harmonic and

Surge

Leakage current Ig1 (mA) 20 ×

1000m

Leakage current Ign (mA) 0 (without noise filter)

Leakage current Ig2 (mA) 20 ×

Motor leakage current Igm

(mA)

70m

1000m

0.14

Total leakage current (mA) 1.66 4.78

Rated sensitivity current

(mA)

( ≥Ig × 10)

30 100

Standard Breaker

= 0.10

= 1.40

WIRING

Others

1.6.2 Power off and magnetic contactor (MC)

(1) Inverter primary side magnetic contactor (MC)

On the inverter primary side, it is recommended to provide an MC for the following purposes.

( Refer to the Instruction Manual (basic) 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) When cycle operation or heavy-duty operation is performed with an optional brake resistor connected, overheat and burnout of the discharging resistor can be prevented if a regenerative brake transistor is damaged due to insufficient heat capacity of the discharging resistor and excess regenerative brake duty.

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 Since the MC on the inverter input side is used for the above purposes, they correspond to the standard duties. Therefore, when making an emergency stop during running, select a JEM1038 class AC3 MC for the inverter input side currents.

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.

z Inverter start/stop circuit example

As shown on the right, always use the start signal (turn on/off terminals STF, STR-SD) to start/stop the inverter. (Refer to page 26.)

Power supply

Operation ready

OFF

Start/Stop

Operation

OFF

MCCB

Inverter

To moto

STF(STR) SD

REMARKS

*1. When the power supply is 400V class, install a step-down transformer. *2. Connect the power supply terminals R1, S1 to the primary side of the MC to hold an alarm signal when the inverter's

protective circuit is activated. At this time, remove jumpers across terminals R-R1 and S-S1. (Refer to page 10 for removal of jumpers)

(2) Handling of secondary 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.

Others

1.6.3 Installation of reactor

When the inverter is connected near a large-capacity power transformer (1000kVA or more and wiring length 10m max.) or when a power capacitor is to be switched over, an excessive peak current may flow in the power input circuit, damaging the converter circuit. To prevent this, always install the DC reactor or AC reactor (FR-HEL/BEL or FR-HAL/BAL).

Power supply

MCCB

AC reactor

(FR-HAL/BAL)

Inverter

(FR-HEL/BEL) *

DC reactor

1500

1000

Power supply

equipment capacity

(kVA)

Reactor

installation

range

Wiring length (m)

REMARKS

* When connecting the FR-HEL/BEL, remove the jumper across terminals P-P1.

The wiring length between the FR-HEL/BEL and inverter should be 5m maximum and minimized. Use the same wire size as that of the power supply wire (R, S, T). ( Refer to the Instruction Manual (basic).)

WIRING

Others

1.6.4 Notes on earthing (grounding)

z Use the dedicated earth (ground) terminal to earth (ground) the inverter. (Do not use the screw in the case,

chassis, etc.) Use a tinned crimping terminal which does not contain zinc to connect the earth (ground) cable. Tighten the screw, taking care not to break its threads.

z Use the largest possible gauge for the earth (ground) cable. The gauge should be equal to or larger than those

indicated in the following table. The earthing (grounding) point should be as near as possible to the inverter to minimize the earth (ground) cable length.

(Unit: mm

Motor Capacity

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

3.7kW 3.5 (4) 2 (2.5)

5.5kW, 7.5kW 5.5 (6) 3.5 (4) 11kW, 15kW 14 (16) 8 (10)

18.5kW to 37kW 22 (25) 14 (16) 45kW, 55kW 38 (35) 22 (25)

Earth (Ground) Cable Gauge

200V 400V

For use as a Low Voltage Directive-compliant product, use the PVC cables indicated in the parentheses for earthing (grounding).

z Earth (Ground) the motor on the inverter side using one wire of the 4-core cable. z Always earth (ground) the motor and inverter.

(1)Purpose of earthing (grounding)

Generally, an electrical apparatus has an earth (ground) terminal, which must be connected to the ground before use. An electrical circuit is usually insulated by an insulating material and encased. However, it is impossible to manufacture an insulating material that can shut off a leakage current completely, and actually, a slight current flow into the case. The purpose of earthing (grounding) the case of an electrical apparatus is to prevent operator from getting an electric shock from this leakage current when touching it. To avoid the influence of external noises, this earthing (grounding) is important to audio equipment, sensors, computers and other apparatuses that handle low-level signals or operate very fast.

(2)Earthing (Grounding) methods and earthing (grounding) work

As described previously, earthing (grounding) is roughly classified into an electrical shock prevention type and a noise-affected malfunction prevention type. Therefore, these two types should be discriminated clearly, and the following work must be done to prevent the leakage current having the inverter's high frequency components from entering the malfunction prevention type earthing (grounding): (a) Where possible, use independent earthing (grounding) for the inverter.

If independent earthing (grounding) (I) is impossible, use joint earthing (grounding) (II) where the inverter is connected with the other equipment at an earthing (grounding) point. Joint earthing (grounding) as in (III) must be avoided as the inverter is connected with the other equipment by a common earth (ground) cable. Also a leakage current including many high frequency components flows in the earth (ground) cables of the inverter and inverter-driven motor. Therefore, they must use the independent earthing (grounding) method and be separated from the earthing (grounding) of equipment sensitive to the aforementioned noises. In a tall building, it will be a good policy to use the noise malfunction prevention type earthing (grounding) with steel frames and carry out electric shock prevention type earthing (grounding) in the independent earthing (grounding) method.

(b) Earthing (Grounding) must conform to the requirements of national and local safety regulations and

electrical codes. (NEC section 250, IEC 536 class 1 and other applicable standards).

indicated in the above table.

(d) The earthing (grounding) point should be as near as possible to the inverter to minimize the earth (ground)

cable length.

(e) Run the earth (ground) cable as far away as possible from the I/O wiring of equipment sensitive to noises

and run them in parallel in the minimum distance.

(f) Use one wire in a 4-core cable with the earth (ground) terminal of the motor and earth (ground) it on the

inverter side.

)

Inverter

(I) Independent earthing (grounding) ... Best

Other equipment

200V class class D earthing (grounding)

400V class class C earthing (grounding)

Inverter

(II) Joint

Other equipment

200V class class D earthing (grounding)

400V class class C earthing (grounding)

earthing (grounding)

... Good

Inverter

(III) Joint earthing (grounding) ... Not allowed

Other equipment

200V class class D earthing (grounding)

400V class class C earthing (grounding)

Others

1.6.5 Inverter-generated noises and their reduction techniques

Some noises enter the inverter to malfunction it and others are radiated by the inverter to malfunction peripheral devices. Though the inverter is designed to be insusceptible to noises, it handles low-level signals, so it requires the following basic techniques. Also, since the inverter chops outputs at high carrier frequency, that could generate noises. If these noises cause peripheral devices to malfunction, measures should be taken to suppress noises. These techniques differ slightly depending on noise propagation paths.

1) Basic techniques

• 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 pair shielded cables for the detector connection and control signal cables, and connect the sheathes of the shield cables to terminal SD.

• Earth (Ground) the inverter, motor, etc. at one point.

2) Techniques to reduce noises that enter and malfunction the inverter When devices that generate many noises (which use magnetic contactors, magnetic brakes, many relays, for example) are installed near the inverter and the inverter may be malfunctioned by noises, the following measures must be taken:

•Provide surge suppressors for devices that generate many noises to suppress noises.

•Fit data line filters (page 18) to signal cables.

•Earth (Ground) the shields of the detector connection and control signal cables with cable clamp metal.

3) Techniques to reduce noises that are radiated by the inverter to malfunction peripheral devices Inverter-generated noises are largely classified into those radiated by the cables connected to the inverter and inverter main circuits (I/O), those electromagnetically and electrostatically induced to the signal cables of the peripheral devices close to the main circuit power supply, and those transmitted through the power supply cables.

Invertergenerated noise

Air-propagated

noises

Magnetic

induction noises

Static induction

noises

Cable-propagated noises

Noises directly radiated by inverter

Noises radiated by power cables

Noises radiated by motor cables

Path 4, 5

Path 6

Noises propagated through power cables

Noise from earth (Ground) cable due to leakage current

Path 1

Path 2

Path 3

Path 7

Path 8

Instrument

Receiver

Motor

Inverter

Telephone

Sensor power supply

Sensor

• By decreasing the carrier frequency, the mains terminal interface voltage* can be reduced. When motor noise does not pose a problem, set the carrier frequency to a low value using Pr. 72. (*Mains terminal interface voltage represents the magnitude of noise propagated from the inverter to the power supply side.)

• Using shield cables as signal cables, induction noise can be reduced greatly (to 1/10 - 1/100). Induction noise can also be reduced by separating the signal cables from the inverter output cables. (Separation of 30cm reduces noise to 1/2-1/3.) By fitting the FR-BSF01 or BLF on the inverter output side, induction noise to the signal cables can be reduced.

WIRING

Others

Noise Propagation

Path

1), 2), 3)

4), 5), 6)

z Data line filters

Measures

When devices that handle low-level signals and are liable to malfunction due to noises, e.g. instruments, receivers and sensors, are contained in the enclosure that contains the inverter or when their signal cables are run near the inverter, the devices may be malfunctioned by air-propagated noises. The following measures must be taken: (1) Install easily affected devices as far away as possible from the inverter. (2) Run easily affected signal cables as far away as possible from the inverter and its I/O cables. (3) Do not run the signal cables and power cables (inverter I/O cables) in parallel with each other and

do not bundle them. (4) Insert line noise filters into I/O and radio noise filters into input to suppress cable-radiated noises. (5) Use shielded cables as signal cables and power cables and run them in individual metal conduits

to produce further effects. When the signal cables are run in parallel with or bundled with the power cables, magnetic and static

induction noises may be propagated to the signal cables to malfunction the devices and the following measures must be taken: (1) Install easily affected devices as far away as possible from the inverter. (2) Run easily affected signal cables as far away as possible from the I/O cables of the inverter. (3) Do not run the signal cables and power cables (inverter I/O cables) in parallel with each other and

do not bundle them. (4) Use shielded cables as signal cables and power cables and run them in individual metal conduits

to produce further effects. When the power supplies of the peripheral devices are connected to the power supply of the inverter in

the same line, inverter-generated noises may flow back through the power supply cables to malfunction the devices and the following measures must be taken: (1) Install the radio noise filter (FR-BIF) to the power cables (input cables) of the inverter. (2) Install the line noise filter (FR-BLF, FR-BSF01) to the power cables (I/O cables) of the inverter.

When a closed loop circuit is formed by connecting the peripheral device wiring to the inverter, leakage currents may flow through the earth (ground) cable of the inverter to malfunction the device. In such a case, disconnection of the earth (ground) cable of the device may cause the device to operate properly.

Noise entry can be prevented by providing a data line filter for the detector cable etc.

z Example of noise reduction techniques

Install filter (FR-BLF, FR-BSF01) on inverter input side.

Inverter power supply

Install FR-BIF filter on inverter input side.

Separate inverter and power line by more than 30cm (at least 10cm) from sensor circuit.

Control power supply

Do not earth (ground) control box directly.

Do not earth (ground) control cable.

Control box

FR-

BLF

FRBIF

Power supply for sensor

Reduce carrier frequency.

FR-

Inverter

BLF

Do not earth (ground) shield but connect it to common cable of signal.

Use twisted pair shield cable.

Install filter (FR-BLF, FR-BSF01) on inverter output side.

Use 4-core cable as motor power cable and use one wire as earth (ground) wire.

Sensor

Motor

Others

1.6.6 Power supply harmonics

Power supply harmonics may be generated from the converter section of the inverter, affecting the power supply equipment, power capacitors, etc. Power supply harmonics are different in generation source, frequency and transmission path from radio frequency (RF) noise and leakage currents. Take the following measures.

z The differences between harmonics and RF noises are indicated below:

Item Harmonics RF Noise

Frequency Normally 40 to 50th degrees (3kHz or less) High frequency (several 10kHz to 1GHz order)

Environment To wire paths, power impedance Across spaces, distance, laying paths

Quantitative understanding Logical computation is possible

Generated amount

Immunity of affected device Specified in standards for each device. Differs according to maker's device specifications.

Examples of safeguard Install a reactor. Increase the distance.

Approximately proportional to load capacity

z Safeguard

The harmonic current generated from the inverter to the power supply differs according to various conditions such as the wiring impedance, whether a reactor is used or not, and output frequency and output current on the load side.

MCCB

For the output frequency and output current, the adequate method is to obtain them under rated load at the maximum operating frequency.

Occurs randomly, quantitative understanding is difficult.

According to current fluctuation rate (larger with faster switching)

DC reactor

Inverter

Motor

AC reactor

Do not insert power factor improving capacitor.

CAUTION The power factor improving capacitor and surge suppressor on the inverter output side may be overheated or damaged by the high frequency 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 reactor on the inverter's primary side or in the DC circuit.

WIRING

Others

1.6.7 Harmonic suppression guidelines

Harmonic currents flow from the inverter to a power receiving point via a power transformer. The harmonic suppression guidelines were established to protect other consumers from these outgoing harmonic currents. The three-phase 200V input specifications 3.7kW or less are previously covered by "Harmonic suppression guideline for household appliances and general-purpose products" and other models are covered by "Harmonic suppression guideline for consumers who receive high voltage or special high voltage". However, the generalpurpose inverter has been excluded from the target products covered by "Harmonic suppression guideline for household appliances and general-purpose products" in January 2004. Later, this guideline was repealed on September 6, 2004. All capacities of all models are now target products of "Harmonic suppression guideline for consumers who receive high voltage or special high voltage" (hereinafter referred to as "guideline for specific consumers").

"Guideline for specific consumers"

This guideline sets forth the maximum values of harmonic currents outgoing from a high-voltage or especially 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 Over 23rd

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

(1) Application of the guideline for specific consumers

New installation/addition/ renewal of equipment

Calculation of equivalent capacity sum

Not more than reference capacity

Over reference capacity

Sum of equivalent capacities

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.

Over maximum value

Harmonic suppression technique is not required.

Table 2 Conversion Factors for FR-V500 Series

Class Circuit Type Conversion Factor Ki

Without reactor K31 = 3.4

Three-phase bridge (Capacitor-smoothed)

With reactor (AC side) K32 = 1.8 With reactor (DC side) K33 = 1.8 With reactors (AC, DC sides) K34 = 1.4

Self-excitation three-phase bridge

When high power factor converter is used K5 = 0

Table 3 Equivalent Capacity Limits

Received Power Voltage Reference Capacity

6.6kV 50kVA

22/33kV 300kVA

66kV or more 2000kVA

Others

Table 4 Harmonic Content (Values of the fundamental current is 100%.)

Reactor 5th 7th 11th 13th 17th 19th 23rd 25th

Not used 65 41 8.5 7.7 4.3 3.1 2.6 1.8 Used (AC side) 38 14.5 7.4 3.4 3.2 1.9 1.7 1.3 Used (DC side) 30 13 8.4 5.0 4.7 3.2 3.0 2.2 Used (AC, DC sides) 28 9.1 7.2 4.1 3.2 2.4 1.6 1.4

1) Calculation of equivalent capacity P0 of harmonic generating equipment The "equivalent capacity" is the capacity of a 6-pulse converter converted from the capacity of consumer's harmonic generating equipment and is calculated with the following equation. If the sum of equivalent capacities is higher than the limit in Table 3, harmonics must be calculated with the following procedure:

P0 = Σ Ki × Pi [kVA] Ki : Conversion factor (refer to Table 2) Pi : Rated capacity of harmonic generating

equipment* [kVA]

i : Number indicating the conversion circuit type

* Rated capacity: Determined by the capacity of the applied

motor and found in Table 5. It should be noted that the rated capacity used here is used to calculate generated harmonic amount and is different from the power supply capacity required for actual inverter drive.

2) Calculation of outgoing harmonic current Outgoing harmonic current = fundamental wave current (value converted from received power voltage)

× operation ratio × harmonic content

• Operation ratio: Operation ratio = actual load factor × operation time ratio during 30 minutes

• Harmonic contents: Found in Table 4

Table 5 Rated Capacities and Outgoing Harmonic Currents for Inverter Drive

Rated Current

Applied

Motor

1.5 5.50 2.75 167 1.95 108.6 68.47 14.20 12.86 7.181 5.177 4.342 3.006

2.2 7.93 3.96 240 2.81 156.0 98.40 20.40 18.48 10.32 7.440 6.240 4.320

3.7 13.0 6.50 394 4.61 257.1 161.5 33.49 30.34 16.94 12.21 10.24 7.092

5.5 19.1 9.55 579 6.77 376.1 237.4 49.22 44.58 24.90 17.95 15.05 10.42

7.5 25.6 12.8 776 9.07 504.4 318.2 65.96 59.75 33.37 24.06 20.18 13.97 11 36.9 18.5 1121 13.1 728.7 459.6 95.29 86.32 48.20 34.75 29.15 20.18 15 49.8 24.9 1509 17.6 980.9 618.7 128.3 116.2 64.89 46.78 39.24 27.16

18.5 61.4 30.7 1860 21.8 1209 762.6 158.1 143.2 79.98 57.66 48.36 33.48 22 73.1 36.6 2220 25.9 1443 910.2 188.7 170.9 95.46 68.82 57.72 39.96 30 98.0 49.0 2970 34.7 1931 1218 252.5 228.7 127.7 92.07 77.22 53.46 37 121 60.4 3660 42.8 2379 1501 311.1 281.8 157.4 113.5 95.16 65.88 45 147 73.5 4450 52.1 2893 1825 378.3 342.7 191.4 138.0 115.7 80.10 55 180 89.9 5450 63.7 3543 2235 463.3 419.7 234.4 169.0 141.7 98.10

[A]

200V 400V 5th 7th 11th 13th 17th 19th 23rd 25th

Fundamen

tal Wave

Current

Converted

from 6.6kV

(mA)

Rated

Capacity

(kVA)

Outgoing Harmonic Current Converted from 6.6kV (mA)

(No reactor, 100% operation ratio)

3) Harmonic suppression technique requirement If the outgoing harmonic current is higher than the maximum value per 1kW contract power × contract power, a harmonic suppression technique is required.

WIRING

+ 202 hidden pages

Mitsubishi Electronics FR-V520-1.5K, FR-V540-1.5K User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

This section is specifically about safety matters

CONTENTS

WIRING

1.1 Internal block diagram

1.2 Main circuit terminal specifications

1.3 Connection of stand-alone option units

1.3.1 Connection of the dedicated external brake resistor (FR-ABR)

1.3.2 Connection of the brake unit (FR-BU)

1.3.3 Connection of the brake unit (BU type)

1.3.4 Connection of the high power factor converter (FR-HC)

1.3.5 Connection of the power regeneration common converter (FR-CV)

1.3.6 Connection of the DC reactor (FR-HEL/BEL)

1.4 Control circuit terminal specifications

1.4.1 Connecting the control circuit to a power supply separately from the main circuit

1.5 Precautions for use of the vector inverter

1.6 Others

1.6.1 Leakage currents and countermeasures

1.6.2 Power off and magnetic contactor (MC)

1.6.3 Installation of reactor

1.6.4 Notes on earthing (grounding)

1.6.5 Inverter-generated noises and their reduction techniques

1.6.6 Power supply harmonics

1.6.7 Harmonic suppression guidelines