Mitsumi electronic H55K, FR-CVL-H7.5K, FR-CV-H7.5K, FR-CVL-7.5K, FR-CV-7.5K User Manual

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Page 1

TRANSISTORIZED INVERTER

FR-CV

INSTRUCTION MANUAL

POWER REGENERATION

COMMON CONVERTER

FR-CV-7.5K to 30K(-AT) FR-CV-37K, 55K FR-CV-H7.5K to H30K(-AT) FR-CV-H37K, H55K FR-CVL-7.5K to 55K FR-CVL-H7.5K to H55K

OUTLINE

INSTALLATION

AND WIRING

PROTECTIVE

FUNCTIONS

SPECIFICATIONS

Page 2

Thank you for choosing this Mitsubishi transistorized inverter option unit. This instruction manual provides handling information and precations for use of the equipment. Before using the inverter option, always read this instruction manual carefully to use the equipment to its optimum. Please forward this instruction manual to the end user. This instruction manual uses the International System of Units (SI). The measuring units in the yard and pound system are indicated in parentheses as reference values.

This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have read through the instruction manual and appended documents carefully and can use the equipment correctly.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.

1. Electric Shock Prevention

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.

WARNING

z While power is on or when the inverter is running, do not open the terminal block cover. You may get an

electric shock.

z Do not run the inverter with the terminal block cover removed. Otherwise, you may access the exposed

high-voltage terminals or the charging part of the circuitry and get an electric shock.

z Before starting wiring or inspection, switch off power, check to make sure that the charge 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 Earth (ground) the inverter. 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.

2. Fire Prevention

CAUTION

z Mount the power regeneration common converter unit and dedicated stand-alone reactor unit to

incombustible material. Mounting it to or near combustible material can cause a fire.

z Do not connect a resistor directly to the DC terminals P/L+, N/L-. 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 power regeneration common

converter unit and dedicated stand-alone reactor unit as they are hot and you may get burnt.

zWhen changing the fan, take care not to get injured.

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4. Additional Instructions

Also note the following points to prevent an accidental failure, injury, electric shock, etc.

1) Transportation and installation

CAUTION

zWhen carrying products, use correct lifting gear to prevent injury. zDo not stack the inverter option boxes higher than the number recommended. zEnsure that installation position and material can withstand the weight of the inverter. z Do not operate if the power regeneration common converter is damaged or has parts missing. z When carrying the inverter option, do not hold it by the terminal block cover or setting dial; it may fall off or

fail.

z Do not stand or rest heavy objects on the inverter option. z Check the inverter option mounting orientation is correct. z Prevent screws, wire fragments, other conductive bodies, oil or other flammable substances from entering

the power regeneration common converter.

z Do not drop the power regeneration common converter, or subject it to impact. z Use the inverter option under the following environmental conditions. Using it outside the operating range

can cause the power regeneration common converter to become faulty.

Ambient temperature

Ambient humidity

Storage temperature

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.

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

90%RH or less (non-condensing)

-20°C to +65°C* (-4°F to 149°F)

Maximum 1000m (3280.80feet) above sea level for standard operation. After that derate by 3% for every extra 500m (1640.40feet) up to

2500m (8202.00feet) (91%). 5.9m/s

or less

2) Operation

WARNING

z Do not modify the equipment. zDo not perform parts removal which is not instructed in this manual. Doing so may lead to fault or damage

of the product.

3) Maintenance, inspection and parts replacement

CAUTION

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

common converter unit.

4) Emergency stop

CAUTION

z When the breaker on the power regeneration common converter input side trips, check for the wiring fault

(short circuit), damage to internal parts of the power regeneration common converter, etc. Identify the cause of the trip, then remove the cause and power on the breaker.

5) Disposing of the inverter

CAUTION

z Treat as industrial waste

6) General instructions

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

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1 OUTLINE 1

1.1 Pre-Operation Information .....................................................................................2

1.1.1 Precautions for operation .......................................................................................................... 2

1.2 Basic Configuration................................................................................................ 4

1.2.1 Basic configuration .................................................................................................................... 4

1.3 Structure ................................................................................................................ 5

1.3.1 Appearance and structure ......................................................................................................... 5

1.3.2 Removal and reinstallation ........................................................................................................ 6

1.3.3 Structure of the power regeneration common converter ........................................................... 8

2 INSTALLATION AND WIRING 9

2.1 Installation............................................................................................................ 10

2.1.1 Instructions for installation ....................................................................................................... 10

2.2 Wiring................................................................................................................... 12

2.2.1 Terminal connection diagram .................................................................................................. 12

2.2.2 Wiring of the main circuit ......................................................................................................... 14

2.2.3 Wiring of the control circuit ...................................................................................................... 21

2.2.4 Design information................................................................................................................... 22

CONTENTS

2.3 Operation .............................................................................................................23

2.3.1 Pre-operation checks............................................................................................................... 23

2.3.2 Power-on and operation .......................................................................................................... 23

2.4 Other wiring.......................................................................................................... 24

2.4.1 Power harmonics..................................................................................................................... 24

2.4.2 Noise types and reduction techniques..................................................................................... 25

2.4.3 Peripheral devices ................................................................................................................... 26

2.4.4 Instructions for UL and cUL ..................................................................................................... 28

3 PROTECTIVE FUNCTIONS 29

3.1 Errors (Alarms)..................................................................................................... 30

3.1.1 Error (alarm) definitions ........................................................................................................... 30

3.1.2 Alarm symptoms and check points.......................................................................................... 31

3.2 Precautions for Maintenance and Inspection....................................................... 32

3.2.1 Precautions for maintenance and inspection........................................................................... 32

3.2.2 Check items............................................................................................................................. 32

3.2.3 Periodic inspection .................................................................................................................. 32

3.2.4 Insulation resistance test using megger .................................................................................. 33

3.2.5 Pressure test ........................................................................................................................... 33

3.2.6 Daily and Periodic Inspection .................................................................................................. 34

3.2.7 Replacement of parts .............................................................................................................. 36

3.2.8 Measurement of main circuit voltages, currents and power .................................................... 40

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4 SPECIFICATIONS 43

4.1 Standard Specifications ....................................................................................... 44

4.1.1 Model specifications ................................................................................................................ 44

4.1.2 Internal block diagram ............................................................................................................. 47

4.1.3 Outline drawings...................................................................................................................... 48

Page 6

CHAPTER 1

OUTLINE

This chapter gives information on the basic "outline" of this product. Always read the instructions in this chapter before using the equipment.

1.1 Pre-Operation Information ......................... 2

1.2 Basic Configuration.................................... 4

1.3 Structure ...................................................... 5

Page 7

Pre-Operation Information

1.1 Pre-Operation Information

1.1.1 Precautions for operation

Incorrect handling might cause the inverter option to operate improperly, its life to be reduced considerably, or at the worst, the inverter option to be damaged. Handle the power regeneration common converter properly in accordance with the information in each section as well as the precautions and instructions of this manual to use it correctly. This manual is written for the power regeneration common converter FR-CV. For handling information on the inverter, stand-alone options, etc., refer to the corresponding manuals.

(1) Unpacking and product check

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

1) Definition of the power regeneration common converter type

FR-CV- K-

Symbol

None

Voltage class

200V class

400V class

Symbol

7.5 to 55

Applicable Inverter Capacity

Indicates capacity in "kW".

Capacity plate

Capactiy plate

FR-CV-11K

Converter type Serial number

Rating plate

Input rating

Output rating

Serial number

2) The power regeneration common converter accessory Instruction manual

3) Definition of the dedicated stand-alone reactor Remember to prepare the dedicated stand-alone reactor as it must be installed.

FR-CVL- K

Symbol

None

Voltage class

200V class

400V class

Capacity plate

Symbol

7.5 to 55

Applicable Converter Capacity

Indicates capacity in "kW".

Symbol

Heat sink outside mounting structure

None

Enclosure inside installation structure

Structure

Rating plate

MITSUBISHI

MODEL

FR-CV-11K

XXXXX

INPUT :

XXXXX

OUTPUT :

SERIAL :

INVERTER

PASSED

Capacity plate

FR-CVL-11K

Reactor type

Converter type

If you have found any discrepancy, damage, etc., please contact your sales representative.

(2) Confirmation of the peripheral device types

The dedicated stand-alone reactor must be installed.

Power regeneration common converter Dedicated stand-alone reactor (required)

FR-CV-7.5K(-AT) FR-CVL-7.5K

FR-CV-11K(-AT) FR-CVL-11K

FR-CV-15K(-AT) FR-CVL-15K

FR-CV-22K(-AT) FR-CVL-22K

FR-CV-30K(-AT) FR-CVL-30K

FR-CV-37K FR-CVL-37K

FR-CV-55K FR-CVL-55K

Note: 400Vclass devices have capacity numbers preceded by H in their type codes.

Page 8

Pre-Operation Information

(3) Installation

To operate the power regeneration common converter with high performance for a long time, install the inverter in a proper place, in the correct direction, and with proper clearances. (Refer to page 10.)

(4) Wiring

Connect the power supply, inverter and control signals to the terminal block. Note that incorrect connection may damage the power regeneration common converter , inverter and peripheral devices. (Refer to page 10.)

OUTLINE

Page 9

Basic Configuration

1.2 Basic Configuration

1.2.1 Basic configuration

The following devices are required to operate the power regeneration common converter. Proper peripheral devices must be selected and correct connections made to ensure proper operation. Incorrect system configuration and connections can cause the inverter to operate improperly, its life to be reduced considerably, and in the worst case, the inverter to be damaged. Please handle the product properly in accordance with the information in each section as well as the precautions and instructions of this manual. (For connections of the peripheral devices, refer to the corresponding manuals.)

Name Description

Use the power supply within the permissible power

(ELB)

(NFB)

(MC)

Dedicated Stand-alone reactor (FR-CVL)

Earth(Ground)

Power regeneration common converter (FR-CV)

Earth (Ground)

Power supply

Earth leakage circuit breaker (ELB) or no-fuse breaker(NFB)

Magnetic contactor

Installation of dedicated stand-alone reactor

Power regeneration common converter

Inverter

supply specifications of the power regeneration common converter. (Refer to page 44.)

The breaker should be selected with care since a large inrush current flows in the power regeneration common converter at power on. (Refer to page 26.)

Install the magnetic contactor to ensure safety. When installed, do not use it to start or stop the inverter. It might reduce the power regeneration common converter life. (Refer to page 26.)

For power coordination, always install the dedicated stand-alone reactor.

Incorrect wiring might lead to power regeneration common converter damage. The control signal lines should be kept away from the main circuit to protect them from noise.

•Use the compatible inverter.

•The inverter life is influenced by ambient temperature.The ambient temperature should be as low as possible within the permissible range. This must be noted especially when the inverter is installed in an enclosure .

•Incorrect wiring might lead to inverter damage.The control signal lines should be kept away from the main circuit to protect them from noise.

Do not connect a power capacitor, surge suppressor or radio noise filter to the output side.

Note: Note that when an electromagnetic

contactor (MC) and a no-fuse breaker (NFB) are installed, switching off the inverter during operation, then on again will cause a starting current to flow, affecting the inverter and motor. When installing a no-fuse breaker (NFB) on the output side, contact the NFB manufacturer for selection of no-fuse breaker.

To prevent an electric shock, always ground the dedicated stand-alone reactor, power regeneration common converter, motor and inverter. The grounding cable provided for reduction of induction noise from the power line of the inverter is recommended to be wired by returning it to the grounding terminal of the inverter.

Earth(Ground)

Earth (Ground)

Devices connected to the output

Earth(Ground)

Note: If connected to the inverter, the power factor improving DC reactor (FR-BEL) does not produce an effect on

power factor improvement. In addition, do not use the power factor improving AC reactor (FR-BAL) since using it may degrade the power regeneration function.

Page 10

1.3 Structure

)

1.3.1 Appearance and structure

FR-CV-7.5K to 30K (-AT), FR-CV-H7.5K to H30K (-AT)

(1) Front view (2) Without front cover

Connector cover for manufacturer setting

LED display Capacity plate

Control circuit terminal block cove

CHARGE lamp

Connector for manufacturer setting (Note)

Control circuit terminal block

Structure

Main cricuit terminal block cover

Main circuit terminal block

Rating plate Cooling fan

Earth screws

FR-CV-37K/55K, FR-CV-H37K/H55K

(1) Front view (2) Without front cover

Front cover Maker setting connector cover LED display Capacity plate Control circuit terminal block cove CHARGE lamp

Main circuit terminal block cover

Rating plate

Fix ture

Maker setting connector (Note

Control circuit terminal block

Main circuit terminal block

Note: Keep the connector for manufacturer setting open.

OUTLINE

Page 11

Structure

1.3.2 Removal and reinstallation

(1) Main circuit terminal block cover

FR-CV-7.5K to 30K (-AT), FR-CV-H7.5K to H30K(-AT)

zRemoval

1)Hold both ends of the cover bottom and pull it toward you.

2)When the bottom of the cover has come off, hold both ends of the cover top and pull it toward you.

zReinstallation

1)Insert the catch at the cover top into the socket in the unit.

2)Using the part of the catch as a support, securely press the catches at both ends of the cover bottom to the unit.

FR-CV-37K/55K, FR-CV-H37K/H55K

zRemoval

1)Remove the installation screws at the top of the main circuit terminal block cover.

zReinstallation

1)Fix the main circuit terminal block cover with the installation screws.

Page 12

(2) Control circuit terminal block cover

zOpening

1)Hold the right end of the cover and pull it toward you.

2)The cover opens, with the left-hand side of the cover acting as a support.

zClosing

1)Securely press the right end of the cover against the unit.

Note: Make sure that the cover has been fitted securely.

Structure

OUTLINE

Page 13

Structure

1.3.3 Structure of the power regeneration common converter

The power regeneration common converter is available in two types: a heat sink outside mounting structure model and an enclosure inside installation structure model.

(1) Heat sink outside mounting structure model (FR-CV-7.5K to 55K, FR-CV-H7.5 to H55K)

Enclosure

Inside

Power regeneration common converter

Outside

Heat sink

Cooling fan

The FR-CV-37K, 55K and FR-CV-H37K, H55K can be used either as a heat sink outside mounting structure model or an enclosure inside installation structure model by changing its mounting foot position. It is shipped from the factory as a heat sink outside mounting structure model. Change the mounting foot position as shown below for installation.

Factory-set mounting foot position

Heat sink outside mounting

(At factory shipment)

Enclosure inside installation

(2) Enclosure inside installation structure model

(FR-CV-7.5K to 30K-AT, FR-CV-H7.5K to H30K-AT)

Enclosure

Power regeneration common converter

Cooling fan

Inside

Outside

Heat sink

Page 14

CHAPTER 2

INSTALLATION AND WIRING

This chapter gives information on the basic "Installation and wiring" of this product. Always read the instructions in this chapter before using the equipment.

2.1 Installation ................................................... 10

2.2 Wiring........................................................... 12

2.3 Operation ..................................................... 23

2.4 Other wiring................................................. 24

Page 15

Installation

2.1 Installation

2.1.1 Instructions for installation

1) Handle the unit carefully. The power regeneration common converter uses plastic parts. Handle it gently to protect it from damage. Also, hold the unit with even strength and do not apply too much strength to the terminal block cover alone.

2) Install the inverter in a place where it is immune to vibration. (5.9 m/s Also note the cart, press, etc.

3) Note on ambient temperature The power regeneration common converter life is under great influence of ambient temperature. Exercise care so that the ambient temperatures of the installation place do not fall out of the permissible range (-10°C to +50°C (14°F to 120°F)). Make sure that the ambient temperatures are within the permissible range at the measurement positions given in 3) on the next page. It is important to check that not only the ambient temperatures of the power regeneration common converter but also those of the inverter contained in the same enclosure fall within the permissible range.

4) Notes on installation surface The power regeneration common converter will be very hot (maximum about 150°C (302°F)). The power regeneration common converter (heat sink outside mounting structure model) can be reduced in the enclosure inside temperature by mounting its heat sink outside the enclosure. Cut the mounting area according to the panel cutting dimensions. Since the cooling section located outside the enclosure has a cooling fan, do not use the equipment in the environment that has water drops, oil mists, dust particles, etc. For installation in an enclosure, use the enclosure inside installation structure model of the power regeneration common converter and install it on an incombustible (e.g. metal) mounting surface. Also leave sufficient clearances around the inverter.

5) Avoid high temperature and high humidity. Avoid direct sunlight and places of high temperature and high humidity.

or less)

6) Avoid places where the inverter option is exposed to oil mist, flammable gases, fluff, dust, dirt etc. Install the inverter option in a clean place or inside a "totally enclosed" panel which does not accept any suspended matter.

7) Note the cooling method when the power regeneration common converter and inverter is installed in an enclosure. When two or more power regeneration common converters and inverters are installed or a ventilation fan is mounted in an enclosure, the inverters and ventilation fan must be installed in proper positions with extreme care taken to keep the ambient temperatures of the power regeneration common converters and inverters below the permissible value. If they are installed in improper positions, the ambient temperatures of the power regeneration common converters and inverters will rise and ventilation effect will be reduced.

8) Install the power regeneration common converter and inverter securely in the vertical direction with screws or bolts.

9) Install the dedicated stand-alone reactor (FR-CVL) on horizontal plane. Failure to observe this may lead to damage of the reactor.

Page 16

3) Note on ambient temperature 4) Clearances around the inverter

10cm (3.94 inches) or more

Measurement position

5cm

(1.97 inches)

5cm

(1.97 inches)

FR-CV

5cm (1.97 inches)

Measurement

osition

or moer

5cm (1.97 inches)

FR-CV

10cm (3.94 inches) or more

or moer

5cm (1.97 inches)

7) For installation in an enclosure

Ventilation fan

Converter

(Correct example)

Position of Ventilation Fan

Converter

(Incorrect example)

Converter

Built-in cooling fan

Converter

(Correct example)

Accommodation of two or more inverters

Converter

(Incorrect example)

Installation

Clearances required to change the cooling fan of the enclosure inside installation structure model (-AT). (Refer to page 36 for fan replacement.)

8) Vertical mounting Power regeneration common converter

9) Horizontal plane installation Dedicated stand-alone reactor

INSTALLATION AND WIRING

Page 17

Wiring

2.2 Wiring

2.2.1 Terminal connection diagram

Main circuit terminal Control circuit input terminal Control circuit output terminal

MCNFB

R S T

3-phase AC power supply

Note : 1. Never connect a power supply to the inverter terminals R, S, T. Such a connection, even if accidental, will damage the inverter and power regeneration common converter.

2. Match the polarities of the P and N terminals by connecting terminal P of the inverter to terminal P of the power regeneration common converter and terminal N of the inverter to terminal N of the power regeneration common converter as shown in the connection example. Incorrect matching of the polarities of the P and N terminals will result in damage to the inverter. Do not remove a jumper across terminal P/+ and P1.

3. For the FR-A700, F700, A500, F500 and V500 series, remove the jumpers across terminals R-R1 and S-S1, and connect power supply to terminals R1, S1 for the control circuit. For the FR-E700, D700, E500, S500, C500 and F500J series, the inverter does not have terminals R1, S1. So you do not need to make this connection.

4. When wiring the dedicated stand-alone reactor and power regeneration common converter as well as when wiring the power supply and terminals R/L11, S/L21, T/MC1, strictly observe the wiring order as shown in the connection example (match phase sequence of the power supply). A wrong connection will damage the power regeneration common converter. Do not insert an MCCB nor MC. The power regeneration common converter functions abnormally.

5. Make sure terminals R/L11, S/L21, T/MC1 are connected to the power supply. Running the inverter without connecting these terminals will damage the power regeneration common converter.

6. Since power to the inverter is supplied by terminals P and N, set Pr.30 to 2 (for use with a high power factor converter, power regeneration common converter) for the FR-A700, F700, A500, F500 and V500 series. This setting disables the built-in brake resistor.

7. For the FR-A700, F700, E700, D700, A500, F500 and V500 series inverter, assign the X10 signal to any of input terminals to use the inverter.

8. You can connect up to six inverters to one power regeneration common converter.

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

FR-CVL

(Note 4)

R/L11 S/L21 T/L31

R2/L12 S2/L22 T2/L32

(Note 5)

(Note 4)

R2/L1 S2/L2 T2/L3

R/L11 S/L21 T/MC1

RES SD

FR-CV

P/L+

N/L-

RDYA RDYB RS0 SE

Open collector

outputs

P24 SD

FR-A720

R/L1 S/L2

(Note 1)

T/L3

R1/L11

(Note 3)

S1/L21

P/+

(Note 2)

N/PC SD

(Note 7)

X10 (MRS) RES SD

FR-A720

R/L1

(Note 1)

S/L2 T/L3

R1/L11

(Note 3)

S1/L21

P/+

(Note 2)

N/-

(Note 7) X10 (MRS) RES SD

FR-A720

R/L1

(Note 1)

S/L2 T/L3

R1/L11

(Note 3)

S1/L21

P/+

(Note 2)

N/-

(Note 7) X10 (MRS) RES SD

CAUTION

Be sure to connect terminal RDY of the FR-CV to the X10 or MRS signal assigned terminal of the inverter, and connect terminal SE of the FR-CV to terminal SD of the inverter. Without proper connecting, FR-CV will be damaged.

Page 18

(1) Description of main circuit terminals

Symbol Terminal Name Description

R2/L1, S2/ L2,T2/L3

P/L+, N/L- DC power output

R/L11, S/ L21, T/MC1

AC power input Connect to the dedicated stand-alone reactor terminals R2/L12, S2/L22, T2/L32.

Connect to the inverter terminals P, N, and keep the inverter terminals R, S, T open. For the FR-A700, F700, A500, F500 or V500 series, set 2 (for use of high power factor converter, power regeneration common converter) in Pr.30.

Power supply phase detection

Ground Securely connect to the earth.

Terminals for power supply phase, power voltage detection and control power input. Connect to the dedicated stand-alone reactor terminals R/L11, S/L21, T/L31. Running the inverter without connecting these terminals will damage the power regeneration common converter.

(2) Description of control circuit terminals

Type Symbol Terminal Name Description

Used to input 24VDC power for alarm output relay drive and reset drive signal

P24 24VDC input

RES Reset

Input signals

Power input, contact

RDYA Ready output

RDYB

Open collector

RSO Converter reset

Output signals

A, B, C Alarm output

Contact

24VDC power common Contact input common

Inverter operation enable

Open collector output common

drive. Connect to the inverter terminal PC. When you do not use the inverter terminal PC, prepare a 24VDC power supply. Permissible input voltage fluctuation: 22V to 26VDC

Used to reset the activated protective circuit. Turn the terminals RES-SD on for longer than 0.1 seconds, then turn them off.

Connect the common of the 24VDC power supply. Shorting the terminal RES and this terminal inputs the reset signal.

Outputs a signal when the power regeneration common converter is ready to operate. This output has opposite logic to RDYB. Permissible load 24V 0.1ADC

Outputs a signal when the power regeneration common converter is faulty or the reset signal is input. Connect to the X10 (MRS) signal of the inverter. This output has opposite logic to RDYA. Permissible load 24V 0.1ADC

Outputs the reset signal to the inverter when the reset signal is input to the power regeneration common converter. Connect to the inverter terminal RES. Permissible load 24V 0.1ADC

Common to the terminals RDYA, RDYB and RSO. Connect to the inverter terminal SD.

Change-over outputs which indicate that the protective function of the power regeneration common converter was activated to stop the output. Alarm: No continuity across B-C (continuity across A-C), normal: Continuity across B-C (no continuity across A-C) Permissible load 230V 0.3AAC, 30V 0.3ADC

Wiring

(3) Description of inverter connection terminals

Type Symbol Terminal Name Description

P, N DC power input Connect to the power regeneration common converter terminals P/L+, N/L-.

For the FR-A700, F700, A500, F500 or V500 series, remove the jumpers across

R1, S1

Main circuit

X10 (MRS)

RES Converter reset

Control circuit

PC 24VDC power

SD Contact input common

Control circuit power input

Ground Securely connect to the earth.

Output stop

Note: When used as the 24V power, the terminal PC cannot prevent a sneak path for transistor output.

the inverter terminals R-R1 and S-S1, and input external power to these terminals. For the FR-E500, S500, C500 or F500J series, the inverter does not have the terminals R1, S1 so uses the DC power input from the terminals P, N as the control power.

Shuts off the inverter output when the power regeneration common converter is faulty or the converter reset signal is input. Connect to the power regeneration common converter terminal RDYB. For the FR-A700, F700, E700, D700, A500, F500 or V500 series, assign the X10 signal to any of the input terminals. For the FR-E500, S500, C500 or F500J series, use the terminal MRS as you cannot assign the X10 signal. If the terminal MRS is already used, assign another MRS signal to any of the input terminals. When the reset signal is input to the power regeneration common converter, the reset signal is also input to the inverter. Connect to the power regeneration common converter terminal RSO. For the D700, S500, C500 and F500J series, assign the RES signal to any one of the input terminals. 24V 0.1ADC power. Connect to the power regeneration common converter terminal P24.(Note) Common to the contact input terminals. Also acts as a common to the 24V

0.1ADC power (terminal PC).

INSTALLATION AND WIRING

Page 19

Wiring

2.2.2 Wiring of the main circuit

(1) Wiring instructions

1) Crimping terminals with insulation sleeves are recommended for use with the power and inverter cables.

2) Strictly observe the order of wiring in the connection example when performing wiring between the dedicated stand-alone reactor and power regeneration common converter and wiring between the power supply and terminals R/L11, S/L21, T/MC1. (Match the phase sequence of the power supply.) Incorrect connection will damage the power regeneration common converter.

3) Make sure to connect the terminal R/L11, S/L21, T/MC1 to the power supply. Running the inverter without connecting the terminals will damage the power regeneration common converter.

4) Connect a DC power supply between the power regeneration common converter and inverter with correct polarity.

5) After wiring, wire off-cuts must not be left in the power regeneration common converter. Wire off-cuts can cause an alarm, failure or malfunction. Always keep the power regeneration common converter clean. When drilling mounting holes in a control box etc., exercise care to prevent chips and other foreign matter from entering the power regeneration common converter.

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

7) When rewiring after operation, make sure that the CHARGE lamp has gone off, and when more than 10 minutes have elapsed after power-off, check with a meter that the voltage is zero. After that, start rewiring work. For some time after power-off, there is a dangerous voltage in the capacitor.

8) Be sure to connect terminal RDY of the FR-CV to the X10 or MRS signal assigned terminal of the inverter, and connect terminal SE of the FR-CV to terminal SD of the inverter. Without proper connecting, FR-CV will be damaged.

Notes on Grounding

z To prevent an electric shock, the dedicated stand-alone reactor, power regeneration common converter, inverter and

motor must be grounded.

z Use the dedicated ground terminal to ground the power regeneration common converter. (Do not use the screws in

the case, chassis, etc.)

z Use the reactor mounting screw to earth the dedicated stand-alone reactor.

Use the screw in the marked .

z The ground cable should be as thick as possible. Its gauge should be equal to or larger than those indicated in the

following table. The grounding point should be as near as possible to the power regeneration common converter to minimize the ground cable length.

(Unit: mm

Capacity

7.5kW (10HP) 5.5 3.5

11kW, 15kW (15HP, 20HP) 14 8

22kW to 37kW

(30 to 50HP)

55kW (75HP) 38 22

Ground Cable Gauge

200V class 400V class

22 14

)

Page 20

Wiring

(2) Terminal block layout of the power circuit

In the main circuit of the power regeneration common converter, the terminals are arranged as shown below:

FR-CV-7.5K/11K(-AT) FR-CV-15K(-AT), FR-CV-H7.5K/H11K/H15K(-AT)

L+

<DC power output terminals> Connect to inverter P and N terminals.

<Supply phase detection terminals> Connect to FR-CVL R,S and T terminals (main supp ly).

<AC power supply input termin als> Connect to FR-CVL R2, S2 and T2 terminals (secondary side).

R2 S2 T2

L+

L-

L11

L21

MC1

Screw size

(M6)

Screw size

(M4)

<DC power output terminals> Connect to inverter P and N terminals.

<Supply phase detection terminals> Connect to FR-CVL R, S and T terminals (main supply).

<AC power supply input terminals> Connect to FR-CVL R2, S2 and T2 terminals (secondary side).

R2 S2 T2

Screw size

L-

L11

L21

MC1

Screw size

(M6)

(M4)

L1 L2 L3

Screw size

(M4)

Screw size

(M5)

FR-CV-22K/30K(-AT), FR-CV-H22K/H30K(-AT)

<DC power output terminals> Connect to inverter P and N terminals.

<Supply phase detection terminals> Connect to FR-CVL R, S and T terminals (main supply).

<AC power supply input terminals> Connect to FR-CVL R2, S2 and T2 terminals (secondary side).

Screw size

(M5)

L+

L-

RTL11

L21

MC1

Screw size

(M5)

L1 L2 L3

Screw size

(M5)

Screw size

(M6)

Screw size

(M4)

R2 S2 T2

L1 L2 L3

INSTALLATION AND WIRING

Screw size

(M8)

Screw size

(M8)

Page 21

Wiring

FR-CV-37K

FR-CV-55K

Screw size

T/MC1

R/L11

S/L21

<Supply phase detectio n terminals> Connect to FR-CVL R, S and T terminals (main supply)

Screw size

(M8)

Screw size

R/L11 S/L21 T/MC1

(M4)

R2/L1 S2/L2

T2/L3

<AC power supply input termin als> Connect to FR-CVL R2, S2, and T2 terminals (secondary side)

Screw size

(M10)

N/L-

<DC power output terminals> Connect to invertor P and N terminals

P/L+

<Supply phase detect ion terminals> Connect to FR-CVL R, S and T terminals (main supply)

Screw size

FR-CV-H37K/H55K

Screw size (M4)

R/L11

<Supply phase detection terminals> Connect to FR-CVL R, S and T terminals (main supply)

4-55

(M8)

S/L21

T/MC1

C172D295H03

R2/L1 S2/L2 T2/L3 N/L- P/L+

<AC power supply input terminals> Connect to FR-CVL R2, S2,and T2 terminals (secondary side)

<DC power output terminals> Connect to invertor P and N terminals

Screw size

(M12)

R2/L1 S2/L2 T2/L3

<AC power supply input terminals> Connect to FR-CVL R2, S2 and T2 terminals (secondary side)

N/L- P/L+

<DC power output terminals> Connect to inverter P and N terminals

C172C295H02

Screw size

(M8)

Screw size

(M8)

Page 22

Wiring

(3) Cables, crimping terminals, etc.

Refer to the following for the cables, crimping terminals and terminal tightening torques used for the power regeneration common converter.

MCNFB

3-phase AC power supply

FR-CVL

R/L11 S/L21 T/L31

R2/L12 S2/L22 T2/L32

FR-CV

2) R2/L1

S2/L2 T2/L3

R/L11 S/L21 T/MC1

P/L+

N/L-

(Note 3)

FR-A720

R/L1 S/L2 T/L3

R1/L11 S1/L21

N/-

FR-A720

R/L1 S/L2 T/L3

R1/L11 S1/L21

N/-

Note: 1. The cables used should be 75°C (167F°) copper cables.

2. Tighten the terminal screws to the specified torques. Undertightening can cause a short or misoperation. Overtightening can cause the screws and unit to be damaged, resulting in a short or misoperation.

3. Do not insert the NFB between terminals P - N (P/L+ - P/+, N/L- - N/-).

FR-A720

R/L1 S/L2 T/L3

R1/L11 S1/L21

N/-

INSTALLATION AND WIRING

Page 23

Wiring

)

1) Connection of power supply and dedicated stand-alone reactor

Dedicated

MCNFB

stand-alone reactor (FR-CVL

R/L11 S/L21 T/L31

R2/L12 S2/L22 T2/L32

Dedicated

Stand-Alone

Terminal Name

Reactor Model

FR-CVL-7.5K FR-CVL-11K M5 2.5 14-5 14 6 FR-CVL-15K M6 4.4 22-6 22 4 FR-CVL-22K M6 4.4 38-6 38 2 FR-CVL-30K M6 4.4 60-6 60 1/0 FR-CVL-37K M10 14.7 100-10 100 4/0 FR-CVL-55K M10 14.7 150-10 150 MCM300 FR-CVL-H7.5K M5 2.5 3.5-5 3.5 12 FR-CVL-H11K M5 2.5 5.5-5 5.5 10 FR-CVL-H15K M5 2.5 14-5 14 6 FR-CVL-H22K M6 4.4 22-6 22 4 FR-CVL-H30K M6 4.4 22-6 22 4 FR-CVL-H37K M8 7.8 38-8 38 2 FR-CVL-H55K M8 7.8 60-8 60 1/0

R/L11, S/L21,

T/L31

Termi nal

Screw Size

M5 2.5 14-5 14 6

Tightening

Torque N•m

Crimping

Termi nals

Cables

AWG

Note: Wire the cables so that the phase sequence is always identical to those of the wiring in 2) and 4).

Connection in wrong phase sequence will damage the power regeneration common converter.

2) Connection of dedicated stand-alone reactor and power regeneration common converter

Dedicated stand-alone reactor (FR-CVL)

R/L11 S/L21 T/L31

R2/L12 S2/L22 T2/L32

FR-CV

R2/L1 S2/L2 T2/L3

10m (32.81 feet) maximum

Dedicated

Stand-Alone

Terminal Name

Reactor Model

R2/L12, S2/L22,

T2/L32

Termi nal

Screw Size

M5 2.5 14-5 14 6

Tightening

Torque N•m

Crimping

Termi nals

Cables

AWG

Page 24

Wiring

Power

Regeneration

Common

Terminal Name

Terminal

Screw Size

Tightening

Tor q u e N•m

Crimping

Terminals

Cables

AWG

Converter Model

FR-CV-7.5K FR-CV-11K M5 2.5 14-5 14 6

FR-CV-15K M5 2.5

FR-CV-22K M8 7.8 38-8 38 2

FR-CV-30K M8 7.8

FR-CV-37K M10 14.7 100-10 100 4/0 FR-CV-55K M12 24.5 150-12 150 MCM300 FR-CV-H7.5K M5 2.5 3.5-5 3.5 12 FR-CV-H11K M5 2.5 5.5-5 5.5 10 FR-CV-H15K M5 2.5 14-5 14 6 FR-CV-H22K M8 7.8 22-8 22 4 FR-CV-H30K M8 7.8 22-8 22 4 FR-CV-H37K M8 7.8 38-8 38 2 FR-CV-H55K M8 7.8 60-8 60 1/0

R2/L1, S2/L2,

T2/L3

M5 2.5 14-5 14 6

22-S6

(Note 2)

CB60-S8

(Note 2)

22 4

60 1/0

Note: 1. Wire the cables so that the phase sequence is always identical to those of the wiring in 1) and 4).

Connection in wrong phase sequence will damage the power regeneration common converter.

2. Manufactured by J.S.T.

3) Connection of power regeneration common converter and inverter

FR-A520

R S T

R1 S1

P/+ N/-

R2/L1 S2/L2 T2/L3

R/L11 S/L21 T/MC1

FR-CV

P/L+

N/L-

5m (16.40 feet) maximum

Note: Do not insert the NFB between terminals P - N (P/L+ - P/+, N/L- - N/-).

Do not remove a jumper across terminal P/+ and P1.

Power

Regeneration

Common

Terminal Name

Terminal

Screw Size

Tightening

Tor q u e N•m

Crimping

Terminals

Cables

AWG

Converter Model

FR-CV-7.5K FR-CV-11K M6 4.4 14-6 14 6 FR-CV-15K M6 4.4 22-6 22 4

FR-CV-22K M6 4.4

FR-CV-30K M6 4.4

FR-CV-37K M10 14.7 100-10 100 4/0 FR-CV-55K M12 24.5 150-12 150 MCM300 FR-CV-H7.5K M6 4.4 3.5-6 3.5 12 FR-CV-H11K M6 4.4 5.5-6 5.5 10 FR-CV-H15K M6 4.4 14-6 14 6 FR-CV-H22K M6 4.4 22-6 22 4 FR-CV-H30K M6 4.4 22-6 22 4 FR-CV-H37K M8 7.8 38-8 38 2 FR-CV-H55K M8 7.8 60-8 60 1/0

P/L+, N/L-

M6 4.4 14-6 14 6

38-S6

(Note 2)

CB60-S6

(Note 2)

38 2

60 1/0

INSTALLATION AND WIRING

Page 25

Wiring

«Example of connecting two or more inverters»

You can connect up to six inverters to one power regeneration common converter. The capacity of the power regeneration common converter should always be greater than the sum of the connected inverter capacities or the sum of rated inverter currents.

zWhen connecting several inverters, pay attention to the selection of the cables sizes since junction terminals or

jumper cables are used to wire the terminals P, N of the inverters. Make selection so that the inverter capacities are added in order, starting with the one of the remotest inverter.

zWhen connecting several inverters, connect the inverters in order of larger capacities. zSpecific example

R2/L1 S2/L2 T2/L3

R/L11 S/L21 T/MC1

P/L+

N/L-

FR-CV-22K

FR-A720-11K

Overall wiring length

=5m (16.40 feet) maximum

P/+ N/-

FR-A720-5.5K

P/+ N/-

FR-A720-3.7K

P/+ N/-

First inverter: Choose 38mm assuming that the converter capacity is 22K according to the sum of inverter capacities, 11K+5.5K+3.7K=20.2K.

Second inverter: Choose 14mm assuming that the converter capacity is 11K according to the sum of inverter capacities,

5.5K+3.7K=9.2K.

Third inverter: Choose 3.5mm according to the inverter capacity, 3.7K.

Note: 1. Correctly connect the terminals P/L+, N/L- with the inverter terminals P, N.

Wrong connection will damage the power regeneration common converter.

2. Do not insert the NFB between terminals P - N (P/L+ - P/+, N/L- - N/-, P/+ - P/+, N/- - N/-).

3. Manufactured by J.S.T.

4) Connection of power supply and power regeneration common converter (power supply phase detection terminals)

R/L11 S/L21 T/L31

R2/L12 S2/L22 T2/L32

R2/L1 S2/L2 T2/L3

Dedicated

Stand-Alone

Reactor Model

FR-CVL-7.5K

10m (32.81 feet) maximum

Terminal Name

R/L11 S/L21 T/MC1

Cables

Termi nal

Screw Size

Tightening

Torque N•m

Crimping

Termi nals

M5 2.5 1.25-5 1.25 16

AWG

FR-CVL-11K M5 2.5 1.25-5 1.25 16 FR-CVL-15K M6 4.4 1.25-6 1.25 16 FR-CVL-22K M6 4.4 1.25-6 1.25 16 FR-CVL-30K M6 4.4 1.25-6 1.25 16 FR-CVL-37K M10 14.7 1.25-10 1.25 16 FR-CVL-55K M10 14.7 1.25-10 1.25 16 FR-CVL-H7.5K M5 2.5 1.25-5 1.25 16

R/L11, S/L21,

T/L31 FR-CVL-H11K M5 2.5 1.25-5 1.25 16 FR-CVL-H15K M5 2.5 1.25-5 1.25 16 FR-CVL-H22K M6 4.4 1.25-6 1.25 16 FR-CVL-H30K M6 4.4 1.25-6 1.25 16 FR-CVL-H37K M8 7.8 1.25-8 1.25 16 FR-CVL-H55K M8 7.8 1.25-8 1.25 16

Page 26

Wiring

Power

Regeneration

Common

Terminal Name

Terminal

Screw Size

Tightening

Tor q u e N•m

Crimping

Terminals

Cables

AWG

Converter Model

FR-CV-7.5K FR-CV-11K M4 1.5 1.25-4 1.25 16 FR-CV-15K M4 1.5 1.25-4 1.25 16 FR-CV-22K M4 1.5 1.25-4 1.25 16 FR-CV-30K M4 1.5 1.25-4 1.25 16 FR-CV-37K M4 1.5 1.25-4 1.25 16 FR-CV-55K M4 1.5 1.25-4 1.25 16 FR-CV-H7.5K M4 1.5 1.25-4 1.25 16 FR-CV-H11K M4 1.5 1.25-4 1.25 16 FR-CV-H15K M4 1.5 1.25-4 1.25 16 FR-CV-H22K M4 1.5 1.25-4 1.25 16 FR-CV-H30K M4 1.5 1.25-4 1.25 16 FR-CV-H37K M4 1.5 1.25-4 1.25 16 FR-CV-H55K M4 1.5 1.25-4 1.25 16

R/L11, S/L21,

T/MC1

M4 1.5 1.25-4 1.25 16

Note: 1. Wire the cables so that the phase sequence of the wiring in 4) is always identical to those of the wiring in

1) and 2). Connection in wrong phase sequence will damage the power regeneration common converter.

2. To prevent a malfunction due to noise, run the cables away from the main circuit wiring.

3. Running the inverter without connecting terminals R/L11, S/L21 and T/MC1 to the power supply will damage the power regeneration common converter.

5) Connection of power supply and inverter When the model used is the one whose control power is input from R1 and S1, control circuit power must be input to R1 and S1 of the inverter. At this time, remove the jumpers across R-R1, S-S1.

Cable size: 0.75mm

to 2mm

FR-A720

R/L1 S/L2 T/L3

R1/L11 S1/L21

N/-

(Note1)

(Note2)

Dedicated stand-alone reactor (FR-CVL)

R/L11 S/L21 T/L31

R2/L12 S2/L22 T2/L32

R2/L1 S2/L2 T2/L3

R/L11 S/L21 T/MC1

FR-CV

P/L+

N/L-

Note: 1. Never connect a power supply to the inverter terminals R, S, T. Accidental connection will damage the

inverter and power regeneration common converter.

2. For the FR-A700, F700, A500, F500 or V500 series, disconnect the jumpers across terminals R-R1, SS1 and connect the control power supply to terminals R1, S1. For the FR-E700, D700, E500, S500, C500 or F500J series, there are no terminals R1, S1 and you need not make the above connection.

2.2.3 Wiring of the control circuit

(1) Wiring instructions

1) The terminals SD, SE are common to the I/O signals and are isolated from each other. Must not be earthed (grounded).

2) Shielded or twisted cables must be used for connection to the control circuit terminals, and also run away from the main and power circuits (including the 200V relay sequence circuit).

3) The input signals to the control circuit are micro currents. When contacts are required, use two or more parallel micro signal contacts or a twin contact to prevent a contact fault.

4) It is recommended to use the cables of 0.3mm terminals.

to 0.75mm2 gauge for connection to the control circuit

INSTALLATION AND WIRING

Page 27

Wiring

(2) Terminal block layout

In the control circuit of the power regeneration common converter, the terminals are arranged as shown below:

A B C

P24

RES

RDYB

RSO

RDYA

(3) Wiring procedure

1) For the wiring of the control circuit, strip the sheaths of the cables and use them as they are. Over-stripping may cause a short circuit with the neighboring cable.Under-stripping may cause cable disconnection.

7mm (0.28inch) 1mm (0.04inch)

2) When using bar terminals or solid cables for wiring, use those of not more than 0.9mm (0.04inch) in diameter. If the diameter is greater than 0.9mm (0.04inch), the screw threads may be damaged when tightened.

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

4) Tighten the screw to the specified torque. Undertightening can cause cable disconnection or malfunction.Overtightening can cause the screw or unit to be damaged, resulting in a short circuit or malfunction. Tightening torque: 0.25N•m to 0.49N•m *Use a screwdriver of No. 0.

Note: Wire the stripped cable after twisting it to prevent it from becoming loose.

2.2.4 Design information

1) If the machine must be prevented from restarting at recovery of power after a power failure, provide a magnetic contactor in the primary side of the power regeneration common converter and also make up a sequence that will not turn on the start signal of the inverter. If the start signal (start switch) of the inverter is held, the inverter will automatically restart at recovery of power.

2) Configure up a circuit that will always turn off the main circuit power supply terminals R2/L1, S2/L2, T2/L3 as soon as the power supply phase detection terminals R/L11, S/L21, T/MC1 turn off.

3) Since the input signals to the control circuit are on a low level, use two parallel micro signal contacts or a twin contact for contact inputs to prevent a contact fault.

4) Do not apply a voltage directly to the alarm output signal terminals (A, B, C). Always apply a voltage to these terminals via a relay coil, lamp, etc.

5) Make sure that the specifications and rating match the system requirements.

3) Low-level signal contacts

Low-level signal contacts

Twin contact

Page 28

Operation

2.3 Operation

2.3.1 Pre-operation checks

When installation and wiring are over, make the following checks prior to power-on.

1) Check the wiring for incorrect connection. Especially check that the phase sequence and polarity of the main circuit wiring are correct.

2) Check for a short circuit caused by wire off-cuts.

3) Check for loose terminal screws.

4) Make sure that the machine is free of damage.

5) Set the parameter values to match the operating machine system environment. For the FR-A700, F700, A500, F500 or V500 series, set 2 (high power factor converter, power

regeneration common converter) in Pr. 30 "Regenerative function selection".

6) Perform test operation after making sure that safety is ensured if the machine should become out of control.

7) Perform test operation and make sure that the machine operates safely under light load at a low frequency. After that, start operation.

Note: Do not conduct an insulation resistance test with a megger in the power regeneration common converter.

2.3.2 Power-on and operation

Before switching power on, check the following:

z Installation check

Make sure that the inverter is installed correctly in a proper location. (Refer to page 10.)

• Wiring check Make sure that the main and control circuits are wired correctly. Make sure that the options and peripheral devices are selected and connected correctly. (Refer to page 12.)

z Switch power on.

Power-on is complete when the CHARGE lamp is lit correctly and the LED displays correct data. The LED display gives the following indications at power-on.

LED

Display

Power on

Converter

status

Note:

If the cooling fan has stopped due to a fault, the LED display shows a flickering . (400V class only)

During initialization

During alarm detection

If the DC voltage is higher than the input power supply voltage at power-on, regenerative operation is performed. At this time, the bottom segment flickers.

Flicker

During normal operation (Driving status)

(Refer to page 30.)

z Start operation.

Turn on the start signal of the inverter. The motor accelerates to a given speed. At this time, the LED display of the power regeneration common converter shows .

INSTALLATION AND WIRING

Turn off the start signal of the inverter. The motor decelerates to a stop. The LED display of the power

regeneration common converter shows according to the magnitude of the regenerative energy.

LED

Display

Converter

status

During driving operation

(During stop)

Flicker

During regenerative operation

When the regeneration converter performs switching operation, the bottom segment flickers.

Note: When the power regeneration common converter is regenerating power, the dedicated stand-alone reactor

generates sound but it is not a fault.

Page 29

Other wiring

2.4 Other wiring

2.4.1 Power harmonics

Power harmonics may be generated from the power regeneration common converter, affecting generators, power capacitors, etc. Power harmonics are different in generation source, frequency and transmission path from radio frequency (RF) noise and leakage currents.

z The differences between harmonics and RF noise indicated below:

Item Harmonics RF Noise

Frequency

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

Quantitative understanding Logical computation is possible

Generated amount

Immunity of affected device

z Safeguard

The harmonic current generated from the power regeneration common converter to the power supply differs according to various conditions such as the wiring impedance, whether a power factor improving reactor is used or not, and output frequency and output current on the load side. For the output frequency and output current, the adequate method is to obtain them under rated load at the maximum operating frequency.

Normally 40th to 50th degrees or less, (up to 3kHz or less)

Approximately proportional to load capacity

Specified in standards for each device.

High frequency (several 10kHz to 1GHz order)

Occurs randomly, quantitative understanding is difficult.

According to current fluctuation rate (larger with faster switching)

Differs according to maker’s device specifications.

Do not insert power factor improving DC reactor

Power factor improving AC reactor

NFB

Do not insert power factor

improving AC reactor

Dedicated stand-alone reactor

Power regeneration

common converter

Power factor improving DC reactor

Inverter

Do not insert power factor improving capacitor

Moto

Note: A power factor improving capacitor or surge suppressor on the inverter’s output may overheat or be

damaged due to the harmonics of the inverter output. Also, when an overcurrent flows in the inverter, the overcurrent protection is activated, Hence, when the motor is driven by the inverter, do not install a capacitor or surge suppressor on the inverter’s output. Do not use the power factor improving AC reactor (FR-BAL) since using it may degrade the power regeneration function.

Page 30

Other wiring

2.4.2 Noise types and reduction techniques

Some noises enter the power regeneration common converter causing it to misoperate and others are radiated by the power regeneration common converter causing misoperation of peripheral devices. Though the power regeneration common converter is designed to be insusceptible to noise, it handles low-level signals, so it requires the following basic measures to be taken. Also, since the inverter chops the output at a high carrier frequency, it could generate noise. If these noises cause peripheral devices to misoperate, measures should be taken to suppress the noise. The measures differ slightly depending on noise propagation paths.

1) Basic measures

• Do not run the power cables (I/O cables) and signal cables of the power regeneration common converter in parallel with each other and do not bundle them.

• Use twisted shielded cables for the detector connection and control signal cables and connect the sheathes of the shielded cables to terminal SD.

• Ground the power regeneration common converter and inverter, motor, etc. at one point.

2) Measures against noises which enter and cause misoperation of the power regeneration common converter When devices which generate many noises (which use magnetic contactors, magnetic brakes, many relays, for example) are installed near the power regeneration common converter and the inverter may be effected by noise, the following measures must be taken:

• Provide surge suppressors for devices that generate noise to suppress noise.

• Fit data line filters to signal cables.

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

3) Measures against noise which is radiated by the power regeneration common converter causing misoperation of peripheral devices. Power regeneration common converter-generated noise is largely classified into those radiated by the cables connected to the power regeneration common converter and power regeneration common converter main circuit (I/O), those electromagnetically and electrostatically inducted to the signal cables of the peripheral devices close to the main circuit power supply, and those transmitted through the power supply cables.

Power regeneration converter generated noise

Air-propagated noise

Magnetic induction noise

Static induction noise

Cable-propagated noise

Noise directly radiated by power regeneration common converter

Noise radiated by power cables

Noise radiated by motor cables



Path 4), 5)



Path 6)

Noise propagated through power cables

Noise from ground cable due to leakage current



Path 1)



Path 2)



Path 3)



Path 7

Path 8

ReceiverInstrument

Motor

Power regeneration

common converter

Inverter

Sensor

power supply

Sensor

Telephone

Noise Path Measures

When devices which handle low-level signals and are susceptible to misoperation due to noise (such as instruments, receivers and sensors) are installed near the power regeneration common converter and their signal cables are contained in the same panel as the inverter or are run near the power regeneration common converter, the devices may be affected by air-propagated noises and the following measures must be taken: (1) Install easily affected devices as far away as possible from the power regeneration common

1) 2) 3)

converter.

(2) Run easily affected signal cables as far away as possible from the power regeneration common

converter.

(3) Do not run the signal cables and power cables (power regeneration common converter I/O cables) in

parallel with each other and do not bundle them. (4) Inset line noise filters into I/O and radio noise filters into input side to suppress cable-radiated noises. (5) Use shielded cables for signal cables and power cables and run them in individual metal conduits to

reduce further effects.

INSTALLATION AND WIRING

Page 31

Other wiring

Noise Path Measures

When the signal cables are run in parallel with or bundled with the power cables, magnetic and static induction noise may be propagated to the signal cables to effect the devices and the following measures must be taken: (1) Install easily affected devices as far away as possible from the power regeneration common

converter.

4) 5) 6)

(2) Run easily affected signal cables as far away as possible form the power regeneration common

converter. (3) Do not run the signal cables and power cables (power regeneration common converter I/O cables) in

parallel with each other and do not bundle them. (4) Use shielded cables for signal cables and power cables and run them in individual metal conduits to

reduce further effects.

When the power supplies of the peripheral devices are connected to the power supply of the power regeneration common converter within the same line, power regeneration common converter-generated noise may flow back through the power supply cables to misoperate 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 power regeneration

common converter. (2) Install the line noise filter (FR-BLF, FR-BSF01) to the power cables (I/O cables) of the power

regeneration common converter.

When a closed loop circuit is formed by connecting the peripheral device wiring to the power regeneration common converter, leakage current may flow through the ground cable of the power regeneration common converter to affect the device. In such a case, disconnection of the ground cable of the device may cause the device to operate properly.

2.4.3 Peripheral devices

(1) Selection of peripheral devices

Refer to the following list and prepare appropriate peripheral devices:

1) 200V class

Power Regeneration

Common Converter Type

FR-CV-7.5K (-AT) 7.5 (10) 17 100AF 60A S-N35

FR-CV-11K (-AT) 11 (15) 20 100AF 75A S-N50

FR-CV-15K (-AT) 15 (20) 28 225AF 125A S-N65

FR-CV-22K (-AT) 22 (30) 41 225AF 175A S-N95

FR-CV-30K (-AT) 30 (40) 52 225AF 225A S-N125

FR-CV-37K 37 (50) 66 400AF 250A S-N150

FR-CV-55K 55 (75) 100 400AF 400A S-N220

2) 400V class

Power Regeneration

Common Converter Type

FR-CV-H7.5K (-AT) 7.5 (10) 17 30AF 30A S-N20

FR-CV-H11K (-AT) 11 (15) 20 50AF 50A S-N20

FR-CV-H15K (-AT) 15 (20) 28 100AF 60A S-N25

FR-CV-H22K (-AT) 22 (30) 41 100AF 100A S-N50

FR-CV-H30K (-AT) 30 (40) 52 225AF 125A S-N65

FR-CV-H37K 37 (50) 66 225AF 150A S-N80

FR-CV-H55K 55 (75) 100 225AF 200A S-N125

Applicable Capacity

(kW (HP))

Applicable Capacity

(kW (HP))

Power Supply

Capacity (kVA)

Power Supply

Capacity (kVA)

Rated current of

Circuit Breaker

Rated current of

Circuit Breaker

Magnetic

Contactor

Magnetic

Contactor

Note: 1. For installations in the United States or Canada, the circuit breaker must be inverse time or

instantaneous trip type.

2. When the breaker on the primary side of the power regeneration common converter tripped, check for wiring fault (e.g.short circuit), damage to internal parts of the inverter (power regeneration common converter), etc. Identify the cause of the breaker trip, then power on the breaker after removing the cause of the trip.

Page 32

Other wiring

(2) Selection the rated sensitivity current for the earth leakage circuit breaker

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

z Breaker for harmonic and surge

Rated sensitivity current: lΔn ≥ 10 × (lg

1 + lgn + lg2 + lgm)

z Standard breaker

Rated sensitivity current: lΔn ≥ 10 × {lg lg

1, lg2 : leakage currents of cable path during

1 + lgn + 3 × (lg2+lgm)}

commercial power supply operation

lgn* : leakage current of noise filter on power

regeneration common converter input side

lgm : leakage current of motor during

commercial power supply operation

22mm

(16.40 feet)

Noise

Ig1 Ign Ig2 Igm

Power regeneration

filter

common converter

Inverter

15K

22mm

(98.43 feet)

30m

200V 15kW (20HP)

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

120

100

Leakage current (mA)

23.5

8142230386080

5.5

Cable size (mm )

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

2.0

1.0

0.7

0.5

0.3

0.2

Leakage current (mA)

150

100

0.1

1.5 3.7

2.2

5.5 18.5

Motor capacity (kW)

7.5 152211373055 45

Leakage current Ig1 (mA)

Breaker for

Harmonic and Surge

5m (16.40 feet)

× =0.25

1000m (3280.80 feet)

Standard Breaker

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

Leakage current Ig2 (mA)

Motor leakage current Igm (mA)

Total leakage current (mA)

Rated sensitivity current (mA) ( ≥Ig × 10)

1000m (3280.80 feet)

0.57

2.32 6.46

30 100

30m (98.43 feet)

× =1.50

Note: 1. The NV should be installed to the primary (power supply) side of the power regeneration common

converter.

2. Ground fault in the secondary side of the inverter can be detected at the running frequency of 120Hz or lower.

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

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

5. 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 NV-ZHA), AA neutral wire, NV with open phase protection

The following models are breakers for harmonic and surge

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

INSTALLATION AND WIRING

* Be careful of the leakage current value of the noise filter installed on the power regeneration common

converter input side.

Page 33

Other wiring

2.4.4 Instructions for UL and cUL

(Standards to comply with: UL 508C, CSA C22.2 No. 14)

(1) Installation

The equipment has been approved as a product for use in an enclosure. Design the enclosure so that the ambient temperature, humidity and ambience of the power regeneration common converter will satisfy the above specifications. (Refer to page 44.)

(2) Branch circuit protection

For installation in United States, branch circuit protection must be provided, in accordance with the National Electrical Code and any applicable local codes. For installation in Canada, branch circuit protection must be provided in accordance with the Canada Electrical Code and any applicable provincial codes.

(3) Short circuit ratings

Suitable For Use in A Circuit Capable of Delivering Not More Than 10kA rms Symmetrical Amperes, 500V Maximum.

(4) Wiring of the power supply and motor

Screw the cables wired to the input (R, S, T) and output (P, N) terminals and control circuit of the power regeneration common converter to the specified tightening torque using UL-recognized, 75°C or higher rated copper wires and round crimping terminals. Crimp the crimping terminals with the crimping tool recommended by the terminal maker.

Page 34

CHAPTER 3

PROTECTIVE FUNCTIONS

This chapter explains the "protective functions" of this product. Always read the instructions before using the equipment.

3.1 Errors (Alarms)............................................ 30

3.2 Precautions for Maintenance

and Inspection............................................. 32

Page 35

Errors (Alarms)

3.1 Errors (Alarms)

If any fault has occurred in the power regeneration common converter, the corresponding protective function is activated and the error (alarm) indication appears automatically on the LED display. When the protective function is activated, find the cause and take proper action. If an alarm stop has occurred, the power regeneration common converter must be reset to restart it. zWhen the protective function is activated, take the corresponding corrective action, then reset the power

regeneration common converter, and resume operation.

zResetting method

When the protective function is activated and the power regeneration common converter has stopped its output, the inverter output is also shut off. Unless reset, the protective function of the power regeneration common converter cannot be deactivated. To reset, use either of the following two methods: switch power off once, then on again; short the reset terminal RES-SD for more than 0.1 seconds, then open.

( CPU alarm may be reset only by switching power off, then on again.)

If RES-SD are kept shorted, the LED shows .

3.1.1 Error (alarm) definitions

(1) Major faults

LED

Display

Name Description Check Point

Overcurrent protection

Main circuit device overheat

Overvoltage protection

Electronic overcurrent protection

Undervoltage

Phase failure

CPU alarm

Instantaneous power failure alarm

Power supply alarm

The current of the power regeneration common converter module exceeded the specified value. (Detected only in the regeneration mode.)

The main circuit device overheated.

The bus voltage (voltage across terminals P/L+ and N/L-) of the power regeneration common converter fell to or below the specified value.

Thermal protection of power regeneration common converter module.

The bus voltage (voltage across terminals P/L+ and N/L-) of the power regeneration common converter fell to or below the specified value.

A phase failure occurred in the input power supply.

The operation of the built-in CPU did not end with the predetermined time. An alarm was detected in the memory circuit or A/D converter of the power regeneration common converter.

An instantaneous power failure of more than 15ms and less than 100ms occurred. When an instantaneous power failure of not less than 100ms occurred, the same operation as in power-on reset is performed.

The power supply frequency fell out of the specified value. Phase detection could not be made at power-on.

Check for sudden acceleration/ deceleration. Check for sudden load change. Check for incorrect wiring. Check for occurrence of instantaneous power failure.

Check that the cooling fan is not at a stop. Check for operation under overload. Check for too high ambient temperatures.

Check for sudden deceleration. Check for sudden load change.

Check for operation under overload.

Check for a start of large-capacity motor.

Check for incorrect wiring.

Contact your sales representative or distributor.

Find the cause of instantaneous power failure.

Check for incorrect wiring.

(2) Minor fault

LED

Display

Fan fault (400V class only)

Name Description Check Point

The cooling fan stopped due to a fault. Check the cooling fan for a fault.

Page 36

Errors (Alarms)

CAUTION

At occurrence of an instantaneous power failure alarm or power supply alarm, the inverter output may be shut off to coast the motor before the power regeneration common converter outputs an alarm. In a system where an alarm will cause an emergency stop, configure up a system that will not only provide alarm outputs of the power regeneration common converter and inverter but also make a stop if the RUN signal of the inverter turns off.

3.1.2 Alarm symptoms and check points

Symptom Check point

Operation is not normal. Check connection.

zCheck for incorrect wiring. zCheck that a normal power supply voltage is applied. zCheck that the phase sequence matches. zCheck for a short across terminals RES-SD.

The CHARGE lamp is not lit. Check connection.

zCheck for incorrect connection. zCheck that the main circuit terminals R2/L1, S2/L2, T2/L3 are wired correctly.

The reactor becomes abnormally hot. Check connection.

zCheck for incorrect connection. zCheck that the phase sequence matches.

The inverter cannot be run. Check setting.

zFor the FR-A700, F700, A500, F500 or V500 series inverter, check that the Pr. 30

"Regenerative function select" setting is 2 (high power factor converter, power regeneration common converter).

PROTECTIVE FUNCTIONS

Page 37

Precautions for Maintenance and Inspection

3.2 Precautions for Maintenance and Inspection

The power regeneration common converter is a static unit mainly consisting of semiconductor devices. Daily inspection must be performed to prevent any fault from occurring due to adverse influence by the operating environment, such as temperature, humidity, dust, dirt and vibration, changes in the parts with time, service life, and other factors.

3.2.1 Precautions for maintenance and inspection

For some short time after the power is switched off, a high voltage remains in the smoothing capacitor. When accessing the power regeneration common converter for inspection, switch power off. When more than 10 minutes have elapsed, make sure that the voltage across the main circuit terminals P/L+-N/L- of the inverter is 30VDC or less using a tester, etc. The dedicated stand-alone reactor is very hot. Exercise care not to get burnt.

3.2.2 Check items

(1) Daily inspections

z Check the following:

1)Improper installation environment

2)Cooling system fault

3)Unusual vibration and noise

4)Unusual overheating and discoloration

z During operation, check the power regeneration common converter input voltages using a tester.

(2) Cleaning

Always run the power regeneration common converter in a clean state. When cleaning the inverter, gently wipe dirty areas with a soft cloth immersed in neutral detergent or ethanol.

Note: Do not use solvent, such as actone, benzene, toluene and alcohol, as they will cause the power

regeneration common converter surface paint to peel off. Do not use detergent or alcohol to clean the LED display section, which is easily affected by them.

3.2.3 Periodic inspection

Check the areas inaccessible during operation and requiring periodic inspection. For periodic inspection, consult us.

1) Cooling system:............................ Clean the air filter, etc.

2) Screws and bolts: ......................... These parts may become loose due to vibration, temperature changes, etc.

Check that they are tightened securely and retighten as necessary.

3) Conductors and insulating materials: Check for corrosion and damage.

4) Insulation resistance: Measure.

5) Cooling fan, relay: Check and change if necessary.

Page 38

Precautions for Maintenance and Inspection

3.2.4 Insulation resistance test using megger

1) Before performing the insulation resistance test using a megger on the external circuit, disconnect the cables

from all terminals of the power regeneration common converter so that the test voltage is not applied to the inverter.

2) For the continuity test of the control circuit, use a meter (high resistance range) and do not use the megger or

buzzer.

3) For the power regeneration common converter, conduct the insulation resistance test on the main circuit only

as shown below and do not perform the test on the control circuit. (Use a 500VDC megger.)

Inverter

INV

Power supply

500VDC megger

R/L1 S/L2 T/L3

Power regeneration common converte

Ground terminal

P/L+

N/L-

3.2.5 Pressure test

Do not conduct a pressure test. The power regeneration common converter's main circuit uses semiconductors, which may be deteriorated if a pressure test is made.

PROTECTIVE FUNCTIONS

Page 39

Precautions for Maintenance and Inspection

3.2.6 Daily and Periodic Inspection

Interval

Daily

{

Periodic

1 year

{

2 year

(Refer to page 10)

Visual and auditory checks.

Measure voltage across power regeneration common converter terminals R2/L1, S2/L2, T2/L3.

(1) Disconnect all

(2) Re-tighten. (3) Visual check.

(1), (2) Visual check. (1), (2) No fault.

Visual check. No fault

Disconnect cables from inverter and measure across terminals R2/L1, S2/L2, T2/L3, P/L+, N/L- with a meter range of 100

(1), (2) Visual check. (3) Use capacitance

(1) Auditory check. (2) Visual check.

(1) Visual check.

Area of

Inspection

General

Mian circuit

Inspection

Item

Surrounding environment

Overall unit

Power supply voltage

General

Conductors, cables

Te rm i na l block

Converter module

Smoothing capacitor

Relay

Resistor

Description

Check ambient temperature, humidity, dust, dirt, etc.

Check for unusual vibration and noese.

Check that main circuit voltage is normal.

(1) Check with

megger (across main circuit terminals and ground termimal).

(2) Check for loose

screws and bolts.

(3) Check for

overheating of each part.

(4)Clean.

(1) Check conductors

for distortion.

(2) Check cable

sheaths for breakage.

Check for damage.

Check resistance across terminals.

(1) Check for liquid

leakage.

(2) Check the safety

valve for projection or bulge.

(3) Measure

capacitance.

(1) Check for chatter

during operation.

(2) Check for rough

surface on contacts.

(1) Check for crack in

resistor insulation.

Method Criterion Instrument

Ambient temperature: (constant torque)

-10°C to + 50°C (14°F to 122°F),

cables from power regeneration common converter and measure across terminals R2/L1, S2/ L2, T2/L3, P/L+, N/ L- and ground terminal with megger.

Ω.

meter to make measurement.

Cement resistor, wire-wound resistor.

non-freezing. (Variable torque)

-10°C to + 40°C (14°F to 104°F), non-freezing. Ambient humidity: 90% or less, non-condensing.

No fault.

Within permissible AC voltage fluctuation (Refer to page 44)

Ω or more.

(1) 5M (2),(3) No fault.

(Refer to page 35) Analog meter

(1), (2) No fault. (3) 85% or more of rated capacitance.

(1) No fault. (2) No fault.

(1) No fault.

Thermometer, hygrometer, recrder

Meter, digital multimeter

500VDC class megger

Capacitance meter

Customer

setting

Page 40

Area of

Inspection

Control

circuit

Protective

circuit

Cooling

system

Display

Inspection

Item

Operation check

Cooling fan

Display

Meter

Description

(1) Perform

sequence protective operation test to make sure of no fault in protective and display circuits.

(1) Check for unusual

vibration and noise.

(2) Check for loose

connection.

(1) Check if LED

lamp is blown.

(2) Clean.

Check that reading is normal.

Interval

Periodic

Daily

{

Precautions for Maintenance and Inspection

Method Criterion Instrument

1 year

2 year

(1) Simulatively

connect or disconnect inverter protective circuit output terminals.

(1) Turn by hand with

power off.

(2) Re-tighten

(1) Light indicator

lamps on panel.

(2) Clean with rag.

Check reading of meters on panel.

(1) Fault must

occur because of sequence.

No unusual vibration, unusual noise.

(1) Check that

lamps are lit.

Must satisfy specified and management values.

Voltmeter, ammeter, etc.

Customer

setting

z Checking the converter module

(1) Disconnect the external power supply cables (R2/L1, S2/L2, T2/L3, P/L+, N/L-). (2) Prepare a meter. (Use 100Ω range.)

Change the polarity of the tester alternately at the converter terminals R2/L1, S2/L2, T2/L3, P/L+, N/L- and check for continuity.

Note: 1. Before measurement, check that the smoothing capacitor is discharged.

2. At the time of continuity, the measured value is several to several ten’s-of ohms depending on the module type, circuit tester type, etc. If all measured values are almost the same, the modules are without fault.

Tester Polarity

R2/L1 P/L+ Discontinuity

Converter module

P/L+ R2/L1 Continuity

S2/L2 P/L+ Discontinuity

P/L+ S2/L2 Continuity

T2/L3 P/L+ Discontinuity

P/L+ T2/L3 Continuity

R2/L1 N/L- Continuity

N/L- R2/L1 Discontinuity

S2/L2 N/L- Continuity

N/L- S2/L2 Discontinuity

T2/L3 N/L- Continuity

N/L- T2/L3 Discontinuity

Measured Value

R2/L1

S2/L2

T2/L3

D1 D2 D3

D5 D6

P/L+

N/L-

PROTECTIVE FUNCTIONS

(Assumes the use of an analog meter.)

Page 41

Precautions for Maintenance and Inspection

3.2.7 Replacement of parts

The power regeneration common converter consists of many electronic parts such as semiconductor devices. The following parts may deteriorate with age because of their structures or physical characteristics, leading to reduced performance or failure of the power regeneration common converter. For preventive maintenance, the parts must be changed periodically. The part replacement guidelines for the power regeneration common converter are indicated in the following table. Lamps and other short-life parts must also be changed during periodic inspection.

Replacement Parts of the power regeneration common converter

Part Name Standard Replacement Interval Description

Cooling fan 2 to 3 years Change (as required)

Smoothing capacitor in main circuit 5 years Change (as required)

Smoothing capacitor on control board 5 years Change the board (as required)

Relays —— Change as required

Note: For part replacement, contact the nearest Mitsubishi FA center.

(1) Cooling fan

The cooling fan cools heat-generating parts such as the main circuit semiconductor devices. The life of the cooling fan bearing is usually 10,000 to 35,000 hours. Hence, the cooling fan must be changed every 2 to 3 years if the inverter is run continuously. When unusual noise and/or vibration is noticed during inspection, the cooling fan must be changed immediately. Change the cooling fan in the following procedure.

z Heat sink outside mounting structure model

FR-CV-7.5K to 30K, FR-CV-H11K to H30K

1) Disconnect the wiring of the power regeneration common converter unit and remove the unit from the enclosure.

2) Remove the screws that fasten the cooling fan.

FR-CV Cooling fan

Remove screws.

Unplug connector.

3) Unplugging the connector of the cooling fan removes the cooling fan from the unit.

4) Replace the cooling fan. Reinstall the cooling fan so that the arrows of the fan point in the directions as shown above.

5) Reinstall it to the power regeneration common converter unit in the reverse procedure.

Note: If the air flow is set in the wrong direction, the inverter life can be shorter.

Page 42

Precautions for Maintenance and Inspection

FR-CV-37K/55K, FR-CV-H37K/H55K

1) Disconnect the wiring of the power regeneration common converter unit.

2) Remove the front cover.

3) Unplug the cooling fan connector from the cooling fan connection cable fastening holder.

Cooling fan connector

Cooling fan connection cable fastening holder

4) Shift the protective covers and unplug the connectors.

Protective cover

PROTECTIVE FUNCTIONS

Page 43

Precautions for Maintenance and Inspection

5) Loosen the screws that fasten the cooling fan mounting fixture and pull out the cooling fan mounting fixture. Pull it out slowly, exercising care not to bring the cooling fan into contact with the printed board. (The screw holes of the cooling fan mounting fixture are pear-shaped.)

Cooling fan mounting fixture

6) Pinch the cable bushing with a pair of long-noise pliers etc. and remove the cable bushing.

7) Remove the cooling fan from the cooling fan mounting fixture, and change the cooling fan. When reinstalling the cooling fan, take care so that the arrows given on the cooling fan point as shown below.

Note: If the air flow is set in the wrong direction, the inverter life can be shorter.

8) Reinstall the cooling fan to the power regeneration common converter unit in the reverse procedure.

Page 44

Precautions for Maintenance and Inspection

z Enclosure inside installation structure model

FR-CV-7.5K to 30K(-AT), FR-CV-H7.5K to H30K(-AT)

1) Disconnect the wiring of the power regeneration common converter unit.

2) Remove the screws in the L-bracket that fasten the cooling fan.

L-bracket

Remove screws.

3) Unplugging the connector of the cooling fan removes the cooling fan from the unit.

4) Remove the L-bracket from the cooling fan to replace the cooling fan. Reinstall the cooling fan so that the arrows of the fan point in the directions as shown above.

5) Reinstall it to the power regeneration common converter unit in the reverse procedure.

Note: If the air flow is set in the wrong direction, the inverter life can be shorter.

FR-CV Coolng fan

Unplug connector.

(2) Smoothing capacitors

A large-capacity aluminum electrolytic capacitor is used for smoothing the DC in the main circuit, and an aluminum electrolytic capacitor is also used for stabilizing the control power in the control circuit. Their characteristics are adversely affected by ripple current, etc. This is greatly influenced by the ambient temperature and operating conditions. When the inverter is operated in on ordinary, air-conditioned environment, change the capacitors about every 5 years. Since the capacitors begin to deteriorate rapidly beyond a given period, check them at least once a year (desirably every six months or less when they are approaching the end of their useful life).

Check the following:

1) Case (side faces and bottom face for expansion)

2) Sealing plate (for remarkable warping and extreme cracks)

3) Explosion-proof valve (for excessive valve expansion and operation)

4) Appearance, external cracks, discoloration, leakage. When the measured capacitance of the capacitor has reduced below 85% of the rating, change the capacitor.

(3) Relays

To prevent a contact fault, etc., relays must be changed according to the number of accumulative switching times (switching life).

PROTECTIVE FUNCTIONS

Page 45

Precautions for Maintenance and Inspection

3.2.8 Measurement of main circuit voltages, currents and power

z Measurement of voltages and currents

When instruments for commercial frequency are used for measurement, measure the following circuits using the instruments given below. When installing measuring instruments etc. on the output side of the power regeneration common converter, choose the measuring instruments that have allowance in current rating since they may generate heat under the influence of line-to-line leakage currents if the wiring distance between the power regeneration common converter and inverter is long. The DC voltage, which is developed across the terminals P/L+ and N/L- of the power regeneration common converter, can be measured with a moving-coil instrument (tester). Though it varies with the power supply voltage, the voltage will reduce under load.

Power supply

W11

W12

W13

Dedicated

stand-alone

reactor

Power regeneration

common converter

R2/L1

P/L+

S2/L2

T2/L3

N/L-

To inverte

< Typical Measuring Points and Instruments >

z Classification and application by the operation principles of electrical indicator

instruments

Type Symbol Principle Indication

Utilizes the force that works between the

Moving-coil type

Moving-iron type

Electrodyn amometer type

Air core

magnetic field of the permanent magnet and the current flowing in the moving coil.

Utilizes the force that is produced between the magnetic field of the current flowing in the fixed coil and the moving iron.

Utilizes the force that works between the currents flowing in two coils.

DC (Average value)

AC (Effective value)

AC/DC (Effective value)

Applicable Instrument

Voltm eter, ammeter, resistance meter, thermometer, flux meter, rotating meter

Voltm eter, ammeter

Wattmeter, Voltm eter, ammeter

Features

High in sensitivity and most often used. Affected little by consumed power and external magnetic field.

Rigidly structured and low priced. Affected greatly by external magnetic field, frequency and waveform.

A wattmeter is graduated equally. Affected greatly by external magnetic field and large in power consumption. Usable as an AC/DC standard instrument.

Item Measuring Point Measuring Instrument

Power supply voltage V1

Power supply side current

Measuring Points and Instruments

Across R2/L1-S2/L2, S2/L2T2/L3, and T2/L3-R2/L1

R2/L1, S2/L2 and T2/L3 line currents

Moving-iron type AC voltmeter

Moving-iron type AC ammeter

Remarks

(Reference Measured Value) *

Commercial power supply Within permissible AC voltage fluctuation (Refer to page 44)

Page 46

Precautions for Maintenance and Inspection

Item Measuring Point Measuring Instrument

At R2/L1, S2/L2 and T2/L3

Power supply side power

Power supply side power factor Pf

Converter output side voltage

Reset Across RES (+) -SD

Alarm signal

and across R2/L1-S2/L2, S2/L2-T2/L3, and T2/L3-R2/ L1

Calculate after measuring power supply voltage, power supply side current and power supply side power.

Across P/L+-N/L-

Across A-C Across B-C

3 V

1 × I1

100

Electrodynamic type single-phase wattmeter

Moving-coil type (such as tester)

Moving-coil type (Tester, etc. may be used) (Internal resistance:

Ω or larger)

50k

Moving-coil type (such as tester)

Note: When a 24VDC power supply is connected across P24-SD.

*Values in parentheses indicate those for 400V class.

Remarks

(Reference Measured Value) *

1 = W11 + W12 + W13

P (3-wattmeter method)

Converter LED display lit

× V1

1.35 Maximum 380V (760V) during regenerative operation

20 to 30VDC when open. ON voltage: 1V or less (Note)

Continuity check

<At OFF> <At ON> Across A-C: Discontinuity Continuity Across B-C: Continuity Discontinuity

SD is common.

PROTECTIVE FUNCTIONS

Page 47

MEMO

Page 48

CHAPTER 4

SPECIFICATIONS

This chapter provides the "specifications" of this product. Always read the instructions before using the equipment.

4.1 Standard Specifications ............................. 44

Page 49

Standard Specifications

4.1 Standard Specifications

4.1.1 Model specifications

z 200V class

Heat sink outside mounting structure

FR-CV- K

Enclosure inside installation

Type

7.511152230

structure FR-CV- K-AT

Applicable inverter capacity (Note 1)

kW 7.5111522303755

HP 10 15 20 30 40 50 75

Applicable current (A) (Note 1) 33 46 61 90 115 145 215

Short-duration

Regenerative

Output

braking torque

rating

Continuous rating

Rated input AC voltage, frequency

Permissible AC voltage fluctuation

Permissible frequency fluctuation

Power supply

Power supply system capacity (kVA) (Note 2)

Three phase 200 to 220V 50Hz, 200 to 230V 60Hz

Three phase 170 to 242V 50Hz, 170 to 253V 60Hz

17 20 28 41 52 66 100

150% torque 60s

100% torque

±5%

Protective structure (JEM 1030) Open type (IP00)

Cooling system Forced air cooling

Heat sink

Approximately w eight (kg (lbs))

outside mounting structure

Enclosure inside installation

5.0

(11.0)

6.5

(14.3)

5.0

(11.0)

6.5

(14.3)

6.0

(13.2)

7.5

(16.5)

9.5

(20.9)

12.5

(27.6)

10.5

(23.1)

13.5

(29.8)

structure

Input signal Reset

Output signal Ready output signal, inverter run enable signal, converter reset, alarm signal

Overcurrent protection, overvoltage protection, electronic overcurrent protection,

Protective functions

undervoltage, phase failure, CPU alarm, instantaneous power failure alarm, power supply alarm

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

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

Storage temperature -20°C to 50°C (-4°F to 122°F)

Ambience Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)

Environment

Maximum 1000m (3280.80feet) above sea level for standard operation.

Altitude

After that derate by 3% for every extra 500m (1640.40feet) up to 2500m (8202.00feet) (91%).

Vibration

Dedicated stand-alone reactor

FR-CVL-

7.5K

FR-CVL-

11K

FR-CVL-

15K

5.9m/s

FR-CVL-

22K

or less

FR-CVL-

30K

(Note 4)55(Note 4)

(75.0)

FR-CVL-

37K

(83.8)

FR-CVL-

55K

Page 50

Standard Specifications

z 400V class

Heat sink outside mounting structure

FR-CV-H K

Enclosure inside installation

Type

7.511152230

structure FR-CV-H K-AT

Applicable inverter capacity (Note 1)

kW 7.5111522303755

HP 10 15 20 30 40 50 75

Applicable current (A) (Note 1) 17 23 31 43 57 71 110

Short-duration

Regenerative

Output

braking torque

rating

Continuous rating

Rated input AC voltage, frequency

Permissible AC voltage fluctuation

Permissible frequency fluctuation

Power supply

Power supply system capacity (kVA) (Note 2)

Three phase 380 to 480V 50Hz/60Hz

Three phase 323 to 528V 50Hz/60Hz

17 20 28 41 52 66 100

150% torque 60s

100% torque

±5%

Protective structure (JEM 1030) Open type (IP00)

Cooling system

Self-

cooling

Forced air cooling

Heat sink

Approximately w eight (kg (lbs))

outside mounting structure

Enclosure inside installation

6.0

(13.2)

7.5

(16.5)

6.0

(13.2)

7.5

(16.5)

6.0

(13.2)

7.5

(16.5)

10.0

(22.0)

13.0

(28.7)

10.0

(22.0)

13.0

(28.7)

structure

Input signal Reset

Output signal Ready output signal, inverter run enable signal, converter reset, alarm signal

Overcurrent protection, overvoltage protection, electronic overcurrent protection,

Protective functions

undervoltage, phase failure, CPU alarm, instantaneous power failure alarm, power supply alarm

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

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

Storage temperature -20°C to 50°C (-4°F to 122°F)

Ambience Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)

Environment

Maximum 1000m (3280.80feet) above sea level for standard operation.

Altitude

After that derate by 3% for every extra 500m (1640.40feet) up to 2500m (8202.00feet) (91%).

Vibration

Dedicated stand-alone reactor

FR-CVL-

H7.5K

FR-CVL-

H11K

FR-CVL-

H15K

5.9m/s

FR-CVL-

H22K

or less

FR-CVL-

H30K

(Note 4)55(Note 4)

32.5

(71.7)

FR-CVL-

H37K

32.5

(71.5)

FR-CVL-

H55K

SPECIFICATIONS

Page 51

Standard Specifications

Note: 1. The applicable inverter capacity is the sum total of the inverter capacities (up to six inverters). For the

FR-V500 series inverter, the capacity of the main circuit smoothing capacitor is larger than that of other types of transistorized inverter with same capacity. Therefore, use the substituted inverter capacity in the table below for selection.

Actual capacity [K]

of the FR-V500

Substituted capacity [K]

of the FR-V500 for use in combination

with the FR-CV.

Example: Applicable inverter capacity for the FR-CV-15K

1.5 2.2 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55

2.2 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55 55

→ •FR-A700 series

1) FR-A720-15K

2) FR-A720-11K + FR-A720-3.7K

•FR-V500 series

1) FR-V520-11K

2) FR-V520-7.5K + FR-V520-2.2K Make selection so that the sum of the rated currents of the used motors does not exceed the applicable current.

2. The power supply capacity changes with the values of the power supply side inverter impedances (including those of the input reactor and cables).

3. Since the dedicated stand-alone reactor is connected, a voltage may drop to cause motor torque shortage or a current may increase to overheat the motor.

4. The FR-CV-37K, 55K and FR-CV-H37K, H55K can be used as either a heat sink outside mounting structure model or an enclosure inside installation structure model by changing its mounting foot position. The mounting foot is factory-set in the heat sink outside mounting position. (Refer to page 8 for changing the mounting foot position.)

Page 52

4.1.2 Internal block diagram

R2/L1

S2/L2

T2/L3

Standard Specifications

FR-CV

P/L+

N/L-

R/L11

S/L21

T/MC1

P24

RES

Control power supply Phase detection Power supply voltage detection

CHARGE

RDYA

RDYB

RS0

SPECIFICATIONS

Page 53

Standard Specifications

4.1.3 Outline drawings

(1) Heat sink outside mounting structure model

z FR-CV-7.5K/11K/15K, FR-CV-H7.5K/H11K/H15K

(0.39)

280 (11.02)

(0.39)

φ6 hole

TB4

300 (11.81)

TB3

TB2

TB1

6 (0.24)

Note : FR-CV-H7.5K is not provided with the cooling fan.

200 (7.87)

Panel cutting dimensions

2-M5 screw

Through

hole

Converter type W W1DD1

FR-CV-7.5K/11K

90 (3.54) 303 (11.93) 103 (4.06) 82 (3.23)

FR-CV-15K

FR-CV-H7.5K/H11K/H15K

(0.35)

280 (11.02)

262 (10.31)

(0.35)

112 (4.41)105 (4.13)305 (12.01)120 (4.72)

z FR-CV-22K/30K, FR-CV-H22K/H30K

(0.39)

360 (14.17)

(0.39)

(2.36)

150 (5.91)

TB1

TB4

TB3

TB2

6 (0.24)

2-φ6 hole

380 (14.96)

200 (7.87)

(Unit: mm (inches))

Panel cutting dimensions

142 (5.59)

(2.36)

Through

hole

Converter type

FR-CV-22K/30K

FR-CV-H22K/H30K

4-M5 screw

9 (0.35)

342 (13.5)

(0.35)

322 (12.68)

305 (12.01)

360 (14.17)

122 (4.80)

105 (4.13)

(Unit: mm (inches))

Page 54

z FR-CV-37K/55K, FR-CV-H37K/H55K

2-φ10 hole

15 (0.59)

Standard Specifications

40 (1.57)

(1.77)

(0.39)

590 (23.23)

620 (24.41)

310 (12.20)

400 (15.75)

10 (0.39)

(0.59)

45 (1.77)

115

(4.53)

250 (9.84)

135

(5.31)

540 (21.26)

40 (1.57)

Can be installed inside enclosure by changing mounting foot position.

Panel cutting

dimensions

390 (15.35)

310 (12.2)

40 (1.57)

(0.79)

380 (14.96)

10 (0.39)

(1.57)

Through hole

4-M8 screw

550 (21.65)20590 (23.23)

(0.79)

(Unit: mm (inches))

SPECIFICATIONS

Page 55

Standard Specifications

(2) Enclosure inside installation structure model

z FR-CV-7.5K/11K/15K-AT, FR-CV-H7.5K/H11K/H15K-AT

2-φ6 hole

8 (0.31)

15 (0.59)

TB4

314 (12.36)

330 (12.99)

TB3

TB2

300 (11.81)

TB1

(0.24)

8 (0.31)

15 (0.59)

200 (7.87)

Note : FR-CV-H7.5K-AT is not provided with the cooling fan.

z FR-CV-22K/30K-AT, FR-CV-H22K/H30K-AT

2-φ7 hole

(0.28)

TB4

410 (16.14)

396 (15.59)

(0.59)

380 (14.96)

315

320

115

(4.53)

120

(4.72)

Converter type W W1 D

FR-CV-7.5K/

11K-AT

(4.33)

FR-CV-15K-AT

FR-CV-H7.5K/

H11K/H15K-AT

(5.12)

110

130

(2.36)

(3.54)

(12.40)

(12.60)

(Unit: mm (inches))

TB1

7 (0.28)

120 (4.72)

160 (6.30)

TB3

TB2

7 (0.28)

(0.59)

200 (7.87)

350 (13.78)

150 (5.91)

(Unit: mm (inches))

Page 56

(3) Dedicated stand-alone reactor

1)200V class

z FR-CVL-7.5K/11K/15K/22K

Standard Specifications

Capacity plate (Note)

R/L11

R2/L12

S/L21

S2/L22

55 (2.17) _

1.5 (0.06)

165 (6.50) 2.5 (0.10)

T/L31

T2/L32

4-8 15 slot

Terminal cover

2-M4 screw

155 (6.10) maximum

Note :

Wire the cables so that the primary side characters read at top and the secondary side ones at bottom on the capacity plate.

D1 1.5 (0.06)

D 2.5 (0.10)

Reactor type

FR-CVL-7.5K

FR-CVL-11K

FR-CVL-15K

FR-CVL-22K

130 (5.12) maximum

140 (5.51) maximum

82 (3.23)

75 (2.95)

105 (4.13)

110 (4.33)

Approximately weight (kg (lbs))D1

4.5 (9.9)

4.0 (8.8)

5.5 (12.1)

6.5 (14.3)

(Unit : mm (inches))

SPECIFICATIONS

Page 57

Standard Specifications

z FR-CVL-30K

Capacity plate (Note)

R/L11

R2/L12 S2/L22

S/L21

Terminal cover

70 (2.76)

1.5 (0.06)

215 (8.46) 2.5 (0.10)

T/L31

T2/L32

4-8 15 slot

2-M4 screw

Note :

Wire the cables so that the primary side characters read at top and the secondary side ones at bottom on the capacity plate.

175 (6.89) maximum

120 (4.72) 1.5 (0.06)

160 (6.30) maximum

Approximately weight (kg (lbs))

11.0 (24.3)

(Unit : mm (inches))

Page 58

z FR-CVL-37K/55K

Capacity plate (Note)

R/L11

R2/L12

S/L21

S2/L22

T/L31

T2/L32

4-10 15 slot

Standard Specifications

Note :

Wire the cables so that the primary side characters read at top and the secondary side ones at bottom on the capacity plate.

Terminal cover

W1 1.5 (0.06)

W 2.5 (0.10)

Reactor type

FR-CVL-37K

FR-CVL-55K

4-M4 screw

320

(12.60)

335

(13.19)

120

(4.72)

135

(5.31)

220

(8.66)

250

(9.84)

200

(7.87)

225

(8.86)

D1 1.5 (0.06)

D 2.5 (0.10)

200 (7.87)

maximum

225 (8.86)

maximum

Approximately

weight (kg (lbs))

16.0 (35.3)

20.0 (44.1)

(Unit : mm (inches))

SPECIFICATIONS

Page 59

Standard Specifications

2)400V class

z FR-CVL-H7.5K/H11K/H15K

L11 L21 L31

Capacity plate (Note)

Terminal cover

4-8 15 slot

Note :

Wire the cables so that the primary side characters read at top and the secondary side ones at bottom on the capacity plate.

L32L22L12

2-M4 screw

135 (5.31) maximum

200 (7.87) 1.5 (0.06)

220 (8.66) 2.5 (0.10)

Reactor type

FR-CVL-H7.5K

FR-CVL-H11K

FR-CVL-H15K

200 (7.87) maximum

205 (8.07) maximum

88 (3.46)

98 (3.86)

D 1.5 (0.06)

Approximately weight (kg (lbs))

7.0 (15.4)

7.5 (16.5)

8.0 (17.6)

(Unit : mm (inches))

Page 60

z FR-CVL-H22K/H30K

Standard Specifications

L11 L21 L31

Capacity plate (Note)

Terminal cover

4-8 15 slot

Note :

Wire the cables so that the primary side characters read at top and the secondary side ones at bottom on the capacity plate.

L32L22L12

2-M4 screw

Reactor type D

FR-CVL-H22K

FR-CVL-H30K

150

(5.91)

185

(7.28)

113

(4.45)

125

(4.92)

220

(8.66)

245

(9.65)

200

(7.87)

225

(8.86)

215 (8.46) maximum

220 (8.66) maximum

D1 1.5 (0.06)

Approximately weight (kg (lbs))

10.5

(23.1)

12.0

(26.5)

(Unit : mm (inches))

SPECIFICATIONS

Page 61

Standard Specifications

z FR-CVL-H37K/H55K

Capacity plate (Note)

Terminal cover

R/L11 S/L21 T/L31

R2/L12 S2/L22 T2/L32

4-10 15 slot

Note :

4-M4 screw

Wire the cables so that the primary side characters read at top and the secondary side ones at bottom on the capacity plate.

Reactor type D

FR-CVL-H37K

FR-CVL-H55K

W1 1.5 (0.06)

W 2.5 (0.10)

125

230

(4.92)

(9.06)

138

230

(5.43)

(9.06)

245

(9.65)

290

(11.42)

225

(8.86)

270

(10.63)

265 (10.43)

maximum

280 (11.02)

maximum

D1 1.5 (0.06)

Approximately weight (kg (lbs))

16.0

(35.3)

22.5

(49.6)

(Unit : mm (inches))

Page 62

MEMO

Page 63

REVISIONS

Print Date

Aug., 2001 IB(NA)-0600075-A First edition

Jan., 2003 IB(NA)-0600075-B

* Manual Number

Additions

•Support the FR-V500, C500 and F500J.

Partial additions

•Wiring

The manual number is given on the bottom left of the back cover.

Revision

Sep., 2008 IB(NA)-0600075-C

Partial additions

•Note for terminal connection diagram

•Instructions for installation

IB(NA)-0600075-C

Mitsumi electronic H55K, FR-CVL-H7.5K, FR-CV-H7.5K, FR-CVL-7.5K, FR-CV-7.5K User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

This section is specifically about safety matters

CONTENTS

1.1 Pre-Operation Information

1.1.1 Precautions for operation

1.2 Basic Configuration

1.2.1 Basic configuration

1.3 Structure

1.3.1 Appearance and structure

1.3.2 Removal and reinstallation

1.3.3 Structure of the power regeneration common converter

2.1 Installation

2.1.1 Instructions for installation

2.2 Wiring

2.2.1 Terminal connection diagram

2.2.2 Wiring of the main circuit

2.2.3 Wiring of the control circuit

2.2.4 Design information

2.3 Operation

2.3.1 Pre-operation checks

2.3.2 Power-on and operation

2.4 Other wiring

2.4.1 Power harmonics

2.4.2 Noise types and reduction techniques

2.4.3 Peripheral devices

2.4.4 Instructions for UL and cUL

3.1 Errors (Alarms)

3.1.1 Error (alarm) definitions

3.1.2 Alarm symptoms and check points

3.2 Precautions for Maintenance and Inspection

3.2.1 Precautions for maintenance and inspection

3.2.2 Check items

3.2.3 Periodic inspection

3.2.4 Insulation resistance test using megger

3.2.5 Pressure test

3.2.6 Daily and Periodic Inspection

3.2.7 Replacement of parts

3.2.8 Measurement of main circuit voltages, currents and power

4.1 Standard Specifications

4.1.1 Model specifications

4.1.2 Internal block diagram

4.1.3 Outline drawings

REVISIONS