Mitsubishi Electric FR-E500 Series User manual

FR-E 500
Frequency Inverter
Instruction Manual
FR-E 520S EC,
FR-E 540 EC
INDUSTRIAL AUTOMATION
MIT
SU
BI
S
HI ELE
C
TRI
C
MIT
SU
BI
S
HI ELE
C
TRI
C
Art. no.: 125256
01 07 2001
Version F

A - 1
Thank you for choosing the Mitsubishi Transistorized inverter.
This instruction manual gives handling information and precautions for use of this
equipment.
Incorrect handling might cause an unexpected fault. Before using the inverter,
please read this manual carefully to use the equipment to its optimum.
Please forward this manual to the end user.
This section is specifically about safety matters
Do not attempt to install, operate, maintain or inspect the inverter until you have read
through this instruction manual and appended documents carefully and can use the
equipment correctly.
Do not use the inverter until you have a full knowledge of the equipment, safety
information and instructions.
In this manual, the safety instruction levels are classified into "WARNING" and
"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.
Note that even the CAUTION level may lead to a serious consequence according to
conditions. Please follow the instructions of both levels because they are important
to personnel safety.
WARNING
CAUTION

A - 2
SAFETY INSTRUCTIONS
1. Electric Shock Prevention
WARNING
!While power is on or when the inverter is running, do not open the front cover.
You may get an electric shock.
!Do not run the inverter with the front cover removed. Otherwise, you may access
the exposed high-voltage terminals or the charging part of the circuitry and get
an electric shock.
!If power is off, do not remove the front cover except for wiring or periodic
inspection. You may access the charged inverter circuits and get an electric
shock.
!Before starting wiring or inspection, switch power off, wait for more than 10
minutes, and check for residual voltage with a meter (refer to chapter 2 for
further details) etc.
!Earth the Inverter.
!Any person who is involved in the wiring or inspection of this equipment should
be fully competent to do the work.
!Always install the inverter before wiring. Otherwise, you may get an electric
shock or be injured.
!Operate the switches and potentiometers with dry hands to prevent an electric
shock.
!Do not subject the cables to scratches, excessive stress, heavy loads or
pinching. Otherwise, you may get an electric shock.
!Do not change the cooling fan while power is on.
It is dangerous to change the cooling fan while power is on.
2. Fire Prevention
CAUTION
!Mount the inverter and brake resistor on an incombustible surface. Installing the
inverter directly on or near a combustible surface could lead to a fire.
!If the inverter has become faulty, switch off the inverter power. A continuous flow
of large current could cause a fire.
!When a brake resistor is used, use an alarm signal to switch power off.
Otherwise, the brake resistor will overheat abnormally due a brake transistor or
other fault, resulting in a fire.
!Do not connect a resistor directly to the DC terminals +, −. This could cause a
fire.

A - 3
3. Injury Prevention
CAUTION
!Apply only the voltage specified in the instruction manual to each terminal to
prevent damage etc.
!Ensure that the cables are connected to the correct terminals. Otherwise,
damage etc. may occur.
!Always make sure that polarity is correct to prevent damage etc.
!While power is on and for some time after power-off, do not touch the inverter or
brake resistor as they are hot and you may get burnt.
4. Additional instructions
Also note the following points to prevent an accidental failure, injury, electric shock, etc.
(1)Transportation and installation
CAUTION
!When carrying products, use correct lifting gear to prevent injury.
!Do not stack the inverter boxes higher than the number recommended.
!Ensure that installation position and material can withstand the weight of the
inverter. Install according to the information in the Instruction Manual.
!Do not operate if the inverter is damaged or has parts missing.
!Do not hold the inverter by the front cover or operation panel; it may fall off.
!Do not stand or rest heavy objects on the inverter.
!Check the inverter mounting orientation is correct.
!Prevent screws, wire fragments or other conductive bodies or oil or other
flammable substance from entering the inverter.
!Do not drop the inverter, or subject it to impact.
!Use the inverter under the following environmental conditions:
Ambient
temperature Constant torque : -10°C to +50°C (non-freezing)
Ambient humidity 90%RH or less (non-condensing)
Storage
temperature -20°C to +65°C *
Ambience Indoors (free from corrosive gas, flammable gas, oil mist, dust
and dirt)
Environment
Altitude, vibration Maximum 1000m above sea level for standard operation. After that derate by 3% for every extra 500m up to 2500m (91%).
5.9m/s2or less (conforming to JIS C 0040)
*Temperatures applicable for a short time, e.g. in transit.

A - 4
(2)Wiring
CAUTION
!Do not fit capacitive equipment such as power factor correction capacitor, radio
noise filter or surge suppressor to the output of the inverter.
!The connection orientation of the output cables U, V, W to the motor will affect
the direction of rotation of the motor.
(3)Trial run
CAUTION
!Check all parameters, and ensure that the machine will not be damaged by a
sudden start-up.
(4)Operation
WARNING
!When you have chosen the retry function, stay away from the equipment as it
will restart suddenly after an alarm stop.
!The [STOP]key is valid only when the appropriate function setting has been
made. Prepare an emergency stop switch separately.
!Make sure that the start signal is off before resetting the inverter alarm. A failure
to do so may restart the motor suddenly.
!The load used should be a three-phase induction motor only. Connection of any
other electrical equipment to the inverter output may damage the equipment.
!Do not modify the equipment.

A - 5
CAUTION
!The electronic overcurrent protection does not guarantee protection of the motor
from overheating.
!Do not use a magnetic contactor on the inverter input for frequent
starting/stopping of the inverter.
!Use a noise filter to reduce the effect of electromagnetic interference. Otherwise
nearby electronic equipment may be affected.
!Take measures to suppress harmonics. Otherwise power harmonics from the
inverter may heat/damage the power capacitor and generator.
!When a 400V class motor is inverter-driven, it should be insulation-enhanced or
surge voltages suppressed. Surge voltages attributable to the wiring constants
may occur at the motor terminals, deteriorating the insulation of the motor.
!When parameter clear or all clear is performed, each parameter returns to the
factory setting. Re-set the required parameters before starting operation.
!The inverter can be easily set for high-speed operation. Before changing its
setting, fully examine the performances of the motor and machine.
!In addition to the inverter's holding function, install a holding device to ensure
safety.
!Before running an inverter which had been stored for a long period, always
perform inspection and test operation.
(5)Emergency stop CAUTION
!Provide a safety backup such as an emergency brake which will prevent the
machine and equipment from hazardous conditions if the inverter fails.
(6)Maintenance, inspection and parts replacement
CAUTION
!Do not carry out a megger (insulation resistance) test on the control circuit of the
inverter.
(7)Disposing of the inverter CAUTION
!Treat as industrial waste.
(8)General instructions
Many of the diagrams and drawings in this instruction manual show the inverter
without a cover, or partially open. Never operate the inverter like this. Always
replace the cover and follow this instruction manual when operating the inverter.

CONTENTS
I
1 OUTLINE 1
1.1 Pre-Operation Information ..........................................................................................1
1.1.1 Precautions for operation.....................................................................................1
1.2 Basic Configuration.....................................................................................................3
1.2.1 Basic configuration...............................................................................................3
1.3 Structure .....................................................................................................................4
1.3.1 Appearance and structure....................................................................................4
1.3.2 Removal and reinstallation of the front cover.......................................................5
1.3.3 Removal and reinstallation of the wiring cover.....................................................6
1.3.4 Removal and reinstallation of the accessory cover..............................................7
1.3.5 Reinstallation and removal of the control panel....................................................8
1.3.6 Removal of the operation panel (FR-PA02-02) front cover.................................10
1.3.7 Exploded view....................................................................................................10
2 INSTALLATION AND WIRING 11
2.1 Installation.................................................................................................................11
2.1.1 Instructions for installation..................................................................................11
2.2 Wiring........................................................................................................................13
2.2.1 Terminal connection diagram (when source logic is selected)...........................13
2.2.2 Wiring of the Main Circuit...................................................................................17
2.2.3 Wiring of the control circuit.................................................................................22
2.2.4 Connection to the PU connector ........................................................................26
2.2.5 Connection of stand-alone option units..............................................................29
2.2.6 Design information .............................................................................................31
2.3 Other wiring...............................................................................................................32
2.3.1 Power supply harmonics ....................................................................................32
2.3.2 Inverter-generated noise and reduction techniques...........................................33
2.3.3 Leakage currents and countermeasures............................................................37
2.3.4 Inverter-driven 400V class motor........................................................................38
2.3.5 Peripheral devices..............................................................................................39
2.3.6 Instructions for compliance with U.S. and Canadian Electrical Codes..............43
2.3.7 Instructions for compliance with the European standards..................................44
Contents

II
3 OPERATION/CONTROL 46
3.1 Pre-Operation Information ........................................................................................46
3.1.1 Types of operation modes..................................................................................46
3.1.2 Power on............................................................................................................48
3.2 About the Control Panel............................................................................................49
3.2.1 Names and functions of the control panel (FR-PA02-02) ...................................49
3.2.2 Control panel mode is changed by pressing the MODE key.................................50
3.2.3 Monitoring...........................................................................................................50
3.2.4 Frequency setting...............................................................................................51
3.2.5 Parameter setting method..................................................................................51
3.2.6 Operation mode..................................................................................................53
3.2.7 Help mode..........................................................................................................53
3.3 Operation..................................................................................................................55
3.3.1 Pre-operation checks .........................................................................................55
3.3.2 External operation mode (Operation using the external
frequency setting potentiometer and external start signal).................................56
3.3.3 PU operation mode (Operation using the control panel)....................................57
3.3.4 Combined operation mode 1 (Operation using both external
start signal and control panel)............................................................................58
3.3.5 Combined operation mode 2..............................................................................59
4 PARAMETERS 60
4.1 Parameter List...........................................................................................................60
4.1.1 Parameter list.....................................................................................................60
4.1.2 List of Parameters Classified by Purpose of Use...............................................66
4.1.3 Parameters recommended to be set by the user...............................................68
4.2 Parameter Function Details ......................................................................................69
4.2.1 Torque boost (Pr. 0, Pr. 46)................................................................................69
4.2.2 Output frequency range (Pr. 1, Pr. 2, Pr. 18)......................................................70
4.2.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19, Pr. 47) .........................71
4.2.4 Multi-speed operation
(Pr. 4, Pr. 5, Pr. 6, Pr. 24 to Pr. 27, Pr. 232 to Pr. 239)......................................72
4.2.5 Acceleration/deceleration time (Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45) .......73
4.2.6 Electronic overcurrent protection (Pr. 9, Pr. 48).................................................75

III
4.2.7 DC injection brake (Pr. 10 to Pr. 12)...................................................................76
4.2.8 Starting frequency (Pr. 13) .................................................................................77
4.2.9 Load pattern selection (Pr. 14)...........................................................................78
4.2.10 Jog operation (Pr. 15, Pr. 16)...........................................................................79
4.2.11 Stall prevention (Pr. 22, Pr. 23, Pr. 66).............................................................80
4.2.12 Acceleration/deceleration pattern (Pr. 29)........................................................82
4.2.13 Regenerative brake duty (Pr. 30, Pr. 70)..........................................................83
4.2.14 Frequency jump (Pr. 31 to Pr. 36)....................................................................84
4.2.15 Speed display (Pr. 37)......................................................................................85
4.2.16 Frequency at 5V (10V) input (Pr. 38)................................................................86
4.2.17 Frequency at 20mA input (Pr. 39) ....................................................................86
4.2.18 Up-to-frequency sensitivity (Pr. 41)..................................................................87
4.2.19 Output frequency detection (Pr. 42, Pr. 43)......................................................88
4.2.20 Monitor display (Pr. 52, Pr. 158).......................................................................89
4.2.21 Monitoring reference (Pr. 55, Pr. 56)................................................................91
4.2.22 Automatic restart after instantaneous power failure (Pr. 57, Pr. 58).................92
4.2.23 Remote setting function selection (Pr. 59)........................................................93
4.2.24 Shortest acceleration/deceleration mode (Pr. 60 to Pr. 63)..............................95
4.2.25 Retry function (Pr. 65, Pr. 67 to Pr. 69)............................................................96
4.2.26 Applied motor (Pr. 71)......................................................................................98
4.2.27 PWM carrier frequency (Pr. 72, Pr. 240)..........................................................99
4.2.28 Voltage input (Pr. 73, Pr. 254)........................................................................100
4.2.29 Input filter time constant (Pr. 74)....................................................................102
4.2.30 Reset selection/disconnected PU detection/PU stop selection (Pr. 75).........102
4.2.31 Parameter write inhibit selection (Pr. 77)........................................................104
4.2.32 Reverse rotation prevention selection (Pr. 78)...............................................105
4.2.33 Operation mode selection (Pr. 79) .................................................................106
4.2.34 General-purpose magnetic flux vector control selection (Pr. 80).........................110
4.2.35 Offline auto tuning function (Pr. 82 to Pr. 84, Pr. 90, Pr. 96)..........................111
4.2.36 Computer link operation (Pr. 117 to Pr. 124, Pr. 338 to Pr. 340, Pr. 342)......117
4.2.37 PID control (Pr. 128 to Pr. 134)......................................................................134
4.2.38 Output current detection function (Pr. 150, Pr. 151).......................................142
4.2.39 Zero current detection (Pr. 152, Pr. 153)........................................................143
4.2.40 Stall prevention function and current limit function (Pr. 156)..........................144
4.2.41 User group selection (Pr. 160, Pr. 173 to Pr. 176) .........................................146
Contents

IV
4.2.42 Actual operation hour meter clear (Pr. 171) ...................................................148
4.2.43 Input terminal function selection (Pr. 180 to Pr. 183).....................................148
4.2.44 Output terminal function selection (Pr. 190 to Pr. 192)...................................150
4.2.45 Cooling fan operation selection (Pr. 244).......................................................151
4.2.46 Slip compensation (Pr. 245 to Pr. 247) ..........................................................152
4.2.47 Stop selection (Pr. 250)..................................................................................153
4.2.48 Output phase failure protection selection (Pr. 251)........................................154
4.2.49 Meter (frequency meter) calibration (Pr. 901).................................................155
4.2.50 Biases and gains of the frequency setting voltage (current)
(Pr. 902 to Pr. 905)..........................................................................................157
5 PROTECTIVE FUNCTIONS 163
5.1 Errors (Alarms)........................................................................................................163
5.1.1 Error (alarm) definitions....................................................................................163
5.1.2 To know the operating status at the occurrence of alarm.................................171
5.1.3 Correspondence between digital and actual characters...................................171
5.1.4 Resetting the inverter .......................................................................................171
5.2 Troubleshooting......................................................................................................172
5.2.1 Motor remains stopped.....................................................................................172
5.2.2 Motor rotates in opposite direction ...................................................................172
5.2.3 Speed greatly differs from the setting...............................................................173
5.2.4 Acceleration/deceleration is not smooth...........................................................173
5.2.5 Motor current is large........................................................................................173
5.2.6 Speed does not increase..................................................................................173
5.2.7 Speed varies during operation..........................................................................173
5.2.8 Operation mode is not changed properly.........................................................174
5.2.9 Control panel display is not operating ..............................................................174
5.2.10 POWER lamp is not lit....................................................................................174
5.2.11 Parameter write cannot be performed............................................................174
5.3 Precautions for Maintenance and Inspection..........................................................175
5.3.1 Precautions for maintenance and inspection ...................................................175
5.3.2 Check items......................................................................................................175
5.3.3 Periodic inspection...........................................................................................175
5.3.4 Insulation resistance test using megger...........................................................176
5.3.5 Pressure test....................................................................................................176

V
5.3.6 Daily and Periodic Inspection...........................................................................177
5.3.7 Replacement of parts.......................................................................................180
5.3.8 Measurement of main circuit voltages, currents and powers............................184
6 SPECIFICATIONS 186
6.1 Standard Specifications..........................................................................................186
6.1.1 Model specifications.........................................................................................186
6.1.2 Common specifications....................................................................................188
6.1.3 Outline drawings...............................................................................................190
APPENDIX 192
Appendix 1 Data Code List...........................................................................................192
Appendix 2 When using the communicaton option.......................................................196
Contents

C H A P T E R 1
O U T L I N E
This chapter gives information on the basic "outline" of this
product.
Always read the instructions before using the equipment.
1.1 Pre-Operation Information ..........................................1
1.2 Basic Configuration.....................................................3
1.3 Structure.....................................................................4
<Abbreviations>
!PU
Control panel and parameter
unit (FR-PU04)
!Inverter
Mitsubishi transistorized inverter
FR-E500 series
!Pr.
Parameter number
CHAPTER 1
OUTLINE
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6

OUTLINE
1
1.1 Pre-Operation Information
1 OUTLINE
1.1 Pre-Operation Information
1.1.1 Precautions for operation
This manual is written for the FR-E500 series transistorized inverters.
Incorrect handling may cause the inverter to operate incorrectly, causing its life to be
reduced considerably, or at the worst, the inverter to be damaged. Handle the inverter
properly in accordance with the information in each section as well as the precautions
and instructions of this manual to use it correctly.
For handling information on the parameter unit (FR-PU04), stand-alone options, etc.,
refer to the corresponding manuals.
(1) Unpacking and product check
Unpack the inverter and check the capacity plate on the front cover and the rating plate
on the inverter side face to ensure that the product agrees with your order and the
inverter is intact.
1) Inverter type
Rating plate
Inverter
type
Input rating
Output rating
Serial number
MITSUBISHI
MODEL INVERTER
FR-E540-0.4K-EC
INPUT :
OUTPUT :
SERIAL :
XXXXX
XXXXX
PASSED
Rating plate
FR-E540-0.4K-EC
Inverter t
y
pe Serial number
Capacity plate
Capacity plate
"
""
"Inverter type
Represents the
inverter capacity
"kW".
Symbol Voltage Class
E540 Three-phase
400V class
FR - E540 -0.4
E520S Single-phase
200V class
K - EC
2) Accessory
Instruction manual
If you have found any discrepancy, damage, etc., please contact your sales
representative.

OUTLINE
2
(2) Preparation of instruments and parts required for operation
Instruments and parts to be prepared depend on how the inverter is operated. Prepare
equipment and parts as necessary. (Refer to page 46.)
(3) Installation
To operate the inverter with high performance for a long time, install the inverter in a
proper place, in the correct direction, with proper clearances. (Refer to page 11.)
(4) Wiring
Connect the power supply, motor and operation signals (control signals) to the terminal
block. Note that incorrect connection may damage the inverter and peripheral devices.
(See page 13.)
1

1.2 Basic Configuration OUTLINE
3
1.2 Basic Configuration
1.2.1 Basic configuration
The following devices are required to operate the inverter. 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 inverter 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
Power
supply Use the power supply within the
permissible power supply specifications
of the inverter. (Refer to page 186.)
Earth leakage
circuit
breaker or
no-fuse
breaker
The breaker should be selected with
care since a large inrush current flows
in the inverter at power on. (Refer to
page 39.)
Magnetic
contactor Do not use this magnetic contactor to
start or stop the inverter. It might reduce
the inverter life. (Refer to page 39.)
Reactors
The reactors must be used when the
power factor is to be improved or the
inverter is installed near a large power
supply system (1000KVA or more and
wiring distance within 10m). Make
selection carefully.
EMC Filter To reduce mains conducted emissions.
Refer to EMC Installation Guidelines
manual.
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. (Refer to page 11.)
•Wrong wiring might lead to inverter
damage. The control signal lines
should be kept away from the main
circuit to protect them from noise.
(Refer to page 13.)
Devices
connected to
the output
Do not connect a power capacitor,
surge suppressor or radio noise
filter to the output side.
Earth
(ground)
To prevent an electric shock, always
earth (ground) the motor and inverter.
The ground wiring from the power line
of the inverter as an induction noise
reduction technique is recommended to
be run by returning it to the ground
terminal of the inverter. (Refer to page
36)
(MC)
(NFB)
or
(ELB)
Earth (ground)
Earth (ground)
A
C reactor
(FR-BAL)
DC reactor
(FR-BEL)

OUTLINE
4
1.3 Structure
1.3 Structure
1.3.1 Appearance and structure
(1) Front view
Front cover
Rating plate
Capacity plate
Accessory cover
Wiring port cover
for option
(2) Without front cover and accessory cover
PU connector*
POWER lamp (yellow)
ALARM lamp (red)
Control circuit terminal block
Main circuit terminal block
Wiring cover
Inboard option
mounting position
Connector for connection
of inboard option
Control logic changing
connector
*The PU connector is used for connection of the FR-PA02-02 or FR-PU04 option or to make RS-485
communication.
1

OUTLINE
5
1.3.2 Removal and reinstallation of the front cover
"
""
"Removal
The front cover is fixed with catches in positions A, B and C.
Push A and B in the directions of arrows at the same time and remove the
cover using C as supporting points.
2) 3)
C
A B
C
1
)
"
""
"Reinstallation
When reinstalling the front cover after wiring, fix the catches securely.
With the front cover removed, do not switch power on.
Note:1. Make sure that the front cover has been reinstalled securely.
2. The same serial number is printed on the capacity plate of the front cover
and the rating plate of the inverter. Before reinstalling the front cover, check
the serial numbers to ensure that the cover removed is reinstalled to the
inverter from where it was removed.

OUTLINE
6
1.3.3 Removal and reinstallation of the wiring cover
"
""
"Removal
Remove the wiring cover by pulling it in the direction of arrow A.
A
Wiring hole
"
""
"Reinstallation
Pass the cables through the wiring hole and reinstall the cover in the original
position.
1

OUTLINE
7
1.3.4 Removal and reinstallation of the accessory cover
"
""
"Removal
Hold down the portion A indicated by the arrow and lift the right hand side
using the portion B indicated by the arrow as a support, and pull out the
accessory cover to the right.
1)
A
B
2) 3)
"
""
"Reinstallation
Insert the mounting catch (left hand side) of the accessory cover into the
mounting position of the inverter and push in the right hand side mounting
catch to install the accessory cover.
Accessory cover
Mounting position
Catch A
1) 2) 3)

OUTLINE
8
1.3.5 Reinstallation and removal of the control panel
To ensure safety, reinstall and remove the optional control panel (FR-PA02-02) after
switching power off.
The charging area and control printed board are exposed on the rear surface of the
control panel. When removing the control panel, always fit the rear cover option
FR-E5P. Never touch the control printed board because touching it can cause the
inverter to fail.
"
""
"Reinstallation
Insert the mounting catch (left hand side) of the accessory cover into the
mounting position of the inverter and push in the right hand side mounting
catch to install the accessory cover.
FR-PA02-02
Mounting position
Catch A
1) 2) 3)
"
""
"Removal of the control panel
Hold down the portion A indicated by the arrow and lift the right hand side
using the portion B indicated by the arrow as a support, and pull out the
accessory cover to the right.
1)
A
B
2) 3)
(If the above procedure is not used for removal, the internal connector may be
damaged by the force applied.)
1