Mitsubishi Electric FR-A5AP User manual

IB(NA)-66848-C (0302)
TRANSISTORIZED INVERTER
Printed in Japan Specifications subject to change without notice.
TRANSISTORIZED INVERTER INSTRUCTION MANUAL
TRANSISTORIZED INVERTER
-INSTRUCTION MANUAL-
HEAD OFFICE:MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100-8310 FR-A5AP
ORIENTATION CONTROL / ENCODER FEEDBACK
CONTROL / PULSE TRAIN INPUT

A-1
Thank you for choosing the Mitsubishi transistorized inverter option unit.
This instruction manual gives handling information and precautions for use of this equipment. Incorrect handling
might cause an unexpected fault. Before using the equipment, please read this manual carefully to use the equipment
to its optimum.
Please forward this manual to the end user.
1. Electric Shock Prevention
This section is specifically about safety matters
Do not attempt to install, operate, maintain or inspect this product until you have read through this instruction
manual and appended documents carefully and can use the equipment correctly. Do not use this product until you
have a full knowledge of the equipment, safety information and instructions.
In this instruction manual, the safety instruction levels are classified into "WARNING" and "CAUTION".
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 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.
SAFETY INSTRUCTIONS
!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 and charging part and get an electric shock.
!Even if power is off, do not remove the front cover except for wiring or periodic inspection. You may access the
charged inverter circuits and get an electric shock.
!Before starting wiring or inspection, switch power off, wait for more than 10 minutes, and check for no residual
voltage with a tester or the like.
WARNING
CAUTION
CAUTION
WARNING

A-2
2. Injury Prevention
3. Additional instructions
Also note the following points to prevent an accidental failure, injury, electric shock, etc.:
(1) Transportation and mounting
(2) Test operation and adjustment
!Any person who is involved in the wiring or inspection of this equipment should be fully competent to do the work.
!Always install the option unit before wiring. Otherwise, you may get an electric shock or be injured.
!Handle this option unit with dry hands to prevent an electric shock.
!Do not subjectthe cables to scratches, excessive stress, heavy loads or pinching. Otherwise, you may get an electric shock.
!Apply only the voltage specified in the instruction manual to each terminal to prevent burst, damage, etc.
!Ensure that the cables are connected to the correct terminals. Otherwise, burst, damage, etc. may occur.
!Always make sure that polarity is correct to prevent burst, damage, etc.
!While power is on or for some time after power-off, do not touch the inverter as it is hot and you may get burnt.
!Do not install or operate the option unit if it is damaged or has parts missing.
!Do not stand or rest heavy objects on the product.
!Check that the mounting orientation is correct.
!Prevent screws, metal fragments or other conductive bodies or oil or other flammable substance from entering the inverter.
!Before starting operation, confirm and adjust the parameters. A failure to do so may cause some machines to
make unexpected motions.
WARNING
CAUTION
CAUTION
CAUTION

A-3
(3) Usage
(4) Maintenance, inspection and parts replacement
(5) Disposal
(6) General instruction
!Do not modify the equipment.
!When parameter clear or all parameter clear is performed, each parameter returns to the factory setting. Re-set
the required parameters before starting operation.
!For prevention of damage due to static electricity, touch nearby metal before touching this product to eliminate
static electricity from your body.
!Do not test the equipment with a megger (measure insulation resistance).
!Treat as industrial waste.
All illustrations given in this manual may have been drawn with covers or safety guards removed to provide in-
depth description. Before starting operation of the product, always return the covers and guards into original
positions as specified and operate the equipment in accordance with the manual.
WARNING
CAUTION
CAUTION
CAUTION

CONTENTS
1.PRE-OPERATION INSTRUCTIONS 1
1.1 Unpacking and Product Confirmation..................................................................................................1
1.2 Packing Confirmation...........................................................................................................................3
1.3 Structure ..............................................................................................................................................3
2.INSTALLATION 4
2.1 Pre-Installation Instructions..................................................................................................................4
2.2 Installation Procedure.........................................................................................................................4
2.3 Wiring...................................................................................................................................................6
3. ORIENTATION CONTROL—A500(L) 7
3.1 Wiring Example....................................................................................................................................7
3.2 Terminals.............................................................................................................................................9
3.3 Wiring Instructions .............................................................................................................................12
3.4 Parameter List....................................................................................................................................14
3.5 Parameter Settings............................................................................................................................16
3.5.1 Setting of stop position command...............................................................................................16
3.5.2 Internal stop position command..................................................................................................17
3.5.3 External stop position command.................................................................................................18
3.5.4 Time setting ................................................................................................................................20
3.5.5 Servo torque selection................................................................................................................21
3.5.6 Changing the monitor display .....................................................................................................24
3.5.7 Break in the cable detection enable/disable selection................................................................24
3.6 Operation...........................................................................................................................................25
3.6.1 Orientation starting during rotation..............................................................................................25
3.6.2 Orientation starting during stop...................................................................................................27

3.6.3 Multi-position orientation.............................................................................................................28
3.7 Instructions........................................................................................................................................29
3.8 Specifications.....................................................................................................................................31
4. ENCODER FEEDBACK CONTROL—A500(L) 32
4.1 Wiring Example..................................................................................................................................33
4.2 Terminals...........................................................................................................................................34
4.3 Wiring Instructions .............................................................................................................................35
4.4 Encoder Feedback Control and Vector Control Parameter List.........................................................37
4.5 Pre-Operation Settings ......................................................................................................................39
4.6 Control Mode Setting.........................................................................................................................40
4.7 Encoder Feedback Control................................................................................................................41
4.8 Vector control (Zero speed control and servo lock) ...........................................................................43
4.8.1 Zero speed control......................................................................................................................43
4.8.2 Servo lock...................................................................................................................................43
4.8.3 Pr. 22 "torque restriction level" (factory setting: 150%)...............................................................45
4.8.4 Pr. 371 "torque characteristic selection" (factory setting: 1) .......................................................45
4.8.5 Pr. 372 "speed control P gain" (factory setting: 100%)...............................................................47
4.8.6 Pr. 373 "speed control I gain" (factory setting: 20%) ..................................................................47
4.8.7 Driving/regenerative status signal output (Y32)..........................................................................47
4.8.8 Operation ready 2 signal (RY2) ..................................................................................................47
4.8.9 Instructions for vector control......................................................................................................47
4.9 Additional Functions...........................................................................................................................49
4.10 Specifications.....................................................................................................................................52
5. PULSE TRAIN INPUT—A500(L) 53
5.1 Wiring Example..................................................................................................................................53
5.2 Terminals...........................................................................................................................................54
5.3 Adjustment.........................................................................................................................................54

5.4 Pulse Train Input Parameter List .......................................................................................................55
5.5 Setting Example.................................................................................................................................56
5.6 Specifications.....................................................................................................................................56
6. ORIENTATION CONTROL AT A MACHINE END—V500 57
6.1 Wiring Example..................................................................................................................................57
6.2 Terminals...........................................................................................................................................58
6.3 Wiring Instructions .............................................................................................................................61
6.4 Parameter List....................................................................................................................................64
6.5 Parameter Setting..............................................................................................................................65
6.5.1 Selecting stop position command...............................................................................................65
6.5.2 Setting the rotation direction.......................................................................................................72
6.5.3 Fine adjustment of the orientation stop position .........................................................................76
6.5.4 Encoder orientation gear ratio setting.........................................................................................77
6.5.5 Adjustment of the servo rigidity...................................................................................................78
6.5.6 Orientation Deceleration Ratio....................................................................................................79
6.5.7 Orientation Switchover Speed ....................................................................................................80
6.6 Instructions........................................................................................................................................81
6.7 Specifications.....................................................................................................................................82
7. PULSE TRAIN INPUT—V500 83
7.1 Wiring Example..................................................................................................................................83
7.2 Terminals...........................................................................................................................................84
7.3 Adjustment.........................................................................................................................................84
7.4 Pulse Train Input Parameter List .......................................................................................................85
7.5 Setting Example.................................................................................................................................86
7.6 Specifications.....................................................................................................................................86

1
1.PRE-OPERATION INSTRUCTIONS
1.1 Unpacking and Product Confirmation
Take the option unit out of the package, check the unit name, and confirm that the product is as you ordered and
intact.
This product is an plug-in option unit designed for exclusive use in the Mitsubishi FR-A500(L)/V500 series
transistorized inverter. Functions available differ between FR-A500(L)/F500(L) series and FR-V500 series,
always check before using. This product can not be used with FR-F500(L) series.
SERIAL number check
• This product may be used with the FR-A500 series manufactured in and after February 1998. Any of the
models may be used with this unit if its SERIAL number indicated on the rating plate and package has the
following version or later.
SERIAL is made up of 1 version symbol, 1 alphabet letter or numeric character indicating month, and 7
numeric characters indicating the year and control number as shown below. (Only the first three digits of the
control number are printed on the package.)
SERIAL number
U 8 2 """"""
Symbol Year Month Control number
Model SERIAL Number Model SERIAL Number
FR-A520-0.4K, 0.75K U82"""""" FR-A540-0.4K to 3.7K L82""""""
FR-A520-1.5K to 11K T82"""""" FR-A540-5.5K, 7.5K K82""""""
FR-A520-15K to 22K U82"""""" FR-A540-11K to 22K L82""""""
FR-A520-30K to 55K K82"""""" FR-A540-30K to 55K D82""""""

2
PRE-OPERATION INSTRUCTIONS
•This product may be used with the FR-V520-1.5K to 7.5K, 30K and 37K manufactured in and after
February 2002. Any of the models may be used with this unit if its SERIAL number indicated on the
rating plate and package has the following version or later.
SERIAL is made up of 1 version symbol, 1 alphabet letter or numeric character indicating month, and 7
numeric characters indicating the year and control number as shown below. (Only the first three digits
of the control number are printed on the package.)
SERIAL number
F 2 2 """"""
Symbol Year Month Control number
Model SERIAL Number Date Manufactured
FR-V520-1.5K to 7.5K F22"""""" in and after
February 2002
FR-V520-30K B22""""""
FR-V520-37K C22""""""

3
PRE-OPERATION INSTRUCTIONS
1.2 Packing Confirmation
Make sure that the package includes the following
•Instruction manual...........................................................................1
•Mounting screws M3 × 10 ...............................................................2
•Terminal resistor jumpers (Jumpers fitted to the terminal block).....3
1.3 Structure
Terminal resistor jumpers Connector
Mounting
hole
Terminal
block
screw
size M3
Terminal
symbol
Front view Mounting holes
Option fixing holes
Rear view Mounting
hole
FR-A5AP
PIN PO 5V PA2PARPB1 PB2PBRPC1PC2PCRSG PA1

4
2.INSTALLATION
2.1 Pre-Installation Instructions
(1) Make sure that the input power of the inverter is off.
(2) When the FR-A5AP unit is used for encoder feedback control or orientation control, anencoder (motor
with encoder) and external power supply are required.
When encoder feedback control and orientation control are used together, the encoder (motor with
encoder) and external power supply are shared between these controls.
(3) When the FR-A5AP unit is fitted, the programmed operation function is made invalid.
2.2 Installation Procedure
(1) Securely insert the connector of the option unit far into the connector of the inverter. At this time, fit the
option fixing holes snugly. For the position of slot, refer to the next page. Also be sure to fit the unit into
the option fixing hook (For the FR-A500(L) series, it is available in Aug., 2000).
(2) Securely fix the two right and left places of the option unit to the inverter with the accessory mounting
screws. If the screw holes do not line up, the connector may not have been plugged snugly. Check for
looseness.
With input power on, do not install or remove the option unit. Otherwise, the inverter and
option unit may be damaged.
CAUTION

5
INSTALLATION
CAUTION
1. Only one type of option per inverter may be used. When two or more options are mounted,
priority is in order of slots 1, 2 and 3, the options having lower priority are inoperative.
2. When the inverter cannot recognize that the option is
mounted, it displays the option error. The errors shown
differ according to the mounting slots 1, 2, 3.
Option unit
ccessory screw
(2 pcs.)
Option side
connector
Inverter
(without cover)
Slot 1
Inverter side connector
Slot 2
Slot 3
Option fixing hook
The slots 1, 2, and 3 are provided
with an option fixing hook.
Mounting Position Error Display
Slot 1 E.OP1
Slot 2 E.OP2
Slot 3 E.OP3

6
INSTALLATION
2.3 Wiring
Route the wires so that they do not take up a lot of space in the control circuit terminal block of the option unit.
Wire the twisted pair shielded cable after stripping its sheath to make its cables loose. Also, protect the
shielded cable of the twisted pair shielded cable to ensure that it will not make contact with the conductive
area.
During wiring, do not leave wire off-cuts in the inverter. They may cause a fault, failure or malfunction.
REMARKS
The wires with large gaze may not be connected to the terminal block. When connected in parallel, all wires may not
fit in the wiring space due to the increased number of wires. In such cases, perform wiring by using a junction
terminal block.
When installing the inverter front cover, the cables to the inverter's control circuit terminals
and option terminals should be routed properly in the wiring space to prevent them from
being caught between the inverter and its cover.
Cable routing
Twisted pair shielded cable
Shielded cable
FR-A500 series FR-V500 series
CAUTION

7
3. ORIENTATION CONTROL—A500(L)
This function is used with a position detector (encoder) installed to the spindle of a machine tool (or the
motor) to allow a rotary shaft to be stopped at the specified position (oriented).
Pr. 350 "stop position command selection" is factory-set to "9999" to make the orientation control function
invalid.
Refer to page 57 for orientation control by the FR-V500 series.
3.1 Wiring Example
Standard motor
with encoder (SF-JR)
IM
encoder
5V
0
NFB R
S
T
STF
STR
SD
U
V
W
FR-A5AP
PA1
PA2
PAR
PB1
PB2
PBR
PC1
PC2
PCR
5V
SG
C
R
A
N
B
P
H
K
E
SE
SD
X11
X10
ORA
X22
X1
X0
DY
Power supply
Forward rotation
Reverse rotation
rientation command
In position
Orientation fault
Output common
External stop
command
Inverter
(*7)
(*1)
(*1) 5VDC
power supply
(*2)
FR-A5AX
ORM
(*4)
(*4)
(*4)
(*6)
(*5)
(a separate power supply)
1kΩ
100Ω
1000pF
PA1
PAR
PA2
PB1
PB2
PBR
5V
SG
+
-
1µF
100Ω
1000pF
1000pF
1000pF
1000pF
PC1
PC2
PCR
1000pF
Jumpers
+
-
+
-
100Ω
100Ω
100Ω
100Ω
100Ω
1kΩ
1kΩ
1kΩ
1kΩ
1kΩ
100Ω
100Ω

8
ORIENTATION CONTROL—A500(L)
*1 When the motor with encoder used is other than the standard motor with encoder (SF-JR), the pin numbers are
different.
To reduce radiated noise, connect the shielded wires of the encoder cables to the case earth (ground) pin.
*2 When orientation control is used with encoder feedback control, the encoder and 5V power supply may be shared
between these controls.
*3 Couple the encoder in line with the motor with a speed ratio of 1 to 1 without any mechanical looseness.
*4 Keep the accessory jumpers connected.
However, when the same encoder is shared between the FR-A5AP and another unit (e.g. NC) which is connected
with a terminal resistor, the built-in terminal resistors are not required and should be removed. (Terminal resistors:
100Ω
ΩΩ
Ω)
*5 Assign this function to any of the input terminals using Pr. 180 to Pr. 186 (input terminal function selection).
*6 Assign this function to any of the output terminals using Pr. 190 to Pr. 195 (output terminal function selection).
*7 When the stop position command is entered from outside the inverter (externally), the FR-A5AX plug-in option is
required.

9
ORIENTATION CONTROL—A500(L)
3.2 Terminals
Symbol Terminal Description
PA1 Encoder A-phase signal input terminal
A-, B- and Z-phase signals are input from the encoder.
For information on the pulse signals, refer to page 13.
PA2 Encoder A-phase inverse signal input
terminal
PB1 Encoder B-phase signal input terminal
PB2 Encoder B-phase inverse signal input
terminal
PC1 Encoder Z-phase signal input terminal
PC2 Encoder Z-phase inverse signal input
terminal
PAR A-phase terminal resistor terminal Factory-connected with "PA2" by the jumper.
Remove the jumper when the terminal resistor is not needed.
PBR B-phase terminal resistor terminal Factory-connected with "PB2" by the jumper.
Remove the jumper when the terminal resistor is not needed.
PCR Z-phase terminal resistor terminal Factory-connected with "PC2" by the jumper.
Remove the jumper when the terminal resistor is not needed.
5V DC power (positive) input terminal Encoder power supply common terminals.
Input encoder power. Connect the positive side to 5V and the
ground side to SG. Also, connect the shield of the shieldedwire to
SG.
4.75 to 6VDC (Current consumption 50mA)
SG DC power ground terminal

10
ORIENTATION CONTROL—A500(L)
<Inverter I/O terminals>
*1 Assign the function of the X22 signal to any of the input terminals using "input terminal function selection" (Pr.180 to
186).
Refer to the inverter manual for details of input terminal function selection.
*2 Assign the functions of the ORA/ORM signal to any of the output terminals using "output terminal function
selection" (Pr.190 to 195).
Refer to the inverter manual for details of output terminal function selection.
Symbol Terminal Description
X22
(*1) Orientation command input terminal Used to enter an orientation signal.
SD Common terminal Common terminal for the orientation signal.
ORA
(*2) In-position signal output terminal Switched low if the orientation has stopped within the in-position
zone while the start and orientation signals are input.
Open collector output. (Permissible load 24VDC, 0.1A)
ORM
(*2) Orientation fault signal output terminal
Switched low if the orientation has not stopped within the
in-position zone while the start and orientation signals are input.
Open collector output. (Permissible load 24VDC, 0.1A)
SE Open collector output common
terminal Common terminal for the ORA and ORM open collector output terminals. Isolated from the common terminal of the control circuit.

11
ORIENTATION CONTROL—A500(L)
<FR-A5AX, inverter input terminals>
* How to use terminal DY (when the stop position is specified from outside the inverter (externally) ).
When terminals DY-SD are open, the inverter does not import
data. Therefore, if the input status of the X0-X11 signals change,
the stop position data before opening of terminals DY-SD is valid.
Also, the position data is imported on the leading edge of the DY
signal.
Symbol Terminal Remarks Description
FR-A5AX
input terminals
X0
to
X11
Digital signal
input terminals
Use a micro current
switching contact relay for
the relay contact.
A transistor with the
following specifications
should be selected for the
open collector signal:
Electrical characteristics of
the transistor used;
•IC ≥ 10mA
•VCE ≥ 30V
•Leakage current 100µA
max.
•If IC ≥ 10mA, VCE(sat)
voltage is 3V max.
Used to input digital signals through either relays or open
collector transistors.
As the command signals are entered, speed or position
commands are selected using Pr. 360.
DY* Data read timing
input signal Used when a digital signal read timing signal is necessary.
Data is only read while terminals DY-SD are shorted. By
opening terminals DY-SD, the data before opening is retained.
Inverter input
terminals
SD Common
terminal (sink) Common terminal for digital signal input terminals and data
read timing signals.
PC
External
transistor
common
terminal
(source)
When connecting the transistor output (open collector
output) of a programmable controller (PLC), etc., connect
the external power common (positive) to this terminal to
prevent a fault occurring due to leakage current.
REMARKS
Pr.300 to Pr.305 settings for the FR-A5AX are made invalid when the stop position is set to be specified from outside
the inverter (externally), with the FR-A5AP (orientation control option) fitted to the inverter and when orientation
control is used.
Pr.300 to Pr.305 of the FR-A5AX are made valid when the stop position is not set from outside the inverter.
DY 200ms or longer
Position data Position command latch

12
ORIENTATION CONTROL—A500(L)
3.3 Wiring Instructions
(1) Connection with the position detector (encoder).
Use twisted pair shielded cables (0.2mm2or larger) to connect the FR-A5AP and position detector
(encoder). Cables to terminals 5V and SGshould be connected in parallel or belarger in size according
to the cable length as indicated in the table below.
To protect the cables from noise, run them away from any source of noise (e.g. the main circuit and
power supply voltage).
(2) Cable length.
1)Cable length within 30m.
2)Cable length of more than 30m.
Use a power supply slightly higher than 5V (approximately 5.5V) in addition to 6 or more parallel
cables of 0.2mm2or cables of 1.25mm2or more. This allows the cable length to be increased up to
100m. Note that the voltage applied across terminals 5V-SG must not exceed 6V.
Cable Length Number of Parallel Cables of 0.2mm2Required Larger-Size Cable
Within 10m At least 2 cables 0.4mm2or larger
Within 20m At least 4 cables 0.75mm2or larger
Within 30m At least 6 cables 1.25mm2or larger
3)Connection with NC. (Or similar device)
When one position detector is shared between the
FR-A5AP and NC (or another device), its output sig-
nals should be connected as shown below. In this
case, the cable length between the FR-A5AP and NC
should be as short as possible, within 5m. NC
FR-A5AP
encoder
Inverter
Max. 5m
(2 parallel cables)
Position detector

13
ORIENTATION CONTROL—A500(L)
(3) Connection of terminal resistors.
Use the jumpers across PA2-PAR, PB2-PBR and PC2-PCR to connect terminal resistors to the A, B
and C-phases of the encoder. Normally, keep the jumpers fitted.
However, remove the jumpers when the same encoder is shared between the FR-A5AP and the other
unit (e.g. NC) which is connected with a terminal resistor.
(4) Position detector (encoder).
Line driver LED type encoder
A. signal 1000ppr to 4096ppr
B. signal 1000ppr to 4096ppr
Z. signal 1ppr
Output pulse specifications
a, b, c and d should be (1/4 ±1/8)P when rotation is clockwise
as viewed from the shaft end of the encoder.
<Example of encoder available on the market>
Use an encoder which has an output circuit equivalent to AM26LS31 or 74LS113.
Pin Numbers of encoder Output Signals
Pin Number Output Signal Pin Number Output Signal Pin Number Output Signal
C A-phase signal N B-phase inverse signal H +5V power supply
R A-phase inverse signal B Z-phase signal K Power supply common
A B-phase signal P Z-phase inverse signal E Case earth (ground)
CAUTION
When encoder feedback control and orientation control are used together, the encoder is shared
between these controls.
Use an encoder which has a pulse count of 1000 to 4096ppr (pulses per revolution).
A
B
Z
P
abcd 2.4 to 5.25V
H1000ppr to 4096ppr
1000ppr to 4096ppr
1000ppr to 4096ppr
1000ppr to 4096ppr
1ppr
1ppr
A
A
B
B
Z
Z
L
0 to 0.4V