Mitsubishi Electric FR-A800 User manual

(FR-A800)
INVERTER SCHOOL TEXT
INVERTER TROUBLE SHOOTING COURSE
Specifications subject to change without notice.
When exported from Japan, this manual does not require application to the
Ministry of Economy, Trade and Industry for service transaction permission.
HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
SH(NA)-060029ENG-A (2110)MEE Printed in Japan
MODEL
MODEL
CODE
INVERTER SCHOOL TEXT
INVERTER TROUBLE SHOOTING
COURSE
(FR-A800)

SAFETY PRECAUTIONS
(Read these precautions before using this product.)
When designing a system, always read the relevant manuals and give due consideration to safety.
In addition, pay careful attention to the following points for proper handling during training.
[Precautions during training]
<Notes on descriptions in this school text>
●Connection diagrams in this school text appear with the control logic of the input terminals as the sink
logic, unless otherwise specified.
WARNING
●To prevent electric shock, do not touch the terminal block while the power is supplied.
●Before opening the safety cover, turn OFF the power, or check that it is sufficiently safe.
●Do not touch moving parts.
CAUTION
●Follow the instructor's directions during training.
●Do not remove the units of a demonstration machine or change the wiring without permission.
Doing so may cause a failure, malfunction, injury and/or fire.
●If the demonstration machine emits an abnormal odor or sound, stop it by operating the Power
supply MCCB switch or Emergency stop button.
●If any trouble occurs, notify the instructor immediately.

Chapter 1 IMPORTANCE OF PRODUCTIVE MAINTENANCE 1
1.1 Importance of maintenance ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1
1.2 Maintenance system ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2
1.3 Maintenance plan ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3
1.4 Management of maintenance document ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
1.5 Maintenance record •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4
1.6 Failure stage ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 5
Chapter 2 UNDERSTANDING INVERTER SYSTEM 6
2.1 Demonstration machine configuration •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6
2.2 Appearance and item name of demonstration machine ••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7
2.3 Precautions for use ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 8
2.4 Operation method••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9
2.4.1 Types of operation methods •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9
2.5 How to use the operation panel FR-DU08 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11
2.5.1 Component names of the operation panel (FR-DU08)••••••••••••••••••••••••••••••••••••••••••••••••••• 11
2.5.2 Basic operation of the operation panel•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12
2.5.3 Parameter setting procedures (parameter display in numerical order) ••••••••••••••••••••••••••••••• 14
2.5.4 Parameter display by function group •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 15
2.5.5 Parameter clear / all parameter clear•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 16
2.5.6 Parameter copy•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 17
2.5.7 Operation using the operation panel (PU operation) ••••••••••••••••••••••••••••••••••••••••••••••••••••• 18
2.5.8 Operation using external switches (External operation) ••••••••••••••••••••••••••••••••••••••••••••••••• 19
2.5.9 Monitoring of output current and output voltage••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 20
2.5.10 First monitored item••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 20
2.5.11 Calibration procedure for terminal FM when using the operation panel (FR-DU08) ••••••••••••••• 21
2.6 Inverter setup software••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 22
2.6.1 Function ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 22
2.6.2 Screen examples •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 22
2.6.3 System configuration ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 23
2.6.4 Setup •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 25
2.6.5 Graph (monitor area) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 28
Chapter 3 MAINTENANCE SYSTEM DESIGN 42
3.1 Preparation for Maintenance•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 42
3.2 Failsafe system which uses the inverter•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 43
Chapter 4 PREVENTIVE MAINTENANCE 46
4.1 Necessity of preventive maintenance ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 46
4.2 Maintenance and inspection •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 46
4.2.1 Precautions for maintenance and inspection •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 46
4.2.2 Inspection items ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 46
4.2.3 Measurement of main circuit voltage, current, and power••••••••••••••••••••••••••••••••••••••••••••••• 49
Chapter 5 BREAKDOWN MAINTENANCE 52
CONTENTS

5.1 Troubleshooting ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 52
5.1.1 When the operation panel does not display the energization••••••••••••••••••••••••••••••••••••••••••• 52
5.1.2 When parameters cannot be set ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 53
5.1.3 When the motor does not start ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 54
5.1.4 When the motor does not accelerate•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 55
5.1.5 When the motor speed does not become the set speed •••••••••••••••••••••••••••••••••••••••••••••••• 56
5.1.6 When the motor speed is unstable •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 57
5.1.7 When the motor does not accelerate•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 58
5.1.8 When automatic restart after instantaneous power failure does not work ••••••••••••••••••••••••••• 59
5.1.9 When abnormal noise is generated from the motor •••••••••••••••••••••••••••••••••••••••••••••••••••••• 60
5.1.10 When the motor vibrates abnormally •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 61
5.1.11 When OC alarm occurs •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 62
5.1.12 When OV alarm occurs •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 63
5.1.13 When analog input cannot be calibrated
(When adjusting gains T203 (Pr.903) and T403 (Pr.905)) •••••••••••••••••••••••••••••••••••••••••••••• 64
5.2 Troubleshooting by the demonstration machine •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 65
5.2.1 Stall prevention (overcurrent) (OL display) [Demonstration] •••••••••••••••••••••••••••••••••••••••••••• 65
5.2.2 Stall prevention stop (E.OLT display) [Demonstration] •••••••••••••••••••••••••••••••••••••••••••••••••• 66
5.2.3 Regenerative overvoltage trip during deceleration (E.OV3 display) [Demonstration]•••••••••••••• 67
5.2.4 Electronic thermal O/L relay pre-alarm (TH display) and motor overload trip (electronic thermal O/
L relay) (E.THM display) [Demonstration] •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 69
5.2.5 Output phase loss (E.LF display) [Demonstration] ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 71
5.2.6 24 VDC power output short circuit (E.P24 display) [Demonstration] •••••••••••••••••••••••••••••••••• 72
5.2.7 Error (Err. display) [Demonstration]•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 73
5.2.8 Instantaneous power failure (E.IPF display), automatic restart after instantaneous power failure
[Demonstration]•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 74
5.2.9 Undervoltage (E.UVT display) [Demonstration] ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 81
5.3 Appendices for demonstration (Confirmation of error descriptions and others) •••••••••••••••••••••••••• 82
5.3.1 Error setting •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 82
5.3.2 Error description ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 84
5.3.3 Error handling procedure •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 85
Chapter 6 CORRECTIVE MAINTENANCE 87
6.1 Improving the maintainability of equipment •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 87
Chapter 7 REVIEW OF INSTALLATION ENVIRONMENT 88
7.1 Power supply of inverter (harmonics and instantaneous power failure)•••••••••••••••••••••••••••••••••••• 88
7.1.1 Harmonics •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 88
7.1.2 Characteristics of rectifier circuit and generated harmonics •••••••••••••••••••••••••••••••••••••••••••• 90
7.1.3 Split-flow path of harmonic current •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 91
7.1.4 Harmonic suppression guidelines•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 92
7.1.5 Overview of harmonic suppression measures••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 95
7.1.6 Influence to inverter at instantaneous power failure •••••••••••••••••••••••••••••••••••••••••••••••••••••• 96
7.1.7 Inverter peripheral circuit and inverter operation at instantaneous power failure ••••••••••••••••••• 98
7.2 Noise •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••102
7.2.1 Principles of noise generation •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••102
7.2.2 Types of noise and propagation path ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••103
7.2.3 Countermeasures against noise•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••106
7.2.4 Leakage current ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••112

7.2.5 Earth (ground) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••114
7.3 Problems and measures when using inverter ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••116
7.3.1 Environment and installation condition •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••116
7.3.2 Connection of the inverter ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••123
7.4 Precautions for storing an inverter in the enclosure•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••132
Chapter 8 LIFE OF INVERTER PARTS 135
8.1 Replacement of parts •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••135
8.2 Inverter parts life display••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••137
8.3 Diagnosis using FR Configurator2••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••141
8.3.1 Explanation of window ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••141
Chapter 9 REPLACEMENT PROCEDURE 142
9.1 Saving FR-A700 parameters and replacing with FR-A800 parameters •••••••••••••••••••••••••••••••••••142
9.2 Setting the parameter •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••144
9.3 Installation of the FR-A800•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••147

1IMPORTANCE OF PRODUCTIVE MAINTENANCE
1.1 Importance of maintenance 1
1
IMPORTANCE OF PRODUCTIVE MAINTENANCE
2
UNDERSTANDING INVERTER SYSTEM
3
MAINTENANCE SYSTEM DESIGN
4
PREVENTIVE MAINTENANCE
5
BREAKDOWN MAINTENANCE
6
CORRECTIVE MAINTENANCE
7
REVIEW OF INSTALLATION ENVIRONMENT
8
LIFE OF INVERTER PARTS
CHAPTER 1 IMPORTANCE OF PRODUCTIVE
MAINTENANCE
When a production system stops due to a failure or power failure, downtime causes a loss
proportional to the duration of the downtime.
Therefore, it is necessary to design a system that is not stopped by a failure or power failure.
In case the production system stops, quick recovery is an important issue. To improve the operating
rate of the production system, each factory must have a team of maintenance personnel.
1.1 Importance of maintenance
With remarkable progress of mechatronics machinery and more complexity and sophistication,
recent production systems have become more black-boxed with increasing difficulty in maintenance,
making it difficult to improve the operating rate.
Therefore, highly reliable products and improved maintenance approach are strongly demanded.
Current production system
Mechatronics machinery Complex and sophisticated
production system
More black-boxed
Use of highly reliable products
Maintenance difficulty increased
Improved maintenance
approach
Establishment of a highly
reliable production system

21.2 Maintenance system
1IMPORTANCE OF PRODUCTIVE MAINTENANCE
1.2 Maintenance system
To establish a highly reliable production system, it is important to a well-organized maintenance
system.
The following chart outlines a maintenance system.
Maintenance
system design When designing new equipment, consider the maintenance systems.
Productive maintenance
Preventive
maintenance
This maintenance applies to the equipment in which failure or
accident occurrence will incur big economical losses and serious
accidents and to which preventive maintenance is more
advantageous, and this maintenance work is done prior to any
foreseeable failure or accident.
Daily maintenance
and inspection
Daily inspection is performed to find in advance
any hazardous conditions which may lead a
production system to a failure stop or harmful
performance reduction.
Periodic
maintenance
and inspection
Periodic inspection is performed to find in
advance any hazardous conditions which may
lead a production system to a failure stop or
harmful performance reduction.
Monitored
maintenance
Status is monitored to find in advance any
hazardous conditions which may lead a
production system to failure stop or harmful
performance reduction.
Breakdown
maintenance
This maintenance applies to the equipment (digital display,
CRTs, various lamps) to which after-damage repair is more
advantageous, and this work is done for sporadic accidents.
Corrective
maintenance
Improvements are made to minimize equipment
deterioration after introduction of the equipment and to
facilitate inspection/repair.

1IMPORTANCE OF PRODUCTIVE MAINTENANCE
1.3 Maintenance plan 3
1
IMPORTANCE OF PRODUCTIVE MAINTENANCE
2
UNDERSTANDING INVERTER SYSTEM
3
MAINTENANCE SYSTEM DESIGN
4
PREVENTIVE MAINTENANCE
5
BREAKDOWN MAINTENANCE
6
CORRECTIVE MAINTENANCE
7
REVIEW OF INSTALLATION ENVIRONMENT
8
LIFE OF INVERTER PARTS
1.3 Maintenance plan
Consider the maintenance for the production system after failures occur.
For the efficient maintenance, build a maintenance plan at the introduction of the production system.
In case of failure, perform the following maintenance systematically to repair the system in a short
time.
Table 1.1 Inverter system maintenance plan
Category Description
Maintenance education
Knowledge
about inverter
•Fundamental knowledge of inverter such as mechanism, function,
performance, etc.
•Characteristics of inverter
•Position of inverter
•Introduction status of inverter (usage condition in one's department)
•Details of introduced (adopted) model (the model, function, performance,
and characteristics of the inverter used)
Maintenance
range and
maintenance
technique
•Maintenance knowledge about inverter (maintenance characteristics and
maintenance item of the inverter)
•Precautions for inverter at maintenance (handling method, key points, and
others)
Training
•Functions related to inverter maintenance
•Functions related to peripheral device maintenance (such as the
troubleshooting function)
•Practice of troubleshooting (peripheral device operation, hardware
replacement, etc.)
Maintenance timing Distinguish clearly between the preventive maintenance target and breakdown maintenance
target, and determine the maintenance period.
Maintenance tool Prepare the spares, members, instruments, and measuring tools for the maintenance.
Maintenance procedure Prepare manuals and define the maintenance methods and details.
Maintenance personnel Secure personnel and determine the positions and tasks.
Improvement of
maintenance method Examine improvement of maintenance methods.
Understanding of customer
service/support system of
the inverter manufacturer
After-sales
service
•Service station (location, contact information, persons in charge, etc.)
•Service range (applicable models, handling range, etc.)
•Service time (start/end time, time required for arrival, emergency service, etc.)
•Service period (warranty period, support service on commercial basis, etc.)
•Service parts supply period (such as repair after production stop, supply period)
•Actions for production stop (such as stop declaration, repair period)
•Period for repair (such as standard, shortest and longest delivery times)
Technical
support
•Support station (location, contact information, persons in charge, etc.)
•Support range (applicable models, hardware/software, and system)
•Support method (telephone, FAX, visit, teaching, and machine operation)
•Manual (effective manual for maintenance)

41.4 Management of maintenance document
1IMPORTANCE OF PRODUCTIVE MAINTENANCE
1.4 Management of maintenance document
To repair a failure in a short time, the documents as listed below must be arranged and managed.
1.5 Maintenance record
After repairing, the maintenance record below must be managed to refer to a maintenance.
Table 1.2 Management of maintenance document
Category Name Description
System-specific documents
System/control
specification
The functions and operations of the corresponding system/control
are described.
(Operation sequence/timing, operational conditions, and operation
procedure)
Electric wiring diagrams
Schematic diagrams
(Power supply circuit, motor circuit, control circuit, operation circuit,
display circuit, and others)
Inter-device/inter-board connection diagrams (Cabling diagram and
earthing (grounding) cable diagram)
Equipment layout
diagrams
In-panel electrical equipment layout diagram, terminal block wire
number layout diagram, and connector pin connection assignment
table
(Diagrams which identify various instrument models name, wire
numbers, and others)
List of the used hardware
List of electrical equipment used in a system
(Model names and specifications of all electrical equipment such as
modules which comprise inverter system, peripheral devices,
electrical parts in enclosure, I/O devices, software packages, and
others)
Instruction manual of the
control target and
Maintenance inspection
manual
For handling (operating) the control target and maintenance/
inspection
General documents
Catalog of the used
hardware Provide model configurations, manufacturers, and others
Instruction manual and
technical information of
the used hardware
For troubleshooting of hardware and software
Table 1.3 Maintenance record to manage
Record item Description
Status of errors and failures Status of apparatus/equipment name, phenomenon, and circumstances
Stop period of the system Occurrence time and stop period
Effect of the accident Effect of amount of loss, loss time, and influence
Cause Method to find cause and cause including estimation
Repair method Method of replacement, repair, and others
Recurrence prevention Recurrence prevention method of similar failure and lessons
Failure record Record of cause, measure, and others
Person in charge

1IMPORTANCE OF PRODUCTIVE MAINTENANCE
1.6 Failure stage 5
1
IMPORTANCE OF PRODUCTIVE MAINTENANCE
2
UNDERSTANDING INVERTER SYSTEM
3
MAINTENANCE SYSTEM DESIGN
4
PREVENTIVE MAINTENANCE
5
BREAKDOWN MAINTENANCE
6
CORRECTIVE MAINTENANCE
7
REVIEW OF INSTALLATION ENVIRONMENT
8
LIFE OF INVERTER PARTS
1.6 Failure stage
Generally, complicated system failure is categorized into three stages, initial failure, random failure,
and wear-out failure as shown in Fig. 1.1. Initial failures are considered to be removed in
manufacturing and inspection processes by a manufacturer. Because random failures are
unforeseen and occur suddenly at any time within the useful life of equipment before it is worn, it is
difficult to take the technical measure. At present, the measure only based on the statistical treatment
can be taken.
Wear-out failures occur at nearly the end of useful life in the course of deterioration or as a result of
wear, and increase suddenly as time proceeds. At Point tb in Fig. 1.1 which means the replacement
years, preventive maintenance will be made proper by changing specific parts for new ones.
Fig. 1.1 Bath-tub curve
Number of years of use
ta tb
0
Failure rate
Early
failure
period
Random failure period
Wear-out
failure period

62.1 Demonstration machine configuration
2UNDERSTANDING INVERTER SYSTEM
CHAPTER 2 UNDERSTANDING INVERTER
SYSTEM
2.1 Demonstration machine configuration
Fig. 2.1 Elementary wiring diagram of inverter demonstration machine
Power
supply
1φ
100V
MCCB Tr1 MC1 Motor
TG N
Motor
speed
SF-JR
0.4kW 4P
Powder
brake
Overheat
detection thermal
Load torque
adjustment
VR
%
MC2 Tr2
Load ON-OFF
RU1 MC3
S
T
U
V
W
U
V
W
Instantaneous
power failure timer
Emergency stop
MC1
Motor phase
loss/Normal
switch MC3
Load torque
Frequency setting
Compensation input
Hz
%
STF
STR RUN
P1
P
PX
PR
TB
SU
IPF
OL
FU
A1
FM
AM
5
2
1PCSD
FR-A820-00077
RES
SD
B1
C1
SE
5
10
10E
RH
RM
RL
MRS
RT
CS
SD
0V
24V
24V
0V
M
Instantaneous power
failure button

2UNDERSTANDING INVERTER SYSTEM
2.2 Appearance and item name of demonstration machine 7
1
IMPORTANCE OF PRODUCTIVE MAINTENANCE
2
UNDERSTANDING INVERTER SYSTEM
3
MAINTENANCE SYSTEM DESIGN
4
PREVENTIVE MAINTENANCE
5
BREAKDOWN MAINTENANCE
6
CORRECTIVE MAINTENANCE
7
REVIEW OF INSTALLATION ENVIRONMENT
8
LIFE OF INVERTER PARTS
2.2 Appearance and item name of demonstration machine
The following figure shows the configuration of the inverter demonstration machine.
Fig. 2.2 Appearance of the inverter demonstration machine
1) FM terminal output ………Displays the output frequency (pulse output) from the inverter.
2) AM terminal output ………Displays the output frequency (analog output) from the
inverter.
3) Running RUN ……………Turns ON when the output frequency is equal to or higher
than the starting frequency, indicating that the inverter is in
operation.
4) Up to frequency SU ……Turns ON when the output frequency enters in the range of
±10% of the set frequency, indicating that the frequency is
reached.
5) Instantaneous
power failure IPF ………Turns ON when the instantaneous power failure or under
voltage protective function is activated, indicating that an
instantaneous power failure has occurred.
6) Overload OL………………Turns ON when the stall prevention operation function is
activated, indicating overload warning.
7) Frequency detection FU…Turns ON when the output frequency is equal to or higher
than the set detection frequency, indicating frequency
detection.
8) Fault output ABC…………Turns ON when the protective function of the inverter is
activated and the output is stopped.
9) Frequency
setting terminal 2…………Outputs the set frequency with analog voltage.
10) Compensation
input terminal 1 …………Outputs extra voltage to be added to the analog voltage of the
frequency setting.
Load torque Motor speed FM terminal output AM terminal output
Forward rotation
STF Reverse rotation STR
Frequency setting Compensation input
Output terminal status
Instantaneous power
Mechanical load High speed
RH
Middle speed
RM
Low speed
RL Running
RUN
Up to
SU
Instantaneous
IPF
Overload
OL
Frequency
FU
Fault output
ABC
Overheat Thermal reset
Second function
RT Output stop MRS
Automatic restart after
CS
Instantaneous power failure
Load
ON/OFF
Always turn off
the switch when
the load is OFF.
Always operate this demonstration
machine at 60 Hz or less.
Inverter reset
RES
Load setting
1
3
19
20 21
22
23
24 25
26
27
28
29
Inverter
FR-A820
MCCB
4
910
11 12 13
14 15 16
17 18
Motor
5678
2
Operation panel
Inverter demonstration machine
Emergency stop
CAUTION
CAUTION
failure time setting frequency power failure detection
Terminal 2 Terminal 1
instantaneous
power failure

82.3 Precautions for use
2UNDERSTANDING INVERTER SYSTEM
11) High speed RH………… Selects "High speed" from the multi-speed setting. Note that
up to seven different speeds can be selected with a
combination of "Middle speed" and "Low speed".
12) Middle speed RM……… Selects "Middle speed" from the multi-speed setting. Note that
up to seven different speeds can be selected with a
combination of "High speed" and "Low speed".
13) Low speed RL ………… Selects "Low speed" from the multi-speed setting. Note that
up to seven different speeds can be selected with a
combination of "High speed" and "Middle speed".
14) Second acceleration/
deceleration RT ……… Selects the second acceleration/deceleration time.
15) Output stop MRS ……… Stops the inverter output.
16) Selection of automatic
restart after instantaneous
power failure CS ……… When the CS signal is selected, the inverter restarts
automatically at power restoration. (The parameter setting is
required for the automatic restart after instantaneous power
failure.)
17) Forward STF ………… Forward rotation start signal
18) Reverse STR ………… Reverse rotation start signal
19) Inverter reset ………… Resets the fault output when the protective function is
activated.
20) Load torque …………… Indicates the load torque applied to the motor.
21) Motor speed …………… Indicates the motor rotation speed.
22) Load setting …………… Sets the load applied to the motor.
23) Load ON/OFF ………… Turns ON or OFF the load applied to the motor.
24) Overheat ……………… Turns ON when the mechanical load applied to the motor
(powder brake) is overheated.
25) Thermal reset ………… Resets the thermal sensor when the mechanical load applied
to the motor (powder brake) is overheated.
26) Power supply MCCB … Molded case circuit breaker for powering ON the
demonstration machine.
27) Emergency stop ……… Shuts OFF the power in case of emergency.
28) Instantaneous power
failure…………………… Shuts OFF the power supply for the inverter.
29) Instantaneous power
failure time setting …… Sets the instantaneous power failure time of when the
instantaneous power failure button is pressed.
2.3 Precautions for use
(3) Do not leave the demonstration machine for a long time with the Load ON/OFF switch set
to ON and the Load setting VR high.
(1) Set the maximum frequency to 60 Hz.
(2) Set the acceleration/deceleration
time to one second or longer.
Technically, frequency can be set to a value higher
than 60 Hz and acceleration time can be set to a
value shorter than one second. However, setting
those values may damage the machine due to the
use of the powder brake, tachogenerator (TG), and
timing belt.
RES

2UNDERSTANDING INVERTER SYSTEM
2.4 Operation method 9
1
IMPORTANCE OF PRODUCTIVE MAINTENANCE
2
UNDERSTANDING INVERTER SYSTEM
3
MAINTENANCE SYSTEM DESIGN
4
PREVENTIVE MAINTENANCE
5
BREAKDOWN MAINTENANCE
6
CORRECTIVE MAINTENANCE
7
REVIEW OF INSTALLATION ENVIRONMENT
8
LIFE OF INVERTER PARTS
2.4 Operation method
2.4.1 Types of operation methods
The inverter can be operated with various signals. This section explains the operations (start, stop,
and speed variation) that can be operated with the inverter demonstration machine.
(1) External operation using external signals (D000 (Pr.79) = "0, 2")
Operate an inverter with a frequency setting potentiometer or start switch connected to the
control circuit terminals of the inverter.
Fig. 2.3 External operation method
External start or
stop signal +
External frequency
setting signal
(STF, STR) Frequency setting potentiometer
(potentiometer)
Contact signal (multi-speed setting)
Compensation input (potentiometer)

M
U
V
W
R
STF (STR)
SD
RH
RM
RL
10
2
5
1
S
T
MCMCCB FR-A800
Inverter 

Motor 
Multi-speed selection
by switching contacts
Frequency setting
potentiometer
Operation by external signal
Start/Stop
Compensation input
potentiometer
10E
Power supply

10 2.4 Operation method
2UNDERSTANDING INVERTER SYSTEM
(2) PU operation using the operation panel or parameter unit (D000 (Pr.79) = "0, 1")
This operation is performed only with the keys of the operation panel or parameter unit.
Fig. 2.4 PU operation method
(3) PU/External combined operation (D000 (Pr.79) = "3 or 4")
When D000 (Pr.79) is set to "3", set frequency using the operation panel or parameter unit, and
input a start command using external start switches.
When D000 (Pr.79) is set to "4", set frequency using an external potentiometer or multi-speed
setting, and input the start command using the keys of the operation panel or parameter unit.
Fig. 2.5 PU/External combined operation (When D000
(Pr.79) = "3")
Fig. 2.6 PU/External combined operation (When D000
(Pr.79) = "4")
PU start signal + PU frequency setting signal
Key operation setting of PU
M
U
V
W
R
S
T
MCMCCB FR-A800
Inverter 

Motor 
Operation panel
(FR-DU08)

Operation using the operation panel
or the parameter unit
Operation panel
(option FR-LU08)
FWD
REV
STOP
RESET
REV
FWD
STOP
RESET
PWR
ALM
FR-LU08
F1 F2 F3
MON
MENU
EXT
PU
Power supply
External start or stop signal +PU frequency setting
(STF, STR) Key operation setting of PU
External frequency
setting signal
Operation
panel
(FR-DU08)
SD
STF
STR
Forward
rotation
start
Reverse
rotation
start
Switch
Inverter
Frequency
setting
potentiometer 5
10
2
Potentiometer
PU start or stop signal
Operation
panel
(FR-DU08)
Inverter
+

2UNDERSTANDING INVERTER SYSTEM
2.5 How to use the operation panel FR-DU08 11
1
IMPORTANCE OF PRODUCTIVE MAINTENANCE
2
UNDERSTANDING INVERTER SYSTEM
3
MAINTENANCE SYSTEM DESIGN
4
PREVENTIVE MAINTENANCE
5
BREAKDOWN MAINTENANCE
6
CORRECTIVE MAINTENANCE
7
REVIEW OF INSTALLATION ENVIRONMENT
8
LIFE OF INVERTER PARTS
2.5 How to use the operation panel FR-DU08
2.5.1 Component names of the operation panel (FR-DU08)
No. Component Name Description
(a) Operation mode indicator
PU: ON to indicate the PU operation mode.
EXT: ON to indicate the External operation mode. (ON at power-ON in the initial setting.)
NET: ON to indicate the Network operation mode.
PU and EXT: ON to indicate the External/PU combined operation mode 1 and 2.
(b) Operation panel mode
LED indicator
MON: ON when the operation panel is in the monitor mode. Quickly blinks twice intermittently
while the protective function is activated.
Slowly blinks when the display-off function of the operation panel is valid.
PRM: ON when the operation panel is in the parameter setting mode.
(c) Control motor indicator
IM: ON when the inverter is set to the induction motor control.
PM: ON when the inverter is set to the PM sensorless vector control.
The indicator blinks when test operation is selected.
(d) Frequency unit indicator ON when the actual frequency is monitored. (Blinks when the set frequency is displayed in the
monitor.)
(e) Monitor (5-digit LED) Shows the frequency, parameter number, etc.
(f) PLC function indicator ON when the PLC function is activated.
(g) FWD key, REV key
FWD key: Starts the forward rotation operation. The LED is ON during forward operation.
REV key: Starts the reverse rotation operation. The LED is ON during reverse operation.
The LEDs blink under the following conditions.
• When the frequency command is not given even if the forward/reverse rotation command is given
• When the frequency command is equal to the starting frequency or lower
• When the MRS signal is being input
(h) STOP/RESET key Used to stop operation commands.
Used to reset the inverter when the protective function is activated.
(i) Setting dial
The setting dial of the Mitsubishi inverters. Turn the setting dial to change the setting of frequency
or parameter.
Press the setting dial to perform the following operations:
• To display a set frequency in the monitor mode
• To display the present setting during calibration
• To display a fault record number in the faults history mode.
(j) MODE key
Switches the operation panel to a different mode.
Switches to the easy setting mode by pressing simultaneously with .
(k) SET key
Used to confirm each selection.
Switches the monitor screen
during the operation.
(l) ESC key Goes back to the previous display.
Holding this key for a longer time changes the display back to the monitor mode.
(m) PU/EXT key
Switches between the PU operation mode and the External operation mode.
Switches to the easy setting mode by pressing simultaneously with .
It also cancels the PU stop.
(a) (b) (c)
(d)
(e)
(g)
(f)
(h)
(i)
(j)
(k)
(l)
(m)
Output frequency
When the initial setting is set
Output current Output voltage

12 2.5 How to use the operation panel FR-DU08
2UNDERSTANDING INVERTER SYSTEM
2.5.2 Basic operation of the operation panel
(1) Basic operation
Operation mode switchover/Frequency setting
Function Monitor
Parameter setting
Fault history
Blinking Blinking Blinking
External operation mode (at power-ON)
Output frequency monitor (at power-ON)
PU operation mode PU JOG operation mode
Output current monitor Output voltage monitor
Value change
(Example)
Frequency setting has been changed!
Alternating
The last eight faults can be displayed.
(On the display of the last fault record (fault record 1), a decimal point LED is ON.)
The present setting
is displayed.
Value change Parameter write completed!!
Alternating
(Example)
(Example) (Example) (Example)
Parameter copy
Initial value change list
IPM initialization
Parameter clear All parameter clear Faults history clear
Automatic parameter setting
Trace function
Fault record 1 Fault record 2 Fault record 8
When the fault history is empty, " " is displayed.
Group parameter setting
Hold down
Parameter setting mode
Function mode

2UNDERSTANDING INVERTER SYSTEM
2.5 How to use the operation panel FR-DU08 13
1
IMPORTANCE OF PRODUCTIVE MAINTENANCE
2
UNDERSTANDING INVERTER SYSTEM
3
MAINTENANCE SYSTEM DESIGN
4
PREVENTIVE MAINTENANCE
5
BREAKDOWN MAINTENANCE
6
CORRECTIVE MAINTENANCE
7
REVIEW OF INSTALLATION ENVIRONMENT
8
LIFE OF INVERTER PARTS
(2) Parameter setting mode
In the parameter setting mode, inverter functions (parameters) are set.
The following table explains the indications in the parameter setting mode.
(3) Digital characters and their corresponding printed equivalents
Digital characters displayed on the operation panel display are as follows.
Operation
panel display/
indicator
Function name Description
Parameter setting
mode
Reads or changes the set value of the displayed parameter
number.
Parameter clear
Clears and resets parameter settings to the initial values.
Calibration parameters and offline auto tuning parameters are
not cleared.
All parameter clear
Clears and resets parameter settings to the initial values.
Calibration parameters and offline auto tuning parameters are
also cleared.
Fault history clear Deletes the fault history.
Parameter copy
Copies the parameter settings saved in the inverter to the
operation panel. The parameters copied to the operation panel
can also be copied to other inverters.
Initial value change list Identifies the parameters that have been changed from their
initial values.
IPM parameter
initialization
Changes the parameters to the settings required to drive an
IPM motor (MM-CF) in a batch.
The parameter settings required to drive an IPM motor can be
returned to parameter settings required to drive an induction
motor.
Automatic parameter
setting
Changes parameter settings as a batch. The target parameters
include communication parameters for the Mitsubishi Electric
human machine interface (GOT) connection and the
parameters for the rated frequency settings of 50 Hz/60 Hz.
Group parameter
setting Displays parameter numbers by function groups.
0
E(e)
1
F(f)
2
G(g)
3
H
4
h
5 6 7 8 9 A B(b) C c D(d)
R r S(s) T(t) U u V v W w X(x) Y(y) Z(z)Q(q)
I(i) J(j) K(k) L(l) M(m) N n O o P(p)

14 2.5 How to use the operation panel FR-DU08
2UNDERSTANDING INVERTER SYSTEM
2.5.3 Parameter setting procedures (parameter display in numerical
order)
This section explains how to change the setting value of Pr.1 Maximum frequency from "120 Hz" to
"60 Hz".
Press the setting dial ( ) in the monitor mode when the PU operation mode or External/
PU combined operation mode (Pr.79 Operation mode selection = "3") is selected to display
the present set frequency.
Operation
1. Turning ON the power of the inverter
The operation panel is in the monitor mode.
2.
Changing the operation mode
Press to choose the PU operation mode. The [PU] indicator turns ON.
3.
Parameter setting mode
Press to choose the parameter setting mode. (The parameter number read previously
appears.)
4.
Selecting the parameter
Turn until " " (Pr.1) appears. Press to read the present set value. " "
(initial value) appears.
5.
Changing the setting value
Turn to change the setting value to " ". Press to enter the setting. " " and
" " are displayed alternately.
• Turn to read another parameter.
• Press to display the setting again.
• Press twice to display the next parameter.
• Press three times to return to the indication of the frequency.

2UNDERSTANDING INVERTER SYSTEM
2.5 How to use the operation panel FR-DU08 15
1
IMPORTANCE OF PRODUCTIVE MAINTENANCE
2
UNDERSTANDING INVERTER SYSTEM
3
MAINTENANCE SYSTEM DESIGN
4
PREVENTIVE MAINTENANCE
5
BREAKDOWN MAINTENANCE
6
CORRECTIVE MAINTENANCE
7
REVIEW OF INSTALLATION ENVIRONMENT
8
LIFE OF INVERTER PARTS
2.5.4 Parameter display by function group
Parameter numbers can be displayed by function group.
Since the parameter numbers are grouped by function, related parameters can be set easily.
(1) Changing to parameter numbers grouped by function
(2) Changing the parameter setting value with group parameter display
The following explains how to change the setting value of H400 (Pr.1) Maximum frequency from
"120 Hz" to "60 Hz".
Pr.MD setting Description
0 Default parameter display
1 Parameter display in numerical order
2 Parameter display by function group
Operation
1. Turning ON the power of the inverter
The operation panel is in the monitor mode.
2.
Parameter setting mode
Press to choose the parameter setting mode. (The parameter number read previously appears.)
3.
Selecting the parameter
Turn until " " (Group parameter setting) appears.
Press to confirm the selection. The setting " " (initial value) will appear.
4.
Changing to the group parameter display
Turn to change the set value to " " (group parameter display). Press to confirm the group parameter
setting. " " and " " are displayed alternately after the setting is completed.
Operation
1. Turning ON the power of the inverter
The operation panel is in the monitor mode.
2.
Changing the operation mode
Press to choose the PU operation mode. The [PU] indicator turns ON.
3.
Parameter setting mode
Press to choose the parameter setting mode. (The parameter number read previously appears.)
4.
Selecting the parameter group
Press several times until " " appears. The parameter group can be selected.
5.
Selecting the parameter group
Turn until " " (Protective function parameter 4) appears. Press to confirm the selection.
" " will appear, and the parameters in the function group of protective function parameter 4 can be
selected.
6.
Selecting the parameter
Turn until " " (P.H400 Maximum frequency) appears. Press to read the present set
value. " " (initial value) appears.
7.
Changing the setting value
Turn to change the set value to " ". Press to enter the setting. " " and
" " are displayed alternately after the setting is completed.