Mitsubishi Electric FR-E540 User manual







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 Japanese harmonic suppression guideline.........................................................33
2.3.3 Inverter-generated noise and reduction techniques............................................33
2.3.4 Leakage currents and countermeasures............................................................37
2.3.5 Inverter-driven 400V class motor........................................................................38
2.3.6 Peripheral devices..............................................................................................39
2.3.7 Instructions for compliance with the UL and CSA standards..............................42
2.3.8 Instructions for compliance with the European standards..................................43
Contents

II
3 OPERATON 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 mode.................................................................................................50
3.2.4 Frequency setting mode.....................................................................................51
3.2.5 Parameter setting mode .....................................................................................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
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 dynamic 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)..............................94
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)......................................................................................100
4.2.29 Input filter time constant (Pr. 74).....................................................................101
4.2.30 Reset selection/PU disconnection detection/PU stop selection (Pr. 75).........101
4.2.31 Parameter write inhibit selection (Pr. 77)........................................................103
4.2.32 Reverse rotation prevention selection (Pr. 78)................................................104
4.2.33 Operation mode selection (Pr. 79)..................................................................105
4.2.34 General-purpose magnetic flux vector control selection (Pr. 80).........................109
4.2.35 Offline auto tuning function (Pr. 82 to Pr. 84, Pr. 90, Pr. 96)..........................110
4.2.36 Computer link operation (Pr. 117 to Pr. 124)..................................................116
4.2.37 PID control (Pr. 128 to Pr. 134) ......................................................................127
4.2.38 Output current detection function (Pr. 150, Pr. 151).......................................135
4.2.39 Zero current detection (Pr. 152, Pr. 153)........................................................136
4.2.40 Stall prevention function and current limit function (Pr. 156)..........................137
4.2.41 User group selection (Pr. 160, Pr. 173 to Pr. 176)..........................................140
Contents

IV
4.2.42 Actual operation hour meter clear (Pr. 171)....................................................142
4.2.43 Input terminal function selection (Pr. 180 to Pr. 183)......................................142
4.2.44 Output terminal function selection (Pr. 190 to Pr. 192)...................................144
4.2.45 Cooling fan operation selection (Pr. 244) .......................................................145
4.2.46 Slip compensation (Pr. 245 to Pr. 247)...........................................................146
4.2.47 Stop selection (Pr. 250)..................................................................................147
4.2.48 Meter (frequency meter) calibration (Pr. 901).................................................149
4.2.49 Biases and gains of the frequency setting voltage (current)
(Pr. 902 to Pr. 905)..........................................................................................151
5 PROTECTIVE FUNCTIONS 156
5.1 Errors (Alarms)........................................................................................................156
5.1.1 Error (alarm) definitions....................................................................................156
5.1.2 To know the operating status at the occurrence of alarm.................................164
5.1.3 Correspondence between digital and actual characters...................................164
5.1.4 Resetting the inverter........................................................................................164
5.2 Troubleshooting ......................................................................................................165
5.2.1 Motor remains stopped.....................................................................................165
5.2.2 Motor rotates in opposite direction....................................................................165
5.2.3 Speed greatly differs from the setting...............................................................166
5.2.4 Acceleration/deceleration is not smooth...........................................................166
5.2.5 Motor current is large........................................................................................166
5.2.6 Speed does not increase..................................................................................166
5.2.7 Speed varies during operation..........................................................................166
5.2.8 Operation mode is not changed properly..........................................................167
5.2.9 Control panel display is not operating...............................................................167
5.2.10 POWER lamp is not lit....................................................................................167
5.2.11 Parameter write cannot be performed............................................................167
5.3 Precautions for Maintenance and Inspection..........................................................168
5.3.1 Precautions for maintenance and inspection....................................................168
5.3.2 Check items......................................................................................................168
5.3.3 Periodic inspection............................................................................................168
5.3.4 Insulation resistance test using megger ...........................................................169
5.3.5 Pressure test ....................................................................................................169
5.3.6 Replacement of parts .......................................................................................173

V
5.3.7 Measurement of main circuit voltages, currents and powers............................177
6 SPECIFICATIONS 179
6.1 Standard Specifications ..........................................................................................179
6.1.1 Model specifications .........................................................................................179
6.1.2 Common specifications ....................................................................................181
6.1.3 Outline drawings...............................................................................................183
APPENDIX 185
Appendix 1 Data Code List ...........................................................................................185
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
FR-E500
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
Ratin
g
plate
Inverter
type
Input ratin
g
Output ratin
g
Serial number
MITSUBISHI
MODEL INVERTER
FR-E540-0.4K-EC
INPUT :
OUTPUT :
SERIAL :
XXXXX
XXXXX
PASSED
Ratin
g
plate
FR-E540-0.4K-EC
Inverter type Serial number
Capacity plate
Capacity plate
Inverter type
Represents the
inverter capacity
"kW".
Symbol Volta
g
e Class
E540 Three-phase
400V class
FR - E540 -0.4
E520S Sin
g
le-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 179.)
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.
Japanese Harmonic Suppression Guideline
The "harmonic suppression
g
uideline for household appliances and
g
eneral-purpose
products" was issued b
y
the Ministr
y
of International Trade and Industr
y
in
September, 1994. This guideline applies to the 2.2K and less models of single-phase
200V classes. B
y
installin
g
the power factor improvin
g
reactor
(
FR-BEL or FR-BAL
)
,
inverters compl
y
with the "harmonic suppression techni
q
ues for transistorized
inverters
(
input current 20A or less
)
" established b
y
the Japan Electrical
Manufacturers' Association.
(MC)
(NFB)
or
(ELB)
Earth (
g
round)
Earth (
g
round)
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
Ratin
g
plate
Capacity plate
Accessory cover
Wirin
g
port cover
for option
(2) Without front cover and accessory cover
PU connector*
POWER lamp (yellow)
ALARM lamp (red)
Control circuit terminal bloc
k
Main circuit terminal block
Wirin
g
cover
Inboard option
mountin
g
position
Connector for connection
of inboard option
Control lo
g
ic chan
g
in
g
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.
CC
1) AB3)2)
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
Wirin
g
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 and press the side of the accessory cover, A indicated by the
arrow in Fig. 1) and remove the accessory cover as shown in Fig. 2).
A
1) 2) 3)
Reinstallation
Install the accessory cover straight as shown in Fig. 1).
1) 2)

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
As shown in Fig. 1), install the control panel using the portion of arrow A as a
support.
2)1) A
Removal of the control panel
Hold down the portion A indicated by the arrow in Fig. 1) and remove the
control panel as shown in Fig. 2).
1)
A
2) 3)
(If the above procedure is not used for removal, the internal connector may be
damaged by the force applied.)
1

OUTLINE
9
Using the connection cable for operation
1) Fit the rear cover option FR-E5P to the back surface of the control panel.
2) Securely plug one end of the connection cable into the PU connector of the
inverter and the other end into the adaptor of the FR-E5P option to connect it
to the control panel. (For the connection cable of the FR-E5P, refer to page
26.)
PU connector
(RS-485 cable specifications)
Mounting the control panel on an enclosure
When you open the control panel front cover, the screw mounting guides for
fixing the control panel to an enclosure appear on the top left and bottom right.
Fit the rear cover of the FR-E5P option, drill holes in the control panel mounting
guides, and securely mount the control panel on the enclosure with screws.

OUTLINE
10
1.3.6 Removal of the operation panel (FR-PA02-02) front cover
1) Open the control panel front cover to 90 degrees.
2) Pull out the control panel front cover to the left to remove it.
90 de
g
rees
1.3.7 Exploded view
Control panel(FR-PA02-02)
Wirin
g
cover
Front cover
W
irin
g
port cover
f
or option
Accessory
cover
1

INSTALLATION AND
WIRING
This chapter gives information on the basic "installation and
wiring" for use of this product.
Always read the instructions in this chapter before using the
equipment.
2.1 Installation.................................................................... 11
2.2 Wiring........................................................................... 13
2.3 Other Wiring................................................................. 32
CHAPTER 2
INSTALLATION AND
WIRINNG
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6

2.1 Installation
INSTALLATION AND WIRING
11
2 INSTALLATION AND WIRING
2.1 Installation
2.1.1 Instructions for installation
1) Handle the unit carefully.
The inverter uses plastic parts. Handle it gently to protect it from damage.
Also, hold the unit with even strength and do not apply too much strength to the front
cover alone.
2) Install the inverter in a place where it is not affected by vibration easily (5.9m/s2
{0.6G} maximum).
Note the vibration of a cart, press, etc.
3) Note on ambient temperature.
The inverter life is under great influence of ambient temperature. In the place of
installation, ambient temperature must be within the permissible range –10 C to
+50C. Check that the ambient temperature is within that range in the positions
shown in figure 3.
4) Install the inverter on a non-combustible surface.
The inverter will be very hot (maximum about 150C). Install it on a non-combustible
surface (e.g. metal). Also leave sufficient clearances around the inverter.
5) Avoid high temperature and high humidity.
Avoid direct sunlight and places of high temperature and high humidity.
6) Avoid places where the inverter is exposed to oil mist, flammable gases, fluff, dust,
dirt etc.
Install the inverter in a clean place or inside a "totally enclosed" panel which does
not accept any suspended matter.
7) Note the cooling method when the inverter is installed in an enclosure.
When two or more inverters are installed or a ventilation fan is mounted in an
enclosure, the inverters and ventilation fan must be installed in proper positions with
extreme care taken to keep the ambient temperatures of the inverters with the
permissible values. If they are installed in improper positions, the ambient
temperatures of the inverters will rise and ventilation effect will be reduced.
8) Install the inverter on an installation surface securely and vertically with screws or
bolts.

INSTALLATION AND WIRING
12
3) Note on ambient
temperatures
Measurement
position
Measurement position
5cm 5cm
5cm
FR-E500
4) Clearances around the inverter
FR-E500
10cm
or more
10cm
or more Leave sufficient
clearances above
and under the
inverter to ensure
adequate ventilation.
Coolin
g
fan
built in the
inverter
1cm or
more* 1cm or
more*
Coolin
g
air
*5cm or more for 5.5K and 7.5K
7) For installation in an enclosure
Inverter
Ventilation
f
an
(Correct example) (Incorrect example)
Position of Ventilation Fan
Inverter
Built-in coolin
g
fan
(Correct example)
Inverter Inverter
When more than one inverter is contained
(Incorrect example)
Inverter
Inverter
8) Vertical mounting
2