Mitsubishi Electric FR-K-400-U User manual

MlTSUBlSHl
VVVF TRANSISTOR INVERTER
-INSTRUCTION MANUAL-
( 208/230V series I
MlTSUBlSHl
ELECTRIC

FORWORD
Thank youforyour purchaseof MitsubishiMulti-PurposeInverter FREQR0L.K .
This is a variable frequency power supply unit to control the speed of squirrel-cageinduction motors . This in-
struction manual is intendedboth toexplainthe unitand to outline operation procedures
.
This unit is not difficult to operate. but incorrect operation may lead to some troubles. so read this instruction
manual carefully before operation
. Ifyou use to unitproperly. we are sure it will give you many years of satisfac-
tion
.
Please make sure toattach this instruction manual tothe unitwhen the unit is shipped .
CONTENTS
1 . UNPACKING 1
2 . TRANSPORTING 1
.........................................................
3 . INSTALLATION 1
4
. WIRING AND POWER SUPPLY RATING ........................................ 1
............................................................
4-1 Wiring 1
4-2 Power supply rating
................................................... 2
........................................................... . 5 OPERATIONS 4
..........................................
5-1 Pointstocheck before operations 4
5-2 Preparationsbefore operations
............................................ 4
.........................................................
5-3 Operations 5
................................................. 5-4 Operation's precautions 6
6
. MAINTENANCEAND INSPECTION ............................................ 7
7 . CONSTRUCTION AND ARRANGEMENTOF CONTROLLER PARTS ..................... 8
8
. TROUBLESHOOTINGAND COUNTERMEASURE .................................. 9
8-1 Troubleshootingchart .................................................. 9
8-2 Failures indicatedby lighting of alarm indication lampsand how to deal with them
.........
13
.............................................
8-3 Measuringvoltage and current 15
9 . STANDARDSPECIFICATIONS ............................................... 17
10. PROTECTIVEFUNCTIONS .................................................. 18
. 11 INPUT/OUTPUTTERMINAL ................................................. 19

1. UNPACKING
After unpacking your FREQROL-K, first check the following points.
0 Refertothe name plate toconfirm thatthe model and the output rating is indeed the one you ordered.
(Seetable
1)
0 Check where there has been any damage or breakagetothe FREQROL-Kduring transportation.
If you have any doubts about the above, or find any damage to the unit, please contact your local service
representative.
Table
1 FR-KSeries Configuration
Motor output (HP) 112
1 2 3 5 7.5 10
Without operation FR-K- FR-K- FR-K- FR-K- FR-K- FR-K- FR-K-
panel 400-U 750-U 1500-U 2200-U 3700-U 5.5K-U 7.5K-U
With operation FR-K- FR-K- FR-K- FR-K- FR-K- FR-K- FR-K-
panel 400M-U 750M-U 1500M-U 2200M-U 3700M-U 5.5KM-U 7.5KM-U
Note: The operation panel is provided with a frequency setter, a frequency meter and a FWDIREV starting
switch.
2. TRANSPORTING
When transporting the FREQROL-K, handle it gently to prevent damage. There are depressions on boththe
top and the bottomwhere the unitcan be grasped, and these should be held when
it is moved.
Do not apply too much force to the fan at the bottom of the unit. The unit is covered with a plastic case,
and care should be taken notto apply force only tothis cover during transport.
a
3. INSTALLATION
o Place the inverter in a clean and well ventilated location. Avoid locations exposed to direct sunlight, or
subject to high temperatures, humidity, dust or corrosive gases.
0 Install the inverter securely on the wall with volts or screws, vertically so that the letters "FREQROL-K"
appears front.
0 Since the inverter does generate some heat during operations, any other equipment or parts should be
installed at least 10cm away from up and the bottom toprevent heat confined.
The brake resistor attached tothe rear of the unitalso generates heat, so the unitshould notbe placed on
awall with lowheat resistance.
0 If your inverter is one equipped with an operation panel, take care to put it in a place where it can be
easily operated.
4. WIRING AND POWER SUPPLY RATING
4-1 Wiring
Connect wiring correctly according to following instructions and refer to Fig. 1, Standard Wiring
Diagram.
Fowwiring of the peripheral devices such as MCCB, refer toTable
2, Selection of Peripherals.
(1) When the wiring cover located at the bottom of the inverter is pushed inward and then pulled
toward the operator, the wiring cover alone
is removed thus exposing all terminal blocks. A
corrugated gripping surface has been provided for your convenience. Nowperformwiring.

(2) The wirings of the frequency setter, FWDIREV start switches, frequency meter and calibration
resistor of meter equippedwith an operationpanel inFig. 1have already connected.
(3) Do not wire the power cable in such a manner that the line source voltage is directly applied to
the outputterminals
U, V and W.
(4) It is notalways necessav to provide wiring to the reset switch, since the circuit can be restored
by cutting off
MCCB or Magnetic Contactor (MS) if the output protective circuit has been
activatedtostop the controller.
(5) Since terminals P and N have been provided for brake unit and discharge resistor connections,
avoidconnectingonly discharge resistor, or any other equipment, tothese terminals.
(6)
It is notnecessary toconsider the phase sequence whenconnectingtoterminals R, Sand T.
(7) Since the frequency settingsignal current is extremely low if it is necessary touse contacts inthe
frequency setting circuit, use two pairs of parallel contacts or twin contacts for extremely low
currenttopreventpoor contact.
(8) Use
shielded wires or twisted wires as the wire cable in connections to the control terminals
(terminals marked as in Fig. 1, Standard Wiring Diagram) to preventthe control circuit from
being induced by other equipment, and also connect them away from the main circuit and high
voltage circuit (Relaysequence circuitof 230V. 115V).
Twisted wire .~. Shieldedwire
Frequency setter Frequency setter
(9) The output wires from the inverter are protected from short-circuiting (i.e., short-circuiting
among terminals
U, V and W) by an overcurrent protective circuit. However, there is no pro-
tection against shortcircuit caused by accidental leakage such as grounding. Therefore, care
should be taken to position the wires so as topreventthem from makingcontactwith the chassis,
etc.
(10)Rotation direction of the motor is counterclockwise as seen from the load side with the normal
wiring tothe output terminals
U, V and W.
4-2 Power supply rating
The FREQROL-K is shipped by the standard power supply ratingof AC 230V 60Hz. Ifyou are going
to install the FREQROL-Kwhere the power supply
is AC 208V 60Hz, change the connectionfor the
transformerTIas shown below.
In this case, take care tocheck the box on the front cover which indicates that the powersupply rating
has beenchanged.
Transformer T1
Change form 230V to 208V
or vice verra.
the terminal black
R1 and T1

Table 2 Selection of Peripherals
Model Current Ratings
/ of MCCR ad MS / Wires R, S. T I Wires U, V, w I
F R-K400-U
F R-K-7504
F R-K-1500-U
Note: 1. A wire size of #19 AWG or more is adequate all circuits other than the main circuit.
2. Select MCCB and MSaccording topower supply capacity.
3. Ifwiring distance exceeds 30 meters, increase wire size.
FR-K-2200-U
FR-K-3700-U
FR-K-5.5K-U
FR-K-7.5K-U
Fig. 1 StandardWiring Diagram
5A mps
10A mps
15A m~s
NFB
IMCCBI MS 1'21
/L 9
20A mps
30A mps
50A mps
60A mps
Calibratiot
Frequency meter
moving coiltype
113~ 10 k
1 mA
(Hz indication]
#14 AWG
#I 4 AWG
#14 AWG
Frequency setter
2W 1 kSL
#14 AWG
#14 AWG
#14 AWG
#14 AWG
#I 2 AWG
#lo AWG
# 6 AWG
- -
1 OCR ('11 Motor
#14 AWG
#12 AWG
#I0 AWG
# 8 AWG
FREOROL-K
Inverter
I
STF Reret aw.
STR
SD SD
FM
are built into inverters
an operation panel.
NOTE:
1. If you are running a motor with
a different capacity from the
inverter,
or more than one motor.
~rovidethermal overload relay to
the inverter's output circuit.
2. The purpores of this MS
as
follows,
11 If the nsrt switch is held
meCnanlCB
v, tne nverter w I
restart a.tomat'ca v nnon the
mner I.OD~Y I am e0 after
.. . . .
the momentary power inter-
ruption. For application when
auto.restart must be avoided.
this MS must be inrtalled.
21 In the
case the inverter must
be restarted until the motor
has sopped coasting,
or the
output transinor might be
damaged.

5. OPERATIONS
5-1 Points to check beforeoperations
After installation and wiring of FREQROL-K
is completed, check the following points before opera-
ting.
If insulation
is tobe checkedwith amegger, perform only the test betweencontroller and grounding.
Never performa megger testbetweenthe inverter's terminals.
Alsodonotperform amegger tenonthe control circuit terminals.
Refer tosection
6 for details on megger insulationtests.
(1) Check whether wiring conforms tothe standardwiring diagram.
(2) Check for pointsshort-circuitedby brokenwire, etc.
(3) Check ifany wire is strained.
(4) Check tightness of screws, of terminalsand other fasteners.
(5) Check motor loadconditions.
5-2 Preparations before operations
When inspection is completed, open the setting panel flap on the inverter front panel and make the
following setting.
5-2-1 Selectionof maximumoutputfrequency (setwith connector)
By changingthe position of the connector on the P.C. board,
set the maximumoutput frequency.
The maximum outputfrequency
is set to60Hz at shipping. (Don't change the connector while inverter
is operating)
1. 60Hz
(At shipping)
Note: If you are using ageneral-type motor, do not set the maximum output frequency to 240Hz.
(Thissetting
is for specialdesignedmotors.)
5-2-2 Selectionof frequency settingsignal (setwith sleect switch)
The settings O-5V and 0-10V are available for frequency signal. The 0-5V position is set at shipping. If
another settingis required, select as follows:
(1) For 0-5V DCsignal:
set the selectswitchtothe down position. (atshipping)
(2) For0-10V DCsignal: set the select switch tothe up position.
5-2-3 Settingof accelerationldeceleration time (setwith ACCE LIDECEL dialsand select switches)
Set acceleration and deceleration times by settingthe ACCEL and DECEL dials and the accelera-
tion anddecelerationtime magnifyingselectswitches.
(1) Acceleration and deceleration times can be
set independantly.
(2) Acceleration and deceleration time refers to the time during which output frequency is
increasingfrom 0 tomaximumfrequency or decreasing from maximum frequency to0.
(3) The relationship betweenthe figures on the notches of the ACCEL and DECELdials and the
position of the accelerat~onand deceleration time magnifying select switch
is shown inthe
figure below. Set them
at positions appropriate according to applications and kinds of the
motor load.

10 -150 rec.
110 secor~ds increment) 0.2
-3 sec.
10.2 second increment1
(4) Both the acceleration and deceleration times are set at 5 seconds at shipping.
5-2-4 Sening of electronic thermal relay (setbysetting dial)
(1) For setting of the electronic thermal relay, the rated output current of the inverter is deter-
mined at 100%. (Thesetting range
is 50 to loo%.)
(2) The electronic thermal relay is
set at 100%at shipping.
(3) Set the setting dial for the electronic thermal relay by calculating the percentageaccording
tothe followingequation.
0 When s single motor is operated by the inverter, the followingequation applies:
Rated current of the motor (A)
Set scale
(%) = -
x 100
Rated output currentof the inverter (A)
Ifthe value of the
set scale (%) exceeds 100%. then set the setting dial to 100%.
Rated outputcurrent
is shown inthe name plate.
(4) If a multipole motor with eight or more poles, an special-purpose motor, or plural motors
are being operated, the built-inelectronic thermal relay will notaffort sufficient protection
so athermal overload relay should be added tothe inverter's output circuit.
If such cases turn the electronic thermal relay setting dial
(TH) as far as it will go inthe
clockwise direction.
5-3 Operations
When the preparations have been completed, begin inverter operations in the following procedure:
(1) First close the
MCCB, then the magnetic contactor (MS) by pushbutton. The power pilot lamp
on the inverter panel should light in yellow. The motor will notyet rotate in this state. Touch the
motorwith your hand tosee that there are no buzzing sounds or vibration.
(2) If there are no zbnormalities, turn the FWD start switch (or REV start switch) on. Gradually turn
the knob of frequency setter clockwise. When the knob is turned to "3Hz" position, the motor
will start rotating. And turned farther clockwise, the frequency (rotation of the motor) will in-
crease gradually ap to
its maximum frequency setting (60Hz. 120Hz or 240Hz)
(3) When the frequency setter has been
set at the desired frequency, and the FWD start switch (or
REV start switch) has been turned on, motor revolutions will increase to the set value within the
time
set by the acceleration time setting dial described above, and then continue tooperate at the
setting frequency. If the motor does not acceleratesmoothly and the ALARM lamp blinks during
the acceieration or the "ALARM" indication lamp lights up, this is because the acceleration time
has been
set at too short period in relation to the motor load, and the acceleration time should
thus be lengthened.

(4) When the FWD start switch (or REV start switch) is turnedoff while the motor is rotating, motor
speed is decelerated in the time'period set by the DECEL dial. When the frequency falls below
3Hz. the DC dynamic brake will be activated and the motor will stop immediately. If the motor
speed does not decelerate smoothly and the ALARM lamp blinks during the deceleration or the
"ALARM" indication lamp lights up, this is because the deceleration time
is notsufficient for the
motor load, and the decelerationtime shouldthus be lengthened.
(5) Ifthe FWD start switch and the REV start switch are turned on simultaneously, the motorwill not
rotate. Also, if the FWD start switch and the REV start switch are simultaneouslyactivatedwhile
the motor
is rotating, the motor will begin decelerating inthe same manneras when the FWD (or
REV)start switch
is turned off.
(6) If the FWD start switch is turned off and the REV start switch turned on while the motor is rotat-
ing forward, the motor speed will decelerate toa frequency of 3Hz. at which point the rotation
direction will automatically be reversed, accelerating gradually tothe frequency that has beenset.
Thesame is also true of movementfrom reverse toforward rotation.
(7) Ifthe settings of the acceleration or deceleration times are changed during motor operations, the
previous settings will remain in memory and the changes will not take effect. Note that this
unit
is designed for changes in the setting of accelerationand deceleration time to be made at a
inverterfrequency below3Hz.
(8) If the protective circuits, such as those against overcurrent and regenerative overvoltage are
activated, the alarm indication lamp will light up in red and the shut-off state will continue. To
reset
after ashut-off, performthe followingoperations:
0 First turn off the power supply with the MCCB or the Magnetic contactor (MS), then turn
it on.
0 Short-circuit the terminals between RES (reset)and SD (common)of the control circuit by the
reset switch, then (after about 0.1 second), re-open.
(9) Use the calibration resistor to adjust the frequency meter so that the frequency is indicatedas 60,
120 or 240Hz when the commanded voltage (across terminals between 2 and 5)
is set to 5V DC
or 10V DC by the frequency settinginputsignal select switch.
Inverters equipped with a frequency meter have already been adjusted at the factory before
shipping.
(10) When the DC dynamic brake activates at below 3Hz during deceleration,
it may cause a high-
pitched noise. This noise is common, and does not indicate any abnormalities (The DC dynamic
brakefunctionsfor about0.5 second.)
5.4 Operation's Precautions
When the confirmations described above have been completed you may begin normaloperations, but
keep thefollowing points in mind when doingso.
(1) When a general type motor is being driven by the inverter, the temperature, noise and vibrations
will be somewhat higherthan they would be with acommercial power supply.
(2) Since cooling efficiency decreases at low speed operations,
it is necessary to reduce the torque
from the rated motor torque. (Refertothe catalogfor the torque reduction ratio.)
(3) The FREQROL-K is capable of controlling plural motors at the same time. When the inverter is
used to control more than one motor, care shouldbe taken that the total current requirementfor
thesimultaneouslyoperatedmotors
is within the rated output current of the inverter.
(4) Ifthe FREQROL-K
is being used to control multipole motors with 8 or more poles, submersible
motors. or other special-purpose motors, carefully examine the rated current and other electrical
specification.

(5) Do not add a capacitor nor surge absorber to the outputcircuit of the inverter. This may activate
the overcurrent protection.
(6) If you are using a motor with mechanical brakes, the brake exciting circuit should not be con-
nected to the inverter output, and make certain theat brake action can be affected after turning
off the inverter's power supply.
(7) If using motors of different capacity or special-purposemotors, or ifmorethan one motor is being
used simultaneously, add
a thermal overload relay to the inverter output circuit to protect the
motor from being burned up. In this case turn the electronic thermal relay setting dial (TH) on
the operation panel as far as
it will go inthe clockwise direction.
(8) Th= FR-K-400 can also be used with a single phase power supply, but when doing so be sure to
connect the power supply toterminals R and
S.
(9) Since the built-in brake resistor will cause temperature increases, mount it on noninflammable
materials such as metal or concrete.
6. MAINTENANCE AND INSPECTION
The FREQROL-K is the static type, so almost no daily maintenance is required. The following maintenance
practices should, however, be observed.
(1) Since the capacitor inthe inverter remains chargedat high voltage for awhile after the inverter isturned
off, perform inspections only after charge indication lamp "CHARGE" goes out. Also, the coolingfan
will continueto runfor some time after the power has beenturned off, so be careful to keep hands away
from this area.
(2) From time totime, inspect the inverter for dust and dirt accumulated inside, and clean it if there is a
buildup.
(3) Check the tightness of terminal block screws and mounting screws. If they come any loose, tighten
them securely. Make certain there are no defects in the wiring parts or components. Replace defective
wiring part if found, or contact your service representative.
(4) Meggertest
a) When performing a megger test on the external equipment, remove all inverter terminals so thatthe
test voltage will not be applied tothe inverter.
b) Perform megger tests only for the main circuit of the inverter as shown in Fig.
2. Do not apply the
test voltage tothe control circuit.
c) TOcheck the FFiEQROL-K control circuit, use a multimeter (settohigh resistance range position).
Do notuse a megger or buzzer.
Fig.
2 Megger Test
-
Earth terminal

7. CONSTRUCTION AND ARRANGEMENT OF INVERTER PARTS
I
As noted above, wiring requires only the removal of the wiring cover at the bottom of the inverter. To
inspect the inverter's interior, however, proceedas follows:
(1) When the wiring cover is removed, the plastic cover's two set screws will be exposed. Remove these
screws and slidethe plastic cover upward.
(2) The P.C. board of the control circuit has been attached by set screws (for inverters below class FR-K-
3700-U)or the board support (for FR-K-5.5K-U and FR-K-7.5K-U).
Fig.
3 Type FR-K-400-U to FR-K-3700-U Fig.
4 Type FR-K-5.5K-U and FR-K-7.5K-U
Controlcircuit terminal arrangement
TR?
Control circuit terminal arrangement
TB4