Mitsubishi Electric FR-S500E User manual

FR-S500E
Frequency Inverter
Instruction Manual
(Detailed)
FR-S520SE-0.2K to 1.5K-EC,
FR-S540E-0.4K – 3.7K-EC
INDUSTRIAL AUTOMATION
MIT
SU
BI
S
HI ELE
C
TRI
C
MIT
SU
BI
S
HI ELE
C
TRI
C
Art. no.: 160474
01 09 2004
IB(NA)-0600211ENG
Version A

A-1
1. Electric Shock Prevention
Thank you for choosing this Mitsubishi Transistorized inverter.
This instruction manual (detailed) provides instructions for advanced use of the FR-
S500 series inverters.
Incorrect handling might cause an unexpected fault. Before using the inverter, always
read this instruction manual and the instruction manual (basic) [IB-0600210ENG]
packed with the product carefully to use the equipment to its optimum.
This section is specifically about safety matters
Do not attempt to install, operate, maintain or inspect the inverter until you have read
through this instruction manual (basic) and appended documents carefully and can
use the equipment correctly. Do not use the inverter until you have a full knowledge
of the equipment, safety information and instructions.
In this instruction manual (detailed), the safety instruction levels are classified into
"WARNING" and "CAUTION".
Assumes that incorrect handling may cause hazardous
conditions, resulting in death or severe injury.
Assumes that incorrect handling may cause hazardous
conditions, resulting in medium or slight injury, or may cause
physical damage only.
Note that even the level may lead to a serious consequence
according to conditions. Please follow the instructions of both levels because they are
important to personnel safety.
WARNING
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 or wiring cover removed. Otherwise,
you may access the exposed high-voltage terminals or the charging part of the
circuitry and get an electric shock. Also, the inverter's ability to withstand
earthquakes will deteriorate.
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, check to make sure that the 3-digit LED inverter
monitor is off, wait for at least 10 minutes after the power supply has been switched
off, and check to make sure that there are no residual voltage using a tester or the
like.
This inverter must be earthed. Earthing must conform to the requirements of
national and local safety regulations and electrical codes. (JIS, NEC section 250,
IEC 536 class 1 and other applicable standards)
Any person who is involved in the wiring or inspection of this equipment should be
fully competent to do the work.
Always install the inverter before wiring. Otherwise, you may get an electric shock
or be injured.
Perform setting dial and key operations with dry hands to prevent an electric
shock.
Do not subject the cables to scratches, excessive stress, heavy loads or pinching.
Otherwise, you may get an electric shock.
Do not change the cooling fan while power is on. It is dangerous to change the
cooling fan while power is on.
When you have removed the front cover, do not touch the connector above the 3-
digit monitor LED display. Otherwise, you get an electrick shock.
WARNING
CAUTION
CAUTION

A-2
2. Fire Prevention
3. Injury Prevention
4. Additional Instructions
Also note the following points to prevent an accidental failure, injury, electric shock,
etc.
(1) Transportation and installation
CAUTION
Mount the inverter on an incombustible surface. Installing the inverter directly on or near
a combustible surface could lead to a fire.
If the inverter has become faulty, switch off the inverter power. A continuous flow of
large current could cause a fire.
Do not connect a resistor directly to the DC terminals +,
- . This could cause a fire.
CAUTION
Apply only the voltage specified in the instruction manual to each terminal to
prevent damage, etc.
Always connect to the correct terminal to prevent damage, etc.
Always make sure that polarity is correct to prevent 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.
CAUTION
When carrying products, use correct lifting gear to prevent injury.
Do not stack the inverter boxes higher than the number recommended.
Ensure that installation position and material can withstand the weight of the
inverter. Install according to the information in the instruction manual.
Do not install or operate if the inverter is damaged or has parts missing.
When carrying the inverter, do not hold it by the front cover or setting dial; it may
fall off or fail.
Do not stand or rest heavy objects on the inverter.
Check the inverter mounting orientation is correct.
Prevent other conductive bodies as screws and metal fragments or other
flammable substance as oil from entering the inverter.
As the inverter is a precision instrument, do not drop or subject it to impact.
Use the inverter under the following environmental conditions: This could cause
the inverter damage.
*Temperatures applicable for a short time, e.g. in transit.
Environment
Ambient
Temperature -10°C to +50°C (non-freezing)
Ambient humidity 90%RH maximum (non-condensing)
Storage
temperature -20°C to +65°C *
Atmosphere Indoors (free from corrosive gas, flammable gas, oil mist,
dust and dirt)
Altitude/
vibration Maximum 1000m above sea level for standard operation.
After that derate by 3% for every extra 500m up to 2500m
(91%). 5.9m/s2or less (conforming to JIS C 60068-2-6)

A-3
(2) Wiring
(3) Trial run
(4) Operation
CAUTION
Do not fit capacitive equipment such as power factor correction capacitor, radio
noise filter (option FR-BIF(-H)) or surge suppressor to the output of the inverter.
The connection orientation of the output cables U, V, W to the motor will affect the
direction of rotation of the motor.
CAUTION
Check all parameters, and ensure that the machine will not be damaged by a
sudden start-up.
When the load GD2is small (at the motor GD or smaller) for 400V from 1.5K to 3.7K, the
output current may vary when the output frequency is in the 20Hz to 30Hz range.
If this is a problem, set the Pr.72 "PWM frequency selection" to 6kHz or higher.
(When setting the PWM to a higher frequency, check for noise or leakage current
problem and take countermeasures against it.)
WARNING
When you have chosen the retry function, stay away from the equipment as it will
restart suddenly after an alarm stop.
The [STOP] key is valid only when the appropriate function setting has been made.
Prepare an emergency stop switch separately.
Make sure that the start signal is off before resetting the inverter alarm. A failure to
do so may restart the motor suddenly.
The load used should be a three-phase induction motor only. Connection of any
other electrical equipment to the inverter output may damage the equipment.
Do not modify the equipment.
Do not perform parts removal which is not instructed in this manual. Doing so may
lead to fault or damage of the inverter.

A-4
(5) Emergency stop
(6) Maintenance, inspection and parts replacement
(7) Disposing of the inverter
(8) General instructions
CAUTION
The electronic thermal relay function does not guarantee protection of the motor
from overheating.
Do not use a magnetic contactor on the inverter input for frequent starting/stopping
of the inverter.
Use a noise filter to reduce the effect of electromagnetic interference. Otherwise
nearby electronic equipment may be affected.
Take measures to suppress harmonics. Otherwise power supply harmonics from
the inverter may heat/damage the power capacitor and generator.
When a 400V class motor is inverter-driven, please use an insulation-enhanced
motor or measures taken to suppress surge voltages. Surge voltages attributable to
the wiring constants may occur at the motor terminals, deteriorating the insulation of
the motor.
When parameter clear or all clear is performed, reset the required parameters
before starting operations. Each parameter returns to the factory setting.
The inverter can be easily set for high-speed operation. Before changing its
setting, fully examine the performances of the motor and machine.
In addition to the inverter's holding function, install a holding device to ensure safety.
Before running an inverter which had been stored for a long period, always
perform inspection and test operation.
CAUTION
Provide a safety backup such as an emergency brake which will prevent the
machine and equipment from hazardous conditions if the inverter fails.
When the breaker on the inverter primary side trips, check for the wiring fault (short
circuit), damage to internal parts of the inverter, etc. Identify the cause of the trip,
then remove the cause and power on the breaker.
When any protective function is activated, take the appropriate corrective action,
then reset the inverter, and resume operation.
CAUTION
Do not carry out a megger (insulation resistance) test on the control circuit of the
inverter.
CAUTION
Treat as industrial waste.
Many of the diagrams and drawings in this instruction manual (detailed) show the inverter
without a cover, or partially open. Never operate the inverter in this manner. Always replace
the cover and follow this instruction manual (detailed) when operating the inverter.

I
CONTENTS
CONTENTS
1. WIRING 1
1.1 Standard connection diagram and terminal specifications ..2
1.1.1 Standard connection diagram .......................................................................2
1.1.2 Explanation of main circuit terminals.............................................................3
1.2 Main circuit terminals ...............................................................6
1.2.1 Terminal block layout ....................................................................................6
1.2.2 Cables, wiring length, and crimping terminals...............................................7
1.2.3 Wiring instructions.........................................................................................8
1.2.4 Selection of peripheral devices .....................................................................9
1.2.5 Leakage current and installation of earth leakage circuit breaker...............10
1.2.6 Power-off and magnetic contactor (MC)......................................................14
1.2.7 Regarding the installation of the power factor improving reactor................15
1.2.8 Regarding noise and the installation of a noise filter...................................16
1.2.9 Earthing precautions ...................................................................................17
1.2.10 Power supply harmonics.............................................................................18
1.2.11 Inverter-driven 400V class motor ................................................................19
1.3 How to use the control circuit terminals...............................20
1.3.1 Terminal block layout ..................................................................................20
1.3.2 Wiring instructions.......................................................................................20
1.3.3 Changing the control logic...........................................................................21
1.4 Input terminals.........................................................................23
1.4.1 Run (start) and stop (STF, STR, STOP) .....................................................23
1.4.2 Connection of frequency setting potentiometer and
output frequency meter (10, 2, 5, 4, AU).....................................................26
1.4.3 External frequency selection (REX, RH, RM, RL).......................................27
1.4.4 Indicator connection and adjustment (AM)..................................................29
1.4.5 Control circuit common terminals (PC, 5, SE).............................................30
1.4.6 Signal inputs by contactless switches.........................................................30
1.5 How to use the input signals
(assigned terminals RL, RM, RH, STR)..................................31
1.5.1 Multi-speed setting (RL, RM, RH, REX signals):
Pr. 60 to Pr. 63 setting "0, 1, 2, 8"
Remote setting (RL, RM, RH signals):
Pr. 60 to Pr. 63 setting "0, 1, 2"...................................................................31
1.5.2 Second function selection (RT signal): Pr. 60 to Pr. 63 setting "3" .............31
1.5.3 Current input selection "AU signal": Pr. 60 to Pr. 63 setting "4"..................31

II
1.5.4 Start self-holding selection (STOP signal): Pr. 60 to Pr. 63 setting "5"....... 32
1.5.5 Output shut-off (MRS signal): Pr. 60 to Pr. 63 setting "6"........................... 32
1.5.6 External thermal relay input: Pr. 60 to Pr. 63 setting "7"............................. 33
1.5.7 Jog operation (JOG signal): Pr. 60 to Pr. 63 setting "9".............................. 33
1.5.8 Reset signal: Pr. 60 to Pr. 63 setting "10"................................................... 34
1.5.9 PID control valid terminal: Pr. 60 to Pr. 63 setting "14"............................... 35
1.5.10 PU operation/external operation switchover: Pr. 60 to Pr. 63 setting "16".. 35
1.6 Connection to the Stand-Alone Option.................................36
1.6.1 Connection of the brake unit (BU type)....................................................... 36
1.6.2 Connection of the high power factor converter (FR-HC)............................. 37
1.6.3 Connection of the power regeneration common converter (FR-CV)........... 38
1.7 Handling of the RS-485 connector ........................................39
1.7.1 Connection of the parameter unit (FR-PU04)............................................. 39
1.7.2 Wiring of RS-485 communication ............................................................... 40
1.8 Design information .................................................................43
2. FUNCTIONS 45
2.1 Function (Parameter) list........................................................46
2.2 List of parameters classified by purpose of use..................59
2.3 Explanation of functions (parameters) .................................61
2.3.1 Torque boost (Pr. 0 , Pr. 46 ) ...................................................................... 61
2.3.2 Maximum and minimum frequency (Pr. 1 , Pr. 2 ) ...................................... 62
2.3.3 Base frequency, base frequency voltage (Pr.3 , Pr.19 , Pr.47 ).................. 63
2.3.4 Multi-speed operation (Pr. 4, Pr. 5, Pr. 6, Pr. 24 to Pr. 27, Pr. 80 to Pr. 87)64
2.3.5 Acceleration/deceleration time (Pr. 7 , Pr. 8 , Pr. 20 , Pr. 44 , Pr. 45 ) ....... 65
2.3.6 Selection and protection of a motor (Pr. 9 , Pr. 71 , H7 )............................ 67
2.3.7 DC injection brake (Pr. 10 , Pr. 11 , Pr. 12 ) ............................................... 69
2.3.8 Starting frequency (Pr. 13 )......................................................................... 70
2.3.9 Load pattern selection (Pr. 14 )................................................................... 71
2.3.10 Jog operation (Pr.15 , Pr.16 )...................................................................... 72
2.3.11 RUN key rotation direction selection (Pr.17 ).............................................. 72
2.3.12 Stall prevention function and current limit function (Pr. 21 ) ....................... 73
2.3.13 Stall prevention (Pr. 22 , Pr. 23 , Pr. 28 ).................................................... 75
2.3.14 Acceleration/deceleration pattern (Pr. 29 ) ................................................. 77
2.3.15 Extended function display selection (Pr. 30 ).............................................. 78
2.3.16 Frequency jump (Pr. 31 to Pr. 36 )............................................................. 78
2.3.17 Speed display (Pr. 37 ) ............................................................................... 79

III
CONTENTS
2.3.18 Biases and gains of the frequency setting voltage (current)
(Pr. 38 , Pr. 39 , C2 to C7 ).........................................................................80
2.3.19 Start-time earth fault detection selection (Pr. 40 ).......................................84
2.4 Output terminal function parameters....................................84
2.4.1 Up-to-frequency (Pr. 41 ).............................................................................84
2.4.2 Output frequency detection (Pr. 42 , Pr. 43 )...............................................85
2.5 Current detection function parameters.................................86
2.5.1 Output current detection functions (Pr. 48 , Pr. 49 )....................................86
2.5.2 Zero current detection (Pr. 50 , Pr. 51 ).......................................................87
2.6 Display function parameters..................................................88
2.6.1 Monitor display (Pr. 52 , Pr. 54 )..................................................................88
2.6.2 Setting dial function selection (Pr. 53 )........................................................89
2.6.3 Monitoring reference (Pr. 55 , Pr. 56 ).........................................................90
2.7 Restart operation parameters ................................................90
2.7.1 Restart setting (Pr. 57 , Pr. 58 , H6 )...........................................................90
2.8 Additional function parameters .............................................93
2.8.1 Remote setting function selection (Pr. 59 ).................................................93
2.9 Terminal function selection parameters ...............................96
2.9.1 Input terminal function selection (Pr. 60 , Pr. 61 , Pr. 62 , Pr. 63 )..............96
2.9.2 Output terminal function selection (Pr. 64 , Pr. 65 ) ....................................98
2.10 Operation selection function parameters .............................99
2.10.1 Retry function (Pr. 66 , Pr. 67 , Pr. 68 , Pr. 69 ) ..........................................99
2.10.2 PWM carrier frequency and long wiring mode (Pr. 70 , Pr. 72 )................101
2.10.3 Voltage input selection (Pr. 73 )................................................................102
2.10.4 Input filter time constant (Pr. 74 )..............................................................103
2.10.5 Reset selection/PU stop selection (Pr. 75 )...............................................103
2.10.6 Cooling fan operation selection (Pr. 76 )...................................................105
2.10.7 Parameter write disable selection (Pr. 77 ) ...............................................106
2.10.8 Reverse rotation prevention selection (Pr. 78 ).........................................107
2.10.9 Operation mode selection (Pr. 79 ) ...........................................................107
2.10.10PID control (Pr. 88 to Pr. 94 )...................................................................111
2.11 Auxiliary parameters.............................................................118
2.11.1 Slip compensation (Pr. 95 , Pr. 96 , Pr. 97 )..............................................118
2.11.2 Automatic torque boost selection (Pr. 98 )................................................119
2.11.3 Motor primary resistance (Pr. 99 ).............................................................120
2.12 Maintenance parameters ......................................................120

IV
2.12.1 Maintenance output function (H1, H2 )..................................................... 120
2.12.2 Current average value monitor signal (H3, H4, H5)................... 121
2.13 Calibration parameters.........................................................124
2.13.1 Meter (frequency meter) calibration (C1 )................................................. 124
2.14 Clear parameters...................................................................127
2.14.1 Parameter clear (CLr ) .............................................................................. 127
2.14.2 Alarm history clear (ECL )......................................................................... 127
2.15 Communication parameters.................................................128
2.15.1 Communication settings (n1 to n7 , n11 )................................................ 130
2.15.2 Operation and speed command source (n8 , n9 ) .................................... 145
2.15.3 Link startup mode selection (n10 )............................................................ 146
2.15.4 E2PROM write selection (n12 )................................................................. 148
2.16 Parameter unit (FR-PU04) setting........................................149
2.16.1 PU display language selection (n13 ) ....................................................... 149
2.16.2 PU buzzer control (n14 )........................................................................... 149
2.16.3 PU contrast adjustment (n15 ).................................................................. 150
2.16.4 PU main display screen data selection (n16 )........................................... 150
2.16.5 Disconnected PU detection/PU setting lock selection (n17 ).................... 151
3. PROTECTIVE FUNCTIONS 153
3.1 Errors (Alarms)......................................................................154
3.1.1 Error (alarm) definitions ............................................................................ 155
3.1.2 To know the operating status at the occurrence of alarm
(only when FR-PU04 is used)................................................................... 163
3.1.3 Correspondence between digital and actual characters........................... 163
3.1.4 Resetting the inverter................................................................................ 163
3.2 Troubleshooting....................................................................164
3.2.1 Motor remains stopped............................................................................. 164
3.2.2 Motor rotates in opposite direction............................................................ 165
3.2.3 Speed greatly differs from the setting....................................................... 165
3.2.4 Acceleration/deceleration is not smooth................................................... 165
3.2.5 Motor current is large................................................................................ 165
3.2.6 Speed does not increase.......................................................................... 165
3.2.7 Speed varies during operation.................................................................. 165
3.2.8 Operation mode is not changed properly.................................................. 166
3.2.9 Operation panel display is not operating................................................... 166
3.2.10 Parameter write cannot be performed ...................................................... 166

V
CONTENTS
3.2.11 Motor produces annoying sound...............................................................166
4. SPECIFICATIONS 167
4.1 Specification list....................................................................168
4.1.1 Ratings......................................................................................................168
4.1.2 Common specifications.............................................................................170
4.2 Outline drawings ...................................................................172
APPENDIX 175
APPENDIX 1 Parameter Instruction Code List .............................176

1
Chapter 2
Chapter 3
Chapter 4
Chapter 1
1. WIRING
This chapter explains the basic "wiring" for use of this product. Always
read the instructions before use.
For description of "installation", refer to the instruction manual (basic).
1.1 Standard connection diagram and terminal
specifications ..................................................... 2
1.2 Main circuit terminals ........................................ 6
1.3 How to use the control circuit terminals.......... 20
1.4 Input terminals.................................................... 23
1.5 How to use the input signals (assigned
terminals RL, RM, RH, STR) .............................. 31
1.6 Connection to the Stand-Alone Option ............ 36
1.7 Handling of the RS-485 connector...................... 39
1.8 Design information............................................. 43
<Abbreviations>
•PU
Operation panel and parameter unit (FR-PU04)
•Inverter
Mitsubishi transistorized inverter FR-S500 series
•FR-S500
Mitsubishi transistorized inverter FR-S500 series
•Pr.
Parameter number

2
Standard connection diagram and terminal specifications
1.1 Standard connection diagram and terminal
specifications
1.1.1 Standard connection diagram
Three-phase 400V power input
REMARKS
*1. You can switch the position of sink and source logic. Refer to page 21.
*2. When the setting potentiometer is used frequently, use a 2W1kΩpotentiometer.
*3. The terminal functions change with input terminal function selection (Pr. 60 to Pr. 63). (Refer to page 96.)
(RES, RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, X14, X16, (STR) signal selection)
*4. The terminal function changes according to the setting of output terminal function selection (Pr. 64, Pr. 65).
(Refer to page 98.) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, Y93, Y95, LF, ABC signal selection)
CAUTION
To prevent a malfunction due to noise, keep the signal cables more than 10cm away
from the power cables.
Inverter Motor
IM
U
V
W
RUN
SE
Running
Alarm output
Operation status
output
Open
collector Open collector
outputs
A
B
C
Frequency setting
potentiometer
1/2W1kΩ
Frequency setting signals (Analog)
10
2
2
3
1
4 to 20mADC(+) 4
0 to 5VDC
0 to 10VDC
5
Current input(-)
(+5V)
(Common)
(4 to 20mADC)
Selected
output
common
Low speed RL
NFB MC
Power factor improving
DC reactor
(FR-BEL: Option)
Jumper: Remove this
jumper when FR-BEL
is connected.
P1
SINK
SOURCE
Multi-speed
selection
Take care not to short
terminals PC-SD.
RS-485
Connector
Three-phase AC
power supply
Control circuit terminalMain circuit terminal
When using the current input as
the frequency setting signal, set
"4" in any of Pr. 60 to Pr. 63 (input
terminal function selection), assign
AU (current input selection) to any
of terminals RH, RM, RL and STR
and turn on the AU signal.
Control input
signals
(No voltage
input allowed)
STF
STR
RM
Forward rotation start
Reverse rotation start
Middle speed
High speed RH
Earth
SD
PC
External transistor common
Contact input common (sink)
Contact input common
24VDC power supply
AM
5
(+)
(-)
Analog signal
output
(0 to 5VDC)
Earth
*3
*1
*3
*3
*3
*4
*4
*4
*4
*2
L1
L2
L3
+
-

3
Standard connection diagram and terminal specifications
1
WIRING
Single-phase 200V power input
1.1.2 Explanation of main circuit terminals
(1) Main circuit
REMARKS
•To ensure safety, connect the power input to the inverter via a magnetic contactor and earth leakage
circuit breaker or no-fuse breaker, and use the magnetic contactor to switch power on-off.
•The output is three-phase 200V.
Terminal
Symbol Terminal Name Description
L1, L2, L3 (*1) AC power input Connect to the commercial power supply.
U, V, W Inverter output Connect a three-phase squirrel-cage motor.
+, −Brake unit
connection
Connect the brake unit (BU), power regeneration
common converter (FR-CV) or high power factor
converter (FR-HC).
+, P1
Power factor
improving DC
reactor
connection
Remove the jumper across terminals + - P1 and connect
the optional power factor improving DC reactor (FR-
BEL(-H)).
Earth For earthing the inverter chassis. Must be earthed.
*1. When using single-phase power input, terminals are L1 and N.
NFB
IM
U
V
W
MC
Power
supply
Motor
Earth
N
L1

4
Standard connection diagram and terminal specifications
(2) Control circuit
Symbol Terminal Name Definition
Input signals Contact input
STF Forward rotation
start
Turn on the STF signal to
start forward rotation and
turn it off to stop.
When the STF and STR
signals are turned on
simultaneously, the stop
command is given.
STR Reverse rotation
start
Turn on the STR signal to
start reverse rotation and
turn it off to stop. The terminal
functions change
with input terminal
function selection
(Pr. 60 to Pr.63).
(*3)
RH
RM
RL
Multi-speed
selection
Turn on the RH, RM and RL signals in
appropriate combinations to select
multiple speeds.
The priorities of the speed commands
are in order of jog, multi-speed setting
(RH, RM, RL, REX) and AU.
SD
(*1)
External
transistor
common,
Contact input
common (sink)
When connecting the transistor output (open collector output),
such as a programmable controller (PLC), connect the negative
external power supply for transistor output to this terminal to
prevent a malfunction caused by undesirable currents.(*6)
When sink logic has been selected, this terminal serves as a
contact input common.
PC
(*1)
24VDC power
supply,
Contact input
common
(source)
Common to the contact input terminals (STF, STR, RH, RM,
RL).
This terminal can be used as a 0.1A 24VDC power supply
across terminals PC-SD.
10 Frequencysetting
power supply 5VDC, Permissible load current 10mA.
Frequency setting
2Frequencysetting
(voltage signal)
Inputting 0 to 5VDC (or 0 to 10V) provides the maximum output
frequency at 5V (10V) and makes input and output proportional.
Switch between 5V and 10V using Pr. 73 "0-5V, 0-10V selection".
Input resistance 10kΩ. Maximum permissible input voltage 20V
4Frequencysetting
(current signal)
Input 4 to 20mADC. It is factory set at 0Hz for 4mA and at
50Hz for 20mA.
Maximum permissible input current 30mA. Input resistance
approximately 250Ω.
Turn ON signal AU for current input.
Turning the AU signal on makes voltage input invalid. Use any of
Pr. 60 to Pr. 63 (input terminal function selection) to set the AU
signal.
5Frequencysetting
input common Common terminal for the frequency setting signals
(terminal 2, 4) and indicator connection (terminal AM). (*6)

5
Standard connection diagram and terminal specifications
1
WIRING
*1. Do not connect terminals SD and PC each other or to the earth.
For source logic (factory setting), terminal PC acts as the common terminal of contact
input. For sink logic, terminal SD acts as the common terminal of contact input. (Refer to
page 21 for switching method.)
*2. Low indicates that the open collector output transistor is on (conducts). High indicates
that the transistor is off (does not conduct).
*3. RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, RES, X14, X16, (STR) signal
selection (Refer to page 96.)
*4. RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, Y93, Y95, LF, ABC signal selection
(Refer to page 98.)
*5. To be compliant with the European Directive (Low Voltage Directive), the operating
capacity of relay outputs (A, B, C) should be 30VDC 0.3A.
*6. Terminals SD, SE and 5 are isolated from each other. Do not earth.
Output signals
A
B
CAlarm output
Changeover contact output indicates
that the inverter protective function has
activated and the output stopped.
230VAC 0.3A, 30VDC 0.3A. Alarm:
discontinuity across B-C (continuity
across A-C), Normal: continuity across
B-C (discontinuity across A-C).(*5)
The function of the
terminals changes
according to the
output terminal
function selection
(Pr. 64, Pr.65).
(*4)
Open collector
RUN Inverter
running
Switched low when the inverter output
frequency is equal to or higher than the
starting frequency (factory set to 0.5Hz
variable). Switched high during stop or
DC injection brake operation. (*2)
Permissible load 24VDC 0.1A (a
voltage drop is 3.4V maximum when
the signal is on)
SE Open collector
common Common terminal for inverter running terminal RUN.
(*6)
Indicator
AM Analog signal
output
The output signal across terminals AM-5 is factory set to about
5VDC at 50Hz and is proportional to the corresponding output
frequency.
Frequency permissible load current 1mA
Output signal 0 to 5VDC
Communication
—— RS-485
connector
Using the parameter unit connection cable (FR-CB201 to
205), the parameter unit (FR-PU04) can be connected.
Communication operation can be performed using RS-485.
For details of RS-485 communication, refer to page 40.
Symbol Terminal Name Definition

6
Main circuit terminals
1.2 Main circuit terminals
1.2.1 Terminal block layout
2)Single-phase 200V power input
1)Three-phase 400V power input
•FR-S540E-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-EC
•FR-S520SE-0.2K, 0.4K, 0.75K-EC •FR-S520SE-1.5K-EC
CAUTION
•Make sure the power cables are connected to the L1, L2, L3 of the inverter. Never
connect the power cable to the U, V, W of the inverter. (Phase need not be
matched)
•Connect the motor to U, V, W. At this time, turning on the forward rotation switch
(signal) rotates the motor in the counterclockwise direction when viewed from the
motor shaft.
P1
Jumper
Power supply Motor
U V W
IM
+
L1 L2 L3
-
P1
Motor
Jumper
U V W
IM
Power supply
L1 N
+
-
P1
Jumper
Motor
U V W
IM
Power supply
+
-
L1 N

7
Main circuit terminals
1
WIRING
1.2.2 Cables, wiring length, and crimping terminals
The following table indicates a selection example for the wiring length of 20m.
1) Three-phase 400V power input
2) Single-phase 200V power input
Wiring length
100m maximum. (50m maximum for the FR-S540E-0.4K-EC.)
Applied Inverter
Ter-
minal
Screw
size
Tight-
ening
Torque
N
⋅ m
Crimping
Terminal Cable
PVC Insulation
Cable
mm2AWG mm2
L1, L2, L3 U, V, W L1, L2, L3 U, V, W L1, L2, L3 U, V, W L1, L2, L3 U, V, W
FR-S540E-0.4K
to 3.7K-EC M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
Applied Inverter
Termi-
nal
Screw
size
Tight-
ening
Torque
N
⋅ m
Crimping
Terminal Cable
PVC Insulation
Cable
mm2AWG mm2
L1, N U, V, W L1, N U, V, W L1, N U, V, W L1, N U, V, W
FR-S520SE-0.2K
to 0.75K-EC M3.5 1.2 2-3.5 2-3.5 2 2 14 14 2.5 2.5
FR-S520SE- 1.5K -
EC M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
CAUTION
•When the wiring length of the 0.2K of the single-phase 200V class and 0.4K
and 0.75K of the three-phase 400V class is 30m or more, set the carrier
frequency to 1kHz.
•When automatic torque boost is selected in Pr. 98 "automatic torque boost
selection (motor capacity)", the wiring length should be 30m maximum. (Refer
to page 119.)

8
Main circuit terminals
1.2.3 Wiring instructions
1) Use insulation-sleeved crimping terminals for the power supply and motor cables.
2) Application of power to the output terminals (U, V, W) of the inverter will damage the
inverter. Never perform such wiring.
3) After wiring, wire offcuts must not be left in the inverter.
Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter
clean.
When drilling a control box etc., take care not to let wire offcuts enter the inverter.
4) Use cables of the recommended size to make a voltage drop 2% maximum.
If the wiring distance is long between the inverter and motor, a main circuit cable
voltage drop will cause the motor torque to decrease especially at the output of a
low frequency.
5) For long distance wiring, the high response current limit function may be reduced or
the devices connected to the secondary side may malfunction or become faulty
under the influence of a charging current due to the stray capacity of wiring.
Therefore, note the maximum overall wiring length.
6) Electromagnetic wave interference
The input/output (main circuit) of the inverter includes high frequency components,
which may interfere with the communication devices (such as AM radios) used near
the inverter. In this case, install a FR-BIF(-H) optional radio noise filter (for use on
the input side only) or FR-BSF01 or FR-BLF line noise filter to minimize
interference.
7) Do not install a power capacitor, surge suppressor or radio noise filter (FR-BIF(-H)
option) on the output side of the inverter.
This will cause the inverter to trip or the capacitor and surge suppressor to be
damaged. If any of the above devices are connected, remove them. (When using
the FR-BIF(-H) radio noise filter with a single-phase power supply, connect it to the
input side of the inverter after isolating the L3 phase securely.)
8) Before starting wiring or other work after the inverter is operated, wait for at least 10
minutes after the power supply has been switched off, and check that there are no
residual voltage using a tester or the like. The capacitor is charged with high
voltage for some time after power off and it is dangerous.

9
1
WIRING
Main circuit terminals
1.2.4 Selection of peripheral devices
Check the capacity of the motor applicable to the inverter you purchased. Appropriate
peripheral devices must be selected according to the capacity.
Refer to the following list and prepare appropriate peripheral devices:
1) Three-phase 400V power input
2) Single-phase 200V power input
*2. For installations in the United States or Canada, the circuit breaker must be inverse
time or instantaneous trip type.
*3. The power factor may be slightly lower.
*4. When the breaker on the inverter primary side trips, check for the wiring fault (short
circuit), damage to internal parts of the inverter, etc. Identify the cause of the trip,
then remove the cause and power on the breaker.
Motor
Output
(kW)
Applied Inverter
Type
No-fuse Breaker
(NFB *1, 4) or
Earth Leakage
Circuit Breaker
(ELB) (Refer to
page 10) (*2, 4)
Magnetic
Contactor
(MC)
(Refer to
page 14)
Power Factor
ImprovingAC
Reactor
(Refertopage
15)
Power Factor
ImprovingDC
Reactor
(Refertopage
15)
0.4 FR-S540E-0.4K -EC 30AF/5A S-N10 FR-BAL-
H0.4K FR-BEL- H0.4K
0.75 FR-S540E-0.75K -EC 30AF/5A S-N10 FR-BAL-
H0.75K FR-BEL- H0.75K
1.5 FR-S540E-1.5K -EC 30AF/10A S-N10 FR-BAL-
H1.5K FR-BEL- H1.5K
2.2 FR-S540E-2.2K -EC 30AF/15A S-N10 FR-BAL-
H2.2K FR-BEL- H2.2K
3.7 FR-S540E-3.7K -EC 30AF/20A S-N20,
S-N21 FR-BAL- H3.7K FR-BEL- H3.7K
Motor
Output
(kW)
Applied Inverter
Type
No-fuse Breaker
(NFB *1, 4) or
Earth Leakage
Circuit Breaker
(ELB) (Refer to
page 10) (*2, 4)
Magnetic
Contactor
(MC)
(Refer to
page 14)
Power Factor
Improving AC
Reactor
(Refertopage
15) (*3)
Power Factor
Improving DC
Reactor
(Refertopage
15) (*3)
0.2 FR-S520SE-0.2K-EC
30AF/10A S-N10 FR-BAL-0.4K FR-BEL-0.4K
0.4 FR-S520SE-0.4K-EC
30AF/10A S-N20,
S-N21 FR-BAL-0.75K FR-BEL-0.75K
0.75 FR-S520SE-0.75K-EC 30AF/15A S-N20,
S-N21 FR-BAL-1.5K FR-BEL-1.5K
1.5 FR-S520SE-1.5K-EC
30AF/20A S-N20,
S-N21 FR-BAL-2.2K FR-BEL-2.2K
*1. •Select the NFB according to the inverter power
supply capacity.
•Install one NFB per inverter.
INV
NFB INV
IM
IM
NFB

10
Main circuit terminals
1.2.5 Leakage current and installation of earth leakage circuit
breaker
Due to static capacitances existing in the inverter I/O wiring and motor, leakage
currents flow through them. Since their values depend on the static capacitances,
carrier frequency, etc., take the following countermeasures.
(1) To-earth leakage currents
Leakage currents may flow not only into the inverter's own line but also into the
other line through the earth cable, etc.
These leakage currents may operate earth leakage circuit breakers and earth
leakage relays unnecessarily.
Countermeasures
•If the carrier frequency setting is high, decrease the carrier frequency (Pr. 72) of the
inverter.
Note that motor noise increases. Selection of Soft-PWM control (Pr. 70) will make it
unoffending. (Factory setting)
•By using earth leakage circuit breakers designed for harmonic and surge
suppression in the inverter's own line and other line, operation can be performed
with the carrier frequency kept high (with low noise).