Mitsubishi Electric FR-V5AX User manual

VECTOR INVERTER
-INSTRUCTION MANUAL-
IB(NA)-0600083-A (0110) MEE
VECTOR INVERTER
Printed in Japan Specifications subject to change without notice.
HEAD OFFICE:MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100-8310
FR-V5AX
HIGH RESOLUTION ANALOG INPUT / EXTRA
CONTACT INPUT / THERMISTOR INTERFACE

A-1
Thank you for choosing the Mitsubishi vector inverter option unit.
This instruction manual gives handling information and precautions for use of this equipment. Incorrect handling
might cause an unexpected fault. Before using the equipment, please read this manual carefully to use the equipment
to its optimum.
Please forward this manual to the end user.
1. Electric Shock Prevention
This section is specifically about safety matters
Do not attempt to install, operate, maintain or inspect this product until you have read through this instruction man-
ual and appended documents carefully and can use the equipment correctly. Do not use this product until you have
a full knowledge of the equipment, safety information and instructions.
In this instruction manual, the safety instruction levels are classified into "WARNING" and "CAUTION".
Assumes that incorrect handling may cause hazardous conditions, resulting in
death or severe injury.
Assumes that incorrect handling may cause hazardous conditions, resulting in
medium or slight injury, or may cause physical damage only.
Note that the CAUTION level may lead to a serious consequence according to conditions. Please follow the instruc-
tions of both levels because they are important to personnel safety.
SAFETY INSTRUCTIONS
!While power is on or when the inverter is running, do not open the front cover. You may get an electric shock.
!Do not run the inverter with the front cover removed. Otherwise, you may access the exposed high-voltage termi-
nals and charging part and get an electric shock.
!If power is off, do not remove the front cover except for wiring or periodic inspection. You may access the
charged inverter circuits and get an electric shock.
!Before starting wiring or inspection, switch power off, wait for more than 10 minutes, and check for no residual
voltage with a tester or the like.
WARNING
CAUTION
WARNING

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

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

CONTENTS
1.PRE-OPERATION INSTRUCTIONS 1
1.1 Unpacking and Product Confirmation..................................................................................................1
1.2 Packing Confirmation...........................................................................................................................1
1.3 Structure ..............................................................................................................................................1
2.INSTALLATION 2
2.1 Pre-Installation Instructions..................................................................................................................2
2.2 Installation Procedure..........................................................................................................................2
2.3 Wiring...................................................................................................................................................3
3.HIGH RESOLUTION ANALOG INPUT 5
3.1 Connection example............................................................................................................................5
3.2 Explanation of terminals.......................................................................................................................5
3.3 Related parameters .............................................................................................................................6
3.4 Calibration............................................................................................................................................8
3.5 Noise reduction techniques..................................................................................................................9
3.6 Specifications.......................................................................................................................................9
4.EXTRA CONTACT INPUT FUNCTION 10
4.1 Overview............................................................................................................................................10
4.2 Explanation of terminals.....................................................................................................................10
4.3 Related Parameters...........................................................................................................................11
4.4 Setting................................................................................................................................................11
4.5 Specifications.....................................................................................................................................12
5.THERMISTOR INTERFACE 13
5.1 Connection example..........................................................................................................................13
5.2 Explanation of terminals.....................................................................................................................13
5.3 Parameter setting...............................................................................................................................14
5.4 Motor thermal relay alarm..................................................................................................................14
5.5 Calibration..........................................................................................................................................15

1
1.PRE-OPERATION INSTRUCTIONS
1.1 Unpacking and Product Confirmation
Take the option unit out of the package, check the unit name, and confirm that the product is as you
ordered and intact.
This product is an option unit designed for exclusive use in the Mitsubishi FR-V500 series vector inverter.
Functions available differ, before using it, always make the following checks.
1.2 Packing Confirmation
Make sure that the package includes the following
" Instruction manual.........................................................................1
" Mounting screws M3 × 10 .............................................................2
1.3 Structure
Connector
Mounting
hole
Terminal
block
screw
size M3
Terminal
symbol
Front view Mounting
holes
Option fixing holes
Rear view Mounting
hole
FR-V5AX
PC2DI11 DI12 DI15 DI16SDTH1 TH2 6 5 DI13 DI14
CON2
Calibration
connector
(Refer to
page 15)

2
2.INSTALLATION
2.1 Pre-Installation Instructions
Make sure that the input power of the inverter is off.
2.2 Installation Procedure
(1) Securely insert the connector of the option unit far into the connector of the inverter. At this time, fit the
option fixing holes snugly.
Also be sure to fit the unit into the option fixing hook.
(2) Securely fix the option unit to the inverter on both sides with the accessory mounting screws. If the
screw holes do not match, the connector may not have been plugged snugly. Check for loose plugging.
With input power on, do not install or remove the option unit. Otherwise, the inverter and
option unit may be damaged.
CAUTION

3
INSTALLATION
2.3 Wiring
Route the wires so that they do not take up a large space in the control circuit terminal block of the option unit.
During wiring, do not leave wire off-cuts in the inverter. They may cause a fault, failure or malfunction.
Use the space on the left side of the Control circuit terminal unit to route the wires.
CAUTION
1. Only one type of option per inverter may be used. When two or more options are mounted, pri-
ority is in order of slots 1, 2 and 3, the options having lower priority are inoperative.
2. When the inverter cannot recognize that the option is
mounted, it displays the option error. The errors shown
differ according to the mounting slots 1, 2, 3.
Option unit
Accessory screw
(2 pcs.)
Option side
connector
Inverter
(without cover)
Slot 1
Inverter side connector
Slot 2
Slot 3
Option fixing hook
The slots 1, 2, and 3 are provided
with an option fixing hook.
Mounting Position Error Display
Slot 1 E.OP1
Slot 2 E.OP2
Slot 3 E.OP3

4
INSTALLATION
REMARKS
The wires with large gaze may not be connected to the terminal block. When connected in parallel, all wires may not
fit in the wiring space due to the increased number of wires. In such cases, perform wiring by using a junction termi-
nal block.
Do not use empty terminals as junction terminals because they are used in the option unit. If
they are used as the junction terminals, the option unit may be damaged.
When installing the inverter front cover, the cables to the inverter's control circuit terminals and
option terminals should be routed properly in the wiring space to prevent them from being
caught between the inverter and its cover.
Cable routing
CAUTION

5
3.HIGH RESOLUTION ANALOG INPUT
Speed command, torque command, speed retriction value and torque restriction value (same level for driv-
ing and regenerative modes) can be set using 0 to 10VDC analog voltage.
3.1 Connection example
3.2 Explanation of terminals
The high resolution analog input function uses the following terminals.
Terminal
symbol Terminal name Rated current, etc. Description
6High resolution
input terminal Max. permissible voltage 20VDC
0 to 10VDC input, high resolution (16-bit) analog voltage
input terminal. Select the terminal function using Pr. 406 " high
resolution analog input selection".
5Analog common
terminal — Common terminal for the No. 6 terminal.
FR-V5AX
6
+10V
-10V
5

6
HIGH RESOLUTION ANALOG INPUT
3.3 Related parameters
Set the high resolution analog input.
When Pr. 406 = "9999" (factory setting), "high resolution analog input selection" does not function.
The Pr. 406 "high resolution analog input selection" setting and control modes are combined as indicated
in the following table.
Parameter
number Name Setting range Minimum setting
increments Factory setting
406 High resolution analog input selection 0, 2 to 5, 9999 1 9999
926 No.6 terminal bias (speed) 0 to 10V, 0 to 3600r/min 0.1r/min 0V, 0r/min
927 No.6 terminal gain (speed) 0 to 10V, 0 to 3600r/min 1r/min 10V, 1500r/min
928 No.6 terminal bias (torque) 0 to 10V, 0 to 400% 0.1% 0V, 0%
929 No.6 terminal gain (torque)) 0 to 10V, 0 to 400% 0.1% 10V, 150%
REMAKS
For Pr.406, write is disabled during operation even when “2” is set in Pr.77. When changing the parameter setting,
stop the operation.
Pr. 406
setting
No. 6 terminal
function for
speed control
No. 6 terminal
function for
torque control
No. 6 terminal
function for
position control
Bias/gain
setting Remarks
0Speed
command Speed limit No function Pr. 926,
Pr. 927
Terminal 2 is made invalid and its functions
are replaced by terminal 6.
When Pr.868=0, terminal 1 acts as auxiliary.
2Regenerative mode torque
limit No function Regenerative
mode torque limit Pr. 928, Pr. 929 When Pr.868=2, terminal 1 is made invalid and its functions are replaced by terminal 6.

7
HIGH RESOLUTION ANALOG INPUT
3 No function Torque
command No function Pr. 928,
Pr. 929 During torque control, terminal 3 is made invalid and its functions are replaced by terminal 6.
4 Torque limit Torque
command Torque limit Pr. 928, Pr. 929
During speed control and position control with
Pr.801=1 and torque control, terminal 3 ismade
invalid and its functions are replaced by terminal 6.
Torque restriction level :Driving/regenration
are the same level:
5 No function (*) Driving side
speed limit No function Pr. 926,
Pr. 927 When Pr.868=5, terminal 1 is made invalid and its functions are replaced by terminal 6.
9999
(factory
setting) No function No function No function
REMAKS
1. *:When performing driving side speed restriction, set "2" in Pr.807 "speed restriction selection".
The speed restriction value becomes Pr.1"maximum setting" when the driving side speed restriction is exercised.
2. The minimum resolution of the speed is 0.1r/min.
3. The setting of Pr. 822 "speed setting filter 1", Pr. 832 "speed setting filter 2", Pr. 826 "torque setting filter" or Pr.
836 "torque setting filter 2" is valid for the No. 6 terminal input.
For parameter details, refer to the Inverter Instruction Manual (detailed).
4. For details of terminals 1, 2, and 3, refer to inverter instruction manual (detailed).
Pr. 406
setting
No. 6 terminal
function for
speed control
No. 6 terminal
function for
torque control
No. 6 terminal
function for
position control
Bias/gain
setting Remarks

8
HIGH RESOLUTION ANALOG INPUT
3.4 Calibration
(1) When Pr. 406 = 0 or 5 (speed setting), calibration is made as shown below.
* When Pr. 406 = 5 (speed limit setting for torque control), the input from the No. 6 terminal is valid for
the driving mode only. It is invalid for the regenerative mode.
(2) When Pr. 406 = 2, 3 or 4 (torque command), calibration is made as shown below.
* When Pr. 406 = 2 (torque limit), the input from the No. 6 terminal is valid for the regenerative mode only.
Pr. 926
Pr. 927
Input voltage
(1500r/min)
Speed Factory setting
010V
-10V
Output torque
Pr. 929
Input voltage
(150%)
010V -10V
(150%)
Pr. 928

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HIGH RESOLUTION ANALOG INPUT
3.5 Noise reduction techniques
Use the following techniques if an analog signal is compounded with noise, resulting in instable operation.
(1) Techniques for wiring
1)Separate the power and signal cables as far as possible.
2)Use a twisted pair shield cable as the signal cable.
Handle the shield cable in any of the following ways.
•Connect it to the No. 5 terminal of the FR-V5AX.
•Connect it to the common terminal on the analog command device side.
•Connect it to both the No. 5 terminal of the FR-V5AX and the common terminal on the analog com-
mand device side.
•Connect it to neither the No. 5 terminal of the FR-V5AX nor the common terminal on the analog
command device side. (Keep the shield cable suspended.)
(2) Techniques on the inverter side
Decrease the setting of Pr. 72 "PWM frequency selection". (Motor-produced sound increases but in-
verter-generated noise reduces.)
Increase the settings of the speed (torque) setting filters, Pr. 822, Pr. 832 (Pr. 826, Pr. 836).
(3) Others
Install the FR-BLF line noise filter (FR-BSF01 for 3.7K or less).
Reinforce or separate earthing.
3.6 Specifications
Resolution 0.003% at 0 to 10V input (16 bits)
Input resistance 14kΩ
Max. input voltage 20V
CAUTION
Changing the speed (torque) setting filter value affects the response level of the inverter to a com-
mand. Therefore, adjust it while simultaneously looking at the machine motion.

10
4.EXTRA CONTACT INPUT FUNCTION
4.1 Overview
Six terminal input points can be added by assigning functions to the DI11 to DI16 input terminals using Pr.
400 to Pr. 405 (input terminal function selection). At this time, since five more points can be chosen with Pr.
180 to Pr. 183 and Pr. 187 "input terminal assignment" of the inverter, a total of 11 input terminals are avail-
able. The signal from the 6 bit data (binary) input terminal can be used as external position command dur-
ing position control.
4.2 Explanation of terminals
This extra contact input function uses the following terminals.
Terminal
symbol Terminal name Description
PC2 External transistor
common
When connecting the transistor output (open collector output) of a programmable con-
troller (PC) or like, connecting the external power supply common for transistor output
to this terminal prevents a malfunction caused by a sneak current.
DI11
Multi-function
input terminal
•Set function assignment in Pr. 400 to Pr. 405 (input terminal function selection).
•Input the binary 6 bit signal during position control.
DI12
DI13
DI14
DI15
DI16
SD Contact input
common Contact input common terminal. Do not connect this terminal with the other common terminal. Do not earth (ground) this terminal.
bit b5b4b3b2b1b0
terminal DI16 DI15 DI14 DI13 DI12 DI11

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EXTRA CONTACT INPUT FUNCTION
4.3 Related Parameters
The functions of the DI11 to DI16 input terminals can be assigned using Pr. 400 to Pr. 405 (input terminal
function selection).
4.4 Setting
The Pr.400 to Pr.405 "input terminal function selection" settings are the same as Pr.180 to Pr.183 and Pr.187
"input terminal function selection". Note that the X10 signal can not be assigned to the FR-V5AX.
When using the X10 signal, assign it to the input terminals DI1 to DI4 of the inverter.
Refer to the instruction manual of the inverter for parameter details.
Parameter
number Name Factory setting Setting range Minimum setting increments
400 DI11 terminal function selection 9999 0 to 99, 9999 1
401 DI12 terminal function selection 9999 0 to 99, 9999 1
402 DI13 terminal function selection 9999 0 to 99, 9999 1
403 DI14 terminal function selection 9999 0 to 99, 9999 1
404 DI15 terminal function selection 9999 0 to 99, 9999 1
405 DI16 terminal function selection 9999 0 to 99, 9999 1
REMAKS
For Pr.400 to Pr.406, write is disabled during operation even when “2” is set in Pr.77. When changing the parameter
setting, stop the operation.

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EXTRA CONTACT INPUT FUNCTION
4.5 Specifications
•Input signal types
Select a signal from among the low-speed operation command, mid-speed operation command, high-
speed operation command, remote setting, second function selection, jog operation selection, 15-
speed selection, third function selection, FR-HC connection (instantaneous power failure detection),
PU operation external interlock, external DC braking start, PID control enable terminal, brake opening
completion signal, PU operation-external operation switch-over, S-pattern acceleration/deceleration C
switching terminal, orientation command, pre-excitation/servo on, output stop, start self-holding selec-
tion, control mode changing, torque limit selection, torque bias selection 1, torque bias selection 2 and
P control selection (P/PI control switching).
•Input signal selection .........Use Pr. 400 to Pr. 405 to make selection.
•Input terminal selection......Open collector output or no-voltage contact signal

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5.THERMISTOR INTERFACE
When the vector inverter motor with a thermistor (SF-V5R) is used, the motor temperature detected by the
thermistor in the motor can be fed back to the inverter to reduce the fluctuation of generated torque caused
by temperature change.
The rauge or motor temperature that can be detected is between -50°C to 200°C (-58°F to 392°F).
5.1 Connection example
Change jumpers of the thermistor calibration connecter to use the themistor. (Refer to page 15)
5.2 Explanation of terminals
This extra contact input function uses the following terminals.
CAUTION
To detect temperatures at the FR-V5AX, always use the SF-V5R vector inverter motor provided
with thermistor.
Terminal symbol Terminal name Description
TH1 Thermistor input 1 A motor side thermistor output signal is input.
TH2 Thermistor input 2
U
V
WIM Thermistor
FR-V5AX
TH1
TH2
Inverter
Twisted pair shield cable

14
THERMISTOR INTERFACE
5.3 Parameter setting
The following parameters are provided for use of the thermistor interface.
5.4 Motor thermal relay alarm
(1) When Pr. 407 = "0 to 100"
Normally, set 30s in Pr. 407. If the response level to a motor temperature is low, make adjustment to
decrease the setting.
•Detection ofa 145°C (293°F)or higher motortemperature continuously for 10s results ina motorthermal
relay alarm (E.THM), shutting off the output.
•Detection of a -30°C(-22°F)or lower motor temperature during operation results in a motor thermal
relay alarm (E.THM), shutting off the output.
During a stop, a motor thermal relay alarm (E.THM) does not occur.
•The OH terminal (thermal relay protector input) is invalid.
(2) When Pr. 407 = "9999"
A motor thermal relay alarm (E.THM) is not detected by the FR-V5AX.
Parameter Name Factory
setting Setting range
Minimum
input
increments Remarks
407 Motor temperature detection filter 9999 0 to 100s, 9999 1s 9999: No function
925 Motor temperature detection calibration 100% 0 to 200% 0.1%
CAUTION
The vector inverter motor with thermistor does not have a thermal relay protector. When using this
type of motor, always set a value other than "9999" in Pr. 407 "motor temperature detection filter".
If the setting remains "9999", motor protection cannot be provided.

15
THERMISTOR INTERFACE
5.5 Calibration
Calibrate the inverter and FR-V5AX (thermistor interface). Always calibrate them at the time of installation.
(1) Calibration method
1) Remove the jumper from the lower pin of CON2 and insert it into the upper pin to choose the ther-
mistor calibration status.
2) Read Pr. 925 and set a compensation value.
(For the setting method of the compensation value, refer to page 16.)
3) After completion of compensation, return the jumper to the lower pin.
REMAKS
If you start the motor in the thermistor calibration status (with the jumper of CON2 inserted in the upper pin), a motor
thermal relay alarm (E.THM) will occur in 10 seconds and the inverter output is shut off.
Likewise, if you start the motor without the thermistor interface being connected, a motor thermal relay alarm
(E.THM) will occur in 10 seconds and the inverter output is shut off.
SDTH1 TH2 6 5
CON2
SDTH1 TH2 6 5
CON2