Mitsubishi Electric FREQROL-K Series User manual

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--
#I #a~ ~zAJBISHI
TRANSISTORIZED --
INVERTER
\
Single-Phase input
220/240VAC series
I, 2.2, 3.OKw)

- -
for your purchase of Mitsubishi General-Purpose Frequency Inverter F REQRO L-K
. .
. 1
Serles. This Inverter IS easy to operate and handle. However, mistakes in handling and operatlon
may cause unforeseen accident, shorten the life of product and reduce the performances of
product. Therefore, please read
ttiis' Instruction manual carefully to use the inverter correctly.
Please keep this lnstructlon manualcarefully for latter use.
Please attach this instruction manual to the machine in which the inverter is. Installed before
shlpment so that the manual IS delivered to the customer.
i
CONTENTS .I
5.1 Frontcover ................................................................ 5
5.2 SettingPanelCover
.......................................................... 6
5.3 Totally EnclosingPlates
..................................................... .7
5.4 ControlPanel .............................................................. 8
6.1 Connection Diagram ......................................................... 9
6.2 Terminal Arrangement ..................................................... .I0
6.3 InputIOutput Terminals
.................................................... .I 1
6.4 Wiring Instructions ........................................................ .14
7.1
Check~ngbefore Adjustment. ................................................ .I5
7.2 Adjustment .......................................................,.......15
7.3 Operation ................................................................ 20
9.1 Troubleshoot~ngChart ..................................................... .24 ;I
9.2 Measuring Methodsfor Voltage and Current. .................................... -28
1 k

After unpackingthe Inverter, first check the following points:
0 Check if there has been any damage to the Inverter due to an acc~dentdurlng transportation.
o Check the nameplate applied to the front cover to confirm that the model and output ratlng
meet your order.
$a INVERTER FR-K-SBOOOM
Type of ~nverter
TD840A505G55 BD Appl~cablepower
SOURCE AC2201240V 50Hz
supply voltage
OUTPUT 13A SERIAL
MlTSUBlSHl ELECTRICCORP. JAPAN
BD990Z214H41
Year and month
manufactured
Nameplate
For the details of standard specifications, see page 30.
If you have any doubts or f~ndany damages tothe unlt, please contact your local service represen-
tatlve.
Carry and handlethe inverter carefully to prevent damage.
When carrylng the inverter, hold
it with care so that force is not applied to the fan at the bottom of
Inverter.
The inverter
IS protected w~th a plast~cenclosure. When carrylng the inverter, however, handle with
care so that undue force
IS not applied to the plastic cover.

1 3. ,EXTERNAL VIEW AND - - NOMENCLATURE . ,
, A I VML~~JMULO n
Fig. 1 and 2 show theexternal view and riomenclature of the inverter.
_ - --
Fig. 1 External View and Nomenclatureof Inverter
Fig.
2 Rear V~ewof Inverter
3

1 ,4,. INSTALLATION
I L?UkN1;;;ML°K ,
(1) Place the lnverter in a clean and well-ventilated location. Avoid locations exposed to dlrect
sunlight or subjected to high temperature, high humld~ty,dust or corrosivegases.
(2) Install the inverter securely with bolts or screws, vertically (fo that the letters "FREQROL-K"
on the front cover of Inverter, face front). Do not mount ;he inverter horizontally or aslant
because efficient ventilation will be impaire.
I
(3) Since the inverter generates heat to some degree, install any /other equipment or parts at least
10 cm away from the top and bottom of inverter and at least 5 cm away from both sldes of in-
verter to allow efficient heat dissipation.
I
cm or more
FR-K
I
cool I ng
fan
5
cm or more 5 cm or more '
Fig. 3 Mounting of lnverter
(4) Repeated breaking operation, may cause, the rear mounted discharging break resistor to reach
a maximum temperature of 150°C. Therefore mount the inv'erter to an incombustible surface
such
as concreteor metal. (See Fig. 2.)
(5) The FR-K serles inverters are available In two types of protective constructions according to
the output rating. Since the two types vary in the maximum allowable ambient temperature,
caution should be
exercised.
The maximum allowable amb~enttemperature of totally enclosed type lnverter is 40°C. By
removing the totally enclosingplates at thetop and bottom of inverter, the maximumallowable
amblent temperature can be changed to 50°C. (For the rehoval procedure, refer to page 6.)
!
Inverter Model
FR-K-S1500
FR-K-S2200
FR-K-S3000
Protective
Construction
Totally enclosed type
(IP50)
M~X. Allowable
Ambient Temperature
' +4ooc
Enclosed type
(lP20) +50°
c

1, 5, DISMOUNTING AND MOUNTING
. -
I-$ VMBluJMUbO K
5.1 Front Cover
To remove the front cover, as shown in Fig. 4, push down the whlte button located at the top
of inverter (arrow
a ), pull the top half of cover toward fron't (arrow a), and further push it
down lightly (arrow @ ). Then, the cover is removed from the chassis. Since mountingscrews
are not used, the cover can be d~smountedeasily.
Fig. 4 Removal of Front Cover
,
To reinstall the cover to the chassis, as shown in Fig. 5, fit the pins lns~dethe cover into the
notches
at the bottom of chassis. Then, lightly press the topjhalf of cover against the chassis.
Nameplate
Fig. 5 lnstallatronof Front Cover
The rating plate IS affixed to the cover. Therefore, be sure to rQinsta11the removed cover to the
same inverter.
,

-1
, 5. ,DISM30UNTINGAND MOUNTING
VlillBlujNWii0 K
As standard, the inverter is supplied wlthout cover fixing screws. However, the cover can also be
fixed by
use of mountlngscrews. Inthis case, ~nstallthe cover, referringtothe follow~ngworking
procedure and Fig.
6.
Working procedure
(1 1 After removingthe front cover, drill holes wlth a drill, etc. at positionsshown in Fig. 6 from
the rear surface of cover. The hole diameter should be
4.5 to 5.0 mm.
(2) After installing the front cover, securely fix the cover by use of the following screws:
Fig. 6 lnstallat~onof Cover w~thScrews
As shown In Fig. 7, lightly push the left end portion of setting panel cover and slide it to the
right. Then, the cover can be removed.
In thls case, the settlng panel cover
is completely removed from the front cover. Therefore,
take care not to drop or lose
it.
Used screws FR-K-S1500,S2200
.. . . . . . .M4 x 0.7 x 30
FR-K-S3000
..........
L~ghtly push and pull to the r~ght
/
.
Fig. 7 Removal of Senlng Panel Cover
After dr~lllngholes In the cover, f~xw~thscrews.
-Top r~ght,top left (2 postt~ons)
SettingPanel Cover

5.3 Totally EnclosingPlates
When the totally enclosed type inverters FR-K-S1500and FR-K-S2200are installedinside
a control
box, etc. and the temperature insidethe control box
is expected to exceed 40°C, only use the Inver-
ter after removing the totally enclosing plates located at the top and bottom. The removal pro-
cedure of totally enclosingplatesare shown in Fig.
8 and 9.
Since the totally enclosed type inverter is not of a waterproof construction, do not lnstall this type
of inverter outdoors or in
a place where the inverter can be splashed with water. oil. etc.
Fig. 8 Removal of Top Totally Enclosing Plate
The bottom totally enclosing
plate 1s f~xedtothe chass~sby
the hooks. After gently pres-
sing these hooks Inward from
the rear surface of Inverter,
remove the totally enclos~ng
plate.
Bottomtotally enclos~ngplate
c-"--1
Fig. 9 Removal of Bottom Totally Enclos~ngCondu~tEntry Plate

5.4 Control Panel
The control panel
is fixed to the printedcircuit board with 4 hooks and a connector.To remove the
control panel, push the lower
2 mounting braces upward.
To reinstall the control panel, exercise care to correctly fit the connector of printed circuit board
with the connector pins of control panel.
Pr~ntedclrcult board
Mount~ng
brace
Hook
Control panel
Push upwardw~thfingers.
Light pressure
IS suffic~ent
Fig. 10 Removal and Relnstallat~on of Control Panel

\, 1 6: WIRING
I .I VMIUU;JNL0 K
:Fig. 11 shows a terminal connection diagram. Referring to this diagram, properly wire the Inverter
according tothe following instructions and as described on page 14.
For the connectton of main circu~tcables, it 1s recommended to use solderless term~nalsprovided
w~thinsulation sleeves.
6.1 Connection Diagram
(1 ) Controlcircuit
With operatlon panel
I Operation panel 1
I Thls ponlon IS connected lnrlde the inverter. 1
, Frequency setter
W~thoutoperatlon panel
Open when I _ I
error occurs Control
Frequency setter
A
2W , krr Frequency settlng
auxlllary Input
Fig. 11 Control Circu~tConnect~on D~agrarns

?, , 6. WIRING i #uwuk3 K
, ' LA -
(2) Main circuit
Do not connect power supply
Input (Mains) to motor ter-
mlnals by m~stake.The Inver-
ter w~llbe damaged.
li i
Terrnlnalsexclus~velyused
for brake unrt
Power supply
Fig. 12 Maln Circu~t Connection Diagram
6.2 Terminal Arrangement
Terminal screw size
Motor
Control clrcult'TB2
Ma~nclrcult TB1
Fig. 13 Terrnlnal BoardScrew Sizes
BN
Model
Earthtermlnal
@f
P
Control
Circu~t
FR-K-S15OO.S22OO M3
Earth
Termlnal
M5
FR-K-S3000 I M3
/ M5 M5
1 M4
u, v, w
LIN
M5
-
UVW
-
M4 M4 M4

r, ,
! '6. WI'RING K&NW~OK :
i
1
Main circuit terminals
Control c~rcuitterminals
Application and Specifications
Termlnals for connect~onof cornmerc~apower supply.
Input voltage ratlng IS single-phase 2201240V AC 50Hz.
of motor.
Connect a three-phase squirrel-cage lnductlon motor.
Do not connect the power
supply by mistake. The Inverter will be
damaged.
Ensure motor
IS connected for 220/24013/50Hz.r [y'ILj ;. d
Earthterm~nalof inverter.
Termlnals for connectlon of regenerative brake unlt.
Donotconnect other equipment.
Terminal
/ Termlnal Name
Symbol
1
LI, N AC power supply Input
term~nals
U, V, w
Terminal
Symbol
Inverter output terrnlnals
I
4 Earthterm~nal
I
P, BN I Converter output termlnal
I
Termtnal Name Application and Specifications
.Output termlnal of power
supply for frequency settlng
I
Termlnal for connectlonof frequency setter.
Output voltage:
5V DC. Allowable load current: 6mA.
5 Common termlnal for Common termlnal of frequency settlng Input slgnal (termlnals
2 and
1 frequency settng signal
1 i.
1 1
Not Isolatedfrom the common clrcult of control clrcuit.
1
lnput termlnal for
2'
1 frequency settlng signal
Input termlnal of command voltage slgnal for the Inverter output
frequency.
i
Output frequency reaches the maxlmum (60Hz, 120Hz or 240Hz)
1 at 5V DC and Inputand output are propon~onal.
I lnput reslstance: 1 lkR. Maxlmumallowable voltage: 20V DC.
I
1
Auxtllary Input termlnal
1 Terminal used for the additlon of voltage slgnal to that of termlnal 2
for frequency setting or when frequency settingslgnal voltage IS 0 to 10V DC.
i signal
When -10 to +10V DC IS Input, output frequency reaches the maxl-
1
mum at +lOV and Input and output are proportional. At the negatrve
! voltage, however, the addlt~onof voltage to termlnal 2 can be
performed but the Inverter comes to stop if voltage
IS applred only
to one terminal.
~
!;Example.-------------------------------------------------7
i ' :
I
1: @ When +1OV applied only to termlnal 1. output frequency i
1 1; reaches the maxlmum.
1
1: @ When -5V IS applied only to termlnal 1, the ~nvertercomes j
i
I I
to stop.
I1
;;
3 When 5V is appl~edto termlnal 2 and -5V to termlnal 1,
'-5V'
I 1: 5V + /i= 2.5V
I
\2i
i 1:
!
! '
operation IS performed at half the maxlmurn output fre- :
! !: quency
,.---------------------__------------------------------------a
I

1 SD Common termlnal for 1 Common term~nalof forwardireverse start slgnal and frequency I
1 forwardireverse start slgnal lndlcator
Isolated from the common clrcult of control clrcult.
-
lnput termlnal for forward
start slgnal
lnput termlnal for reverse
start slgnal
- - -
S~gnalInputs for startlng the lnverter
Forward command IS glven when short IS caused across STF and SD,
and stop command
IS glven when the clrcult IS opened.
Reverse command
IS glven when short IS caused across STR and SD,
and stop command
IS glven when the clrcult IS opened
When short
IS caused across STF and SD and across STR and SD
s~multaneously,stop command IS glven.
Controllable by open cpllector output.
Output termlnal for
frequency meter Termlnal for
connection of frequency lndlcator
Average voltage reaches approximately 5VDC at the maxlmum
output frequency (60Hz. 120Hz or 240Hz) and IS proportional to
output frequency.
Output voltage has pulseshaped waveform Connect 1mA movlng-
i
i
1 1
coll type DC ammeter in serles to lOkR graduat~oncallbratlng pot. /
RES lnput termlnal for reset
I
I
slgnal
j
Termlnal for resetting the error retention of lnverter
Cause short across RES and SD for 0.1 or more seconds and then
open them.
I
MRS I
/ JOG mode lnput 1 Termlnal for selecting jogging mode such as lnchlng.
termlnal
1
Causlng short across JOG and SD allows jogging operation (flxedat
I
5Hz). After causlng short across JOG ans SD, operate and stop the
I Inverter by STF (forward)or STR (reverse)slgnal.
1 Though causlng short across JOG and SD, jogglng operatlon can not
be done when STF (orSTR)
IS ON
I
!
lnput termlnal to stop
/
Slgnal lnput termlnal whlch stops lnverter output to avold lnverter
RUN 1 Output termlnal of S~gnalfor checklng the run of lnverter and provldlng Interlock w~th
i ~nverter'srun ) the operation of other equipment.
!
I
L level durlng run of Inverter at hlgher frequency than mlntmum
I
/
start frequency H level durlng stop or DC dynamlc brake actuatlon.
I
1
Open collector output. 24V DC 0.1A ratlng.
Inverter output overcurrent trlp at the
actuation of brake when mechan~calbrake
(suchas motor wlth brake)
IS used.
,
Before applylngthe brake, cause short across MRS and SD.
1
lnverter output 1s shut off and the motor IS brought tocoastingstate.
I
When the clrcult IS opened across MRS and SD again, the lnverter IS
I
restarted lf STF or STR IS on.
!
I
i Output termlnal for
1
Slgnal for checklng that the output frequency of lnverter has reached
su ,
/ frequency arrlval
I
i
1
the preset frequency and advancing thesequenceof other equipment.
L level when output frequency IS wlthln &lo%of preset frequency.
Open collector output.
24V DC 0.1 A rating

Output term~nalsfor alarm
Open collector output
1 NC contact output termlnal for ~nd~cat~ngthat the protectlve
Common term~nalof RUN and SU term~nals
funct~onof Inverter has been act~vated.
0 Closed clrcult dur~ngnormal operatlon and when the power
supply
IS shut.
0 Open c~rcultwhen Inverter protectlve funct~on IS act~vated.
(Inverter output IS shut off at the same t1me.1
0 When the power IS turned off, the clrcult IS opened for 10to
20 seconds, then the clrcult
IS closed.
Contact capacity: 230V AC 0.3A, 30V DC 0.3A.
common term~nal
,
Isolatedfrom the common c~rcultof control clrcult
Termlnal exclus~velyused by manufacturer. Cannot be used.
I

6.4 Wiring lnstruct~ons
Miswiring may lead to the failure of inverter. Therefore, take note of the following polnts
4
descr~bedinthetable.
i
i
I
i
CircurtSystem
Maln
CI~CUI~
Control
clrcult
MiswlrlngWhich Should Be Avo~ded
Do not connect the power supply to termlnals U, V and W of
maln clrcult. Also, check lf external sequences may apply
voltage to those termlnals.
Ma~nclrcuit termlnals P and EN are used toconnect the brake
unlt and dlscharg~ngreslstor.
Do not connect any other equipment or only the reslstor.
Do not apply 20VDC or larger voltage to the Input termlnal
for frequency senlng "2" and the aux~llaryInputtermlnal for
frequency settlng
"1".
Do not cause short across the output termlnal of power supply
for frequency settlng
"10" and the common termlnal for
frequency settlngslgnal
"5".
Result
Ma~nclrcult parts
will be damaged.
Control clrcult parts
wlll be damaged.

7.1 Checkingbefore Adjustment
After the inverter has been installed and w~red,check the follow~ngpoints before adjustment.
3 a
(1) Check if there is miswir~ng.Especially, check if the power supply is wired to the output ter-
minal.
I
(2) Check for short circuit due to wire strands touch~ngadjacent terminals.
1
11
Y
(3) Check ifthe wire is deformed, and check for damaged cable insulation.
1
(4) Check that all screws, terminals and other fasteners are securely tightened.
1
1
(5) Check that the load is in good condition, and safe to run.
I
Il
(6) Check if there is ground fault on the output side (loadside).
I
' 7. ADJUSTMENT AND OPERATION
When a megger is used for checking, use it only for measuring resistance to earth.
Never use the megger for measurement across the terminalsof inverter.
Do not use the megger for measurement across the terminals of control circuit. For
details of checkingw~ththe megger, referto Section
8 on page 23.
i
7.2 Adjustment
11
After the checking 1s completed, set and adjust the following itemsaccording tothe load specifica-
I
tlons.
i
I.-,. . - I i
2. ,??LLY. &<
1
Note* When the inverter
is equ~ppedwith the operation panel and the frequency setting signal n input from
i I
the exter~orof rnverter, move thrs swrtch to the OFF posrtion
I
1
*I
!I
'i
1
!
Adjustment (Sett~ng)Item
Accelerat~on/deceleratrontlme
Boost control
. .Max~mumoutput frequency and
base frequency (VIFpattern)
Use of frequency setter
(only when
operation panel IS prov~ded)
Adjuster (Setter)
ACCELIDECEL settlng d~aland
magn~flcat~onswltch
Automatic and manual boost pots
8 ONIOFF sw~tches
-
rr
* Swltch for connection to frequency setter
Location
Sett~ngpanel
I
Bottom r~ghtof
pr~ntedctrcult board
Operat~onpanel

- I
, .
J
7.. ADJUSTMENT AND OPERATION
K?/$$JO[O K
On Setting Panel
Acceleration trme magnification swltch and
accelerat~ontlme settlng dial
Decelarat~ontlme
magn~ficat~onsw~tchand
decelarat~ontlme settlng dial
The dlal for settlng the decelerat~ontime (seconds) from when output
frequency
1s the maxlmum (60Hz, 120Hz or 240Hz) to when ~t reaches 0
and the swltch for settlng ~ts magn~f~catlon
!
I
I
I
?
i
I
I
Note-
1. When the maxrmum output
frequency 1s IZOHz, theshortest
accel/decel trme 1s 0.4 seconds
When the max~mum output
frequency n 240Hz, theshorrea
accel/decel trme 1s 0.8 seconds
2. Do not set the acceleratronand
deceleratron senrng drals (AC-
L
CEL/DECEL) to notch "0". If
Example
Magnlf~cat~onsettlng sw~tch .x 10
Tlme settlngd~al . 4
Decelerat~ontlme = 4 seconds x 10 = 40 seconds
The dial for settlng the acceleratlon tlme
(seconds)from when output frequency is 0 to
when
~t reaches the maxlmum (60Hz, 120Hz
or 240Hz) and the sw~tchfor settlng ~ts
rnagn~f~cat~on.
Example:
Magn~f~cat~onsettlng sw~tch . x 0.2
T~mesettingdial . . . . . . . . . .12
Accelerat~ontime = 12 seconds x 0.2
= 2.4 seconds
' 40 seconds
set to notch "0", the rnverter
may not operate normally.
(Notch "0"
a a dral posrtion set
when optron a used.)
3. The senrng cannot be changed
durrng operatron (or accleratron
or deceleration).
Slnce deta~ledsettlng IS done In Sect~onof "Operat~on" on page 2C
temporar~ly set to 5 seconds. Decelerat~ontlme ~sfactory-setto 5 seconds
I
(Second)
2.4 seconds
Slnce detailed settlng 1s done In Sect~onof
"Operat~on" on page 20, temporarily set to 5
)I
seconds. Accelerat~on tlme IS factory-set II
to 5 seconds. I
n
II

I i 7. ADJUSTMENT AND OPERATION
I
Operat~onindicat~nglamps
lnd~cator
POWER
I
Lit when Instantaneous power fa~lureor l~nevoltage drop
occurs.
Lamp Decrlptlon
Lit when the power IS turned on.
Kept Ilt approximately
10 to 30 seconds after the power IS
shut off.
OCT
OVT
I THT 1 Lltwhen elenron~cthermal relav 1s act~vated. 1
Lltwhen ~nverteroutput overcurrentoccurs.
Lit when the converter voltage ~nsldeInverter becomes over-
voltaqe durlnq reqeneratlon of motor
slm,onr, Lltwhen CPU fault prevention IS actsated.
I
OVTITHT
s~multaneous"on"
1
--
OL , I Fl~ckerswhen load IS large durlng stall prevention ] For detalls, refer topage 32.
- -
I
Litwhen coolingfin IS overheated.
. -.
0
L,
'(I
POWER OCT OVT IPF TMT OL
I I
I I
I- t
80 i
,
Electron~cthermal relay settingpot
-
Thls pot IS factory-setto 100%and can be ajusted
by manufacturer only. (Labeled"Not Used")

-
,- ( 7: AD,JUSTMENT AND OPERATION
! -- 31 U u (jyji3
No re:
7. Settrngs not lndrcated above are as shown at rrght. O
uu
. . . The maximum output frequency becomes 60Hr
Autornatlc boost (AIBST) Manual boost (MIBST)
8 E 6 . . Constant-toroue V/F pattern up to 1ZOH.z
When larger motor torque IS required, automatic
Increase of output voltage allows the Increase of
motor output torque. Thls
IS especially effective In
low-speed operation and approx~mately 150%
torque can be obtalned
at 6Hz
If the swltch 1s turned too clockw~se,overcurrent
trlp (OCT) may result durlng operation. The swltch
IS factory-setto OFF posltlon.
o constant-torque V/F
up to 50Hz for combrnatron
with sw~tch 6 at ONpositron.
2. Special motor should be applled for V/F patterns of 0, ). and @.
3, Do not move theswitchesduring the operation of inverter. Inverter will trip.
As shown In the flgure below, V/F pattern
can be changed
according to motor charac-
terlstlcs. Clockw~se turn increases motor
torque
especially In low-frequency opera-
tion. However, vlbratlon and nose may
become larger and the
electronic thermal
relay (TH)or overcurrent trlp (OCT)may be
act~vatedIn low-frequency operation.
-
-
7)
I li
:I
Maxtrnum output frequency (frnax)and base frequency (VIFbend)
Counterclockw~seturn decreases vlbratlon
and nolse but motor torque becomes smaller
In low-frequency operatlon When hlgh-
efflcrency motor IS operated, it may be
necessary to turn the swltch counterclock-
wise depending on motor character~st~cs.
The swltch IS factorv-set to about notch 5
pos~tion.
Note: The manual torque boost is activated
only when
the auromatlc torque
boost is off. (Autornatlc torque
boost is grven prrorrty.
)
v
4-
-
;"p P Fa; setting
-
3 /
4- : ',,*
0,
Output frequency f
Set V/F pattern accord~ngto load and motor character~st~cs
I Posltlon of swltch
~00
678
p/
66 ------
I a
0
If
mnz
110 OT && - -- - - - -
1
0
1
vLf
o 24014~
nnu
678
I,o bf - - - - - -
a
12
ffllu
o
icyf
l2OW
:'vvL
I
'f
o 120 2-2
PUP
678
;vLf
0 wnz
:$y?jf OH2
la?qf
I
no 240~
ON
OFF 6 78
v
%vLf I I
I I
I
0
50wz
v
zv-;
I
I
I
w
12 Z
'?-f
I
50
240~~
V/F bend
2
5
3
u
E
Le
4-
4- 2
;
3
5
'
60Hz
ONuu
OFFl
120Hz
on
12
240Hz
an
12

I
,7'. ADJUSTMENT AND OPERATION
VMElu_JiiilUII°K i !
Analogue operation panel
11 \i Reverse srarr sw~tch ]
The operatlon panel can be mounted easily by inserting ~t carefully into the connector on the
prlnted clrcult board. After mounting, push the surface of operatlon panel .gently to check if it
has been connected securely.
Note: These switches are set to position ON when shipping. When inputt~ngthe external signal,
please refer topage
9, Wirlnglnstruct~ons.
A DIGITAL OPERATION PANEL IS ALSO AVAILABLE AS AN EXTRA OPTION.