Mitsubishi FR-A500 Series User manual

TRANSISTORIZED INVERTER
INSTRUCTION MANUAL
FR-A500(-NA)(-EC)
TRANSISTORIZED INVERTER
FR-A500
INSTRUCTION MANUAL
OUTLINE
PARAMETERS
SPECIFICATIONS
INSTALLATION
AND WIRING
PROTECTIVE
FUNCTIONS
OPERATION
/CONTROL
Chapter 6
OPTIONS Chapter 7
Chapter 5
Chapter 4
Chapter 3
Chapter 2
Chapter 1
IB (NA) 66790-G (0101) ROD Printed in Japan Specifications subject to change without notice.
HEAD OFFICE:MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100-8310
FR-A520-0.4K to 55K(-NA)
FR-A540-0.4K to 55K(-NA)(-EC)
HIGH FUNCTION
&
LOW ACOUSTIC NOISE

A - 1
Thank you for choosing this Mitsubishi transistorized Inverter.
This instruction manual gives handling information and precautions for use of this
equipment.
Incorrect handling might cause an unexpected fault. Before using the inverter, please read
this manual carefully to use the equipment to its optimum.
Please forward this manual to the end user.
This instruction manual uses the International System of Units (SI). The measuring units in
the yard and pound system are indicated in parentheses as reference values.
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 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, 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 instructions of both levels because they are important to personnel safety.
CAUTION
WARNING

A - 2
SAFETY INSTRUCTIONS
1. Electric Shock Prevention
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 removed. Otherwise, you may access the exposed high-
voltage terminals or the charging part of the circuitry 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 at least 10 minutes and check
for the presence of any residual voltage with a meter (check chapter 2 for further details.) etc.
!Earth the inverter.
!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.
!Operate the switches 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. To do so will invite a hazardous condition.
2. Fire Prevention
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 P/+, N/-. This could cause a fire.
3. Injury Prevention
CAUTION
!Apply only the voltage specified in the instruction manual to each terminal to prevent damage etc.
!Ensure that the cables are connected to the correct terminals. Otherwise, damage etc. may occur.
!Always make sure that polarity is correct to prevent damage etc.
!After the inverter has been operating for a relatively long period of time, do not touch the inverter as it
may be hot and you may get burnt.

A - 3
4. Additional instructions
Also note the following points to prevent an accidental failure, injury, electric shock, etc.:
(1) Transportation and installation
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 operate if the inverter is damaged or has parts missing.
!Do not hold the inverter by the front cover; it may fall off.
!Do not stand or rest heavy objects on the inverter.
!Check the inverter mounting orientation is correct.
!Prevent screws, wire fragments, conductive bodies, oil or other flammable substances from entering
the inverter.
!Do not drop the inverter, or subject it to impact.
!Use the inverter under the following environmental conditions:
Ambient temperature
Constant torque: -10°C to +50°C (14°F to 122°F) (non-freezing)
(-10°C to +40°C with FR-A5CV"" attachment)
Variable torque: -10°C to +40°C (14°F to 104°F) (non-freezing)
(-10°C to +30°C with FR-A5CV"" attachment)
Ambient humidity 90%RH or less (non-condensing)
Storage temperature -20°C to +65°C* (-4°F to 149°F)
Ambience Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)
Environment
Altitude, vibration Maximum 1000m (3280.80 feet.) above sea level for standard operation. After that derate by 3% for every extra 500m up to 2500m (91%).
5.9 m/s2or less (conforming to JIS C 0040)
*Temperatures applicable for a short time, e.g. in transit.
(2) Wiring
CAUTION
!Do not fit capacitive equipment such as a power factor correction capacitor, noise filter 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.
(3) Trial run
CAUTION
!Check all parameters, and ensure that the machine will not be damaged by a sudden start-up.
(4) Operation
CAUTION
!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.

A - 4
CAUTION
!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.
!The electronic overcurrent protection 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 harmonics from the inverter may
heat/damage the power capacitor and generator.
!When a 400V class motor is inverter-driven, it should be insulation-enhanced or surge voltages
suppressed. 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, each parameter returns to the factory setting. Re-set
the required parameters before starting operation.
!The inverter can be easily set for high-speed operation. Before changing its setting, examine the
performance 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.
(5) Emergency stop
CAUTION
!Provide a safety backup such as an emergency brake which will prevent the machine and equipment
from hazardous conditions if the inverter fails.
(6) Maintenance, inspection and parts replacement
CAUTION
!Do not carry out a megger (insulation resistance) test on the control circuit of the inverter.
(7) Disposing of the inverter
CAUTION
!Treat as industrial waste.
(8) General instructions
Many of the diagrams and drawings in this instruction manual show the inverter without a cover, or partially
open. Never run the inverter like this. Always replace the cover and follow this instruction manual when
operating the inverter.

CONTENTS
I
1 OUTLINE 1
1.1 Pre-Operation Information.........................................................................................................................................1
1.1.1 Precautions for operation ...................................................................................................................................1
1.2 Basic Configuration ...................................................................................................................................................2
1.2.1 Basic configuration.............................................................................................................................................2
1.3 Structure....................................................................................................................................................................3
1.3.1 Appearance and structure..................................................................................................................................3
1.3.2 Removal and reinstallation of the front cover.....................................................................................................4
1.3.3 Removal and reinstallation of the operation panel .............................................................................................6
2 INSTALLATION AND WIRING 7
2.1 Installation .................................................................................................................................................................7
2.1.1 Instructions for installation..................................................................................................................................7
2.2 Wiring ........................................................................................................................................................................9
2.2.1 Terminal connection diagram.............................................................................................................................9
2.2.2 Wiring of the main circuit..................................................................................................................................12
2.2.3 Wiring of the control circuit...............................................................................................................................18
2.2.4 Connection to the PU connector.......................................................................................................................22
2.2.5 Connection of stand-alone option units............................................................................................................24
2.2.6 Design information............................................................................................................................................28
2.3 Other wiring.............................................................................................................................................................29
2.3.1 Power harmonics..............................................................................................................................................29
2.3.2 Japanese harmonic suppression guidelines.....................................................................................................30
2.3.3 Inverter-generated noises and reduction techniques .......................................................................................33
2.3.4 Leakage currents and countermeasures..........................................................................................................36
2.3.5 Inverter-driven 400V class motor......................................................................................................................37
2.3.6 Peripheral devices............................................................................................................................................38
2.3.7 Instructions for compliance with U.S. and Canadian Electrical Codes....................................................................40
2.3.8 Instructions for compliance with the European standards................................................................................41
2.3.9 Earthing (EC version) .......................................................................................................................................43
3 OPERATION/CONTROL 45
3.1 Pre-Operation Information.......................................................................................................................................45
3.1.1 Devices and parts to be prepared for operation...............................................................................................45
3.1.2 Power on...........................................................................................................................................................47
3.2 Operation Panel.......................................................................................................................................................48
3.2.1 Names and functions of the operation panel (FR-DU04)..................................................................................48
3.2.2 Monitor display changed by pressing the
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MODE key...........................................................................................49
3.2.3 Monitoring.........................................................................................................................................................49
3.2.4 Frequency setting.............................................................................................................................................49
3.2.5 Parameter setting method................................................................................................................................50
3.2.6 Operation mode................................................................................................................................................51
3.2.7 Help mode ........................................................................................................................................................51
3.2.8 Copy mode .......................................................................................................................................................53
3.3 Operation.................................................................................................................................................................54
3.3.1 Pre-operation checks........................................................................................................................................54
3.3.2 External operation mode (Operation using external input signals)...................................................................55
Contents

II
3.3.3 PU operation mode (Operation using the operation panel (FR-DU04))...........................................................56
3.3.4 Combined operation mode (Operation using the external input signals and PU)............................................57
4 PARAMETERS 58
4.1 Parameter List.........................................................................................................................................................58
4.1.1 Parameter list ...................................................................................................................................................58
4.1.2 List of Parameters Classified by Purpose of Use .............................................................................................64
4.1.3 Parameters recommended to be set by the user..............................................................................................65
4.2 Parameter Function Details.....................................................................................................................................66
4.2.1 Torque boost (Pr. 0, Pr. 46, Pr. 112) ................................................................................................................66
4.2.2 Output frequency range (Pr. 1, Pr. 2, Pr. 18)....................................................................................................67
4.2.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19, Pr. 47, Pr. 113)....................................................................68
4.2.4 Multi-speed operation (Pr. 4 to Pr. 6, Pr. 24 to Pr.27, Pr. 232 to Pr. 239) .......................................................69
4.2.5 Acceleration/deceleration time (Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45, Pr. 110, Pr. 111) ..........................70
4.2.6 Electronic overcurrent protection (Pr. 9)...........................................................................................................71
4.2.7 DC injection brake (Pr. 10, Pr. 11, Pr. 12)........................................................................................................72
4.2.8 Starting frequency (Pr. 13)................................................................................................................................73
4.2.9 Load pattern selection (Pr. 14).........................................................................................................................74
4.2.10 Jog operation (Pr. 15, Pr. 16)..........................................................................................................................75
4.2.11 MRS input selection (Pr. 17)............................................................................................................................76
4.2.12 Stall prevention (Pr. 22, Pr. 23, Pr. 66, Pr. 148, Pr. 149, Pr. 154)...................................................................77
4.2.13 Multi-speed input compensation (Pr. 28).........................................................................................................78
4.2.14 Acceleration/deceleration pattern (Pr. 29, Pr. 140 to Pr. 143).........................................................................79
4.2.15 Regenerative brake duty (Pr. 30, Pr. 70).........................................................................................................80
4.2.16 Frequency jump (Pr. 31 to Pr. 36) ...................................................................................................................81
4.2.17 Speed display (Pr. 37, Pr. 144)........................................................................................................................82
4.2.18 Up-to-frequency sensitivity (Pr. 41) .................................................................................................................83
4.2.19 Output frequency detection (Pr. 42, Pr. 43, Pr. 50, Pr. 116)............................................................................83
4.2.20 Second/third stall prevention (Pr. 48, Pr. 49, Pr. 114, Pr. 115)........................................................................84
4.2.21 Monitor display/FM, AM terminal function selection (Pr. 52 to Pr. 54, Pr. 158) ..............................................85
4.2.22 Monitoring reference (Pr. 55, Pr. 56)...............................................................................................................88
4.2.23 Automatic restart after instantaneous power failure (Pr. 57, Pr. 58, Pr. 162 to Pr. 165).................................89
4.2.24 Remote setting function selection (Pr. 59).......................................................................................................91
4.2.25 Intelligent mode selection (Pr. 60)...................................................................................................................92
4.2.26 Acceleration/deceleration reference current/lift mode starting frequency (Pr. 61 to Pr. 64)...........................94
4.2.27 Retry function (Pr. 65, Pr. 67 to Pr. 69) ...........................................................................................................95
4.2.28 Applied motor (Pr. 71)......................................................................................................................................97
4.2.29 PWM carrier frequency (Pr. 72, Pr. 240) .........................................................................................................98
4.2.30 Voltage input (Pr. 73).......................................................................................................................................99
4.2.31 Input filter time constant (Pr. 74) ...................................................................................................................100
4.2.32 Reset selection/PU disconnection detection/PU stop selection (Pr. 75) .......................................................100
4.2.33 Alarm code output selection (Pr. 76).............................................................................................................102
4.2.34 Parameter write inhibit selection (Pr. 77).......................................................................................................103
4.2.35 Reverse rotation prevention selection (Pr. 78) ..............................................................................................104
4.2.36 Operation mode selection (Pr. 79).................................................................................................................105
4.2.37 Motor capacity/number of motor poles/speed control gain (Pr. 80, Pr. 81, Pr. 89).......................................108
4.2.38 Offline auto tuning function (Pr.82 to Pr. 84, Pr. 90 to Pr. 94, Pr.96)..................................................................109
4.2.39 Online auto tuning selection (Pr. 95).............................................................................................................116
4.2.40 V/F control frequency (voltage) (Pr. 100 to Pr. 109)......................................................................................118
4.2.41 Computer link operation (Pr. 117 to Pr. 124, Pr. 342) ...................................................................................119

III
4.2.42 PID control (Pr. 128 to Pr. 134).....................................................................................................................130
4.2.43 Commercial power supply-inverter switch-over function (Pr. 135 to Pr. 139)...............................................137
4.2.44 Output current detection function (Pr. 150, Pr. 151)......................................................................................141
4.2.45 Zero current detection (Pr. 152, Pr. 153).......................................................................................................142
4.2.46 RT signal activated condition selection (Pr. 155)...........................................................................................143
4.2.47 Stall prevention function and current limit function (Pr. 156).........................................................................143
4.2.48 OL signal output timer (Pr. 157).....................................................................................................................145
4.2.49 User group selection (Pr. 160, Pr. 173 to Pr. 176).........................................................................................146
4.2.50 Watt-hour meter clear/actual operation hour meter clear (Pr. 170, Pr. 171) .................................................147
4.2.51 Input terminal function selection (Pr. 180 to Pr. 186) ....................................................................................147
4.2.52 Output terminal function selection (Pr. 190 to Pr. 195)..................................................................................150
4.2.53 User initial value setting (Pr. 199)..................................................................................................................152
4.2.54 Programmed operation function (Pr. 200 to Pr. 231).....................................................................................153
4.2.55 Cooling fan operation selection (Pr. 244)......................................................................................................157
4.2.56 Stop selection (Pr. 250).................................................................................................................................158
4.2.57 Output phase failure protection selection (Pr. 251).......................................................................................159
4.2.58 Override bias/gain (Pr. 252, Pr. 253).............................................................................................................159
4.2.59 Power failure-time deceleration-to-stop function (Pr. 261 to Pr. 266)...........................................................160
4.2.60 Stop-on-contact, load torque high-speed frequency selection (Pr. 270)........................................................161
4.2.61 High-speed frequency control (Pr. 271 to Pr. 274)........................................................................................162
4.2.62 Stop on contact (Pr. 275, Pr. 276).................................................................................................................166
4.2.63 Brake sequence function (Pr. 278 to Pr. 285)................................................................................................169
4.2.64 Droop control (Pr. 286, Pr. 287).....................................................................................................................173
4.2.65 Meter (frequency meter) calibration (Pr. 900, Pr. 901)..................................................................................174
4.2.66 Frequency setting voltage (current) bias and gain (Pr. 902 to Pr. 905).........................................................176
4.2.67 Buzzer control (Pr. 990).................................................................................................................................181
5 PROTECTIVE FUNCTIONS 182
5.1 Errors (Alarms)......................................................................................................................................................182
5.1.1 Error (alarm) definitions..................................................................................................................................182
5.1.2 To know the operating status at the occurrence of an alarm..........................................................................191
5.1.3 Correspondences between digital and actual characters...............................................................................191
5.1.4 Alarm code output ..........................................................................................................................................192
5.1.5 Resetting the inverter......................................................................................................................................192
5.2 Troubleshooting.....................................................................................................................................................193
5.2.1 Motor remains stopped...................................................................................................................................193
5.2.2 Motor rotates in opposite direction..................................................................................................................193
5.2.3 Speed greatly differs from the setting.............................................................................................................193
5.2.4 Acceleration/deceleration is not smooth.........................................................................................................193
5.2.5 Motor current is large......................................................................................................................................193
5.2.6 Speed does not increase................................................................................................................................194
5.2.7 Speed varies during operation........................................................................................................................194
5.2.8 Operation mode is not changed properly........................................................................................................194
5.2.9 Operation panel (FR-DU04) display is not provided.......................................................................................194
5.2.10 POWER lamp is not lit...................................................................................................................................194
5.2.11 Parameter write cannot be performed...........................................................................................................194
5.3 Precautions for Maintenance and Inspection ........................................................................................................195
5.3.1 Precautions for maintenance and inspection..................................................................................................195
5.3.2 Check items....................................................................................................................................................195
5.3.3 Periodic inspection .........................................................................................................................................195
Contents

IV
5.3.4 Insulation resistance test using megger.........................................................................................................196
5.3.5 Pressure test ..................................................................................................................................................196
5.3.6 Daily and Periodic Inspection.........................................................................................................................196
5.3.7 Replacement of parts .....................................................................................................................................199
5.3.8 Inverter replacement.......................................................................................................................................200
5.3.9 Measurement of main circuit voltages, currents and power ...........................................................................201
6 SPECIFICATIONS 203
6.1 Standard Specifications.........................................................................................................................................203
6.1.1 Model specifications .......................................................................................................................................203
6.1.2 Common specifications ..................................................................................................................................205
6.1.3 Outline drawings.............................................................................................................................................207
7 OPTIONS 211
7.1 Option List .............................................................................................................................................................211
7.1.1 Stand-alone options........................................................................................................................................211
7.1.2 Inboard dedicated options..............................................................................................................................213
APPENDICES 218
Appendix 1 Data Code List..........................................................................................................................................218
Appendix 2 Operating the Inverter Using a Single-Phase Power Supply....................................................................224

CHAPTER 1
OUTLINE
This chapter gives information on the basic "outline" of this
product.
Always read the instructions in this chapter before using the
equipment.
1.1 Pre-Operation Information........................................1
1.2 Basic Configuration..................................................2
1.3 Structure..................................................................3
<Abbreviations>
!DU
Operation panel (FR-DU04)
!PU
Operation panel (FR-DU04) and parameter unit (FR-PU04)
!Inverter
Mitsubishi transistorized inverter FR-A500 series
!Pr.
Parameter number
!PU operation
Operation using the PU (FR-DU04/FR-PU04)
!External operation
Operation using the control circuit signals
!Combined operation
Operation using both the PU (FR-DU04/FR-PU04) and
external operation
!FR-A200E
Mitsubishi transistorized inverter FR-A200 series
<EXCELLENT> series
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7

1.1 Pre-Operation Information OUTLINE
1
1 OUTLINE
1.1 Pre-Operation Information
1.1.1 Precautions for operation
Incorrect handling might cause the inverter to operate improperly, its life to be reduced considerably, or at the
worst, the inverter to be damaged. Handle the inverter properly in accordance with the information in each
section as well as the precautions and instructions of this manual to use it correctly.
This manual is written for the FR-A500 series transistorized inverters.
For handling information on the parameter unit (FR-PU04), inboard options, stand-alone options, etc., refer to
the corresponding manuals.
(1)Unpacking and product check
Unpack the inverter and check the capacity plate on the front cover and the rating plate on the inverter side
face to ensure that the product agrees with your order and the inverter is intact.
1) Inverter type
FR-A520-0.4K/
Capacity plate
Inverter type Serial number
Capacity plate Rating plate
FR- A520 - 0.4K -
Symbol Voltage Class
A520
A540 200V class 400V class
Symbol Applicable Motor Capacity
0.4K to 55K Indicates capacity in "kW". Symbol Specifications None
NA Japanese specifications U.S. specifications
EC European specifications
Rating plate
Input rating
Output rating
Serial number
Inverter type
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MITSUBISHI
MODEL INVERTER
FR-A520-0.4K
INPUT :
OUTPUT :
SERIAL :
XXXXX
XXXXX
PASSED
2) Accessory
Instruction manual
If you have found any discrepancy, damage, etc., please contact your sales representative.
(2)Preparations of instruments and parts required for operation
Instruments and parts to be prepared depend on how the inverter is operated. Prepare equipment and parts
as necessary. (Refer to page 45.)
(3)Installation
To operate the inverter with high performance for a long time, install the inverter in a proper place, in the
correct direction, and with proper clearances. (Refer to page 7.)
(4)Wiring
Connect the power supply, motor and operation signals (control signals) to the terminal block. Note that
incorrect connection may damage the inverter and peripheral devices. (See page 9.)

1.2 Basic Configuration OUTLINE
2
1.2 Basic Configuration
1.2.1 Basic configuration
The following devices are required to operate the inverter. Proper peripheral devices must be selected and
correct connections made to ensure proper operation. Incorrect system configuration and connections can
cause the inverter to operate improperly, its life to be reduced considerably, and in the worst case, the
inverter to be damaged.
Please handle the inverter properly in accordance with the information in each section as well as the
precautions and instructions of this manual. (For connections of the peripheral devices, refer to the
corresponding manuals.)
Name Description
Power supply Use the power supply within the permissible power supply specifications of the inverter.
(Refer to page 203.)
Earth leakage
circuit breaker
(ELB) or no-fuse
breaker (NFB)
The breaker should be selected with care
since a large inrush current flows in the
inverter at power on. (Refer to page 38.)
Magnetic
contactor
The magnetic contactor need not be
provided. When installed, do not use it to
start or stop the inverter. It might reduce the
inverter life.
(Refer to page 38.)
Reactors
The reactors must be used when the power
factor is to be improved or the inverter is
installed near a large power supply system
(1000kVA or more and wiring distance
within 10m (32.81 feet)). Make selection
carefully.
Inverter
!The inverter life is influenced by ambient
temperature. The ambient temperature
should be as low as possible within the
permissible range.
This must be noted especially when the
inverter is installed in an enclosure.
(Refer to page 7.)
!Incorrect wiring might lead to inverter
damage. The control signal lines should
be kept away from the main circuit to
protect them from noise. (Refer to page
9.)
Devices
connected to the
output
Do not connect a power capacitor, surge
suppressor or radio noise filter to the output
side.
(MC)
Ground
DC reactor
(FR-BEL)
Ground
(NFB)
or
(ELB)
AC reactor
(FR-BAL)
Ground
To prevent an electric shock, always ground
the motor and inverter.
The grounding cable provided for reduction
of induction noise from the power line of the
inverter is recommended to be wired by
returning it to the grounding terminal of the
inverter. (Refer to page 35.)
Japanese Harmonic Suppression Guideline
The "harmonic suppression guideline for household appliances and general-purpose products" was issued
by the Ministry of International Trade and Industry in September, 1994. This guideline applies to the
FR-A520-0.4K to 3.7K. By connection of the power factor improving reactor (FR-BEL or FR-BAL), this
product conforms to the "harmonic suppression technique for transistorized inverters (input current 20A or
less)" set forth by the Japan Electrical Manufactures' Association.
1

1.3 Structure OUTLINE
3
1.3 Structure
1.3.1 Appearance and structure
(1) Front view (2) Without front cover
POWER lamp
ALARM lamp
Operation panel (FR-DU04)
Brake resistor* (Fitted to the back)
Accessory cover
Wiring port cover for option
Front cover
Rating plate
Capacity plate Wiring cover
PU connector
(Provided with modular jack type relay connector
)
(For use with RS-485 cable communication)
Modular jack type relay connector compartment
Inboard option mounting positions
Control circuit terminal block
Main circuit terminal block
*7.5K or less inverters are equipped with an inboard brake resistor.
Note: The "EC" version of the FR-A500 uses pheonix type connectors for the control circuit terminal block.

OUTLINE
4
1.3.2 Removal and reinstallation of the front cover
FR-A520-0.4K to 11K, FR-A540-0.4K to 7.5K
•Removal
1) Hold both sides of the front cover top and push the front cover down.
2) Hold down the front cover and pull it toward you to remove.
(The front cover may be removed with the PU (FR-DU04/FR-PU04) on.)
Front cover Inverter
Catch
•Reinstallation
1) Insert the catches at the bottom of the front cover into the sockets of the inverter.
2) Using the catches as supports, securely press the front cover against the inverter.
Note: When the operation panel is mounted and the front cover is removed, remove the operation
panel before reinstalling the front cover.
FR-A520-15K to 22K, FR-A540-11K to 22K
•Removal
1) Remove the installation screw at top of the front cover.
2) Hold both ends of the front cover top.
3) Pull the front cover toward you to remove.
(The front cover may be removed with the PU (FR-DU04/FR-PU04) on.)
•Reinstallation
1) Insert the catches at the front cover bottom into the sockets of the inverter.
2) Using the catches as supports, securely press the front cover against the inverter.
3) Fix the front cover with the top screw.
Note: When the operation panel is mounted on the front cover removed, remove the operation panel
before reinstalling the front cover.
1

OUTLINE
5
FR-A520-30K to 55K, FR-A540-30K to 55K
•Removal
1) Remove the front cover mounting screws.
•Reinstallation
1) Fix the front cover with the mounting screws.
Note: 1. Make sure that the front cover has been reinstalled securely.
2. The same serial number is printed on the capacity plate of the front cover and the rating plate of
the inverter. Before reinstalling the front cover, check the serial number to ensure that the cover
removed is reinstalled to the inverter from where it was removed.

OUTLINE
6
1.3.3 Removal and reinstallation of the operation panel
To ensure safety, remove and reinstall the operation panel after switching power off.
•Removal
Hold down the top button of the operation panel and pull the operation panel toward you to remove.
"Removal Reinstallation
To reinstall, insert straight and mount securely.
•Reinstallation using the connection cable
1) Remove the operation panel.
2) Disconnect the modular jack type relay connector. (Place the disconnected modular jack type relay
connector in the modular jack type relay connector compartment.)
Modular jack type relay connector compartmen
t
Modular jack type relay connector
3) Securely plug one end of the connection cable into the PU connector (modular jack type relay
connector) of the inverter and the other end into the operation panel.
Note: Install the operation panel only when the front cover is on the inverter.
1

2
CHAPTER 2
INSTALLATION AND WIRING
This chapter gives information on the basic "installation and
wiring" of this product.
Always read the instructions in this chapter before using the
equipment.
2.1 Installation................................................................ 7
2.2 Wiring ...................................................................... 9
2.3 Other wiring .............................................................29
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7

2.1 Installation INSTALLATION AND WIRING
7
2 INSTALLATION AND WIRING
2.1 Installation
2.1.1 Instructions for installation
1) Handle the unit carefully.
The inverter uses plastic parts. Handle it gently to protect it from damage. Also, hold the unit with even
strength and do not apply too much strength to the front cover alone.
2) Install the inverter in a place where it is immune to vibration. (5.9 m/s2or less)
Also note the cart, press, etc.
3) Note on ambient temperature
The inverter life is under great influence of ambient temperature. In the place of installation, ambient
temperature must be within the permissible range (depending upon the operation mode and conditions
(see ambient temperature specifications on page 203). Check that the ambient temperature is within that
range in the positions shown in figure 3).
4) Install the inverter on a non-combustible surface.
The inverter will be very hot (maximum about 150°C). Install it on a non-combustible surface (e.g. metal).
Also leave sufficient clearances around the inverter.
5) Avoid high temperature and high humidity.
Avoid direct sunlight and places of high temperature and high humidity.
6) The amount of heat generated in an enclosure can be reduced considerably by placing the heat sink
outside the enclosure.
Note: 1. Use the option (FR-A5CN##) for installation. The mounting area should be cut to the panel
cutting dimensions.
2. The cooling section outside the enclosure has the cooling fan. Do not use the inverter in any
environment where it is exposed to waterdrops, oil mist, dust, etc.
7) Avoid places where the inverter is exposed to oil mist, flammable gases, fluff, dust, dirt etc.
Install the inverter in a clean place or inside a "totally enclosed" panel which does not accept any
suspended matter.
8) Note the cooling method when the inverter is installed in an enclosure.
When two or more inverters are installed or a ventilation fan is mounted in an enclosure, the inverters and
ventilation fan must be installed in proper positions with extreme care taken to keep the ambient
temperatures of the inverters below the permissible value. If they are installed in improper positions, the
ambient temperatures of the inverters will rise and ventilation effect will be reduced.
9) Install the inverter securely in the vertical direction with screws or bolts.
3) Note on ambient temperature
Measurement
position
Measurement
position
5cm
(1.97 inches)
5cm
(1.97 inches)
5cm
(1.97 inches)
4) Clearances around the inverter
10cm (3.94 inches)
5cm (1.97 inches) or more *
*: 1cm (0.39 inches) or more for model 3.7K or less
Leave sufficient
clearances above
and under the
inverter to ensure
adequate ventilation.
Cooling fan built
in the inverter
Cooling air
5cm (1.97 inches) or more *
or more
10cm (3.94 inches)
or more
These clearances are also necessary for changing the cooling fan.

INSTALLATION AND WIRING
8
8) For installation in an enclosure
Ventilation fan
(Correct example)
Position of Ventilation Fan
Inverter Inverter
Inverter
(Correct example) (Incorrect example)
Built-in cooling fan
Inverter Inverter
Inverter
Accommodation of two or more inverters
(Incorrect example)
9) Vertical mounting
(1)Wiring cover and handling (22K or less)
1) When cable conduits are not connected
Cut the protective bushes of the wiring cover with nippers or a cutter before running the cables.
Wiring cover
Protective bush
WARNING
Do not remove the protective bushes. Otherwise, the cable sheathes may be scratched by the wiring cover
edges, resulting in a short circuit or ground fault.
2) When cable conduits are connected
Remove the corresponding protective bushes and connect the cable conduits.
2

2.2 Wiring INSTALLATION AND WIRING
9
2.2 Wiring
2.2.1 Terminal connection diagram
NFB
R
S
T
R1
S1
PC
STF
STR
STOP
RH
RM
RL
JOG
RT
MRS
RES
AU
CS
SD
10E(+10V)
10(+5V)
2
5
2
3
1
1
4 (4 to 20mADC)
Frequency setting
potentiometer
1/2W1kΩ
RUN
SU
IPF
OL
FU
SE
FM
SD
IM
A
B
C
U
V
W
P1
P/
PX
PR
N/–
+−
(−)
(+)
AM
5
R
Ground
Main circuit terminal
Control circuit input terminal
Control circuit output terminal
3-phase AC power supply
Jumper
24VDC power output and external transistor common
(Contact input common for source logic)
Forward rotation start
Reverse rotation start
Start self-holding selection
High
Middle
Low
Jog mode
Second acceleration/deceleration time selection
Output stop
Reset
Current input selection
Selection of automatic restart
after instantaneous power failure
(Contact input common for sink logic)
Control input signals (no voltage input allowed)
Frequency setting signals (analog)
Common
Auxiliary input
Current input
0 to 5VDC
0 to 10VDC Selected
(Analog common)
0 to ± 5VDC
0 to ±10VDC Selected
PU
connector
(Note)
(Note)
Motor
Ground
Jumper
Remove this jumper when using FR-BEL.
Jumper
Remove this jumper when using FR-ABR.
Note: Terminals PR, PX are provided for
FR-A520-0.4K to 7.5K.
FR-A540-0.4K to 7.5K
Alarm output
Running
Up to frequency
Instantaneous power failure
Overload
Frequency detection
Open collector output common
Common to sink and source
Open collector
outputs
Meter
(e.g. frequency meter)
Moving-coil type
1mA full-scale
Analog signal output
(0 to 10VDC)
Multi-speed selection
(RS-485)
NFB
L1
L2
L3
L11
L21
3-phase AC power supply
Jumper
EC version
P1
+
PX
PR
–
EC version
Calibration
resistor*
+
* Not needed when the operation panel (FR-DU04)
or parameter unit (FR-PU04) is used for
calibration. Used when calibration must be made
near the frequency meter for such a reason as a
remote frequency meter. However, the frequency
meter needle may not deflect to full-scale if the
calibration resistor is connected. In this case, use
this resistor and the operation panel or parameter
unit together to make calibration.