Mitsubishi FREQROL-Z200-UL User manual

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Thank you for your purchase of Mitsubishi Transistor inverter FREQ,ROL-2200.
This inverter is a variable frequency power supply unit used to control a squirrel-
cage induction motor.
IMPORTANT NOTE
This instruction manual describes handling, installation, operation and maintenance
of the inverter.
.Although it is easy to use the inverter, improper use and mis-operation might
cause unforeseen trouble. Before operating the inverter, read this manual carefully.
Your inverter is built to a high standard of quality and reliability.
Correct application and regular inspection, should give you long, trouble free,
operation.
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-C 0 N T E N T S-
- INVERTER \
HANDLING GUIDANCE ...............
Q 1. CONSTRUCTICN ...............
9 2. UNPACKING AND CHECKING ...............
Q 3. INSTALLATION ...............
3.1 Handling during transfer and installation ...............
3.2 Environment ...............
3.3 Mounting position and clearances ...............
3.4 Inverter housed in enclosure ...............
§ 4, WIRING ...............
6
6
6’
7
8
4.1 Main circuit ............... 8
4.2 Control circuit
4.3 Terminals for wiring
4.4 Field wiring reference table
8 5. OPERATION
5.1 Operation modes
5.2 Pre-operation checks
5.3 Pre-operation settings and adjustments
5.4 Check points at test operation
8 6. MAINTENANCE AND. INSPECTION
6.1 Caution for maintenance and inspection
...............
6.2 Inspection points
...............
...............
...............
...............
...............
. . . . . . . . . . . . . . .
...............
...............
...............
...............
12
15
17
20
20
20
21
24
27
27
27
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_--
.._-*
--.
.’
6.3 Method of measuring main circuit voltage;
current and output power .......... ........ ‘31
6.4 Measuring instrument, selection and usage ............... 34
6.5 Transistor modules and diode modules ............... 36
6.6 Parts replacement ............... 38 -’
Q 7. TROUBLESHOOTING ............... 46
7.1 Troubleshooting ......*........ 46
7.2 Protective functions ............... 44
Q 8: SPECIFICATIONS .................. 51
8.1 Block diagram ................ 51
8.2 Terminals ................ 53
8.3 Standard specifications ............... 58
8.4 External dimensions ............... 64
8.5 Selection of peripheral devices ............... 65
8.6 Drip shield kit ...............
66
. .
8.7 Overload protection
...
.
.
............... 68
r PARAMETER UNIT I
Q 1.. INSTALLATION ............... 79
8 2. OUTLINE OF FUNCTIONS ............... 72
1 Q 3. FUNCTION KEY DESCRIPTIONS ............... 73
Q4. OPERATION ............... 76
4.1 Operation modes
4.2 Operation with external signals
4.3 Operation with PU
....... ........ 76
............... 77
............... 78
4.4 Common setting errors
see also Page 92
Q 5. SETTINGS OF CONTROL VARIABLES (PARAMETERS)
............... 81
:.............. 83
5.1 Control functions and setting method .:............. 83
5.2 Examples of operation .......i.......
85
.. 5.3 Caution (iIlega1 settings) ............... 87
8 6. MONITOR .’ ............... 88
$37. DISPLAY ..I .I .........*.:...
92
7.1 Alarm display .. ...............
92
..
7.2 Indicator lamps ......*....1.;.
93
7.3 Characters appearing in readout ‘, ,,..,..........
93
9 8. LIST OF FUNCTIONS NUMBERS ............... 94
.,.’
0
Q
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g 9. DETAILS OF EACH FUNCTION ............... 97
8 10. PARAMETER UNIT SPECIFICATIONS
‘-was- ...............
112
§ll. EXTERNAL DIMENSIONS AND CABLE DETAILS ............... 113
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1 HANDLING GUIDANCE 1
Improper use and operation might cause unforeseen trouble. Betore using your
inverter, please read this manual carefully to operate inverter for long time
without trouble.
No-fuse
breaker
(NPB)
When the icvcrtcr is connected close LO a lurgc-
capwily lwwcr supply (Ins than 1Om wiring distonw
lrom IOOOkVA or lorgcr power supply) , bc sure 1.0
inscrl. an AC reactor (option) inlo Lhc power input ciwuit. /
Magnetic
contactor
(MC)
,
INSI’ALLATION
OF I.VVERTRIZ
When the invortcr is located, coasidcr the in&mu, 111
ambirnt temperature on the life of invcrtcr. I.ocutc the
invcrlcr. whcrc the ambient temperaturn is within l.hc
speGic~d range.
I -
Refer 1.0 8.3
” Standard specifications .
AC reactor for
power factor
enhancement
Refer lo 93. ‘lNSThLLA1’ION”.
7
Rl?MOVAL AND The cover of models smallcr than llkW/2OOV and
INSI’ALLATION 7SkW/4OOV can be easily removed and installed without
OF PRONT using u LOOI (screwdriver)
Refer to 1.2 ‘Removal and installation of front cover”. J
MONITOR
Output frequency, voltage, motor current and alarm are
dbplaycd by 7-segment LED readout.
Rdcr LO 9 6. ‘MONlTOR”.
Rofcr to 8 7. “DISPLAY”. A
time wn bc set by using the paramctcr unit.
Not+ that mixwiring not only ~1~80s damogc to the
invcrtrr, but also cndongers the operator.
Refer lo I) 4. ‘WIRING”.
Mom
Refer LO 8.2 “Terminals’.
Refer to 4.3 “Terminals Ior wiring”.
‘DEVICES CONNlGI’I’E:D ‘I’0 OUTPUT CIRCUIT \
Do not connect power Tactor correcting capacitor, surbw killer or n&c
filter FR-RIP (oplion) .
\. J
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8 1. CONSTRUCTION
1.1 External views and name of each part
0
.FR-2220-0.4K(~)-11K0, FR-Z240-2.2K(P)-7.5KCP)
~~ -
FRONT VIEW
Chassis heatsink
(die cast) \f--
, Rating plate
- ALARM indicator lamp
. POWER lamp
- LED Readout
- Parameter unit
(For models having no parameter
unit. an accessory cov*r is
installed hem.)
Discharge resistor for brake
(regenerative brake r&i&or) BACK VIEW
(For FR-Z220-0.4K)
l FR-Z220-15K-55K, FR-Z240-llK-55K
- POWER. atid ALARM indicator lamps
- A-ory cover (made of steel)
When a parameter unit is used,
remove this cover and .instaU
the paraineter unit.
3
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/ . . . ..3 .
1..2 Removal and installation of front cover
(FR-Z220-0.4K--11 K, FR-Z240-2.2K-7.5K)
f-
How to remove the front cover (see Fig. 1) :
While pressing the white button at the top of the inverter, ease the cover
forward and lift the plastic top cover from the bottom location sockets.
How to attach the front cover (see Fig. 2 ) :
Insert the lugs at the bottom of the front cover into the sockets at the
chassis bottom and press the cover lightly against the chassis. Ensure white
button engages securely.
Inverter having no parameter unit is equipped with an accessory cover. The
accessory cover can be removed by pulling it to the front while holding
the side wall lightly (Fig. 3 ) .
Fig. 1 Removal of front cover
Fig. 2 Installation of front cover Fig. 3 Removal of access cover
CAUTION: 1 . After the front cover is installed, make sure it is held in
position securely,
2, The rating plate is stuck on. the front cover. Do not attach
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the cover to another invertor.
3. When the parameter unit was removed for removal of the
front cover, be sure to install it as instructed in 1.3.
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1.3 Removal and installation of parameter unit
How to remove the parameter unit (Fig. 4 > : i
Remove two parameter unit mounting screws and ease the unit forward.
How to install the parameter unit:
Put the plug (connector) of the para-
meter unit into the connector of the
inverter.
While holding the parameter unit in
position, tighten two mounting screws.
(Do not over-tighten)
CAUTION: never install the parame-
ter unit to the inverter
with the front cover re-
moved.
Connector
hc%ptacle)
If the inverter must be operated with
‘the front covw removed always use
the extension cable. See page 113.
Fig. 4 Removal and installation
of parameter unit
0
0
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b 2. UNPACKING AND CHECKING
After unpacking the inverter, check the following points.
(11 Check the rating plate on the front cover of inverter to make sure the
model and output ratings meet your order.
(21 Check that the inverter has not been damaged during transportation.
Report damage immediately.
a > To the carrier b > To the inverter supplier
Invc&r model
Applicable motor
Line voltage and
Serial k
Pig. 5 Rating plate
INVERTER MODEL DESIGNATION.
FR-224003.7KP-UL
pcz@iJ- L < yI+-%q
KILOWATT
I
SylllbOl Volta@clam
SpllbOl
Appl=bb
motor c8pacity
SyUlbOI ParalMtw unit
zm 2OOV 0.4
capacity k P Providad
akoun in Wnm
2240 4OOV 55 of LW. NOM Nona
-5-
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8 3. INSTALLATION
3.1 Handling during unpacking and installation
Carefully handle the inverter when it is transferred and installed.
When the inverter is carried, do not hold it in such a manner that force
is exerted on only the front panel.
3.2 Environment
(1) Place the inverter in a clean and well-ventilated location.
Do not install the inverter .in direct sunlight, high temperature, high humi-
dity, dense dust, corrosive gases, or hazardous areas.
If the inverter must .be used in an environment where dense dust or
corrosive gas arises, house it in an enclosure which does not allow
entrance of dust or gas. .. .
Note: When the inverter is ..hous&d: in an enclosure, a suitable cooling
means should be used and/or the enclosure should be designed so
that temperature .around the inverter. do& not exceed the specified
“ambient ttemperature“ listed under paragrapo 8.3.
(2) Install the inverter in a vibration free location.
0
(31 Cover the top and the bottom of the unit with drip shield kits (option)
when an inverter is wall-mounted. (See page 66)
Do not install the drip shield kits when the unit is mounted within
another cabinet.
3.3 Mounting position and- clearances
(1) Install the inverter securely and vertically with bolts so that the letters
“FREQROL-Z200” face front.
(2) Since the inverter generates heat, provide sufficient clearance around the
inverter to assure effective radiation of heat.
(31 When braking is repeated frequently, the surface temperature of the brake
discharge resistor (for models under FR-Z220/Z240-?.5K) , mounted at the
.,
rear of the inverter, may become high (maximum approx. 150°C) .
Therefore, install the inverter on a non-flammable panel (such as metal
plate) . p
-6-
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.,-
r
‘W
r‘
--- ---- I?
1Wmm ( 4 ‘1 or mGre
0
FREQROL-2200
1OOmm(4”) or more1OOmm(4”) or more
or mot-c
spaces to aaunspaces to aaun Air stream rAir stream r
good cooling effect.good cooling effect. AA,:AA,: //
1: /1: /
00
//
I // i 22 //
II
In*lw*In*lw* //
Fig. 6 Minimum clearance around inverter
CONSIDERATION FOR AMBIENT TEMPERATURE
The life time of the inverter depends on
the ambient temperature. The ambient
temperature should not exceed the permis-
sive value.
50mm (2’ 1
5Omm (2’ )
Moamwing point
Measure the ambient temperature at the
positions shown in figure A. Fig. A
Permissive ambient temperature: +5O”c (+ 122°F)
3.4 Inverter housed in enclosure
When two or more. inverters are housed in an enclosure equipped with a
fan, locate each inverter and fan so that the maximum cooling efficiency
can be achieved.
(GOOD) (WRONG)
I--"1
i Iawtter 1
II lpeDi
Two or more inverters housed in an enclosure
(GOOD) (WRONG)
Location of ventilating fan
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Q 4. WIRING
4.1 Main circuit.
(1) Connection to power source and motor
For models FR-%220-0.4K to 1.5K For models larger than
PR-Z220-2.2K and Z240-2.2K
Power supply
I I I
Power supply
* When the inverter is connected as shown above, the motor runs counber-
0
clockwise, as viewed from the load side, with “forward” (normal) command
signal.
IMPORTANT
Notes: 1 . DCJ not ‘connect power supply to the output terminals (II, V, W)
-._ _ ..- L __...____. _...__---. .-- ---- .--
directly because such miswiring n~ay cause not only damage Lo
--.- _.-- -._. _._.-- _ .-
the inverter, but also danger to the operator.
------ -..-_
The same danger ..may be caused by backflow of current if the
invorter is connected as shown below. To prevent backflow, MC 1
and MC 2 .should be interlocked with each other (electrically as
well as m&hanically) .
2. The inverter is not equipped with a” means to. protect persons
-from .acci&nts due to leakage. ‘. . :’
Pay attention so that cables do not touch the. chassis, etc.
‘Be’ sure to earth the inverter with the earth terminal.
0
0
- 8 --
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3. If magnetic contactor (MC) is not inserted on the inverter primary
side and a power failure occurs for a short time (instantaneous
power failure) , the inverter will restart automatically at the same
time as the power source is restored.
If it is likbly that this automatic restart may cause damage to
the machine or persinnel, connect .(MC> so that restart is possible
only after’ safety is verified.
For a better understanding, refer to the following diagrams and
descriptions:
Para. 4.3 “Wiring diagram”
Para. 8.2 “Terminals for wiring”
Para: 8.1 “Block diagram”
- CAUTION FOR WIRING OF PERIPHERAL DEVICES
When MC, NFB and other peripheral devices are being connected to the
inverter, cover the inverter to prevent wire chips, screws and other foreign
matter from entering into the inverter through slits and other openings of
the inverter.
(21 Connection of discharge resistor for increased braking (regenerative brake
resistor unit ****** option)
A built-in discharge resistor is been connected to terminals P and PR
-internally, .as standard. ’
However when braking operation is particularly frequent and may exceed
the thermal capacity of the built-in resistor, replace the built-in discharge
resistor with optional discharge resistor unit.
Apply this option with care, due to increased heat losses which have to
be dissipated.
- 9.’
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Do not connect any resistor other than those specified by us, to
terminals P and PR.
-
\
--* I3
Yh
? >
-J
MYS
type
LT
resistor for
(option)
discharge
brake
0
(3) Connection of BU type .brake unit (option)
BU type braka unit
.’ Note: Wires used to connect discharge resistor(s) and BU type brake
0
unit to the inverter should be less than 2 m (5 m when twisted
wires are used) .
(41 Connection of control circuit power supply, independent of main circuit
If the magnetic contactor (MC) on the inverter input power supply side is
opened when a protective device is activated, the inverter control circuit
is also turned off and the alarm signal (output signal) is no longer held.
0
I
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r‘v
To hold alarm signal, the inverter control circuit should be fed with an
independent power supply as shown below.
‘For models FR-Z220-0.4K to 1.5K
RrmOW
these
jumpers.
Main ‘povJk control oircuit power supply
For models larger than FR-Z220-2.2K and Z240-2.2K
CON 6
from tennina RI and Sl.
Control circuit power SuPPlY
.Main power circuit
-ll-
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4.2 Control circuit
(1) Input signal circuits
darn4 if terminal
10 is connected to
Check the wiring
Frequency reference
(2W 1KQ)
c_( Current input DC4 - 20mA
0
-< Auxiliary input DC 0 - +lOV 1OV
___( Apxiliary input DC0 - f 5 V SV
A B C FM SD 10 2 5 4 1 K 1E SD STF STR JoG
SE RUN SU IPF OL FU RL RM RH RT AU STOPMRS RES SD
Multi-speed selection
uzl
CS SD
This terminal is available in models larger than FR-Z220-15K
and FR-Z240-11K. Use it for “restart after instantaneous
power failure”, or for “commercial power/inverter select “.
0Restart after instantaneous power failure ****** Short-circuit
between terminals CS and SD.
0Commercial power/inverter select ***-** Use a circuit which
closes the MC inserted on the inverter output side and
at the same time short-circuit between terminals CS and
SD.
.O
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For details, refer to the technical information.
’ f-
*2. STOP terminal
This terminal can be used to hold “start” signal.
1
Note: 1. Terminals SD and 5 are common terminals for input/output
signals, and insulated from each other.
,Do not connect these terminals to ground.
2. For signal wires connected to control circuit terminals of
inverter, use shielded wires or twisted wires.
These wires should be separated from cables for the main
circuit and high-voltage circuits (including 200V relay sequence
circuit) .
3. The speed reference signal is a faint current. To prevent mis-
contact, use two parallel connections of faint signal contacts or
twin contacts.
-13-
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(21 Output signal circuits
Frequency nieter
( 1mA full scale)
Alarm signal output
(IC contactoutput)
(1/3W lOKn>
This potentiometer is not required
when meter ie calibrated on parameter
(for method of calibration. refer. to
8 5. ‘SETTING OF EACH PARAMETER “.>
. Y /
Open collector output
- SIGNAL INPUT BY SEMICONDUCTOR SWITCH
A semiconductor can be used, instead of contacts (relay, switch, etc.) , to
generate an input signal.
0 Applicable input signal terminals
All input signals except for
analog input signals ( 2, 5 , 4,
1K and 1E) (see the circuit
diagram on page 12) .
l Electric characters required for
transistor
(Wiring example)
IC1 lOOmA A--
VCEZ 50V
Note: For details, refer to the relevant technical information.
0
0
0
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4.3 Terminals for wiring
Concontrd circuit terminal block
U VW N PPR
- Control circuit terminal block
(M51m w ,Mp
e+ CM51
‘Jumper
rc/ v
Control circuit terminal block (M4) (M4)
f=====jpqm
. TBl TB2 TB3
TB4
Screw sizes
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