Mitsubishi Electric FR-E500 User manual

TRANSISTORIZED INVERTER

FR-E500

FR-E520-0.1KND to 7.5KND

INSTRUCTION MANUAL

OUTLINE

OPERATION/

CONTROL

PARAMETERS

SPECIFICATIONS

INSTALLATION

AND WIRING

PROTECTIVE

FUNCTIONS

Chapter 6

Chapter 5

Chapter 4

Chapter 3

Chapter 2

Chapter 1

A - 1

Thank you for choosing the 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 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 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 even 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.

WARNING

CAUTION

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 10

minutes, and check for residual voltage with a meter (refer to 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 and potentiometers with dry hands to prevent an electric

shock.

!

Do not subject the cables to scratches, excessive stress, heavy loads or

pinching. Otherwise, you may get an electric shock.

!

Do not change the cooling fan while power is on.

It is dangerous to change the cooling fan while power is on.

!

While power is on, do not move the node address setting switches. Doing so

can cause an electric shock.

2. Fire Prevention

CAUTION

!

Mount the inverter and brake resistor 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.

!

When a brake resistor is used, use an alarm signal to switch power off.

Otherwise, the brake resistor will overheat abnormally due a brake transistor or

other fault, resulting in a fire.

!

Do not connect a resistor directly to the DC terminals P (+), N (

−

). This could

cause a fire.

A - 3

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.

!

While power is on and for some time after power-off, do not touch the inverter or

brake resistor as they are hot and you may get burnt.

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.

!

When carrying the inverter, do not hold the front cover or accessory cover.

!

Do not stand or rest heavy objects on the inverter.

!

Check the inverter mounting orientation is correct.

!

Prevent screws, wire fragments or other conductive bodies or oil or other

flammable substance 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 (non-freezing)

Ambient humidity 90%RH or less (non-condensing)

Storage

temperature

-20

°

C to +65

°

C *

Ambience

Indoors (free from corrosive gas, flammable gas, oil mist, dust

and dirt)

Environment

Altitude, vibration

Maximum 1000m above sea level for standard operation. After

that derate by 3% for every extra 500m up to 2500m (91%).

5.9m/s

2

or less (conforming to JIS C 0040)

* Temperatures applicable for a short time, e.g. in transit.

A - 4

(

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

WARNING

!

When you have chosen the retry function, stay away from the equipment as it

will restart suddenly after an alarm stop.

!

The load used should be a three-phase induction motor only. Connection of any

other electrical equipment to the inverter output may damage the equipment.

!

Do not modify the equipment.

CAUTION

!

The electronic overcurrent protection does not guarantee protection of the motor

from overheating.

!

Do not use a ma

g

netic 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 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 easil

y

set for hi

g

h-speed operation. Before chan

g

in

g

its

setting, fully examine the performances of the motor and machine.

!

In addition to the inverter's holdin

g

function, install a holdin

g

device to ensure

safety.

!

Before runnin

g

an inverter which had been stored for a lon

g

period, alwa

y

s

perform inspection and test operation.

A - 5

(

5

)

Emergency stop

CAUTION

!

Provide a safet

y

backup such as an emer

g

enc

y

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

Man

y

of the dia

g

rams and drawin

g

s in this instruction manual show the inverter

without a cover, or partiall

y

open. Never operate the inverter like this. Alwa

y

s

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.....................................................................................................3

1.2.1 Basic configuration...............................................................................................3

1.3 Structure .....................................................................................................................4

1.3.1 Appearance and structure....................................................................................4

1.3.2 Functions..............................................................................................................4

1.3.3 Removal and reinstallation of the front cover.......................................................5

1.3.4 Removal and reinstallation of the wiring cover.....................................................6

1.3.5 Removal and reinstallation of the accessory cover..............................................7

1.3.6 Exploded view......................................................................................................8

2 INSTALLATION AND WIRING 9

2.1 Installation...................................................................................................................9

2.1.1 Instructions for installation....................................................................................9

2.2 Wiring........................................................................................................................11

2.2.1 Terminal connection diagram.............................................................................11

2.2.2 Wiring of the main circuit....................................................................................14

2.2.3 Wiring of the control circuit.................................................................................18

2.2.4 DeviceNet communication signal wiring.............................................................21

2.2.5 Connection to the PU connector ........................................................................26

2.2.6 Connection of stand-alone option units..............................................................29

2.2.7 Design information .............................................................................................32

2.3 Other Wiring..............................................................................................................33

2.3.1 Power supply harmonics....................................................................................33

2.3.2 Japanese harmonic suppression guideline ........................................................34

2.3.3 Inverter-generated noise and reduction techniques...........................................37

2.3.4 Leakage currents and countermeasures............................................................41

2.3.5 Peripheral devices..............................................................................................42

2.3.6 Instructions for compliance with U.S. and Canadian Electrical Codes...............46

Contents

II

3 OPERATION/CONTROL 47

3.1 Inverter Settings........................................................................................................47

3.1.1 Node address of the inverter..............................................................................47

3.2 Configuration.............................................................................................................49

3.2.1 General description............................................................................................49

3.2.2 Set baud rate:.....................................................................................................50

3.2.3 Set node address:..............................................................................................50

3.2.4 DeviceNet I/O assembly:....................................................................................50

3.3 Operation..................................................................................................................52

3.3.1 Operation modes................................................................................................52

3.3.2 Functions available in the operation modes.......................................................52

3.3.3 Input from DeviceNet to inverter.........................................................................53

3.3.4 Output from inverter to DeviceNet......................................................................53

3.3.5 Operation on alarm occurrence..........................................................................54

3.3.6 Inverter reset......................................................................................................54

3.3.7 Setting frequency (f) value..................................................................................54

3.3.8 Parameter clear (Pr Clr) commands...................................................................54

3.3.9 Control input commands ....................................................................................54

4 PARAMETERS 55

4.1 Parameter List...........................................................................................................55

4.1.1 Parameter list.....................................................................................................55

4.1.2 List of parameters classified by purpose of use.................................................60

4.1.3 Parameters recommended to be set by the user ...............................................61

4.2 Parameter Function Details ......................................................................................62

4.2.1 Torque boost (Pr. 0, Pr. 46)................................................................................62

4.2.2 Output frequency range (Pr. 1, Pr. 2, Pr. 18)......................................................63

4.2.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19, Pr. 47) .........................64

4.2.4 Multi-speed operation

(Pr. 4, Pr. 5, Pr. 6, Pr. 24 to Pr. 27, Pr. 232 to Pr. 239).......................................65

4.2.5 Acceleration/deceleration time (Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45) .......66

4.2.6 Electronic overcurrent protection (Pr. 9, Pr. 48).................................................68

4.2.7 DC injection brake (Pr. 10 to Pr. 12)...................................................................69

4.2.8 Starting frequency (Pr. 13).................................................................................70

III

4.2.9 Load pattern selection (Pr. 14)...........................................................................71

4.2.10 Stall prevention (Pr. 22, Pr. 23, Pr. 66).............................................................72

4.2.11 Acceleration/deceleration pattern (Pr. 29)........................................................74

4.2.12 Regenerative brake duty (Pr. 30, Pr. 70)..........................................................75

4.2.13 Frequency jump (Pr. 31 to Pr. 36)....................................................................76

4.2.14 Speed display (Pr. 37)......................................................................................77

4.2.15 Up-to-frequency sensitivity (Pr. 41) ..................................................................78

4.2.16 Output frequency detection (Pr. 42, Pr. 43)......................................................78

4.2.17 Monitor display (Pr. 52) ....................................................................................79

4.2.18 Automatic restart after instantaneous power failure (Pr. 57, Pr. 58).................81

4.2.19 Shortest acceleration/deceleration mode (Pr. 60 to Pr. 63)..............................82

4.2.20 Retry function (Pr. 65, Pr. 67 to Pr. 69)............................................................84

4.2.21 Applied motor (Pr. 71)......................................................................................86

4.2.22 PWM carrier frequency (Pr. 72, Pr. 240)..........................................................87

4.2.23 Reset selection/disconnected PU detection/PU stop selection (Pr. 75) ...........88

4.2.24 Parameter write inhibit selection (Pr. 77)..........................................................90

4.2.25 Reverse rotation prevention selection (Pr. 78).................................................90

4.2.26 Operation mode selection (Pr. 79) ...................................................................91

4.2.27 General-purpose magnetic flux vector control selection (Pr. 80)...........................92

4.2.28 Offline auto tuning function (Pr. 82 to Pr. 84, Pr. 90, Pr. 96)............................93

4.2.29 Computer link operation (Pr. 117 to Pr. 124)....................................................99

4.2.30 Settings for connection of FR-PU04 (Pr. 145, Pr. 990, Pr. 991).....................112

4.2.31 Output current detection function (Pr. 150, Pr. 151).......................................113

4.2.32 Zero current detection (Pr. 152, Pr. 153)........................................................114

4.2.33 Stall prevention function and current limit function (Pr. 156)..........................115

4.2.34 User group selection (Pr. 160, Pr. 173 to Pr. 176) .........................................117

4.2.35 Actual operation hour meter clear (Pr. 171)...................................................118

4.2.36 Input terminal (DeviceNet input) function selection (Pr. 180 to Pr. 183).........118

4.2.37 Output terminal (DeviceNet input) function selection (Pr. 190 to Pr. 192)......120

4.2.38 Cooling fan operation selection (Pr. 244).......................................................121

4.2.39 Slip compensation (Pr. 245 to Pr. 247) ..........................................................122

4.2.40 Ground fault detection at start (Pr. 249).........................................................123

4.2.41 Stop selection (Pr. 250)..................................................................................123

4.2.42 DeviceNet specific parameters (Pr. 345 to Pr. 348) .............................................125

Contents

IV

5 PROTECTIVE FUNCTIONS 127

5.1 Errors (Alarms)........................................................................................................127

5.1.1 Operation at alarm occurrence.........................................................................127

5.1.2 Error (alarm) definitions....................................................................................128

5.1.3 To know the operating status at the occurrence of alarm.................................134

5.1.4 Correspondence between digital and actual characters...................................134

5.1.5 Resetting the inverter .......................................................................................134

5.2 Troubleshooting......................................................................................................135

5.2.1 Motor remains stopped.....................................................................................135

5.2.2 Motor rotates in opposite direction ...................................................................135

5.2.3 Speed greatly differs from the setting...............................................................136

5.2.4 Acceleration/deceleration is not smooth...........................................................136

5.2.5 Motor current is large........................................................................................136

5.2.6 Speed does not increase..................................................................................136

5.2.7 Speed varies during operation..........................................................................136

5.2.8 The operation mode does not change to the DeviceNet operation mode........137

5.2.9 The inverter does not start even after entering the DeviceNet operation mode.....137

5.2.10 Parameter write cannot be performed............................................................137

5.2.11 How to check for errors using the operation status indicator LED .........................138

5.2.12 Inspecting display on parameter unit and status LED....................................139

5.3 Precautions for Maintenance and Inspection..........................................................140

5.3.1 Precautions for maintenance and inspection ...................................................140

5.3.2 Check items......................................................................................................140

5.3.3 Periodic inspection...........................................................................................140

5.3.4 Insulation resistance test using megger...........................................................141

5.3.5 Pressure test....................................................................................................141

5.3.6 Daily and periodic inspection............................................................................142

5.3.7 Replacement of parts.......................................................................................145

5.3.8 Measurement of main circuit voltages, currents and powers............................147

6 SPECIFICATIONS 149

6.1 Standard Specifications..........................................................................................149

6.1.1 Model specifications.........................................................................................149

6.1.2 Common specifications....................................................................................150

V

6.1.3 Outline dimension drawings .............................................................................152

6.1.4 DeviceNet specifications..................................................................................156

APPENDIX 157

APPENDIX 1 Object Map .............................................................................................157

APPENDIX 2 Electronic Data Sheets (EDS files).........................................................180

APPENDIX 3 DeviceNet Parameters............................................................................181

APPENDIX 4 Data Code List........................................................................................185

Contents

C H A P T E R 1

O U T L I N E

This chapter gives information on the basic "outline" of this

product.

Always read the instructions before using the equipment.

1.1 Pre-Operation Information ..........................................1

1.2 Basic Configuration.....................................................3

1.3 Structure.....................................................................4

!

PU

Parameter unit (FR-PU04)

!

Inverter

Mitsubishi transistorized inverter

FR-E500 series

!

FR-E500KND

Mitsubishi transistorized inverter

FR-E500 series DeviceNet type

!

Pr.

Parameter number

CHAPTER 1

OUTLINE

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

OUTLINE

1

1.1 Pre-Operation Information

1 OUTLINE

1.1 Pre-Operation Information

1.1.1 Precautions for operation

This manual is written for the FR-E520KND series DeviceNet-compatible transistorized

inverters.

Incorrect handling may cause the inverter to operate incorrectly, causing 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.

DeviceNet is a registered trademark of Open DeviceNet Vendor Association, Inc.

DeviceNet Manager™ is a registered trademark of Allen-Bradley Company, Inc.

For handling information on the parameter unit (FR-PU04), 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

Inverter type Serial number

Capacity plate

Rating plate

Capacity plate

Rating plate

FR-E520-0.1KND/

Inverter type

Input rating

Output rating

Serial number

MITSUBISHI

MODEL

INVERTER

FR-E520-0.1KND

INPUT :

OUTPUT :

SERIAL :

XXXXX

PASSED

"

""

"

Inverter type

FR E520 0.1

K N D

Symbol Voltage class

200V class

DeviceNet

TM

t

y

pe

E520

Inverter

Indicates capacity

"kW".

2) Accessory

Instruction manual

If you have found any discrepancy, damage, etc., please contact your sales

representative.

OUTLINE

2

(2) Preparation 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 49.)

(3) Installation

To operate the inverter with high performance for a long time, install the inverter in a

proper place, in the correct direction, with proper clearances. (Refer to page 9.)

(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 11.)

(5) Ground

To prevent an electric shock, always ground the motor and inverter.

The ground wiring from the power line of the inverter as an induction inverter reduction

technique is recommended to be run by returning it to the ground terminal of the

inverter. (Refer to page 40 for examples of noise countermeasures.)

1

OUTLINE

3

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.)

(MC)

(NFB)

or

(ELB)

Ground

DC reactor

(FR-BEL)

AC reactor

(FR-BAL)

Earth leakage

circuit breaker

or no-fuse breaker

Power supply

Magnetic

contactor

Inverter

DeviceNet master

Terminal resistor

DeviceNet drop cable

Each master accepts up to 63 inverters.

Terminal resistor

Master controller

Harmonic Suppression Guideline

The "harmonic suppression guideline for household appliances and general-purpose

products" issued by ex-Ministry of International Trade and Industry (present Ministry of

Economy, Trade and Industry) in September, 1994 applies to the 3.7K and less models.

By installing the power factor improving reactor (FR-BEL or FR-BAL), inverters comply

with the "harmonic suppression techniques for transistorized inverters (input current 20A

or less)" established by the Japan Electrical Manufacturers' Association.

OUTLINE

4

1.3 Structure

1.3.1 Appearance and structure

(1) Front view

POWER lamp

(yellow)

Accessory cover

ALARM lamp (red)

Operating status

indicator LEDs

Rating plate

Front cover

Capacity plate

Wiring cover

(2) Without accessory cover and front cover

POWER lamp (yellow)

Operating status indicator LEDs

Control logic changing connector

Control circuit terminal block

PU connector*

ALARM lamp (red)

DeviceNet

TM

terminal block

Main circuit terminal block

Wiring cover

Node address setting switches

* Use the PU connector for the FR-PU04 (option) and RS-485 communication.

1.3.2 Functions

Name Function

Node address setting

switches

SW1(

×

10)

0

9

8

7

6

5

4

3

2

1

0

9

8

7

6

5

4

3

2

1

SW2(

×

1)

Used to set the inverter node address between

0 and 63.

For details, refer to page 47, 51.

POWER lamp (yellow) Lit to indicate that power is input (present).

ALARM lamp (red) Lit to indicate that a protective function is activated.

Operating status

indicator LED

The operating status indicator LED is a 2 color (Red and Green) LED.

For details on the operating status please refer to page 25 which

details the system state and corresponding LED status.

1

OUTLINE

5

1.3.3 Removal and reinstallation of the front cover

"

""

"

Removal

(For the FR-E520-0.1KND to 3.7KND)

The front cover is secured by catches in positions A and B as shown below.

Push either A or B in the direction of arrows, and using the other end as a

support, pull the front cover toward you to remove.

1

)

2

)

3

)

A

B

(For the FR-E520-5.5KND, 7.5KND)

The front cover is fixed with catches in positions A, B and C.

Push A and B in the directions of arrows at the same time and remove the

cover using C as supporting points.

1) 2) 3)

C

B

C

A

"

""

"

Reinstallation

When reinstalling the front cover after wiring, fix the catches securely.

With the front cover removed, do not switch power on.

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 numbers to ensure that the cover removed is reinstalled to the

inverter from where it was removed.

OUTLINE

6

1.3.4 Removal and reinstallation of the wiring cover

"

""

"

Removal

The wiring cover is fixed by catches in positions 1) and 2).

Push either 1) or 2) in the direction of arrows and pull the wiring cover

downward to remove.

1)

2)

Wirin

g

hol

e

"

""

"

Reinstallation

Pass the cables through the wiring hole and reinstall the cover in the original

position.

1

OUTLINE

7

1.3.5 Removal and reinstallation of the accessory cover

"

""

"

Removal of the control panel

Hold down the portion A indicated by the arrow and lift the right hand side

using the portion B indicated by the arrow as a support, and pull out the

control panel to the right.

1

)

2) 3)

A

B

"

""

"

Installation

Insert the mounting catch (left hand side) of the accessory cover into the

mounting position of the inverter and push in the right hand side mounting catch

to install the control panel.

Mounting position

Accessory cover

Catch

2)1)

A

3)

OUTLINE

8

1.3.6 Exploded view

1

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