Mitsubishi FR - S500 Replacement of parts, Cooling fan, Inverter Model No Fan Type

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3.3.7 Replacement of parts

The inverter consists of many electronic parts such as semiconductor devices. The following parts may deteriorate with age because of their structural or physical characteristics, leading to reduced performance and/or failure of the inverter. For preventive maintenance, the parts must be changed periodically.

Part Name

Standard Replacement

Interval

Description

Cooling fan	2 to 3 years	Change (as required)
Smoothing capacitor in main circuit	5 years	Change (as required)
Smoothing capacitor on control board	5 years	Change the board (as required).
Relays	———	Change as required

CAUTION

For parts replacement, consult the nearest Mitsubishi FA Center.

(1) Cooling fan

The cooling fan used to cool heat-generating parts such as the main circuit semiconductors has a bearing whose life is said to be 10,000 to 35,000 hours. Hence, the cooling fan must be changed every 2 to 3 years if the inverter is run continuously. When unusual noise and/or vibration is noticed during inspection, the cooling fan must be changed immediately.

	Inverter Model No.	Fan Type
	FR-S520-1.5K, 2.2K, 3.7K	MMF-06D24DS BKO-C2416H07
	FR-S520S-1.5K	MMF-06D24DS BKO-C2416H07
	FR-S520S-1.5K
	FR-S540-1.5K, 2.2K, 3.7K	MMF-06D24ES-FC4 BKO-CA1027H09

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Contents SR5 0 Conditions, resulting in death or severe injury This section is specifically about safety mattersCause physical damage only Page Page Page Multi-speed setting RL, RM, RH, REX signals Setting 0, 1, 2 How to Use the Input SignalsFrequency jump Handling of the RS-485 ConnectorBiases and gains of the frequency setting voltage current Stall preventionRetry function PWM carrier frequency Applied motor Restart settingOperation mode selection PID control 101 Monitoring referenceCorrespondence between digital and actual characters 145 To know the operating status at the occurrence of alarm137 145Abbreviations WiringJapanese Version Terminal connection diagramFR-S520-0.1K to 3.7K -R -C FR-S540-0.4K to 3.7K -R FR-S520S-0.1K to 1.5K -R -C FR-S510W-0.1K to 0.75K -R Layout and wiring of main circuit terminalsNFB MC Inverter North America VersionFR-S520-0.1K to 3.7K-NA FR-S540-0.4K to 3.7K-NA R FR-S510W-0.1K, 0.2K, 0.4K-NA FR-S510W-0.75K-NA Reduce the output current FR-S540-0.4K to 3.7K-ECR European VersionFR-S540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-EC R FR-S520S-0.2K to 1.5K-EC RFR-S520S-0.2K, 0.4K, 0.75K-EC R FR-S520S-1.5K-EC R Terminal names in parentheses are those of the EC version Description of I/O Terminal SpecificationsMain circuit Control circuitRUN FR-S510W-0.1K to 0.75K -R FR-S510W-0.1K to 0.75K-NA How to Use the Main Circuit TerminalsCables, wiring lengths, crimping terminals, etc FR-S520S-0.1K to 1.5K -R FR-S520S-0.2K to 1.5K-EC RWiring instructions Selection of peripheral devices Peripheral devicesL1, N AC Reactor DC Reactor ModelCables mm2 Line-to-line leakage currents To-ground leakage currents∆ n ≥ 10 ⋅ lg1+Ign+lg2+lgm During commercial powerType SP, CF, SF, CP Rated sensitivity currentSTF STR Power-off and magnetic contactor MCInverters primary side magnetic contactor MC OFFNFB FR-BAL Regarding noise and the installation of a noise filterBIF Grounding precautionsNoise reduction examples BLFJapanese power harmonic suppression guideline Regarding power harmonicsReceived Power Voltage 5th 7th 11th 13th 17th 19th 23rd Over Conversion Factors for FR-S500 Series No reactor, 100% operation ratio Harmonic suppression technique requirementHarmonic suppression techniques Rated 6kVTerminal block layout How to Use the Control Circuit TerminalsM3 A, B, C terminals Al 0.5-6WH Using tweezers, a pair of long Input signals are set to sinkChanging the control logic RUN 24VDC STRSTR R Input Terminals Right The forward/reverse rotation signal isRun start and stop STF, STR, Stop Three-wire type connection STF, STR, Stop STR-SD STF-SDBasic Voltage input 10, 2AU-SD on OFF Manual-Automatic SwitchingExternal frequency selection REX, RH, RM, RL Current input 4, 5, AUREX External commandJapanese version FM Indicator connection and adjustmentOutput waveform of terminal FM CPU NA and EC version AMControl circuit common terminals SD, 5, SE Signal inputs by contactless switchesCurrent input selection AU signal Setting Second function selection RT signal SettingStart self-holding selection Stop signal Setting External thermal relay input Setting Output shut-off MRS signal SettingReset signal Setting Jog operation JOG signal SettingJog operation using external signals Use the optional FR-CB2 PID control valid terminal SettingPU operation/external operation switching Setting When connecting the parameter unitRS-485 communication System configuration examples4P Twisted pair cable, 4 pairs Wiring of one RS-485 computer and one inverter Wiring methodsMC1 Design InformationCommunication Parameters Only for the Type FunctionsFunction Parameter List Func- Pa- Indica- tion rame- tion ter Minimum Factory Cus Name Setting RangeMinimum Factory Refer Cus Name Setting Range FM AM OHT, OLT, PE, OPT THM, THT, GFPWM Selection functions PID ECL Alarm history 115 ClearCation Func TionNA, EC Com Minimum For details of the program, refer to page 118 onwardsList of Parameters Classified by Purpose of Use Related to monitoring Torque boost SettingName Factory Setting Remarks Explanation of Functions ParametersMaximum and minimum frequency Parameter Name Factory Setting Setting Range EC versionBase frequency, Base frequency voltage EC version Remarks Range Multi-speed operation to toAcceleration/deceleration time Frequency setting Hz 120 Acceleration Deceleration time s DC injection brake Electronic overcurrent protectionOperation, etc. or the timing of operating Name Factory Starting frequencyLoad pattern selection Refer to Refer to , Name Factory Setting Setting Range RemarksJog frequency RUN key rotation direction selectionDeceleration Operation Not Activated Regenerative Driving Stall Prevention OL Signal Operation Fast OutputStall prevention function and current limit function CelerationDe Operation ActivatedStall prevention Where, a = 100Set the acceleration/deceleration pattern Acceleration/deceleration patternFunction Description Frequency jump Extended function display selectionSpeed display Use Pr , calibration parameter C4 for Biases and gains of the frequency setting voltage currentSetting Name Factory SettingSet value Hz How to change the highest frequencyFlicker ... Parameter setting complete OperationDisplayPress the SET key to set the value Voltage gain appears Press the SET key to show the analogKey to return to Turn the setting dial to read another parameterKey twice to show the next parameter Output Terminal Function Parameters Start-time ground fault detection selectionUp-to-frequency sensitivity Output frequency detection On OFF Parameter Name Factory Setting Remarks RangeCurrent Detection Function Parameters Output current detection functionsZero current detection Monitor display Display Function ParametersLED Press the RUN key to start the inverter Setting dial function selectionRefer to Maximum output voltage of terminal AM is 5VDC Restart settingRestart Operation Parameters Monitoring referenceStfstr Setting DescriptionRefer to the following table and set the parameters Automatic restart operation afterAdditional Function Parameters Remote setting function selectionOr PU digital preset frequency Operation panel operation procedurePr Setting Frequency setting storage conditionsFunction E 2PROM Input terminal function selection Terminal Function Selection ParametersJOG Setting Signal Functions Related Parameters NameMRS REXReferred to Setting Signal Function Operation ParametersOutput terminal function selection Same function may be set to more than one terminalProtective Functions Major Failures for Retries Pr Setting Number of Retries Alarm Signal OutputOperation Selection Function Parameters Retry functionPWM carrier frequency Parameter Number Setting DescriptionYou can change the motor sound Acceleration/deceleration time, which is a slope up/down to Applied motorVoltage input selection Set the motor usedReset Selection PU Stop Selection Setting Reset selection/PU stop selectionParameter Name Factory Setting Setting Range Remarks Setting RemarksOperation panel Restarting method with Shown Key input fromCooling fan operation selection Parameter write inhibit selection Pr Setting FunctionReverse rotation prevention selection Operation mode selectionRUN EXT Mode SignalFunction LED Indication * PU EXTMRS PU operation interlockX16 Signal Operation Mode Operation mode switching by external signalPID control to PID action overview Setting Basic PID control configuration102 Variable output frequency if Deviation X = set point PID actionReverse action Increases the manipulatedRUNFUP,FDN Wiring exampleDeviation Negative105 O signalsParameter setting Name Setting Description106 Adjustment procedureEND Calibration example107 StartDetector output calibration Set point input calibration108 Automatic torque boost selection Auxiliary Function ParametersSlip compensation 11.2110 Operating conditionsOrdinary V/F control and torque boost Pr , Pr are valid Meter frequency meter calibration Japanese version Parameter Name Factory Setting RemarksCalibration Parameters Motor primary resistance112 Flicker ... Parameter setting completeMeter frequency meter calibration NA and EC version Operation When the FR-PU04 is used, make calibration with Pr 114Display Parameter clear Alarm history clearErases the alarm history Clear ParametersOperational functions Symbol Switching TypeOperation mode-based functions 118 Communication settings14.1 Communication-related parameters119 Description SettingCR LF Operation Run Running Computer programming Communication protocolInverter Monitor Parame 121 Data formatReply data from inverter to computer during data write Reply data from inverter to computer during data readControl codes Signal Ascii Code DescriptionData definitions Send data from computer to inverter during data readSTX ACK ENQ 123HFF 124Instruction Data H7FPage 126 Setting items and set dataFF = Nication Tion 127Calibra HECDescription Data Error Code ListError Definition 128Program example Operation at alarm occurrenceCommunication error General flowchartLocation Selection N8 Pr Operation Command write Operation and speed command writeN9 Pr Speed Command write Explanation of table External Link start mode selectionN8 Pr operation Command write N10 Link start mode Setting is enabled when Pr = Selection14.4 E2PROM write selection 15.2 Parameter Unit FR-PU04 SettingParameter unit display language switching N13 Setting Display LanguageN16 100 PU contrast adjustmentN15 PU contrast adjustment Setting is enabled when Pr = PU main display screen data selectionMonitor display and Resetstop key are valid PU disconnection detection/PU setting lockN17 Setting PU Disconnection Detection PU Setting Lock 136 FunctionsOC1 FR-PU04 Errors AlarmsError alarm definitions Major failuresOV1 FR-PU04 138OC2 FR-PU04 OC3 FR-PU04THT 139OV3 THMOPT FR-PU04 140OHT FR-PU04 OLT FR-PU04PUE Minor failuresFor only the type having the RS-485 communication function 141142 Er1 FR-PU04 Control Mode Write errors143 Er3 FR-PU04 Incr I/P Er2 FR-PU04 PU/EXT Mode144 Operator ERRCorrespondence between digital and actual characters Resetting the inverterActual Display Motor remains stopped TroubleshootingMotor current is large Speed greatly differs from the settingMotor rotates in opposite direction Acceleration/deceleration is not smoothMotor produces annoying sound Operation mode is not changed properlyOperation panel display is not operating Parameter write cannot be performedPeriodic inspection Precautions for Maintenance and InspectionPrecautions for maintenance and inspection Check itemsInterval Daily Insulation resistance test using meggerPressure test Daily and periodic inspectionDaily 1 year 151Inspection Description IntervalInspection Interval Checking method Checking the inverter and converter modules PreparationModule device numbers and terminals to be checked Inverter Model No Fan Type Replacement of partsPart Name Standard Replacement Interval Description Cooling fanAIR Flow Relays Smoothing capacitorsTypical Measuring Points and Instruments Measurement of main circuit voltages, currents and powersMeasuring Point Remarks Instrument Reference Measured Value Pf1=Pf2= 158Measuring Remarks Instrument Measuring PointRH, RM, RL, MRS RES-SD160 CationsPhase 200V power supply Specification ListRatings Phase 400V power supply Single-phase 200V power supply Single-phase 100V power supply Common specifications NA, EC Outline Drawings 168 Parameter unit FR-PU04 Outline drawing Panel cut dimension drawing170 InstructionsPeripheral Selecting Instructions Selecting InstructionsHandling of secondary side magnetic contactor Installation of thermal relayDisuse of power factor improving capacitor power capacitor Handling of primary side magnetic contactorOperation Cable thickness and wiring distanceWiring Operating InstructionsPower supply InstallationRectifying the motor insulation Inverter-driven 400V class motorSuppressing the surge voltage on the inverter side 176 AppendixLink Data Func- Parameter tion NumberData Code Computer ExtensionData Code Computer Link Parameter Extension 178Read 179 180 Name Link Data Tion Link Parameter Extension Setting Data Code 7F/FF181 Data Code Computer FuncPrint Date Manual Number Revision Manual number is given on the bottom left of the back cover