FR-F500
This section is specifically about safety matters
Safety Instructions
Additional instructions
Emergency stop
Treat as industrial waste
Contents
103
100
102
104
163
Watt-hour meter clear/actual operation hour meter clear
195
184
192
Chapter Outline
Chapter
Wiring
Precautions for operation
Installation
Pre-Operation Information
Japanese Harmonic Suppression Guideline
Basic Configuration
Basic configuration
Name Description
Front view
Structure
Appearance and structure
Without front cover
Removal and reinstallation of the front cover
FR-F520-0.75K to 11K, FR-F540-0.75K to 11K
FR-F520-30K to 55K, FR-F540-30K to 55K
Removal and reinstallation of the operation panel
Chapter
Clearances around the inverter
Installation
Instructions for installation
97inches1.97inches
Vertical mounting
Wiring cover and handling 22K or less
For installation in an enclosure
NFB
Description of main circuit terminals
Symbol Terminal Name Description
Type Symbol Terminal Name Description
Description of control circuit terminals
RUN
Type
Terminal Name Description
IPF
Overall wiring length 1.5K or more
Wiring of the main circuit
Wiring instructions
Inverter Capacity 75K 5K or more
Motor Capacity Ground Cable Gauge 200V class 400V class
FR-F520-5.5K, 7.5K FR-F520-55K
Terminal block layout
FR-F520-1.5K, 2.2K, 3.7K FR-F520-45K
FR-F520-11K
FR-F540-15K, 18.5K, 22K
400V class FR-F540-0.75K, 1.5K, 2.2K, 3.7K FR-F540-30K, 37K
FR-F540-5.5K, 7.5K, 11K FR-F540-45K, 55K
Terminal names in parentheses are those of the EC version
Connection of the power supply and motor
Cables, crimping terminals, etc
Model FR-F520-5.5K to 55K, FR-F540-5.5K to 55K
Connection procedure
Model FR-F520-0.75K to 3.7K, FR-F540-0.75K to 3.7K
Wiring of the control circuit
Terminal screw size M3.5 Tightening torque 1.2 N⋅ m
Changing the control logic
Current flow related to RUN signal
How to use terminals STOP, CS and PC
PU connector pin-outs
Connection to the PU connector
Recommended cable connector
System configuration example
RS-485 terminal Computer
Wiring method
Wiring of one RS-485 computer and one inverter
Max m
Connection of stand-alone option units
Connection of the FR-BU brake unit option
Connection of the FR-HC high power factor converter option
Connection of the conventional BU brake unit option
Connection of the FR-RC power regeneration converter option
Connection of the power factor improving DC reactor option
MC1
Interlock Power Supply MC2 Leakage current
Design information
Harmonics RF Noise
Other wiring
Power harmonics
Conversion Factors for FR-F500 Series
Received Power 5th 7th 11th 13th 17th 19th 23rd Over 23rd
Japanese harmonic suppression guidelines
Class Circuit Type
Harmonic Content Values at the fundamental current of 100%
Equivalent Capacity Limits
FR-HC
Harmonic suppression techniques
ACL, DCL
Inverter-generated noises and reduction techniques
Following measures must be taken
Data line filter
Noise Path Measures
Bundle them
Noise Terminal Voltage of Inverter and Example
Noise Induced to Signal Cables by Inverter Output
Data examples
Its Reduction by Noise Filters
# Example of counter measures against noise
Leakage currents and countermeasures
To-ground leakage currents
# Countermeasures
Rectifying the motor insulation
Inverter-driven 400V class motor
Line-to-line leakage currents
Suppressing the surge voltage on the inverter side
400V class
Peripheral devices
Selection of peripheral devices
Example
Branch circuit protection
Standard to comply UL 508C 1 Installation
Wiring of the power supply and motor
Short circuit ratings
EMC Directive
Instructions for compliance with the European standards
Motor overload protection
Our view of transistorized inverters for the EMC Directive
90% RH or less
Low Voltage Directive
During operation Storage During transportation
Maximum Altitude 000 m 10,000 m
Earthing methods
Earthing EC version
Earthing and Earth Leakage Current
Unit mm2
OPERATION/CONTROL
External/PU combined operation mode
External operation mode factory setting
PU operation mode
Devices and parts to be prepared for operation
Communication operation mode
Power on
Before switching power on, check the following
Key indications
Operation Panel
Names and functions of the operation panel FR-DU04
Unit indications, operating status indications
Monitoring
Frequency setting
Used to set the running frequency in the PU operation mode
Parameter setting method
Alarm history
Operation mode
Help mode
All clear
Alarm history clear
Parameter clear
User clear
Copy mode
#Parameter setting mode
Parameter checking
Parameter Checking and Setting
Simple mode parameter list
Pr user group read selection
Name Application
Setting of minimum frequency Pr minimum frequency
Main parameter settings
Setting of maximum frequency Pr maximum frequency
Parameter Factory Setting
Gain
Application Setting
Selection of load pattern Pr load pattern selection
0Hz at 4mADC, 60Hz at
Operation
Pre-operation checks
Description Image
Operation at 60Hz
External jog operation
Stop Press
PU jog operation
Start Press
Motor is decelerated to a stop
Start
Decelerates when Pr = 9999 to a stop
Step Description
Hold down the key to change the frequency
Parameters
Parameter List
Parameter list
Setting Tion
F4 fourth frequency voltage
Minimum Factory Refer Cust Func Parameter Setting
Can be accessed when Pr =
PID
List of Parameters Classified by Purposes of Use
Function rewrite prevention
Parameter Function Details
Setting
Parameter Factory Setting Range Remarks
Torque boost Pr , Pr
120Hz To 120Hz
Pr maximum frequency Pr minimum frequency
Use Pr to set the lower limit of the output frequency
9999 To 120Hz Function invalid
Base frequency, base frequency voltage Pr , Pr , Pr
8888
60Hz To 120Hz 30Hz 10Hz 24 to 9999
Parameter Factory Setting Setting Range Remarks
Multi-speed operation Pr to Pr , Pr to Pr.27
Factory Setting Range Remarks
To 3600 s minimum setting increments 0.1 s
To 360 s minimum setting increments 0.01 s
Acceleration/deceleration time Pr , Pr , Pr , Pr , Pr , Pr
Acceleration
Electronic overcurrent protection Pr
Pr electronic thermal O/L relay
Decelerationtime s
Value Operated
DC injection brake Pr to Pr
Operated at
To 10 s
5Hz To 60Hz
Starting frequency Pr
Pr starting frequency
Load pattern selection Pr
Parameter Factory Setting Range
Output Characteristics
Pr load pattern selection
Pr jog frequency
Pr jog acceleration/deceleration timereference frequency
Jog operation Pr , Pr
Related parameters
MRS input selection Pr
Wiring example
Pr Setting Specifications of MRS Signal
Pr MRS input selection
To 120Hz 148
Parameter Number Factory Setting Setting Range Remarks
Stall prevention Pr , Pr , Pr , Pr , Pr , Pr
149
Not compensated
Multi-speed input compensation Pr
Pr multi-speed input compensation
Compensated
Acceleration/deceleration pattern Pr , Pr.140 to Pr.143
Function Description
Regenerative brake duty Pr.30
Setting When using the brake unit, power return converter
When using the high power factor converter FR-HC
Pr regenerative function selection
Frequency jump Pr to Pr
Pr.3335Hz Pr.3430Hz
Speed display Pr , Pr
Pr speed display Pr speed setting switch-over
Running Speed Parameter Setting Unit Pr Setting
144 4, 6, 8, 10 104, 106, 108
Up-to-frequency sensitivity Pr
Factory Setting Setting Range Setting Capacity
Automatic torque boost Pr , Pr
Pr up-to-frequency sensitivity
Output Signal
Output Signal
6Hz To 120Hz 9999 Same as Pr Setting
Output frequency detection Pr , Pr , Pr
120%
Pr Setting Operation
Second stall prevention Pr , Pr
Second stall prevention function is not activated
Parameter Number Factory Setting Setting Range
Set Pr to Pr and Pr in accordance with the following table
Set value 17, 24 monitor
Output frequency monitor
Output current monitor
100
Maximum output voltage of terminal AM is 10VDC
Setting Parameter
Monitoring reference Pr , Pr
To 120Hz Rated output
Frequency 162 Search No frequency 163
Parameter Factory Setting Remarks
9999 1 to No restart
164
Parameter Setting Description
To the load inertia moment, torque 165
Remote setting function selection Pr
Pr remote setting function selection
FrequencyOutput
Operation Mode Description Automatically Set
Intelligent mode selection Pr
Pr intelligent mode selection
Ordinary operation
Pr Ref. I for intelligent mode decel %
Setting Pr Reference I for intelligent mode
Pr Ref. I for intelligent mode accel
Setting Reference Current
Retry function Pr , Pr to Pr
Use Pr to select alarms to be reset for retry
Errors Reset for Retry Setting
P24
To 10 times Not output 101 to Output
Use Pr to set the number of retries at alarm occurrence
Retry is not made
Motor
Applied motor Pr
Pr applied motor
PWM carrier frequency Pr , Pr
Pr PWM frequency selection Pr Soft-PWM setting
Parameter Factory Setting Description
Refer to the following list and set the parameters
Related parameters
Voltage input Pr
Pr 0-5V/0-10V selection
To 5, 10 to
Pr filter time constant
Reset Selection PU Disconnection Detection
Input filter time constant Pr
Key from the PU during
Alarm code output
Alarm code output selection Pr
Pr alarm code output selection
Pr Setting Output Terminals
Parameter Name
Pr parameter write disable selection
Parameter write inhibit selection Pr
Reverse rotation prevention selection Pr
Pr reverse rotation prevention selection
External signal input terminal STF, STR
Operation mode selection Pr
Pr operation mode selection
To 4, 6 to
X12 MRS Function/Operation
Switch-over mode
PU operation interlock
Operating Condition
Operation mode external signal switching function
X16 Signal Operation Mode
X12 MRS
Parameter Number
Confirm the settings of Pr , Pr and Pr
38 V/F control frequency voltage Pr to Pr
Computer link operation Pr to Pr
117 118 192 119 Data length 120 121 To 10 122 9999
Parameter Factory Setting Range Number
Parameter Description Setting
123 9999 To 150ms 124
Data format
Required after no data error ACK. Refer to
Computer programming Communication protocol
Send data from computer to inverter during data read
Data definitions
Reply data from inverter to computer during data read
Control codes
Number of Bits
Response time
= Data sending time s
Stop bit length Bit Bits Data length Parity check
HFF
Instruction Data
H7F
Instructions for the program
Return
Setting items and set data
Instruction
H6E
HFA
H7A
H6D
H6C
Error Code List
Error Definition Inverter Operation
HEC
Communication error
Communication specifications for RS-485 communication
Operation at alarm occurrence
Operation Mode Operation Location
Pr = 10
Setting Basic PID control configuration
PID control Pr to Pr
Pr = 20
PID action overview
Deviation
Sink logic
Pr =
Reverse action Forward action
Function Description Remarks
O signals
Signal
Entry Description
Gain K = 1/proportional band 9999
Parameter setting
Adjustment procedure
132
Calibration example
Start
Set point input calibration
Detector output calibration
138 139 9999 To 60.0Hz No automatic
135 136
137
Sink logic, Pr = 7, Pr = 6, Pr = 17, Pr = 18, Pr =
NFB MC1
Signal Terminal Used Description
Signals
Magnetic Place of Installation Role
Roles of the magnetic contactors MC1, MC2, MC3
Operation sequence
Parameter Name Setting Description
Commercial power To 60.0Hz 139
Sets the MC2 and MC3 operation interlock time
Signal on-off after parameter setting
Operation procedure
Operation procedure for running Operation pattern
OFF OFF →
Pr to Pr % Refer to Pr Pr , Pr % Refer to Pr
Zero current detection period
Zero current detection Pr , Pr
Zero current detection level
Related parameters Pr to Pr
Stall prevention function and current limit function Pr
RT signal activated condition selection Pr
Pr RT signal activated condition
Pr stall prevention operation selection
100 Driving
#...Operation not #...Not activated Acceleration
Deceleration
101 Driving
157 To 25 s No signal output
OL signal output timer Pr
Pr OL signal waiting time
Related parameters Pr RUN terminal function selection
160 9999 10, 11 173 174
User group selection Pr , Pr to Pr
Examples of use
Batch deletion
Jog operation selection JOG
Input terminal function selection Pr to Pr
184 Current input selection AU For the NA and EC 185
Setting Signal Functions Relevant Parameters
Output terminal function selection Pr to Pr
Refer to the following table and set the parameters
FAN
Commercial power supply Inverter switch-over MC1
Commercial power supply Inverter switch-over MC3 125
Sleep
Setting example
User initial value setting Pr
Pr users initial value setting
199
Cooling fan operation selection Pr
Output phase failure protection selection Pr
Pr output phase failure protection selection
Pr cooling fan operation selection
50%
Override bias/gain Pr , Pr
Pr override bias Pr override gain
150%
Advanced PID control Pr to Pr NA, EC versions only
Pr =0
Pr motor switch-over selection = 0 Basic Method
Pr motor switch-over selection = 1 Alternative Method
Pr =1
Pr motor switch-over selection = 0 Basic Method Example
Pr motor switch-over selection = 2 Direct Method
System configuration
DC24V
Parameter Number Name
Parameter Number Name Additional Setting Description
Signal name Function
Start
Motor switch-over timing
Start Stop
Name Setting Range
Output stop detection
Stopstart
Sleep
Status transition chart
M1 operation
Supply operation
Commercial power
EC version 50Hz
Calibration of terminal FM
Meter frequency meter calibration Pr , Pr
Pr FM terminal calibration Pr AM terminal calibration
Calibration of terminal AM
Operation procedure
When operation panel FR-DU04 is used
904 4mA 0Hz To 20mA To 60Hz 905
Frequency setting voltage current bias and gain Pr to Pr
902 0Hz To 60Hz 903
To 20mA To 120Hz
Mode
Power-on monitoring mode
Mode
Least significant
#Parameter setting mode
#Setting change
# Analog voltage A/D value % Across terminals
To 90 to Current setting of gain frequency
Press to change the set frequency Press for 1.5 s
⋅ 9 times
#Press
Once to display the current For 0V 0mA, 100% for
Analog voltage calibration value 5V 10V, 20mA
990 Without beep, 1 With beep
Buzzer control Pr
Pr buzzer control
Protective Functions
Major faults
Errors Alarms
Error alarm definitions
Check for too slow acceleration
OC During Dec
OV During Acc
Decrease the acceleration time
Remedy the instantaneous power failure
Instantaneous power failure is within 15ms
Find the cause of instantaneous power failure occurrence
Output side ground fault overcurrent protection
Set the ambient temperature to within the specifications
Ground Fault
Check for a ground fault in the motor and connection cable
Check the communication cable for wire breakage
Option slot alarm 1 to
Check for a wrong option function setting and operation
Parameter storage device alarm
Fault
Find the cause of alarm occurrence
CPU Fault
CPU error
P24
Check for a short circuit in the PU connector cable
Output phase failure protection
Check for a short circuit in the PC terminal output
Minor fault
Key of the PU has been set in Pr PU
Reduce the load volume or the frequency of operation
PU stop Stop made by pressing
Stop selection
Actual Digital
To know the operating status at the occurrence of an alarm
Correspondences between digital and actual characters
Key to reset the inverter
Alarm code output
Resetting the inverter
Motor remains stopped
Troubleshooting
Speed greatly differs from the setting
Motor rotates in opposite direction
Motor current is large
Operation mode is not changed properly
Power lamp is not lit
Speed does not increase
Check items
Precautions for Maintenance and Inspection
Precautions for maintenance and inspection
Periodic inspection
Daily and Periodic Inspection
Insulation resistance test using megger
Pressure test
Analog meter Converter Across terminals
Inspection Description Periodic Method Crlterlon Instrument
Disconnect cables
Assumes the use of an analog meter
Checking method
Module device numbers and terminals to be checked
Tester Polarity Measured Value
Cooling fan
Replacement of parts
Part Name Standard Replacement Interval Description
Smoothing capacitor in main circuit
Relays
Inverter replacement
Smoothing capacitors
Typical Measuring Points and Instruments
Measurement of main circuit voltages, currents and power
Measurement of voltages and currents
5VDC
Measuring Points and Instruments
Measuring Point
10VDC
Specifications
Standard Specifications
Model specifications
Voltage, frequency Permissible AC
36.0
Collector output
Common specifications
Setting To +10V, 11 bits/-5 to +5V
Alarm
Outline drawings
Unit mm inches
# FR-F520-5.5K, 7.5K, 11K # FR-F540-5.5K, 7.5K, 11K
Unit mm inches
FR-F520-55K 480 410 460 700 675 250 154
Inverter Type FR-F520-37K 340 270 320 550 530 195 71.5
FR-F520-45K 450 380 430 550 525 250 154
W1 W2 H H1 FR-F540-30K,37K 340 270 320 550 195 71.5
Outline drawing Panel cutting dimension drawing
# Operation panel FR-DU04
Chapter Options
Option List
Stand-alone options
193
Inboard dedicated options
Name Type Function
Appendices
Data Codes
Appendix Data Code List
Multi-speed setting speed
Read
118 Communication speed
PID
Read Write
Func
Name Read
Auxiliary motor start delay frequency
Motor switch-over selection
Output stop cancel process value level
Auxiliary motor stop delay frequency
Manual number is given on the bottom left of the back cover
Print Data Manual Number Revision