Manuals / Mitsumi electronic / Power Tools / Welding System

Mitsumi electronic FR-F520-0.75K, 55K Manual number is given on the bottom left of the back cover

Models: FR-F520-0.75K 55K

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REVISIONS

				* The manual number is given on the bottom left of the back cover.

Print Data	*Manual Number				Revision

Dec., 1998	IB(NA)-66868-A	First edition

Mar., 1999	IB(NA)-66868-B
Mar., 1999	IB(NA)-66868-B			Addition
			•	Three-phase, 200V power input specifications

Jul., 2000	IB(NA)-66868-C
Jul., 2000	IB(NA)-66868-C			Addition
			•	FR-F520-11K to 55K-NA
			•	FR-F540-11K to 55K-NA
			•	Advanced PID control (Pr. 500 to Pr. 516) (NA, EC versions only)

				Modification
			•	Alarm displays (E. 6, E. 7)
			•	Instructions for compliance with U.S. and Canadian Electrical Codes
			•	Factory setting of Pr. 9 "electronic thermal O/L relay"

Jan., 2001	IB(NA)-66868-D
Jan., 2001	IB(NA)-66868-D			Modification
			•	Instructions for compliance with U.S. and Canadian Electrical Codes

Mar., 2001	IB(NA)-66868-E
Mar., 2001	IB(NA)-66868-E			Addition
			•	FR-A5AC, FR-A5AN (NA version only)

				Modification
			•	Factory setting of Pr. 509 to Pr. 511

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Mitsumi electronic FR-F520-0.75K, 55K instruction manual Manual number is given on the bottom left of the back cover

Contents

FR-F500 This section is specifically about safety matters Safety Instructions Additional instructions Treat as industrial waste Emergency stop Contents 102 100103 104 Watt-hour meter clear/actual operation hour meter clear 163 192 184195 Chapter Chapter Outline Installation Precautions for operationWiring Pre-Operation Information Basic configuration Basic ConfigurationJapanese Harmonic Suppression Guideline Name Description Appearance and structure StructureFront view Without front cover FR-F520-0.75K to 11K, FR-F540-0.75K to 11K Removal and reinstallation of the front cover FR-F520-30K to 55K, FR-F540-30K to 55K Removal and reinstallation of the operation panel Chapter Instructions for installation InstallationClearances around the inverter 97inches1.97inches For installation in an enclosure Wiring cover and handling 22K or lessVertical mounting NFB Type Symbol Terminal Name Description Symbol Terminal Name DescriptionDescription of main circuit terminals Description of control circuit terminals Terminal Name Description TypeRUN IPF Wiring instructions Wiring of the main circuitOverall wiring length 1.5K or more Inverter Capacity 75K 5K or more Motor Capacity Ground Cable Gauge 200V class 400V class FR-F520-1.5K, 2.2K, 3.7K FR-F520-45K Terminal block layoutFR-F520-5.5K, 7.5K FR-F520-55K FR-F520-11K FR-F540-5.5K, 7.5K, 11K FR-F540-45K, 55K 400V class FR-F540-0.75K, 1.5K, 2.2K, 3.7K FR-F540-30K, 37KFR-F540-15K, 18.5K, 22K Terminal names in parentheses are those of the EC version Cables, crimping terminals, etc Connection of the power supply and motor Model FR-F520-0.75K to 3.7K, FR-F540-0.75K to 3.7K Connection procedureModel FR-F520-5.5K to 55K, FR-F540-5.5K to 55K Terminal screw size M3.5 Tightening torque 1.2 N⋅ m Wiring of the control circuit Changing the control logic Current flow related to RUN signal How to use terminals STOP, CS and PC Recommended cable connector Connection to the PU connectorPU connector pin-outs System configuration example Wiring of one RS-485 computer and one inverter Wiring methodRS-485 terminal Computer Max m Connection of the FR-BU brake unit option Connection of stand-alone option units Connection of the conventional BU brake unit option Connection of the FR-HC high power factor converter option Connection of the power factor improving DC reactor option Connection of the FR-RC power regeneration converter option Design information Interlock Power Supply MC2 Leakage currentMC1 Power harmonics Other wiringHarmonics RF Noise Japanese harmonic suppression guidelines Received Power 5th 7th 11th 13th 17th 19th 23rd Over 23rdConversion Factors for FR-F500 Series Class Circuit Type Equivalent Capacity Limits Harmonic Content Values at the fundamental current of 100% ACL, DCL Harmonic suppression techniquesFR-HC Inverter-generated noises and reduction techniques Noise Path Measures Data line filterFollowing measures must be taken Bundle them Data examples Noise Induced to Signal Cables by Inverter OutputNoise Terminal Voltage of Inverter and Example Its Reduction by Noise Filters To-ground leakage currents Leakage currents and countermeasures# Example of counter measures against noise # Countermeasures Line-to-line leakage currents Inverter-driven 400V class motorRectifying the motor insulation Suppressing the surge voltage on the inverter side Selection of peripheral devices Peripheral devices400V class Example Wiring of the power supply and motor Standard to comply UL 508C 1 InstallationBranch circuit protection Short circuit ratings Motor overload protection Instructions for compliance with the European standardsEMC Directive Our view of transistorized inverters for the EMC Directive During operation Storage During transportation Low Voltage Directive90% RH or less Maximum Altitude 000 m 10,000 m Earthing and Earth Leakage Current Earthing EC versionEarthing methods Unit mm2 OPERATION/CONTROL PU operation mode External operation mode factory settingExternal/PU combined operation mode Devices and parts to be prepared for operation Communication operation mode Before switching power on, check the following Power on Names and functions of the operation panel FR-DU04 Operation PanelKey indications Unit indications, operating status indications Used to set the running frequency in the PU operation mode Frequency settingMonitoring Parameter setting method Help mode Operation modeAlarm history Parameter clear Alarm history clearAll clear User clear #Parameter setting mode Copy mode Simple mode parameter list Parameter Checking and SettingParameter checking Pr user group read selection Name Application Setting of maximum frequency Pr maximum frequency Main parameter settingsSetting of minimum frequency Pr minimum frequency Parameter Factory Setting Selection of load pattern Pr load pattern selection Application SettingGain 0Hz at 4mADC, 60Hz at Pre-operation checks Operation External jog operation Operation at 60HzDescription Image Start Press PU jog operationStop Press Motor is decelerated to a stop Step Description Decelerates when Pr = 9999 to a stopStart 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 PID Can be accessed when Pr = Function rewrite prevention List of Parameters Classified by Purposes of Use Parameter Factory Setting Range Remarks SettingParameter Function Details Torque boost Pr , Pr Use Pr to set the lower limit of the output frequency Pr maximum frequency Pr minimum frequency120Hz To 120Hz 8888 Base frequency, base frequency voltage Pr , Pr , Pr9999 To 120Hz Function invalid Multi-speed operation Pr to Pr , Pr to Pr.27 Parameter Factory Setting Setting Range Remarks60Hz To 120Hz 30Hz 10Hz 24 to 9999 To 360 s minimum setting increments 0.01 s To 3600 s minimum setting increments 0.1 sFactory Setting Range Remarks Acceleration/deceleration time Pr , Pr , Pr , Pr , Pr , Pr Pr electronic thermal O/L relay Electronic overcurrent protection PrAcceleration Decelerationtime s Operated at DC injection brake Pr to PrValue Operated To 10 s Pr starting frequency Starting frequency Pr5Hz To 60Hz Output Characteristics Parameter Factory Setting RangeLoad pattern selection Pr Pr load pattern selection Jog operation Pr , Pr Pr jog acceleration/deceleration timereference frequencyPr jog frequency Related parameters Pr Setting Specifications of MRS Signal Wiring exampleMRS input selection Pr Pr MRS input selection Stall prevention Pr , Pr , Pr , Pr , Pr , Pr Parameter Number Factory Setting Setting Range RemarksTo 120Hz 148 149 Pr multi-speed input compensation Multi-speed input compensation PrNot compensated Compensated Function Description Acceleration/deceleration pattern Pr , Pr.140 to Pr.143 When using the high power factor converter FR-HC Setting When using the brake unit, power return converterRegenerative brake duty Pr.30 Pr regenerative function selection Pr.3335Hz Pr.3430Hz Frequency jump Pr to Pr Running Speed Parameter Setting Unit Pr Setting Pr speed display Pr speed setting switch-overSpeed display Pr , Pr 144 4, 6, 8, 10 104, 106, 108 Automatic torque boost Pr , Pr Factory Setting Setting Range Setting CapacityUp-to-frequency sensitivity Pr Pr up-to-frequency sensitivity 6Hz To 120Hz 9999 Same as Pr Setting Output SignalOutput Signal Output frequency detection Pr , Pr , Pr Second stall prevention Pr , Pr Pr Setting Operation120% Second stall prevention function is not activated Set Pr to Pr and Pr in accordance with the following table Parameter Number Factory Setting Setting Range Output current monitor Output frequency monitorSet value 17, 24 monitor 100 Monitoring reference Pr , Pr Setting ParameterMaximum output voltage of terminal AM is 10VDC To 120Hz Rated output 9999 1 to No restart Parameter Factory Setting RemarksFrequency 162 Search No frequency 163 164 To the load inertia moment, torque 165 Parameter Setting Description Pr remote setting function selection Remote setting function selection Pr FrequencyOutput Pr intelligent mode selection Intelligent mode selection PrOperation Mode Description Automatically Set Ordinary operation Pr Ref. I for intelligent mode accel Setting Pr Reference I for intelligent modePr Ref. I for intelligent mode decel % Setting Reference Current Errors Reset for Retry Setting Use Pr to select alarms to be reset for retryRetry function Pr , Pr to Pr P24 Retry is not made Use Pr to set the number of retries at alarm occurrenceTo 10 times Not output 101 to Output Pr applied motor Applied motor PrMotor Parameter Factory Setting Description Pr PWM frequency selection Pr Soft-PWM settingPWM carrier frequency Pr , Pr Refer to the following list and set the parameters Pr 0-5V/0-10V selection Voltage input PrRelated parameters To 5, 10 to Input filter time constant Pr Reset Selection PU Disconnection DetectionPr filter time constant Key from the PU during Pr alarm code output selection Alarm code output selection PrAlarm code output Pr Setting Output Terminals Parameter write inhibit selection Pr Pr parameter write disable selectionParameter Name Pr reverse rotation prevention selection Reverse rotation prevention selection Pr Pr operation mode selection Operation mode selection PrExternal signal input terminal STF, STR To 4, 6 to PU operation interlock Switch-over modeX12 MRS Function/Operation X16 Signal Operation Mode Operation mode external signal switching functionOperating Condition X12 MRS 38 V/F control frequency voltage Pr to Pr Confirm the settings of Pr , Pr and PrParameter Number Computer link operation Pr to Pr Parameter Description Setting Parameter Factory Setting Range Number117 118 192 119 Data length 120 121 To 10 122 9999 123 9999 To 150ms 124 Computer programming Communication protocol Required after no data error ACK. Refer toData format Reply data from inverter to computer during data read Data definitionsSend data from computer to inverter during data read Control codes = Data sending time s Response timeNumber of Bits Stop bit length Bit Bits Data length Parity check H7F Instruction DataHFF Return Instructions for the program Instruction Setting items and set data H7A HFAH6E H6D Error Definition Inverter Operation Error Code ListH6C HEC Operation at alarm occurrence Communication specifications for RS-485 communicationCommunication error Operation Mode Operation Location PID control Pr to Pr Setting Basic PID control configurationPr = 10 Pr = 20 PID action overview Pr = Sink logicDeviation Reverse action Forward action Signal O signalsFunction Description Remarks Entry Description Adjustment procedure Parameter settingGain K = 1/proportional band 9999 132 Start Calibration example Detector output calibration Set point input calibration 137 135 136138 139 9999 To 60.0Hz No automatic NFB MC1 Sink logic, Pr = 7, Pr = 6, Pr = 17, Pr = 18, Pr = Magnetic Place of Installation Role SignalsSignal Terminal Used Description Roles of the magnetic contactors MC1, MC2, MC3 Commercial power To 60.0Hz 139 Parameter Name Setting DescriptionOperation sequence Sets the MC2 and MC3 operation interlock time Operation procedure for running Operation pattern Operation procedureSignal on-off after parameter setting OFF OFF → Pr to Pr % Refer to Pr Pr , Pr % Refer to Pr Zero current detection level Zero current detection Pr , PrZero current detection period Related parameters Pr to Pr Pr RT signal activated condition RT signal activated condition selection PrStall prevention function and current limit function Pr Pr stall prevention operation selection Deceleration #...Operation not #...Not activated Acceleration100 Driving 101 Driving Pr OL signal waiting time OL signal output timer Pr157 To 25 s No signal output Related parameters Pr RUN terminal function selection Examples of use User group selection Pr , Pr to Pr160 9999 10, 11 173 174 Batch deletion 184 Current input selection AU For the NA and EC 185 Input terminal function selection Pr to PrJog operation selection JOG Setting Signal Functions Relevant Parameters Refer to the following table and set the parameters Output terminal function selection Pr to Pr Commercial power supply Inverter switch-over MC3 125 Commercial power supply Inverter switch-over MC1FAN Sleep Pr users initial value setting User initial value setting PrSetting example 199 Pr output phase failure protection selection Output phase failure protection selection PrCooling fan operation selection Pr Pr cooling fan operation selection Pr override bias Pr override gain Override bias/gain Pr , Pr50% 150% Advanced PID control Pr to Pr NA, EC versions only Pr motor switch-over selection = 1 Alternative Method Pr motor switch-over selection = 0 Basic MethodPr =0 Pr =1 System configuration Pr motor switch-over selection = 2 Direct MethodPr motor switch-over selection = 0 Basic Method Example DC24V Signal name Function Parameter Number Name Additional Setting DescriptionParameter Number Name Start Stop Motor switch-over timingStart Name Setting Range Stopstart Output stop detection M1 operation Status transition chartSleep EC version 50Hz Commercial powerSupply operation Pr FM terminal calibration Pr AM terminal calibration Meter frequency meter calibration Pr , PrCalibration of terminal FM Calibration of terminal AM When operation panel FR-DU04 is used Operation procedure 902 0Hz To 60Hz 903 Frequency setting voltage current bias and gain Pr to Pr904 4mA 0Hz To 20mA To 60Hz 905 To 20mA To 120Hz Mode Power-on monitoring modeMode #Setting change #Parameter setting modeLeast significant Press to change the set frequency Press for 1.5 s To 90 to Current setting of gain frequency# Analog voltage A/D value % Across terminals ⋅ 9 times Analog voltage calibration value 5V 10V, 20mA Once to display the current For 0V 0mA, 100% for#Press Pr buzzer control Buzzer control Pr990 Without beep, 1 With beep Protective Functions Error alarm definitions Errors AlarmsMajor faults OV During Acc OC During DecCheck for too slow acceleration Decrease the acceleration time Find the cause of instantaneous power failure occurrence Instantaneous power failure is within 15msRemedy the instantaneous power failure Ground Fault Set the ambient temperature to within the specificationsOutput side ground fault overcurrent protection Check for a ground fault in the motor and connection cable Check for a wrong option function setting and operation Option slot alarm 1 toCheck the communication cable for wire breakage Parameter storage device alarm CPU Fault Find the cause of alarm occurrenceFault CPU error Output phase failure protection Check for a short circuit in the PU connector cableP24 Check for a short circuit in the PC terminal output Minor fault PU stop Stop made by pressing Reduce the load volume or the frequency of operationKey of the PU has been set in Pr PU Stop selection Correspondences between digital and actual characters To know the operating status at the occurrence of an alarmActual Digital Resetting the inverter Alarm code outputKey to reset the inverter Speed greatly differs from the setting TroubleshootingMotor remains stopped Motor rotates in opposite direction Power lamp is not lit Operation mode is not changed properlyMotor current is large Speed does not increase Precautions for maintenance and inspection Precautions for Maintenance and InspectionCheck items Periodic inspection Pressure test Insulation resistance test using meggerDaily and Periodic Inspection Disconnect cables Inspection Description Periodic Method Crlterlon InstrumentAnalog meter Converter Across terminals Module device numbers and terminals to be checked Checking methodAssumes the use of an analog meter Tester Polarity Measured Value Part Name Standard Replacement Interval Description Replacement of partsCooling fan Smoothing capacitor in main circuit Smoothing capacitors Inverter replacementRelays Measurement of voltages and currents Measurement of main circuit voltages, currents and powerTypical Measuring Points and Instruments Measuring Point Measuring Points and Instruments5VDC 10VDC Specifications Model specifications Standard Specifications 36.0 Voltage, frequency Permissible AC Setting To +10V, 11 bits/-5 to +5V Common specificationsCollector output Alarm Unit mm inches Outline drawings Unit mm inches # FR-F520-5.5K, 7.5K, 11K # FR-F540-5.5K, 7.5K, 11K FR-F520-45K 450 380 430 550 525 250 154 Inverter Type FR-F520-37K 340 270 320 550 530 195 71.5FR-F520-55K 480 410 460 700 675 250 154 W1 W2 H H1 FR-F540-30K,37K 340 270 320 550 195 71.5 # Operation panel FR-DU04 Outline drawing Panel cutting dimension drawing Chapter Options Stand-alone options Option List 193 Name Type Function Inboard dedicated options Appendices Multi-speed setting speed Appendix Data Code ListData Codes Read PID 118 Communication speed Read Write Name Read Func Output stop cancel process value level Motor switch-over selectionAuxiliary motor start delay frequency Auxiliary motor stop delay frequency Print Data Manual Number Revision Manual number is given on the bottom left of the back cover

REVISIONS

* The manual number is given on the bottom left of the back cover.

Print Data

*Manual Number

Revision