Main
TRANSISTORIZED INVERTER
FR-F
INSTRUCTION MANUAL
FR-F520-0.75K to 55K FR-F540-0.75K to 55K(-EC) FR-F520-11K to 55K-NA FR-F540-11K to 55K-NA
Page
SAFETY INSTRUCTIONS 1. Electric Shock Prevention
WARNING
2. Fire Prevention
3. Injury Prevention
4. Additional instructions
(1) Transportation and installation
(2) Wiring
(3) Trial run
(4) Operation
(5) Emergency stop
(6) Maintenance, inspection and parts replacement
(7) Disposing of the inverter
(8) General instructions
CONTENTS
I
1 OUTLINE 1
Contents
2 INSTALLATION AND WIRING 7
II
4 PARAMETERS 60
Contents
III
5 PROTECTIVE FUNCTIONS 163
IV
CHAPTER 1 OUTLINE
1.1 Pre-Operation Information........................................ 1
1.2 Basic Configuration.................................................. 2
1.3 Structure.................................................................. 3
1.1 Pre-Operation Information
1
1.1.1 Precautions for operation
FR-F520-0.75K/
(1) Unpacking and product check
1.2 Basic Configuration
2
1.2.1 Basic configuration
Japanese Harmonic Suppression Guideline
1.3 Structure
1.3.1 Appearance and structure
(1) Front view
(2) Without front cover
1.3.2 Removal and reinstallation of the front cover
FR-F520-0.75K to 11K, FR-F540-0.75K to 11K
FR-F520-15K to 22K, FR-F540-15K to 22K
FR-F520-30K to 55K, FR-F540-30K to 55K
1.3.3 Removal and reinstallation of the operation panel
INSTALLATION AND WIRING
2.1 Installation
2.1.1 Instructions for installation
8
(1) Wiring cover and handling (22K or less)
WARNING
2.2 Wiring
2.2.1 Terminal connection diagram
10
(1) Description of main circuit terminals
(2) Description of control circuit terminals
Page
12
2.2.2 Wiring of the main circuit
(1) Wiring instructions
CAUTION
Notes on Grounding
14
(2) Terminal block layout
FR-F520-15K, 18.5K, 22K, 30K, 37K
FR-F520-1.5K, 2.2K, 3.7K
FR-F520-45K
2) 400V class FR-F540-0.75K, 1.5K, 2.2K, 3.7K
FR-F540-30K, 37K
Note: Terminal names in parentheses are those of the EC version.
FR-F540-5.5K, 7.5K, 11K
FR-F540-45K, 55K
FR-F520-0.75K to 55K
FR-F540-0.75K to 55K
(4) Connection of the power supply and motor
17
(5) Connecting the control circuit to a power supply separately from the main circuit
Model FR-F520-0.75K to 3.7K, FR-F540-0.75K to 3.7K
2.2.3 Wiring of the control circuit
(1) Wiring instructions
(2) Terminal block layout
Japanese and NA version
EC version
19
(3) Changing the control logic
Page
21
(4) How to use terminals "STOP", "CS" and "PC"
22
2.2.4 Connection to the PU connector
(1) When connecting the operation panel or parameter unit using a connection cable
(2) For RS-485 communication
2) When a computer having an RS-232C interface is used with inverters
Computer
(Note 2)
Distribution terminal
Terminal resistor
2.2.5 Connection of stand-alone option units
(1) Connection of the FR-BU brake unit (option)
25
(2) Connection of the conventional BU brake unit (option)
Connect the BU brake unit correctly as shown below. Incorrect connection will damage the inverter.
(3) Connection of the FR-HC high power factor converter (option)
26
(4) Connection of the FR-RC power regeneration converter (option)
(5) Connection of the power factor improving DC reactor (option)
2.2.6 Design information
2.3 Other wiring
2.3.1 Power harmonics
29
2.3.2 Japanese harmonic suppression guidelines
(1) Application of the harmonic suppression guideline for specific consumers
Page
4) Harmonic suppression techniques
2.3.3 Inverter-generated noises and reduction techniques
Page
35
2.3.4 Leakage currents and countermeasures
(1) To-ground leakage currents
36
(2) Line-to-line leakage currents
2.3.5 Inverter-driven 400V class motor
(1) Rectifying the motor insulation
(2) Suppressing the surge voltage on the inverter side
37
2.3.6 Peripheral devices
(1) Selection of peripheral devices
2) 400V class
38
(2) Selection the rated sensitivity current for the earth leakage circuit breaker
39
2.3.7 Instructions for compliance with U.S. and Canadian Electrical Codes
(Standard to comply: UL 508C) (1) Installation
200V class
400V class
(2) Branch circuit protection
2.3.8 Instructions for compliance with the European standards
(1) EMC Directive
41
(2) Low Voltage Directive
42
2.3.9 Earthing (EC version)
(1) Earthing and Earth Leakage Current
(2) Earthing methods
CHAPTER 3 OPERATION/CONTROL
3.1 Pre-Operation Information
43
3.1.1 Devices and parts to be prepared for operation
(1) External operation mode (factory setting)
(2) PU operation mode
44
(4) Communication operation mode
3.1.2 Power on
3.2 Operation Panel
3.2 Operation Panel
Note: The frequency setting mode is displayed only in the PU operation mode.
#Help mode
Up-down Key
3.2.3 Monitoring
#Frequency setting mode
Press to change the set frequency.
#Set frequency write
To 3.2.5 Parameter setting method
3.2.5 Parameter setting method
49
3.2.6 Operation mode
To 3.2.7 Help mode
#External operation #PU operation #PU jog operation
Note: If operation mode changing cannot be made, refer to page 175.
3.2.7 Help mode
50
(2) Alarm history clear
Clears all alarm history.
(3) Parameter clear
(4) All clear
3.2.8 Copy mode
3.3 Parameter Checking and Setting
52
Simple mode parameter
3.3.1 Parameter checking
(1) Pr. 160 "user group read selection"
53
Simple mode parameter
3.3.2 Main parameter settings
Page
3.4 Operation
3.4.1 Pre-operation checks
57
3.4.2 External operation mode (Operation using external input signals)
(1) Operation at 60Hz
(2) External jog operation
58
3.4.3 PU operation mode (Operation using the operation panel (FR-DU04))
(1) Operation at 60Hz
While the motor is running, repeat the following steps 2 and 3 to vary the speed:
(2) PU jog operation
3.4.4 Combined operation mode (Operation using the external input signals and PU)
PARAMETERS
4.1 Parameter List .........................................................60
4.2 Parameter Function Details......................................66
4.1 Parameter List
4.1.1 Parameter list
Page
Page
Page
Page
4.1.2 List of Parameters Classified by Purposes of Use
4.2 Parameter Function Details
66
4.2.1 Torque boost (Pr. 0, Pr. 46)
Pr. 0 "torque boost" Pr. 46 "second torque boost"
67
4.2.2 Output frequency range (Pr. 1, Pr. 2)
Pr. 1 "maximum frequency" Pr. 2 "minimum frequency"
68
4.2.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19, Pr. 47)
Pr. 3 "base frequency" Pr. 19 "base frequency voltage" Pr. 47 "second V/F (base frequency)
69
4.2.4 Multi-speed operation (Pr. 4 to Pr. 6, Pr. 24 to Pr.27)
70
4.2.5 Acceleration/deceleration time (Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45)
71
4.2.6 Electronic overcurrent protection (Pr. 9)
Pr. 9 "electronic thermal O/L relay"
72
4.2.7 DC injection brake (Pr. 10 to Pr. 12)
Install a mechanical brake. No holding torque is provided.
73
4.2.8 Starting frequency (Pr. 13)
Pr. 13 "starting frequency"
74
4.2.9 Load pattern selection (Pr. 14)
Pr. 14 "load pattern selection"
75
4.2.10 Jog operation (Pr. 15, Pr. 16)
Pr. 15 "jog frequency" Pr. 16 "jog acceleration/deceleration time"
4.2.11 MRS input sel ecti on (Pr . 17)
77
4.2.12 Stall prevention (Pr. 22, Pr. 23, Pr. 66, Pr. 148, Pr. 149, Pr. 154)
78
Pr. 24 to Pr. 27
Refer to Pr. 4 to Pr. 6.
4.2.13 Mult i - speed i nput compensati on (Pr . 28)
Pr. 28 "multi-speed input compensation"
79
4.2.14 Acceleration/deceleration pattern (Pr. 29, Pr.140 to Pr.143)
Related parameters
80
4.2.15 Regenerative brake duty (Pr.30)
Pr. 30 "regenerative function selection"
(1) When using the brake unit, power return converter
(2) When using the high power factor converter (FR-HC)
4.2.16 Frequency jump (Pr. 31 to Pr. 36)
82
4.2.17 Speed display (Pr. 37, Pr. 144)
Pr. 37 "speed display" Pr. 144 "speed setting switch-over"
83
4.2.18 Automatic torque boost (Pr. 38, Pr. 39)
Pr. 38 "automatic torque boost" Pr. 39 "automatic torque boost operation starting current"
4.2.19 Up-to-frequency sensitivity (Pr. 41)
Pr. 41 "up-to-frequency sensitivity"
4.2.20 Output frequency detection (Pr. 42, Pr. 43, Pr. 50)
85
4.2.21 Second stall prevention (Pr. 48, Pr. 49)
Refer to Pr. 42.
Pr. 50
CAUTION
Related parameters
86
4.2.22 Monitor display / FM, AM terminal function selection (Pr. 52 to Pr. 54, Pr. 158)
Page
88
4.2.23 Monitoring reference (Pr. 55, Pr. 56)
Related parameters
Pr. 55 "frequency monitoring reference" Pr. 56 "current monitoring reference"
Referring to the above figures and following table, set Pr. 55 and Pr. 56:
89
4.2.24 Automatic restart after instantaneous power failure (Pr. 57, Pr. 58, Pr. 162 to Pr. 165)
Setting Setting
Number Factory
Range Remarks 57 9999 0, 0.1 to 5 s, 9999 9999: No restart 58 1.0 s 0 to 60 s 162 0 0, 1
0: Frequency search 1: No frequency search 163 0 s 0 to 20 s 164 0% 0 to 100% 165 120% 0 to 150%
Page
91
4.2.25 Remote setting function selection (Pr. 59)
Pr. 59 "remote setting function selection"
When selecting this function, re-set the maximum frequency according to the machine.
93
4.2.26 Intelligent mode selection (Pr. 60)
Pr. 60 "intelligent mode selection"
4.2.27 Acceleration/deceleration reference current/lift mode starting frequency (Pr. 61 to Pr. 63)
95
4.2.28 Retry function (Pr. 65, Pr. 67 to Pr. 69)
Use Pr. 65 to select alarms to be reset for retry.
96
Refer to Pr. 22.
Pr. 66
97
4.2.29 Applied motor (Pr. 71)
Pr. 71 "applied motor"
98
4.2.30 PWM carrier frequency (Pr. 72, Pr. 240)
Pr. 72 "PWM frequency selection" Pr. 240 "Soft-PWM setting"
99
4.2.31 Voltage input (Pr. 73)
Pr. 73 "0-5V/0-10V selection"
100
4.2.32 Input filter ti me constant (Pr . 74)
Pr. 74 "filter time constant"
4.2.33 Reset selection/disconnection PU detection/PU stop selection (Pr. 75)
Pr. 75 "reset selection/disconnection PU detection/PU stop selection"
101
How to make a restart after a stop made by the
external operation
102
4.2.34 Alarm code output selection (Pr. 76)
Pr. 76 "alarm code output selection"
103
4.2.35 Parameter write inhibit selection (Pr. 77)
Pr. 77 "parameter write disable selection"
4.2.36 Reverse rotation prevention selection (Pr. 78)
105
4.2.37 Operation mode selection (Pr. 79)
Pr. 79 "operation mode selection"
106
(1) Switch-over mode
(2) PU operation interlock
107
<Function/operation changed by switching on-off the X12 (MRS) signal>
(3) Operation mode external signal switching function
4.2.38 V/F control frequency (voltage) (Pr. 100 to Pr. 109)
4.2.39 Computer link operation (Pr. 117 to Pr. 124)
# For the data codes of the parameters, refer to the data code list in the appendices.
* To make communication, set any value other than 0 in Pr. 122 "communication check tim e interval".
111
<Computer programming> (1) Communication protocol
Data communication between the computer and inverter is performed using the following procedure:
(2) Communication operation presence/absence and data format types
Communication operation presence/absence and data format types are as follows:
112
(4) Data definitions
Page
Page
115
(5) Instructions for the program
116
<Setting items and set data>
Page
118
<Error Code List>
119
(6) Communication specifications for RS-485 communication
(7) Operation at alarm occurrence
(8) Communication error
120
4.2.40 PID control (Pr. 128 to Pr. 134)
(1) Basic PID control configuration
121
(2) PID action overview
122
Relationships between deviation and manipulated variable (output frequency)
Deviation Positive Negative Reverse action &' Forward action '&
(3) Wiring example
Sink logic Pr. 128 = 20 Pr. 183 = 14 Pr. 192 = 16 Pr. 193 = 14 Pr. 194 = 15
123
(4) I/O signals
124
(5) Parameter setting
(6) Adjustment procedure
125
(7) Calibration example
126
<Set point input calibration>
<Detector output calibration>
4.2.41 Commercial pow er supply-inverter switch-over function (Pr. 135 to Pr. 139)
128
(1) Wiring example
Sink logic, Pr. 185 = 7, Pr. 186 = 6, Pr. 192 = 17, Pr. 193 = 18, Pr. 194 = 19
129
Roles of the magnetic contactors (MC1, MC2, MC3)
<I/O signals>
130
(2) Parameter setting
<Operation sequence>
131
(3) Operation procedure
1) Operation procedure for running Operation pattern
2) Signal on-off after parameter setting
Page
133
4.2.42 Zero current detection (Pr. 152, Pr. 153)
Refer to Pr. 22.
Pr. 154
Pr. 152 "zero current detection level" Pr. 153 "zero current detection period"
134
4.2.43 RT signal activated conditi on sel ecti on (Pr. 155)
Pr. 155 "RT signal activated condition"
4.2.44 Stall prevention function and current limit function (Pr. 156)
Pr. 156 "stall prevention operation selection"
Refer to the following table and set the parameter as required:
136
Refer to Pr. 54.
Pr. 158
4.2.45 OL signal output timer (Pr. 157)
Pr. 157 "OL signal waiting time"
137
4.2.46 User group selecti on (Pr . 160, Pr. 173 to Pr. 176)
Number Factory
<Examples of use>
(1) Parameter registration to user group (when registering Pr. 3 to user group 1)
(2) Parameter deletion from user group (when deleting Pr. 5 from user group 1)
4.2.47 Watt-hour meter clear / actual operation hour meter clear (Pr. 170, Pr. 171)
4.2.48 Input terminal functi on selection (Pr. 180 to Pr. 186)
Page
140
4.2.49 Output terminal function selection (Pr. 190 to Pr. 195)
You can change the functions of the open collector and contact output terminals.
Note: Setting may be made for the NA and EC versions only.
Refer to the following table and set the parameters:
Page
142
4.2.50 User initial value setting (Pr. 199)
Refer to Pr. 72.
Pr. 240
Pr. 199 "user's initial value setting"
<Setting example>
4.2.51 Cooling fan operation selection (Pr. 244)
Pr. 244 "cooling fan operation selection"
<Reference>
4.2.52 Output phase failure protection selection (Pr. 251)
Pr. 251 "output phase failure protection selection"
4.2.53 Override bias/gain (Pr. 252, Pr. 253)
Pr. 252 "override bias" Pr. 253 "override gain"
4.2.54 Advanced PID control (Pr. 500 to Pr. 516) (NA, EC versions only)
146
(1) Pr. 501 "motor switch-over selection" = "0" (Basic Method)
(2) Pr. 501 "motor switch-over selection" = "1" (Alternative Method)
147
(3) Pr. 501 "motor switch-over selection" = "2" (Direct Method)
<System configuration>
(1) Pr. 501 "motor switch-over selection" = 0 (Basic Method)
Example
(2) Pr. 501 "motor switch-over selection" = 1 (Alternative Method), 2 (Direct Method)
Example
Page
150
<Motor switch-over timing>
Page
152
<Output stop detection>
153
<Status transition chart>
(1) Pr. 501 "motor switch-over selection" = 0 (Basic method) (For four motors)
(2) Pr. 501 "motor switch-over selection" = 1 (Alternative method) (For two motors)
(3) Pr. 501 "motor switch-over selection" = 2 (Direct method) (For two motors)
155
4.2.55 Meter (frequency meter) calibration (Pr. 900, Pr. 901)
Pr. 900 "FM terminal calibration" Pr. 901 "AM terminal calibration"
(1) Calibration of terminal FM
(2) Calibration of terminal AM
Page
157
4.2.56 Frequency setting voltage (current) bias and gain (Pr. 902 to Pr. 905)
158
FR-DU04
Page
Page
/
/
162
4.2.57 Buzzer control (Pr. 990)
Pr. 990 "buzzer control"
PROTECTIVE FUNCTIONS
5.1 Errors (Alarms)
163
5.1.1 Error (alarm) definitions
(1) Major faults
Page
Page
Page
Page
Page
Page
170
(2) Minor fault
(3) Warnings
Page
5.1.2 To know the operating status at the occurrence of an alarm
5.1.3 Correspondences between digital and actual characters
5.1.4 Alarm code output
5.1.5 Resetting the inverter
5.2 Troubleshooting
5.2.1 Motor remains stopped
5.2.2 Motor rotates in opposite direction
5.2.3 Speed greatly differs from the setting
5.2.4 Acceleration/deceleration is not smooth
5.2.5 Motor current is large
5.2.6 Speed does not increase
5.2.7 Speed varies during operation
5.2.8 Operation mode is not changed properly
5.2.9 Operation panel (FR-DU04) display is not provided
5.3 Precautions for Maintenance and Inspection
176
5.3.1 Precautions for maintenance and inspection
5.3.2 Check items
(1) Daily inspections
5.3.4 Insulation resistance test using megger
5.3.5 Pressure test
5.3.6 Daily and Periodic Inspection
Page
179
Checking the inverter and converter modules
<Preparation>
<Checking method>
<Module device numbers and terminals to be checked>
(Assumes the use of an analog meter.)
5.3.7 Replacement of parts
(1) Cooling fan
5.3.8 Inverter replacement
182
5.3.9 Measurement of main circuit voltages, currents and power
Measurement of voltages and currents
W W W
W W
Measuring Points and Instruments
SPECIFICATIONS
6.1 Standard Specifications
6.1.1 Model specifications
# ##
#Japanese version FR-F520-0.75K to 55K # ##
#NA version FR-F520-11K to 55K-NA
Page
6.1.2 Common specifications
Page
6.1.3 Outline drawings
189
#FR-F520-5.5K, 7.5K, 11K
400V class
#FR-F540-5.5K, 7.5K, 11K
200V class
(Unit: mm (inches))
#FR-F520-30K
400V class
#FR-F520-37K, 45K, 55K
#FR-F540-30K, 37K, 45K, 55K
200V class
# Operation panel (FR-DU04)
<Outline drawing> <Panel cutting dimension drawing>
Select the installation screw length which will not exceed the effective installation screw depth.
# Parameter unit (FR-PU04)
<Outline drawing> <Panel cutting dimension drawing>
OPTIONS
7.1 Option List
7.1.1 Stand-alone options
Page
7.1.2 Inboard dedicated options
Inboard options
Page
Appendix 1 Data Code List
Page
Page
Page
Page
REVISIONS
IV