LARGE CAPACITY INVERTER FR-A 500L HIGH PERFORMANCE HIGH-FUNCTIONS FR-A560L-375K~900K-NA - INSTRUCTION MANUAL - Supplementary Manual Refer to Operation/Instruction Manual for FR-A500L.
Thank you for choosing this Mitsubishi Large Capacity 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. This manual describes the parts which are different from the FR-A500L chassis drive, up to 280kw. Please refer to the FR-A500L instruction manual for further details.
SAFETY INSTRUCTIONS 1. Electric Shock Prevention WARNING z While power is on or when the inverter is running, do not open the front door. You may get an electric shock. z Do not run the inverter with the front door opened. Contact with the exposed high-voltage terminals or charging part of circuitry will cause an electric shock. z If power is off, do not open the front door except for wiring or periodic inspection. You may access the charged inverter circuits and get an electric shock.
. Additional instructions Also note the following points to prevent an accidental failure, injury, electric shock, etc.: (1) Transportation and installation CAUTION z When carrying products, use correct lifting gear to prevent injury. z Ensure that installation position and material can withstand the weight of the inverter. Install according to the information in the Instruction Manual. z Do not operate if the inverter is damaged or has parts missing. z Do not stand or rest heavy objects on the inverter.
(4) Operation CAUTION z When you have chosen the retry function, stay away from the equipment as it will restart suddenly after an alarm stop. z The [STOP] key is valid only when the appropriate function setting has been made. Prepare an emergency stop switch separately. z Make sure that the start signal is off before resetting the inverter alarm. A failure to do so may restart the motor suddenly. z The load used should be a three-phase induction motor only.
CONTENTS 1 OUTLINE .........................................................................................................................................1 1.1 Pre-Operation Information .............................................................................................................. 1 1.1.1 Precautions for operation......................................................................................................... 1 1.2 Basic Configuration.................................................
CHAPTER 1 OUTLINE This chapter gives information on the basic "outline" of this product. Always read the instructions in this chapter before using the equipment. 1.1 Pre-Operation Information ･･･････････････････ 1 1.2 Basic Configuration ････････････････････････ 2 DU Operation panel (FR-DU04) y PU Operation panel (FR-DU04) and parameter unit (FR-PU04) y Inverter Mitsubishi Large Capacity inverter FR-A500L series y FR-A500L Mitsubishi Large Capacity inverter FR-A500L series y Pr.
1.1 Pre-Operation Information OUTLINE 1.1.1 Precautions for operation Incorrect handling might cause the inverter to operate improperly, 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. This manual is written for the FR-A500L series large capacity inverters.
1.2 Basic Configuration OUTLINE 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.
CHAPTER 2 INSTALLATION AND WIRING This chapter gives information on the basic "installation and wiring" of this product. Always read the instructions in this chapter before using the equipment. 2.1 Installation ････････････････････････････････ 3 2.
2.1 Installation INSTALLATION AND WIRING 2.1.1 Instructions for installation 1) Handle the unit carefully. The inverter uses plastic parts. Handle it gently to protect it from damage. Also, hold the unit with even strength and do not apply too much strength to the front cover alone. 2) Install the inverter where it is not subjected to vibration. Note the vibration of a cart, press, etc. 3) Note on ambient temperature The inverter life is under great influence of ambient temperature.
INSTALLATION AND WIRING 3) Note on ambient temperatures FR-A560L-530∼900K 40°C at 5cm (1.
2.2 Wiring INSTALLATION AND WIRING 2.2.
INSTALLATION AND WIRING (1) Description of main circuit terminals Type Symbol R, S, T U, V, W R1, S1 Main circuit P, N <+,-> P, P1 P, PR <+, PR> Terminal Name AC power input Inverter output Power supply for control circuit Optional converter connection DC reactor connection Brake resistor connection Ground Note:< Description Connect to the commercial power supply. Keep these terminals unconnected when using the high power factor converter (MT-HC).
INSTALLATION AND WIRING Type Symbol Terminal Name 10E Analog frequency setting Open collector Output signals Contact Input signals 10 2 Frequency setting (voltage) 4 Frequency setting (current) 1 Auxiliary frequency setting 5 Frequency setting input common A，B，C Inverter running SU Up to frequency OL Overload alarm IPF Instantaneous power failure FU Frequency detection Pulse FM Analog AM RS485 Alarm output RUN SE Communication Frequency setting power supply Descripti
INSTALLATION AND WIRING 2.2.2 Wiring of the main circuit (1) Wiring instructions 1) Power must not be applied to the output terminals (U, V, W) of the inverter. Otherwise the inverter will be damaged. 2) After wiring, wire off-cuts must not be left in the inverter. Wire off-cuts can cause an alarm, failure or malfunction. Always keep the inverter clean. 3) Use thick cables to make a voltage drop of 2% or less.
INSTALLATION AND WIRING (2) Terminal block layout In the main circuit of the inverter, the terminals are arranged as shown below: FR-A560L-530K∼900K Left Side Front Right Side MAIN CIRCUIT TERMINAL (Detail) 40 17.5 17.5 40 17.
INSTALLATION AND WIRING FR-A560L-375K, 450K 4-φ 4 - 30 30 1100 500 R g [ p l 1900 U T S R P1 N P V W P0 430 230 152 96 96 156 210 505 155 R P U S N V T P1 108 96 96 96 104 (Bottom View) W P0 U, V, W, P0 P1, P, N [TERMINAL q (Detail) R, S, T TERMINAL (Detail) [ q 37.5 40 35 40 40 45 37.5 35 40 17.5 17.5 17.5 40 17.
(3) Connection of the power supply and motor INSTALLATION AND WIRING (4)Connecting the control circuit to a power supply separately from the main circuit If the magnetic contactor (MC) in the inverter power supply is opened when the protective circuit is operated, the inverter control circuit power is lost and the alarm output signal cannot be kept on. To keep the alarm signal on terminals R1 and S1 are available.
INSTALLATION AND WIRING 2.2.3 Wiring of the control circuit (1) Wiring instructions 1) Terminals SD, SE and 5 are common to the I/O signals and isolated from each other. These common terminals must not be connected to each other or earthed. 2) Use shielded or twisted cables for connection to the control circuit terminals and run them away from the main and power circuits (including the 200V relay sequence circuit). 3) The frequency input signals to the control circuit are micro currents.
INSTALLATION AND WIRING (3) Changing the control logic The input signals are set to sink logic for the NA version, and to source logic for the EC version. To change the control logic, the connector on the back of the control circuit terminal block must be moved to the other position. (The output signals may be used in either the sink or source logic independently of the connector position.) 1) Loosen the two mounting screws in both ends of the control circuit terminal block. (The screws cannot be removed.
INSTALLATION AND WIRING 4) Sink logic type • In this logic, a signal switches on when a current flows out of the corresponding signal input terminal. Terminal SD is common to the contact input signals. Terminal SE is common to the open collector output signals. AX40 RUN R 1 R Current R STF R SU STR 2 R R SD 8 SE 9 DC24V • When using an external power supply for transistor output, use terminal PC as a common to prevent misoperation caused by leakage current.
INSTALLATION AND WIRING 5) Source logic type • In this logic, a signal switches on when a current flows into the corresponding signal input terminal. Terminal PC is common to the contact input signals. Terminal SE is common to the open collector output signals. PC SE AX80 Current STF STR RUN 1 R R R SU R 2 R R DC24V 8 9 • When using an external power supply for transistor output, use terminal SD as a common to prevent misoperation caused by leakage current.
INSTALLATION AND WIRING 2.2.4 Connection to the PU connector (1) When connecting the operation panel or parameter unit using a connection cable • Parameter unit connection cable (FR-CB2) (option) or the following connector and cable. • Connector: RJ45 connector Example: 5-554720-3, Nippon AMP • Cable: Cable conforming to EIA568 (e.g. 10BASE-T cable) Example: SGLPEV 0.5mm×4P, MITSUBISHI CABLE INDUSTRIES, LTD. Note: The maximum wiring length is 20m (65.62 feet).
INSTALLATION AND WIRING 2.2.5 Design information 1) For commercial power supply-inverter switch-over operation, provide electrical and mechanical interlocks for MC1 and MC2 designed for commercial power supply-inverter switch-over. When there is a commercial power supply-inverter switch-over circuit as shown below, the inverter will be damaged by leakage current from the power supply due to arcs generated at the time of switch-over or chattering caused by a sequence error.
CHAPTER 3 OPERATION This chapter provides the basic "operation" information for use of this product. Always read this chapter before using the equipment. 3.1 Pre-Operation Information ････････Refer to FR-A540L/A560L 3.
CHAPTER 4 PARAMETERS This chapter explains the "parameters" of this product. Always read the instructions before using the equipment. 4.1 Parameter List ･･････････････････ 18 4.2 Parameter Function Details･･･････ Refer to FR-A540L/A560L Note: By making parameter settings, you can change the functions of contact input terminals RL, RM, RH, RT, AU, CS and open collector output terminals RUN, SU, IPF, OL, FU.
4.
Parameter Number 52 DU/PU main display data selection 53 PU level display data selection 54 FM terminal function selection 55 Frequency monitoring reference 56 Current monitoring reference 57 Operation selection functions Additional function Automatic restart functions Function Display functions PARAMETERS Motor constants Setting Range Minimum Setting Increments Factory Setting Refer To Page: 1 0 67 1 1 67 0, 5 to 14, 17, 18, 20, 23, 24, 25, 100 0 to 3, 5 to 14, 17, 18 1 t
PARAMETERS Third functions 5-point flexible V/F characteristics Function Parameter Number Communication functions PID control Commercial power supplyinverter switch-over Minimum Setting Increments Factory Setting Refer To Page: 0 to 1000V 0.1V 0 98 V/F4 (fourth frequency voltage) (Note 1) 108 V/F5 (fifth frequency) (Note 1) 0 to 400Hz, 9999 0.01Hz 9999 98 109 V/F5 (fifth frequency voltage) (Note 1) 0 to 1000V 0.
PARAMETERS 150 Output current detection level 0 to 200% 150% 120 151 Output current detection period 0 to 10 sec 0.1 sec 0 120 152 Zero current detection level 0 to 200% 0.1% 5.0% 121 153 0.01 sec 0.5 sec 121 0, 1 1 1 121 155 *156 157 Zero current detection period Voltage reduction selection during stall prevention operation RT activated condition Stall prevention operation selection OL signal waiting time 0 to 1 sec Sub functions Refer To Page: 1 1 0.
PARAMETERS Stop on contact High-speed frequency control Selection function Power failure stop function Sub Stop selection Sub functions Multi-speed operation functions function Programmed operation Function Parameter Number Name Setting Range Minimum Setting Increments Factory Setting Refer To Page: 200 Programmed operation minute/second selection 0 to 3 1 0 131 201 Program set 1 1 to 10 1 0.1Hz Minute or second 0 9999 0 131 211 Program set 2 11 to 20 1 0.
PARAMETERS Additiona Calibration functions l function Brake sequence functions Function Parameter Number 278 279 285 *570 900 901 902 Brake opening frequency (Note 3) Brake opening current (Note 3) Brake opening current detection time (Note 3) Brake operation time at start (Note 3) Brake operation frequency (Note 3) Brake operation time at stop (Note 3) Deceleration detection function selection (Note 3) Overspeed detection frequency CT/VT Selection FM terminal calibration AM terminal calibration Freq
CHAPTER 5 PROTECTIVE FUNCTIONS This chapter explains the "protective functions" of this product. Always read the instructions before using the equipment. 5.1 Errors (Alarms) ････････････････････････････ 24 5.2 Troubleshooting ･･･････････････････････････ 30 5.
5.1 Errors (Alarms) PROTECTIVE FUNCTIONS If any fault has occurred in the inverter, the corresponding protective function is activated and the error (alarm) indication appears automatically on the PU display. When the protective function is activated, refer to "5.2 Troubleshooting" and clear up the cause by taking proper action. If an alarm stop has occurred, the inverter must be reset to restart it. 5.1.1 Error (alarm) definitions Operatio n Panel Display (FR-DU04) Paramete r Unit (FR-PU04) E.
PROTECTIVE FUNCTIONS Operatio n Panel Display (FR-DU04) Paramete r Unit (FR-PU04) Name E. GF Ground Fault Output side ground fault overcurrent protection E.OHT OH Fault External thermal relay operation (Note 3) E.OLT (When stall prevention operation has reduced the running frequency to 0. OL during stall prevention operation) E.OPT E.OP1 to OP3 E.
PROTECTIVE FUNCTIONS Operatio n Panel Display (FR-DU04) Paramete r Unit (FR-PU04) Name Description When the operation panel power (P5S of the PU connector) is shorted, this function shuts off the power output. At this time, the operation panel (parameter unit) cannot be used and RS-485 communication from the PU connector cannot be made. To reset, enter the RES signal or switch power off, then on again. Inverters of 7.5K or less contains a brake resistor.
PROTECTIVE FUNCTIONS Main circuit error [E,15] details Name Details Brake unit cooling fin overheating The inverter output will stop if the brake unit's cooling fin temperature rises above the specified value. Control board ambient temperature error The inverter output will stop if the ambient temperature of the control board rises above the specified value. Output overcurrent The inverter output will stop if the inverter's output current flows above the specified value.
PROTECTIVE FUNCTIONS ● To know the operating status at the occurrence of alarm When any alarm has occurred, the display automatically switches to the indication of the corresponding protective function (error). By pressing the [MODE] key at this point without resetting the inverter, the display shows the output frequency. In this way, it is possible to know the running frequency at the occurrence of the alarm. It is also possible to know the current in the same manner.
PROTECTIVE FUNCTIONS 5.1.3 Alarm code output By setting Pr. 76 "alarm code output selection", an alarm definition can be output as a 4-bit digital signal. This signal is output from the open collector output terminals equipped as standard on the inverter. Correlations between alarm definitions and alarm codes are as follows. Operation Panel Display （FR-DU04） E.OC1 E.OC2 E.OC3 E.OV1 E.OV2 E.OV3 E.THM E.THT E.IPF E.UVT E.FIN E. 15 E. GF E.
5.2 Troubleshooting PROTECTIVE FUNCTIONS If any function of the inverter is lost due to occurrence of a fault, clear up the cause and make correction in accordance with the following procedure. Contact your sales representative if the corresponding fault is not found below, the inverter has failed, parts have been damaged, or any other fault has occurred. 5.2.
PROTECTIVE FUNCTIONS Operation Panel Display Check Point Remedy 2 Reduce the load GD . Reduce the braking frequency. Brake unit cooling fin overheating Is the usage frequency of the brake unit appropriate? Are the cooling fins clogged? Is there any error in the inverter unit cooling fan? Control board ambient temperature error Is there an error in the cooling fan? Is the ambient temperature too high? Repair the output short circuit and ground fault. (Repair or replace the motor.
PROTECTIVE FUNCTIONS 5.2.2 Faults and check points POINT: Check the corresponding areas. If the cause is still unknown, it is recommended to initialize the parameters (return to factory settings), re-set the required parameter values, and check again. (1) Motor remains stopped. 1) Check the main circuit Check that a proper power supply voltage is applied (operation panel display is provided). Check that the motor is connected properly. · · 2) Check the input signals Check that the start signal is input.
PROTECTIVE FUNCTIONS (5) Motor current is large. · Check that the load is not too heavy. · Check that the torque boost (Pr. 0, Pr. 46, Pr. 112) setting is not too large. (6) Speed does not increase. · Check that the maximum frequency (Pr. 1) setting is correct. · Check that the load is not too heavy. (In agitators, etc., load may become heavy in winter.) · Check that the torque boost (Pr. 0, Pr. 46, Pr. 112) setting is not too large to activate the stall prevention function.
5.3 Precautions for Maintenance and Inspection PROTECTIVE FUNCTIONS The transistorized inverter is a static unit mainly consisting of semiconductor devices. Daily inspection must be performed to prevent any fault from occurring due to adverse influence by the operating environment, such as temperature, humidity, dust, dirt and vibration, changes in the parts with time, service life, and other factors. 5.3.
5.3.4 Insulation resistance test using megger PROTECTIVE FUNCTIONS 1) Before performing the insulation resistance test using a megger on the external circuit, disconnect the cables from all terminals of the inverter so that the test voltage is not applied to the inverter. 2) For the continuity test of the control circuit, use a tester (high resistance range) and do not use the megger or buzzer.
PROTECTIVE FUNCTIONS Daily and Periodic Inspection Area of Inspection Inspection Item Inverter module, Converter module Smoothing capacitor Main circuit Relay Resistor Control circuit Operation Protective check circuit Cooling fan Cooling system Cooling fan power supply Display Display Meter General Description Interval Periodic Daily 1 2 year years Check resistance across terminals. (1) Check for liquid leakage. (2) Check for safety valve projection and bulge.
PROTECTIVE FUNCTIONS z Checking the inverter and converter modules (1) Disconnect the external power supply cables (R, S, T) and motor cables (U, V, W). (2) Prepare a tester. (Use 100Ω range.) Change the polarity of the tester alternately at the inverter terminals R, S, T, U, V, W, P and N , and check for continuity. Note: 1. Before measurement, check that the smoothing capacitor is discharged. 2.
PROTECTIVE FUNCTIONS 5.3.6 Replacement of parts The inverter consists of many electronic parts such as semiconductor devices. The following parts may deteriorate with age because of their structures or physical characteristics, leading to reduced performance or failure of the inverter. For preventive maintenance, the parts must be changed periodically. (1) Cooling fan The cooling fan cools heat-generating parts such as the main circuit semiconductor devices.
PROTECTIVE FUNCTIONS 5.3.7 Measurement of main circuit voltages, currents and power ● Measurement of voltages and currents Since the voltages and currents on the inverter power supply and output sides include harmonics, accurate measurement depends on the instruments used and circuits measured. When instruments for commercial frequency are used for measurement, measure the following circuits using the instruments given on the next page.
PROTECTIVE FUNCTIONS Measuring Points and Instruments Item Remarks (Reference Measured Value) ＊ Commercial power supply Within permissible AC voltage fluctuation（Refer to Page 40） Measuring Point Measuring Instrument Power supply voltage V1 Across R-S, S-T and T-R Moving-iron type AC voltmeter Power supply side current I1 R, S and T line currents Moving-iron type AC ammeter At R, S and T, and across R-S, S-T and T-R Electrodynamic type s
CHAPTER 6 SPECIFICATIONS This chapter provides the "specifications" of this product. Always read the instructions before using the equipment. 6.
6.1 Standard specification SPECIFICATIONS 6.1.
SPECIFICATIONS Control specifications 6.1.2 Common specifications Control system Soft-PWM control/high carrier frequency PWM control (V/F control or advanced magnetic flux vector control can be selected) Output frequency range 0.2 to 400Hz Frequency setting resolution Analog input 0.015Hz/60Hz (terminal 2 input: 12 bits/0 to 10V, 11 bits/0 to 5V, terminal 1 input: 12 bits/−10 to +10V, 11 bits/−5 to +5V) Digital input 0.01Hz Frequency accuracy Within ±0.
SPECIFICATIONS Display Display on operation panel FR-DUO4 or parameter unit FR-PU04 Additional display on parameter unit (FR-PU04) only Operating status Selection can be made from output frequency, motor current (steady or peak value), output voltage, frequency setting, running speed, motor torque, converter output voltage (steady or peak value), electronic overcurrent protection load factor, input power, output power, load meter, motor exciting current, cumulative energization time, actual operation t
SPECIFICATIONS 6.1.3 Outline drawings l FR-A560L-450K, 375K This (Top attachment) should be removed at operating because of air exhaust. Air exhaust Control Panel These (Side attachments) can be used for fixing this inverter unit. Air inlet Cabling Hole (For main circuit) Bottom View l Accessory DC REACTOR (for FR-A560L-450K, 375K) 2-M12 bolt 2-terminal (4-φ 15hole) U U X X 330 over 4.
SPECIFICATIONS z ∼900K FR-A560L-530K∼ DC reactor is internally mounted and wired.
SPECIFICATIONS 46
APPENDICES This chapter provides the "appendices" for use of this product. Always read the instructions before using the equipment.
Appendix 3 APPENDICES Appendix 3 Installation procedure for cooling fan (FR-A560L-530K∼ ∼900K) 1. Install and fix bolts and screws. Step1 Put cooling fans and fan covers. Step2 Fix cooling fans and fan covers by M12 bolts. Step3 Put cooling fan ceilings and fix by M4 screws.
INSTALLATION AND WIRING 2. Wiring between cooling fan and terminals is as follows; EF-40ETB EF-30ETB E K 1 W E R 2 EF-40ETB G 3 K 4 1 CONVERTER W E R 2 G 3 K 4 1 CONTROL W R 2 3 K : Black W : White R : Red G : Green G 4 INVERTER Step 4 Connect cooling fan wires as above drawing. 3.
Appendix 4 APPENDICES Appendix 4 Installation procedure for brake unit (option) (FR-A560L-530K∼ ∼900K) Step1 Connect wires as the next drawing. Wiring between FR-A500L and MT-BR5 (option) Step2 Set parameter 30 : when brake unit is used, set to 1. Step3 Set parameter 70 : when brake unit is used, set to 10%. This brake unit and brake resistor are designed at 10%.
Appendix 5 APPENDICES Appendix 5 Shipment case example 50
MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE : MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100-8310 IB-T7260-06 (200203) Printed in Japan Specifications subject to change without notice.
