FR-S500 INSTRUCTION MANUAL (BASIC)

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TRANSISTORIZED INVERTERFR-S500FR-S500ETRANSISTORIZED INVERTERINSTRUCTION MANUAL (BASIC)HEAD OFFICE:TOKYO BLDG MARUNOUCHI TOKYO 100-8310CIB(NA)-0600151E-C (0706) MEEPrinted in JapanSpecifications subject to change without notice.INSTRUCTION MANUAL (BASIC)FR-S520E-0.1K to 3.7K(-C)FR-S540E-0.4K to 3.7KFR-S520SE-0.1K to 1.5KFR-S510WE-0.1K to 0.75KThank you for choosing this Mitsubishi transistorized inverter.If this is the first time for you to use the FR-S500 series, please read through this instruction manual (basic)carefully and use the inverter safely.If you are going to use the inverter for higher-level applications, the FR-S500 instruction manual (detailed)[IB(NA)-0600152E] is separately available from where you purchased the inverter or a Mitsubishi salesrepresentative.CONTENTS12CONNECTION OF PERIPHERAL DEVICES (BASIC CONFIGURATION) . 3INSTALLATION METHOD. 63SPECIFICATIONS OF WIRING AND TERMINALS . 74DRIVE THE MOTOR . 215ADJUSTMENT OF THE FREQUENCY SETTINGPOTENTIOMETER AND INDICATOR. 416712.1 Installation of the inverter.63.1 Terminal connection diagram .73.2 Main circuit.83.3 Control circuit .123.4 Failsafe of the system which uses the inverter .194.1 Step of operation .214.2 Run and operation .224.3 Operation by the start command from the operation panel (PU operation mode) .244.4 Operation by the start command of the terminal block (external operation) .314.5 Clearing the parameters .394.6 Monitoring the output current .405.1 Changing the output frequency setting of the frequency setting potentiometer(bias and gain of frequency setting voltage (current)) .425.2 Adjustment (calibration) of the frequency meter (indicator) .46FUNCTION LIST . 476.1 Basic function parameter list.476.2 Explanation of the basic function parameters .486.3 Setting the parameters .506.4 Display the extended function parameter .516.5 Extended function parameter list .5223456ERRORS AND PROTECTIVE FUNCTIONS . 667.1 About errors (definitions) .667.2 Checking of the alarm history .697.3 To know the operating status at the occurrence of alarm(only when FR-PU04 is used) .707.4 Correspondence between digital and actual characters .707.5 Resetting the inverter.707.6 Troubleshooting .717.7 Precautions for maintenance and inspection.748SPECIFICATIONS . 809OUTLINE DIMENSION DRAWINGS . 86Appendix 1 Instructions for compliance with the European Directive . 89Appendix 2 Instructions for UL and cUL. 91788.1 Ratings.808.2 Common specifications.849

This instruction manual (basic) provides handling information and precautions for useof the equipment.Please forward this instruction manual (basic) to the end user.This section is specifically about safety mattersDo not attempt to install, operate, maintain or inspect the inverter until you have readthrough this instruction manual (basic) and appended documents carefully and canuse the equipment correctly. Do not use the inverter until you have a full knowledgeof the equipment, safety information and instructions.In this instruction manual (basic), the safety instruction levels are classified into"WARNING" and "CAUTION".WARNINGAssumes that incorrect handling may cause hazardousconditions, resulting in death or severe injury.CAUTIONAssumes that incorrect handling may cause hazardousconditions, resulting in medium or slight injury, or may causephysical damage only.Note that even theCAUTION level may lead to a serious consequenceaccording to conditions. Please follow the instructions of both levels because they areimportant to personnel safety.1. Electric Shock PreventionWARNINGz While power is on or when the inverter is running, do not open the front cover. Youmay get an electric shock.z Do not run the inverter with the front cover or wiring cover removed. Otherwise,you may access the exposed high-voltage terminals or the charging part of thecircuitry and get an electric shock. Also, the inverter's ability to withstandearthquakes will deteriorate.z Even if power is off, do not remove the front cover except for wiring or periodicinspection. You may access the charged inverter circuits and get an electric shock.z Before starting wiring or inspection, check to make sure that the 3-digit LED invertermonitor is off, wait for at least 10 minutes after the power supply has been switchedoff, and check to make sure that there are no residual voltage using a tester or thelike.z This inverter must be earthed (grounded). Earthing (grounding) must conform tothe requirements of national and local safety regulations and electrical codes.(NEC section 250, IEC 536 class 1 and other applicable standards)z Any person who is involved in the wiring or inspection of this equipment should befully competent to do the work.z Always install the inverter before wiring. Otherwise, you may get an electric shockor be injured.z Perform setting dial and key operations with dry hands to prevent an electricshock.z Do not subject the cables to scratches, excessive stress, heavy loads or pinching.Otherwise, you may get an electric shock.z Do not change the cooling fan while power is on. It is dangerous to change thecooling fan while power is on.z When you have removed the front cover, do not touch the connector above the 3digit monitor LED display. Otherwise, you get an electrick shock.A-1

2. Fire PreventionCAUTIONz Install the inverter and brake resistor on an incombustible wall without holes, etc.Installing the inverter and brake resistor directly on or near a combustible surface couldlead to a fire.z If the inverter has become faulty, switch off the inverter power. A continuous flow oflarge current could cause a fire.z When using a brake resistor, make up a sequence that will turn off power when analarm signal is output. Otherwise, the brake resistor may excessively overheat dueto damage of the brake transistor and such, causing a fire.z Do not connect the resistor directly to the DC terminals P and N. This could cause a fire.3. Injury PreventionCAUTIONz Apply only the voltage specified in the instruction manual to each terminal toprevent damage, etc.z Always connect to the correct terminal to prevent damage, etc.z Always make sure that polarity is correct to prevent damage, etc.z While power is on or for some time after power-off, do not touch the inverter as it ishot and you may get burnt.4. Additional InstructionsAlso note the following points to prevent an accidental failure, injury, electric shock,etc.(1) Transportation and installationCAUTIONEnvironmentz When carrying products, use correct lifting gear to prevent injury.z Do not stack the inverter boxes higher than the number recommended.z Ensure that installation position and material can withstand the weight of theinverter. Install according to the information in the instruction manual.z Do not install or operate if the inverter is damaged or has parts missing.z When carrying the inverter, do not hold it by the front cover or setting dial; it mayfall off or fail.z Do not stand or rest heavy objects on the inverter.z Check the inverter mounting orientation is correct.z Prevent other conductive bodies as screws and metal fragments or otherflammable substance as oil from entering the inverter.z As the inverter is a precision instrument, do not drop or subject it to impact.z Use the inverter under the following environmental conditions: This could causethe inverter damage.Ambient-10 C to 50 C (non-freezing)Temperature(-10 C to 40 C for totally enclosed structure feature)Ambient humidity 90%RH maximum (non-condensing)Storage-20 C to 65 C *temperatureIndoors (free from corrosive gas, flammable gas, oil mist,Atmospheredust and dirt)Altitude/Max.1000m above sea level 5.9m/s2 or lessvibration*Temperatures applicable for a short time, e.g. in transit.A-2

(2) WiringCAUTIONz Do not fit capacitive equipment such as power factor correction capacitor,capacitor type filter (option FR-BIF(-H)) or surge suppressor to the output of theinverter.z The connection orientation of the output cables U, V, W to the motor will affect thedirection of rotation of the motor.(3) Trial runCAUTIONz Check all parameters, and ensure that the machine will not be damaged by asudden start-up.z When the load GD2 is small (at the motor GD or smaller) for 400V from 1.5K to 3.7K, theoutput current may vary when the output frequency is in the 20Hz to 30Hz range.If this is a problem, set the Pr.72 "PWM frequency selection" to 6kHz or higher.(When setting the PWM to a higher frequency, check for noise or leakage currentproblem and take countermeasures against it.)(4) OperationWARNINGz When you have chosen the retry function, stay away from the equipment as it willrestart suddenly after an alarm stop.z Since the [STOP] key is valid only when functions are set (refer to page 59),provide a circuit and switch separately to make an emergency stop (power off,mechanical brake operation for emergency stop, etc).z Make sure that the start signal is off before resetting the inverter alarm. A failure todo so may restart the motor suddenly.z The load used should be a three-phase induction motor only. Connection of anyother electrical equipment to the inverter output may damage the equipment.z Do not modify the equipment.z Do not perform parts removal which is not instructed in this manual. Doing so maylead to fault or damage of the inverter.A-3

CAUTIONz The electronic thermal relay function does not guarantee protection of the motorfrom overheating.z Do not use a magnetic contactor on the inverter input for frequent starting/stoppingof the inverter.z Use a noise filter to reduce the effect of electromagnetic interference. Otherwisenearby electronic equipment may be affected.z Take measures to suppress harmonics. Otherwise power supply harmonics fromthe inverter may heat/damage the power capacitor and generator.z When a 400V class motor is inverter-driven, please use an insulation-enhancedmotor or measures taken to suppress surge voltages. Surge voltages attributable tothe wiring constants may occur at the motor terminals, deteriorating the insulation ofthe motor.z When parameter clear or all clear is performed, reset the required parametersbefore starting operations. Each parameter returns to the factory setting.z The inverter can be easily set for high-speed operation. Before changing itssetting, fully examine the performances of the motor and machine.z In addition to the inverter's holding function, install a holding device to ensure safety.z Before running an inverter which had been stored for a long period, alwaysperform inspection and test operation.(5) Emergency stopCAUTIONz Provide a safety backup such as an emergency brake which will prevent themachine and equipment from hazardous conditions if the inverter fails.z When the breaker on the inverter primary side trips, check for the wiring fault (shortcircuit), damage to internal parts of the inverter, etc. Identify the cause of the trip,then remove the cause and power on the breaker.z When any protective function is activated, take the appropriate corrective action,then reset the inverter, and resume operation.(6) Maintenance, inspection and parts replacementCAUTIONz Do not carry out a megger (insulation resistance) test on the control circuit of theinverter.(7) Disposing of the inverterCAUTIONz Treat as industrial waste.(8) General instructionsMany of the diagrams and drawings in this instruction manual (basic) show the inverterwithout a cover, or partially open. Never operate the inverter in this manner. Always replacethe cover and follow this instruction manual (basic) when operating the inverter.A-4

Harmonic Suppression GuidelineAll models of general-purpose inverters used by specific consumers are covered by"Harmonic suppression guideline for consumers who receive high voltage or specialhigh voltage". (For further details, refer to Instruction Manual (detailed).)Product Checking and Parts IdentificationUnpack the inverter and check the capacity plate on the front cover and the ratingplate on the inverter side face to ensure that the product agrees with your order andthe inverter is intact. Parts and name plateRating plateOperation panelInverter typeInput ratingOutput ratingFront coverSerial numberCapacity plate Inverter typeWiring coverFR-S520E-0.1KFR-S520E-0.1KInverter typeXXXXXXSerial numberFR - S520E - 0.1 K Voltage classSymbolS520E Three-phase 200V classS540E Three-phase 400V classS520SE Single-phase 200V classSymbol Structure, terminal symbol,etc.Invertercapacity"kW"NoneCS510WE Single-phase 100V class1Enclosed typeTotally enclosed structure IP40

z Removal and reinstallation of thefront coverRemove the front cover by pulling ittoward you in the direction of arrow.To reinstall, match the cover to theFR-S520E-0.1K to 0.75Kinverter front and install it straight.FR-S520E-1.5K to 3.7KFR-S520SE-0.1K to 0.75K FR-S520SE-1.5KFR-S510WE-0.1K to 0.4K FR-S540E-0.4K to 3.7KFR-S510WE-0.75Kz Removal and reinstallation of the wiring coverThe cover can be removed easily by pulling it towardyou.To reinstall, fit the cover to the inverter along the guides.Wiring coverz RS-485 communication connectorWhen using the RS-485 connector to wire the cable, youcan cut off the tab of the wiring cover to wire it. (Cutting offTabthe tab will provide protective structure IP10.)CAUTIONThe connector above the operation panel is formanufacturer use. Do not touch it as doing so maycause an electric shock.2

CONNECTION OF PERIPHERAL DEVICES (BASICCONFIGURATION)Power supplyUse within the permissible power supply specificationsof the inverter. (Refer to page 80.)Moulded case circuit breaker or earth leakagecircuit breakerThe breaker must be selected carefully since an in-rushcurrent flows in the inverter at power on.Magnetic contactorInstall for your safety. Do not use this magnetic contactorto start and stop the inverter. Doing so will cause theinverter life to be shorten. (Refer to page 18.)Installation of a reactorA reactor must be used when the power harmonicsmeasure is taken, power factor is to be improved or theinverter is installed near a large supply system (500kVAor more and wiring distance within 10 m).Make the selection carefully.Devices connected to the outputDo not install a power factor correction capacitor, surgesuppressor or capacitor type filter on the output side of theinverter.When installing a moulded case circuit breaker on theoutput side of the inverter, contact each manufacturer forselection of the moulded case circuit breaker.Earth (Ground)To prevent an electric shock, always earth (ground) themotor and inverter.For reduction of induction noise from the power line ofthe inverter, it is recommended to wire the earth(ground) cable by returning it to the earth (ground)terminal of the inverter.(For details of noise reduction techniques, refer to theinstruction manual (detailed).)31CONNECTION OF PERIPHERAL DEVICES (BASIC CONFIGURATION)1.

CONNECTION OF PERIPHERAL DEVICES(BASIC CONFIGURATION)Selection of peripheral devices (selection changes with the power inputspecifications of the inverter)1) Three-phase 200V power inputMotorOutput(kW)Applied (-C)Moulded CaseMagneticCircuit BreakerContactor AC Reactor DC Reactor(MCCB *1, 4) or(MC)FR-HAL- K FR-HEL- KEarth Leakage(Refer to FR-BAL- K FR-BEL- KCircuit Breakerpage 18)(ELB) (*2, 4)30AF/5AS-N100.4 (*3)0.4 (*3)30AF/5AS-N100.4 (*3)0.4 3.73.72) Three-phase 400V power inputMotorOutput(kW)Applied d CaseMagneticCircuit BreakerAC Reactor DC ReactorContactor(MCCB *1, 4) orFR-HAL- K FR-HEL- K(MC)Earth LeakageFR-BAL- K FR-BEL- K(Refer toCircuit Breakerpage 18)(ELB) (*2, S-N21H3.7H3.74

CONNECTION OF PERIPHERAL DEVICES(BASIC CONFIGURATION)3) Single-phase 200V power inputMotorOutput(kW)Applied InverterTypeMoulded CaseMagneticCircuit BreakerAC Reactor DC ReactorContactor(MCCB *1, 4) or(*3)(*3)(MC)Earth LeakageFR-HAL- K FR-HEL- K(Refer toCircuit BreakerFR-BAL- K FR-BEL- Kpage 18)(ELB) (*2, A0.4FR-S520SE-0.4K30AF/10A0.75 0.40.750.751.51.52.22.24) Single-phase 100V power inputMotorOutput(kW)Applied -0.75K30AF/30AS-N10S-N10S-N20,S-N21S-N20,S-N21*1. Select the MCCB according to the power supply capacity. Install one MCCB per inverter.0.751.5 2.2 3.7 MCCBINVIMMCCBINVIM*2. For installations in the United States or Canada, the circuit breaker must be inversetime or instantaneous trip type.*3. The power factor may be slightly lower.*4. When the breaker on the inverter primary side trips, check for the wiring fault (shortcircuit), damage to internal p

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