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Mitsubishi Electric FATEC FR-A800 Manual

Inverter school text, inverter trouble shooting course
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INVERTER SCHOOL TEXT
INVERTER TROUBLE SHOOTING
COURSE (FR-A800)
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Summary of Contents for Mitsubishi Electric FATEC FR-A800

  • Page 1 INVERTER SCHOOL TEXT INVERTER TROUBLE SHOOTING COURSE (FR-A800)
  • Page 2 SAFETY PRECAUTIONS (Read these precautions before using this product.) When designing a system, always read the relevant manuals and give due consideration to safety. In addition, pay careful attention to the following points for proper handling during training. [Precautions during training] WARNING ●...

  • Page 3: Table Of Contents

    CONTENTS Chapter 1 IMPORTANCE OF PRODUCTIVE MAINTENANCE Importance of maintenance ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 Maintenance system ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2 Maintenance plan ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 3 Management of maintenance document ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 Maintenance record •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 Failure stage ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 5 Chapter 2 UNDERSTANDING INVERTER SYSTEM Demonstration machine configuration •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6 Appearance and item name of demonstration machine •••••••••••••••••••••••••••••••••••••••••••••••••••••••••...
  • Page 4 Troubleshooting ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 52 5.1.1 When the operation panel does not display the energization••••••••••••••••••••••••••••••••••••••••••• 52 5.1.2 When parameters cannot be set ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 53 5.1.3 When the motor does not start ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 54 5.1.4 When the motor does not accelerate •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 55 5.1.5 When the motor speed does not become the set speed ••••••••••••••••••••••••••••••••••••••••••••••••...
  • Page 5 7.2.5 Earth (ground) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••114 Problems and measures when using inverter ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••116 7.3.1 Environment and installation condition•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••116 7.3.2 Connection of the inverter ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••123 Precautions for storing an inverter in the enclosure•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••132 Chapter 8 LIFE OF INVERTER PARTS Replacement of parts •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••135 Inverter parts life display••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••137 Diagnosis using FR Configurator2••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••141 8.3.1...

  • Page 6: Chapter 1 Importance Of Productive Maintenance

    IMPORTANCE OF PRODUCTIVE MAINTENANCE CHAPTER 1 IMPORTANCE OF PRODUCTIVE MAINTENANCE When a production system stops due to a failure or power failure, downtime causes a loss proportional to the duration of the downtime. Therefore, it is necessary to design a system that is not stopped by a failure or power failure. In case the production system stops, quick recovery is an important issue.

  • Page 7: Maintenance System

    IMPORTANCE OF PRODUCTIVE MAINTENANCE Maintenance system To establish a highly reliable production system, it is important to a well-organized maintenance system. The following chart outlines a maintenance system. Productive maintenance Maintenance When designing new equipment, consider the maintenance systems. system design This maintenance applies to the equipment in which failure or Preventive accident occurrence will incur big economical losses and serious...

  • Page 8: Maintenance Plan

    IMPORTANCE OF PRODUCTIVE MAINTENANCE Maintenance plan Consider the maintenance for the production system after failures occur. For the efficient maintenance, build a maintenance plan at the introduction of the production system. In case of failure, perform the following maintenance systematically to repair the system in a short time.

  • Page 9: Management Of Maintenance Document

    IMPORTANCE OF PRODUCTIVE MAINTENANCE Management of maintenance document To repair a failure in a short time, the documents as listed below must be arranged and managed. Table 1.2 Management of maintenance document Category Name Description The functions and operations of the corresponding system/control System/control are described.

  • Page 10: Failure Stage

    IMPORTANCE OF PRODUCTIVE MAINTENANCE Failure stage Generally, complicated system failure is categorized into three stages, initial failure, random failure, and wear-out failure as shown in Fig. 1.1. Initial failures are considered to be removed in manufacturing and inspection processes by a manufacturer. Because random failures are unforeseen and occur suddenly at any time within the useful life of equipment before it is worn, it is difficult to take the technical measure.

  • Page 11: Chapter 2 Understanding Inverter System

    UNDERSTANDING INVERTER SYSTEM CHAPTER 2 UNDERSTANDING INVERTER SYSTEM Demonstration machine configuration Motor MCCB U1 MC3 Power SF-JR supply 0.4kW 4P 1φ 100V FR-A820-00077 Instantaneous power failure timer Instantaneous power failure button Motor speed Emergency stop Motor phase loss/Normal switch Frequency setting   Compensation input Overheat Powder...

  • Page 12: Appearance And Item Name Of Demonstration Machine

    UNDERSTANDING INVERTER SYSTEM Appearance and item name of demonstration machine The following figure shows the configuration of the inverter demonstration machine. Inverter demonstration machine Forward rotation Reverse rotation Load torque Motor speed FM terminal output AM terminal output Operation panel Frequency setting Compensation input Terminal 2...

  • Page 13: Precautions For Use

    UNDERSTANDING INVERTER SYSTEM 11) High speed RH………… Selects "High speed" from the multi-speed setting. Note that up to seven different speeds can be selected with a combination of "Middle speed" and "Low speed". 12) Middle speed RM……… Selects "Middle speed" from the multi-speed setting. Note that up to seven different speeds can be selected with a combination of "High speed"...

  • Page 14: Operation Method

    UNDERSTANDING INVERTER SYSTEM Operation method 2.4.1 Types of operation methods The inverter can be operated with various signals. This section explains the operations (start, stop, and speed variation) that can be operated with the inverter demonstration machine. (1) External operation using external signals (D000 (Pr.79) = "0, 2") Operate an inverter with a frequency setting potentiometer or start switch connected to the control circuit terminals of the inverter.
  • Page 15 UNDERSTANDING INVERTER SYSTEM (2) PU operation using the operation panel or parameter unit (D000 (Pr.79) = "0, 1") This operation is performed only with the keys of the operation panel or parameter unit. PU start signal + PU frequency setting signal Key operation setting of PU  ...

  • Page 16: How To Use The Operation Panel Fr-Du08

    UNDERSTANDING INVERTER SYSTEM How to use the operation panel FR-DU08 2.5.1 Component names of the operation panel (FR-DU08) Component Name Description PU: ON to indicate the PU operation mode. EXT: ON to indicate the External operation mode. (ON at power-ON in the initial setting.) Operation mode indicator NET: ON to indicate the Network operation mode.

  • Page 17: Basic Operation Of The Operation Panel

    UNDERSTANDING INVERTER SYSTEM 2.5.2 Basic operation of the operation panel (1) Basic operation Operation mode switchover/Frequency setting External operation mode at power-ON) PU JOG operation mode PU operation mode Alternating (Example) Value change Frequency setting has been changed! Output current monitor Output voltage monitor Output frequency monitor (at power-ON) The present setting...
  • Page 18 Changes parameter settings as a batch. The target parameters Automatic parameter include communication parameters for the Mitsubishi Electric setting human machine interface (GOT) connection and the parameters for the rated frequency settings of 50 Hz/60 Hz.

  • Page 19: Parameter Setting Procedures (Parameter Display In Numerical Order)

    UNDERSTANDING INVERTER SYSTEM 2.5.3 Parameter setting procedures (parameter display in numerical order) This section explains how to change the setting value of Pr.1 Maximum frequency from "120 Hz" to "60 Hz". Operation Turning ON the power of the inverter The operation panel is in the monitor mode. Changing the operation mode Press to choose the PU operation mode.

  • Page 20: Parameter Display By Function Group

    UNDERSTANDING INVERTER SYSTEM 2.5.4 Parameter display by function group Parameter numbers can be displayed by function group. Since the parameter numbers are grouped by function, related parameters can be set easily. (1) Changing to parameter numbers grouped by function Pr.MD setting Description Default parameter display Parameter display in numerical order...

  • Page 21: Parameter Clear / All Parameter Clear

    UNDERSTANDING INVERTER SYSTEM 2.5.5 Parameter clear / all parameter clear Set Pr.CLR Parameter clear or ALL.CL All parameter clear to "1" to initialize parameters. (Parameters cannot be cleared when E400 (Pr.77) Parameter write selection = "1".) Operation 1. Turning ON the power of the inverter The operation panel is in the monitor mode.

  • Page 22: Parameter Copy

    UNDERSTANDING INVERTER SYSTEM 2.5.6 Parameter copy The parameter setting values for one inverter can be copied to multiple inverters. Pr.CPY setting Description 0.--- Initial display 1.RD Copy the source parameters to the operation panel. 2.WR Write the parameters stored in the operation panel to the target inverter. 3.VFY Verify the parameters in the inverter and operation panel.

  • Page 23: Operation Using The Operation Panel (Pu Operation)

    UNDERSTANDING INVERTER SYSTEM 2.5.7 Operation using the operation panel (PU operation) Use the operation panel (FR-DU08) to give a start command and a frequency command. (PU operation) Operation panel (FR-DU08) Operation example Operate at 30 Hz. Operation Turning ON the power of the inverter The operation panel is in the monitor mode.

  • Page 24: Operation Using External Switches (External Operation)

    UNDERSTANDING INVERTER SYSTEM 2.5.8 Operation using external switches (External operation) Turn ON the STF/STR signal to give a start command. Use the potentiometer (frequency setting potentiometer) to give a frequency command. (by connecting it across terminals 2 and 5 (voltage input)). [Connection diagram] (The inverter supplies 5 V power to the frequency setting potentiometer (Terminal 10)) Inverter...

  • Page 25: Monitoring Of Output Current And Output Voltage

    UNDERSTANDING INVERTER SYSTEM 2.5.9 Monitoring of output current and output voltage Press on the operation panel in the monitor mode to switch the monitor item between output frequency, output current, and output voltage. Operation Press during operation to monitor the output frequency. [Hz] indicator turns ON. Press to monitor the output current.

  • Page 26: Calibration Procedure For Terminal Fm When Using The Operation Panel (Fr-Du08)

    UNDERSTANDING INVERTER SYSTEM 2.5.11 Calibration procedure for terminal FM when using the operation panel (FR-DU08) Operation 1. Turning ON the power of the inverter The operation panel is in the monitor mode. Changing the operation mode Press to choose the PU operation mode. The [PU] indicator turns ON. Calibration is also possible in the External operation mode.

  • Page 27: Inverter Setup Software

    UNDERSTANDING INVERTER SYSTEM Inverter setup software FR Configurator2 (SW1DND-FRC2-E) Inverter setup software provides a comfortable environment for operating the inverter as a support tool for the inverter operations from startup to maintenance. Parameter setting and monitoring can be effectively performed on the screen of the Windows personal computer.

  • Page 28: System Configuration

    UNDERSTANDING INVERTER SYSTEM 2.6.3 System configuration The following devices are required to use FR Configurator2. Configure the system in accordance with the instruction manuals of each device. FR Configurator2 Commercially available printer Serial USB connector ∗7 connector port or serial port ∗4 A USB cable is used.
  • Page 29 UNDERSTANDING INVERTER SYSTEM [Connection example of USB cable and USB connector] For the inverter, connect the USB cable to the USB device (mini B connector). USB host (A connector) Communication status LED indicator USB device (mini B connector) Connecting the demonstration machine For the demonstration machine, use a USB cable.

  • Page 30: Setup

    UNDERSTANDING INVERTER SYSTEM 2.6.4 Setup (1) Operation mode setting To operate the inverter with FR Configurator2 (operation such as the parameter setting and test operation), setting the operation mode of the inverter is required. The operation mode can be selected on the "Test operation" or "Parameter list" window. Parameter setting ...
  • Page 31 UNDERSTANDING INVERTER SYSTEM (2) Creating a project Start up FR Configurator2, select [New] in the [Project] menu or select on the toolbar to display the "System setting" window. (a) Enter the information required for creating a project. Enter the system name to be set (up to 32 characters) for the System name in the "System setting"...
  • Page 32 UNDERSTANDING INVERTER SYSTEM (c) The inverter information can be reflected to the system setting by detecting the connected inverters automatically or selecting the inverters manually. Automatic detection Click to start detecting the communicable inverters. When automatic inverter detection is finished, the inverter information is reflected to the system window.

  • Page 33: Graph (Monitor Area)

    UNDERSTANDING INVERTER SYSTEM 2.6.5 Graph (monitor area) Data such as output frequency and current of the inverter can be sampled, and the results can be displayed in a waveform graph. The sampled data can be saved in a file (the *.jpg, *.emf, *.gp4, or *.csv file) to be read and displayed (import the *.gp4 or *.st1 file).
  • Page 34 UNDERSTANDING INVERTER SYSTEM (1) Explanation of window Symbol Name Function and description Toolbar Provides file operations, history management, and graph display settings. Property window Used to set the measurement conditions, display conditions, and cursor. Displays the contents of the analog CH and digital CH set in the [Waveform] setting tab of the property Sampling item column window.
  • Page 35 UNDERSTANDING INVERTER SYSTEM (2) Sampling settings Select the [Setting] tab in the property window to display the sampling settings column. The time, trigger, station, and waveform of the analog CH can be set as analog data, and that of the digital CH can be set as digital data.
  • Page 36 UNDERSTANDING INVERTER SYSTEM Setting range and setting unit of sampling interval and sampling time  The setting range of the sampling interval and the sampling time are different for high speed sampling and monitor sampling. (a) High speed sampling (only for USB connections) The sampling interval can be about 0.125 [ms] (mask count: 1) to about 20 [ms] (mask count: 30).
  • Page 37 UNDERSTANDING INVERTER SYSTEM ・Sampling item list For details on the monitor items, refer to the Instruction Manual (Detailed) of the inverter. For sampling items of the digital data, refer to the Instruction Manual (Detailed) of the inverter. High speed sampling is applicable to the items whose name contains an asterisk (  ) at the beginning.
  • Page 38 UNDERSTANDING INVERTER SYSTEM (3) Trigger settings Setting a trigger allows sampling to start when a fault occurs or sampling item conditions are met. Symbol Name Function and description Select the signal that triggers the start of sampling. The trigger signals are as follows. ...
  • Page 39 UNDERSTANDING INVERTER SYSTEM Trigger standby state Set sampling item and trigger setting. Standby Click to shift the state to the pre-trigger state. The data before the trigger is satisfied is collected. (The sampling does not start even though Pre-trigger the trigger condition is satisfied in the pre-trigger state.) After the retrieval of the pre-trigger data by the ratio set in trigger position,...
  • Page 40 UNDERSTANDING INVERTER SYSTEM (4) Changing the scale and graph display The scale and waveform data on the displayed graph can be changed. Graph area is divided into vertical 10 grids and horizontal 10 grids. The vertical scale and horizontal scale can be changed by setting the value for each grid.
  • Page 41 UNDERSTANDING INVERTER SYSTEM (5) Cursor function The numeric value of the waveform at the cursor, effective value, maximum value, and minimum value between any 2 points can be displayed. Symbol Name Function and description Vertical/horizontal Used to specify cursor A and cursor B as the vertical axis or horizontal axis. cursor Cursor bar Used to specify the position between cursor A and cursor B.
  • Page 42 UNDERSTANDING INVERTER SYSTEM (6) History display Data of the past 20 samplings (including the current data) can be saved and displayed. The graph data at the time of sampling is stopped is saved. When the number of records exceeds 20, the oldest set of data will be deleted for every new data sampled.
  • Page 43 UNDERSTANDING INVERTER SYSTEM (7) Example of graph measuring procedure (monitoring output frequency, terminal RUN, and terminal FU)  Measurement without a trigger (a) Specify the station number to be measured as "Tgt. St." Set the station to be measured. (Target station). Select "Output frequency".
  • Page 44 UNDERSTANDING INVERTER SYSTEM  Measurement including the data sampled before the trigger occurs for 10% of the sampling time (sampling is started at the rise of the terminal RUN signal) (a) Specify the station number to be measured as "Tgt. St." Set the station to be measured.
  • Page 45 UNDERSTANDING INVERTER SYSTEM Remark In this example, "Trigger position" is set to "10%". After clicking [ Start], the rise of terminal RUN signal within 10% of the sampling time will be ignored, and measurement will not start.  Measurement including the data sampled before the trigger occurs for 90% of the sampling time (sampling is started at the occurrence of a fault) (a) Specify the station number to be measured as "Tgt.
  • Page 46 UNDERSTANDING INVERTER SYSTEM (f) The graph display can be The selected digital waveform adjusted. can be moved up and down. The display position of the vertical axis scale can be changed. The waveform can be moved up and down. Remark In this example, "Trigger position"...

  • Page 47: Chapter 3 Maintenance System Design

    MAINTENANCE SYSTEM DESIGN Chapter 3 MAINTENANCE SYSTEM DESIGN It is necessary to design a system for maintenance to prevent failures and accidents with a maintenance-friendly design. Preparation for Maintenance (1) Using products unlikely to fail In simple terms, this means using highly reliable products. It is recommended to consider the following points.

  • Page 48: Failsafe System Which Uses The Inverter

    MAINTENANCE SYSTEM DESIGN Failsafe system which uses the inverter When a fault is detected by the protective function, the protective function activates and outputs a fault output signal. However, a fault output signal may not be output at an inverter's fault occurrence when the detection circuit or output circuit fails, etc.
  • Page 49 MAINTENANCE SYSTEM DESIGN 3) Checking the inverter operating status by the start signal input to the inverter and inverter running signal The inverter running signal (RUN signal) is output when the inverter is running. (RUN signal is assigned to terminal RUN in the initial setting.) Check if Y12 signal is being output while inputting a start signal to the inverter.
  • Page 50 MAINTENANCE SYSTEM DESIGN (2) Backup method outside the inverter Even if the interlock is provided by the inverter status signal, enough failsafe is not ensured depending on the failure status of the inverter itself. For example, if an inverter CPU fails in a system interlocked with the inverter's fault, start, and RUN signals, no fault output signal will be output and the RUN signal will be kept ON because the inverter CPU is down.

  • Page 51: Chapter 4 Preventive Maintenance

    PREVENTIVE MAINTENANCE CHAPTER 4 PREVENTIVE MAINTENANCE Preventive maintenance consists of daily maintenance and periodic maintenance. Necessity of preventive maintenance It is inefficient to repair the production system after failures occur. The primary goal is to avoid failures and equipment suspension. Preventive maintenance prevents critical failures, as well as leading to fast repair in case of failure.
  • Page 52 PREVENTIVE MAINTENANCE (Note) Understand the contents of the power supply display indicating that the inverter is running and error (fault) display indicating a trouble on general inverter. Also check the electronic thermal O/L relay and the acceleration/deceleration time from the parameter unit, and record the normal setting value.
  • Page 53 PREVENTIVE MAINTENANCE Daily and periodic inspection Inspection Inspection Corrective action at fault Customer's interval Inspection item Description Periodic area occurrence check Daily  (1) Check that the output voltages  Contact the manufacturer. across phases are balanced while operating the inverter alone.

  • Page 54: Measurement Of Main Circuit Voltage, Current, And Power

    PREVENTIVE MAINTENANCE 4.2.3 Measurement of main circuit voltage, current, and power ● How to measure the voltage and current of each part Since the voltages and currents on the inverter power supply and output sides include harmonics, measurement data depends on the circuits measured. When instruments for commercial frequency are used for measurement, measure the following circuits with the instruments given on the next page.
  • Page 55 PREVENTIVE MAINTENANCE Measuring points and instruments Item Measuring point Measuring instrument Remarks (reference measured value) Commercial power supply Power supply voltage Across R and S, S and T, T Moving-iron type AC Within permissible AC voltage fluctuation voltmeter  and R (Refer to the Instruction Manual of the inverter.) Power supply side current Moving-iron type AC...
  • Page 56 PREVENTIVE MAINTENANCE Measuring points and instruments Item Measuring point Measuring instrument Remarks (reference measured value) Conduction check () Across A Across A and C Moving-coil type No conduction Conduction Alarm signal and C Across B and C (such as tester) Across B Conduction No conduction...

  • Page 57: Chapter 5 Breakdown Maintenance

    BREAKDOWN MAINTENANCE CHAPTER 5 BREAKDOWN MAINTENANCE Troubles can be caused by failures or accidents even though preventive maintenance is performed. If the inverter becomes faulty by any unexpected reason and the production system stops, breakdown maintenance is required. Troubleshooting The troubleshooting flowcharts for each phenomenon are shown below. Perform an appropriate troubleshooting depending on the trouble.

  • Page 58: When Parameters Cannot Be Set

    BREAKDOWN MAINTENANCE 5.1.2 When parameters cannot be set Parameter cannot be set.   Is the operation Is the operation Is the operation Powered display panel on? panel on? panel on? Is Err displayed Is Err displayed Is Err displayed at power-on? at power-on? at power-on? Parameter setting...

  • Page 59: When The Motor Does Not Start

    BREAKDOWN MAINTENANCE 5.1.3 When the motor does not start The motor does not start. Accelerated. Has Pr. been It does not start. changed? Has the motor started so far? Return the changed Pr. It is not on. to its original value and check the status.

  • Page 60: When The Motor Does Not Accelerate

    BREAKDOWN MAINTENANCE 5.1.4 When the motor does not accelerate The motor does not accelerate. Does the It does not accelerate. motor start? It does not start. Has the motor accelerated so far?   Review the control. Accelerated. the magnetic flux Which vector selected? To middle or high speed...

  • Page 61: When The Motor Speed Does Not Become The Set Speed

    BREAKDOWN MAINTENANCE 5.1.5 When the motor speed does not become the set speed The motor speed does not reach the set speed. Does the motor accelerate normally? It does not accelerate. Does the motor decelerate normally? It does not decelerate. Is the speed command set correctly?

  • Page 62: When The Motor Speed Is Unstable

    BREAKDOWN MAINTENANCE 5.1.6 When the motor speed is unstable The motor speed is unstable. Does OL alarm occur? Is the The speed is unstable. fluctuation in the speed large? Review the control. Does the Is the speed command vector control change? used? Review the speed command.

  • Page 63: When The Motor Does Not Accelerate

    BREAKDOWN MAINTENANCE 5.1.7 When the motor does not accelerate It does not decelerate. The motor does not decelerate to a stop. Does OV 12-A Braking capability alarm occur? Does OL alarm occur? Is the stall prevention level 150% or less? Does the motor decelerate partway?

  • Page 64: When Automatic Restart After Instantaneous Power Failure Does Not Work

    BREAKDOWN MAINTENANCE 5.1.8 When automatic restart after instantaneous power failure does not work The automatic restart after instantaneous power failure does not work. Are the related Pr.s set correctly? A702 (Pr.57): Set the restart coasting time to value other than 9999. A703 (Pr.58): Set the restart cushion time to 1.0 second or more.

  • Page 65: When Abnormal Noise Is Generated From The Motor

    BREAKDOWN MAINTENANCE 5.1.9 When abnormal noise is generated from the motor The motor generates an abnormal acoustic noise. Is the motor immediately before a stop? Review G100 (Pr.10) to G110 (Pr.12) that are related to the DC injection brake operation. What kind of sound? Mechanical cause Chattering...

  • Page 66: 5.1.10 When The Motor Vibrates Abnormally

    BREAKDOWN MAINTENANCE 5.1.10 When the motor vibrates abnormally The motor vibrates unusually. Is there a mechanical scrape, contact, or looseness? Check installing condition of 10-A shafts, bearings, and fan motors. Is the speed 1800 r/m or Resonance phenomenon Is the slower at IPM? motor resonating with the machine?

  • Page 67: 5.1.11 When Oc Alarm Occurs

    BREAKDOWN MAINTENANCE 5.1.11 When OC alarm occurs OC alarm occurs. Has the load changed suddenly? Can the Rail joint check load be stabilized? Reduction gear/wheel check Can a Mechanical looseness adjustment mechanical cause be considered? Improve the load. Is the stall Has the prevention operation level operating condition...

  • Page 68: 5.1.12 When Ov Alarm Occurs

    BREAKDOWN MAINTENANCE 5.1.12 When OV alarm occurs OV alarm occurs. Is the power supply voltage high? Set the power supply voltage correctly. Is the surge overlapped with the power supply? Power supply improvement AC or DC reactor installation Is it caused by mechanical factors? Rail joint check...

  • Page 69: 5.1.13 When Analog Input Cannot Be Calibrated

    BREAKDOWN MAINTENANCE 5.1.13 When analog input cannot be calibrated (When adjusting gains T203 (Pr.903) and T403 (Pr.905)) Analog input cannot be calibrated. Operation at 60 Hz or higher is not available.   Has calibration been performed? Is the maximum frequency correct? Select the PU operation mode.

  • Page 70: Troubleshooting By The Demonstration Machine

    BREAKDOWN MAINTENANCE Troubleshooting by the demonstration machine Perform troubleshooting using the demonstration machine. Check the symptom and take measures following the described procedures for operation. 5.2.1 Stall prevention (overcurrent) (OL display) [Demonstration] Change H500 (Pr.22) (Stall prevention operation level) from the initial value "150%" to "45%", and turn ON STF and high speed RH.

  • Page 71: Stall Prevention Stop (E.olt Display) [Demonstration]

    BREAKDOWN MAINTENANCE 5.2.2 Stall prevention stop (E.OLT display) [Demonstration] Check that the stall prevention stop (E.OLT display) occurs. Change H500 (Pr.22) (Stall prevention operation level) from the initial value "150%" to "10%", and turn ON STF and high speed RH. Check that E.OLT is displayed in 3 or 4 seconds. (1) Corrective action 1) Use FR Configurator2 to check the output current value.

  • Page 72: Regenerative Overvoltage Trip During Deceleration (E.ov3 Display) [Demonstration]

    BREAKDOWN MAINTENANCE 5.2.3 Regenerative overvoltage trip during deceleration (E.OV3 display) [Demonstration] Change F011 (Pr.8) (Deceleration time) from the initial value "5" to "1" second and turn ON STF and high speed RH. Turn OFF STF after 60 Hz is displayed and check that E.OV3 is displayed. The shorting bar between PX and PR on the terminal block on the rear side of the demonstration machine is removed.
  • Page 73 BREAKDOWN MAINTENANCE Task 1 Change F011 (Pr.8) (Deceleration time) and obtain the setting value at which E.OV3 is displayed, and the level of the converter output voltage. Task 2 When F011 (Pr.8) (Deceleration time) is increased, the display changes from E.OV3 to OL warning.

  • Page 74: Electronic Thermal O/L Relay Pre-Alarm (Th Display) And Motor Overload Trip

    BREAKDOWN MAINTENANCE 5.2.4 Electronic thermal O/L relay pre-alarm (TH display) and motor overload trip (electronic thermal O/L relay) (E.THM display) [Demonstration] Change H000 (Pr.9) (Electronic thermal O/L relay) from "2.0" (setting value of the electronic thermal O/L relay for the demonstration machine) to "1.00". Turn ON STF and high speed RH, and turn the potentiometer of the load setting to the right as far as it goes after 60 Hz is displayed.
  • Page 75 BREAKDOWN MAINTENANCE Electronic thermal O/L relay operation characteristic (THM) H000 (Pr.9) = 50% setting H000 (Pr.9) = 100% setting of inverter rating ∗1, 2 of inverter rating ∗2 30 Hz or more ∗3 30 Hz 20 Hz or more ∗3 Operation region 10 Hz Region on the right of 20 Hz characteristic curve 10 Hz...

  • Page 76: Output Phase Loss (E.lf Display) [Demonstration]

    BREAKDOWN MAINTENANCE 5.2.5 Output phase loss (E.LF display) [Demonstration] Check that E.LF is displayed in a few minutes due to the U phase loss after switching the left switch on the rear side to the motor phase loss side and turning ON STF and high speed RH. Motor PS and phase loss...

  • Page 77: Vdc Power Output Short Circuit (E.p24 Display) [Demonstration]

    BREAKDOWN MAINTENANCE 5.2.6 24 VDC power output short circuit (E.P24 display) [Demonstration] Switch the right switch on the rear side to PC-SD short circuit, and check that E.P24 is displayed immediately. PS and Motor phase loss SD short Normal Open Push the tab up.

  • Page 78: Error (Err. Display) [Demonstration]

    BREAKDOWN MAINTENANCE 5.2.7 Error (Err. display) [Demonstration] Press and hold the RESET button while ON, and check that Err. display blinks. Corrective action 1) Use FR Configurator2 to check that the error signal is ON. 2) Press the inverter reset RES button of the demonstration machine, and release the RESET button to turn OFF the error signal.

  • Page 79: Instantaneous Power Failure (E.ipf Display), Automatic Restart After Instantaneous Power Failure

    BREAKDOWN MAINTENANCE 5.2.8 Instantaneous power failure (E.IPF display), automatic restart after instantaneous power failure [Demonstration] Turn ON STF and high speed RH to display 60 Hz. Turn ON the load button and turn the potentiometer of the load setting to the right as far as it goes. Set the load torque to 150%. Set the timer of the instantaneous power failure to 0.03 to 0.05 seconds, and press the instantaneous power failure button.
  • Page 80 BREAKDOWN MAINTENANCE (1) Procedure on the instantaneous power failure 1) Use FR Configurator2 to check the graph when E.IPF is displayed. Set the trigger position to 50%. Instantaneous power failure occurs. 2) Check that the operation continues when setting the instantaneous power failure time setting timer to 0 second and pressing the instantaneous power failure button.
  • Page 81 BREAKDOWN MAINTENANCE The time chart when an instantaneous power failure occurs to the inverter Coasting [F102 (Pr.13)   Starting frequency] A800 F700 Within 15 ms A800 F700 E700 D700 ∗1 Over 15 ms Over 10 ms E700 D700 Approx. 20 ms Within 10 ms A800 F700...
  • Page 82 BREAKDOWN MAINTENANCE (2) Setting the automatic restart after instantaneous power failure When the automatic restart after instantaneous power failure function is set, the motor restarts when the power is restored after the instantaneous power failure. (E.IPF is not activated.) Change A702 (Pr.57) (Restart coasting time) from the initial value "9999" to "0", set the automatic restart after turning ON instantaneous power failure CS, and press the instantaneous power failure button.
  • Page 83 BREAKDOWN MAINTENANCE (3) Setting the power failure time deceleration-to-stop function (A730 (Pr.261) to A735 (Pr.266), A785 (Pr.294)) Change A730 (Pr.261) (Power failure stop selection) from the initial value "0" to "2" (without UV avoidance, re-accelerate if power is restored) to restart the motor without E.IPF display. The power failure time deceleration-to-stop function decelerates and stops the motor to prevent motor coasting when power failure or undervoltage occurs.
  • Page 84 BREAKDOWN MAINTENANCE Initial value Parameter Setting Name Description number range A786 Power failure stop Adjust the response during operation of the deceleration time 100% 0 to 200% (668) frequency gain automatic adjustment function.  When the setting value of F001 (Pr.21) Acceleration/deceleration time increments is "0" (initial value), the setting range is "0 to 3600 s"...
  • Page 85 BREAKDOWN MAINTENANCE (c) Power failure stop function (A730 (Pr.261) = "1, 11, 21") • Even if power is restored during deceleration triggered by a power failure, deceleration stop is continued after which the inverter stays stopped. To restart operation, turn the start signal OFF then ON again.

  • Page 86: Undervoltage (E.uvt Display) [Demonstration]

    BREAKDOWN MAINTENANCE 5.2.9 Undervoltage (E.UVT display) [Demonstration] The shorting bar between P and P1 on the terminal block on the rear side of the demonstration machine is removed. Check that E.UVT is displayed right after the inverter is powered ON due to the decreased bus power voltage.

  • Page 87: Appendices For Demonstration (Confirmation Of Error Descriptions And Others)

    BREAKDOWN MAINTENANCE Appendices for demonstration (Confirmation of error descriptions and others) Following the 5.2 Troubleshooting by the demonstration machine in the previous section, this section provides the simple errors descriptions. Check the error details by following "Error setting", "Error description", and "Error handling procedure"...
  • Page 88 BREAKDOWN MAINTENANCE (8) E.RET display Change H302 (Pr.68) (Retry waiting time) from "1" to "5" seconds and change H301 (Pr.67) (Number of retries at fault occurrence) from "0" to "3" times. Change H000 (Pr.9) (Electronic thermal O/L relay) to "1". Check that E.THM is displayed in 1 second when STF and high speed RH are turned ON and that E.RET is displayed by performing three retries after the automatic reset without fault output.

  • Page 89: Error Description

    BREAKDOWN MAINTENANCE 5.3.2 Error description (1) The motor does not rotate. The motor does not rotate when STR is turned ON. (2) The frequency does not reach the set value. When STF and high speed RH are ON, 55 Hz is displayed. High speed RH of 60 Hz is required.

  • Page 90: Error Handling Procedure

    BREAKDOWN MAINTENANCE 5.3.3 Error handling procedure (1) Prevention of reverse rotation Follow the flowchart on 5.1.3 When the motor does not start to check that ON signals of STR and high speed RH are input using FR Configurator2. Change D020 (Pr.78) (Reverse rotation prevention selection) to the initial value "0".
  • Page 91 BREAKDOWN MAINTENANCE (7) E.USB display Change N041 (Pr.548) (USB communication check time interval) to "9999", and put the USB cable back. (8) E.RET display 1) Use FR Configurator2 to measure the graph from when the electronic thermal O/L relay (E.THM display) occurs to when retries are performed for three times in five seconds.

  • Page 92: Chapter 6 Corrective Maintenance

    CORRECTIVE MAINTENANCE CHAPTER 6 CORRECTIVE MAINTENANCE Reduce the deterioration of equipment and facilitate maintenance work to increase maintainability of the production system. Improving the maintainability of equipment (1) Improvement to reduce deterioration of equipment 1) Review the surrounding environment and install an air conditioning system or a ventilation system as necessary to prevent abnormal deterioration of equipment.

  • Page 93: Chapter 7 Review Of Installation Environment

    REVIEW OF INSTALLATION ENVIRONMENT CHAPTER 7 REVIEW OF INSTALLATION ENVIRONMENT Power supply of inverter (harmonics and instantaneous power failure) This section explains the influence of harmonics generated from the inverter on the power supply and its system to which an inverter is connected. Determine the level of influence on the peripheral devices according to the amount of harmonics generated from the inverter to consider concrete countermeasures against harmonics.
  • Page 94 REVIEW OF INSTALLATION ENVIRONMENT Fundamental wave Composition Second harmonics Distorted wave Third harmonics Fig. 7.1 Fundamental wave and harmonics Fig. 7.2 Distorted wave 7.1 Power supply of inverter (harmonics and instantaneous power failure)

  • Page 95: Characteristics Of Rectifier Circuit And Generated Harmonics

    REVIEW OF INSTALLATION ENVIRONMENT Table 7.1 Differences between harmonics and noise Item Harmonics Noise Normally 40th to 50th degrees or Frequency High frequency (several 10 kHz to MHz order) less (3 kHz or less). Source Converter section Inverter section Cause Rectifier circuit commutation Transistor switching To-electric channel, power...

  • Page 96: Split-Flow Path Of Harmonic Current

    REVIEW OF INSTALLATION ENVIRONMENT 7.1.3 Split-flow path of harmonic current When harmonic current is used in the power distribution system, the power supply of the harmonic current is not a general commercial power supply but the source of harmonics (the converter section for the general-purpose inverter).

  • Page 97: Harmonic Suppression Guidelines

    REVIEW OF INSTALLATION ENVIRONMENT 7.1.4 Harmonic suppression guidelines The harmonic current flows from the inverter to a power receiving point via a power transformer. The Harmonic Suppression Guidelines was established to protect other consumers from this outgoing harmonic current. The three-phase 200 V input specifications 3.7 kW or lower were previously covered by the "Harmonic Suppression Guidelines for Household Appliances and General-purpose Products"...
  • Page 98 REVIEW OF INSTALLATION ENVIRONMENT For compliance with the "Harmonic Suppression Guideline of the General-purpose Inverter (Input Current of 20A or Less) for Consumers Other Than Specific Consumers" published by JEMA Input power Applicable Countermeasures supply capacity Connect the AC reactor or DC reactor recommended in the catalog or instruction manual.
  • Page 99 REVIEW OF INSTALLATION ENVIRONMENT Follow the procedure below to examine the necessity of the harmonic suppression techniques along the "Harmonic Suppression Guidelines for Consumers Who Receive High Voltage or Special High Voltage". New specific consumer The guideline does not apply  ...

  • Page 100: Overview Of Harmonic Suppression Measures

    REVIEW OF INSTALLATION ENVIRONMENT 7.1.5 Overview of harmonic suppression measures The following table lists the basis and characteristics overview of the methods to suppress and absorb harmonics. Item Description Effect, etc. Connect an AC reactor on the power supply side of the inverter or/and a DC Reactor for inverter Harmonic current is suppressed to reactor on the DC side of the inverter to...

  • Page 101: Influence To Inverter At Instantaneous Power Failure

    REVIEW OF INSTALLATION ENVIRONMENT 7.1.6 Influence to inverter at instantaneous power failure When an instantaneous power failure occurs, the power supply voltage of the control circuit for the inverter is shut off. To prevent malfunction of control due to this power failure, activate the instantaneous power failure protection to stop the inverter output and keep the output stopped.
  • Page 102 REVIEW OF INSTALLATION ENVIRONMENT (c) Power failure for 100 ms or more The protective function is reset automatically at the power restoration and the inverter can be restarted. [Note] When the start signal (STF, STR) is ON, the inverter restarts at the power restoration. If the motor is coasting at this time, the 100 ms Power...

  • Page 103: Inverter Peripheral Circuit And Inverter Operation At Instantaneous Power Failure

    REVIEW OF INSTALLATION ENVIRONMENT 7.1.7 Inverter peripheral circuit and inverter operation at instantaneous power failure (1) For a magnetic contactor (MC) at the inverter's input line MCCB Inverter   When the instantaneous power failure time is short and both the magnetic contactor MC and relay RA do not trip (start signal STF remains ON), the operation is as described in Subsection 7.1.6.
  • Page 104 REVIEW OF INSTALLATION ENVIRONMENT (3) Automatic restart after instantaneous power failure control (a) Electronic bypass and automatic restart after instantaneous power failure function These functions operate properly only when one motor is connected to the CAUTION inverter. Using multiple motors disrupts proper operation of the functions. •...
  • Page 105 REVIEW OF INSTALLATION ENVIRONMENT (b) Operation of automatic restart after instantaneous power failure 1) When an instantaneous power failure occurs during operation, the motor starts coasting. 2) After a power restoration, applying the DC voltage from the inverter to the coasting motor carries the DC to the motor.
  • Page 106 REVIEW OF INSTALLATION ENVIRONMENT Power failure time deceleration-to-stop function Usually, when a power failure occurs, the motor starts coasting. However, if the power failure time deceleration-to-stop function is used, the motor can be decelerated in a relatively short time by using the regenerative power. Even though the start signal is ON, it does not restart at a power restoration.

  • Page 107: Noise

    REVIEW OF INSTALLATION ENVIRONMENT Noise As electronic devices is widely used, troubles due to the noise tend to increase. Since an inverter generates the noise in accordance with the operating principle, it may affect adjacent devices. The influence rate varies depending on circumstances such as the inverter control method, noise capacity of the adjacent device, wiring status, installation interval, and earthing (grounding) method.

  • Page 108: Types Of Noise And Propagation Path

    REVIEW OF INSTALLATION ENVIRONMENT 7.2.2 Types of noise and propagation path The inverter-generated noise is largely classified into those radiated by the cables connected to the inverter and inverter main circuits (I/O), those electromagnetically and electrostatically induced to the signal cables of the peripheral devices close to the main circuit power supply, and those transmitted through the power supply cables.
  • Page 109 REVIEW OF INSTALLATION ENVIRONMENT (1) Air propagated noise (Path 1) to 3)) The noise generated by an inverter is radiated and transmitted into the air following the three paths as shown in Fig. 7.14. 1) Radiation from the inverter 2) Radiation from the input cable 3) Radiation from the motor connection cable 3) Radiation from the motor...
  • Page 110 REVIEW OF INSTALLATION ENVIRONMENT Failure example: Noise [Failure] When using an inverter for the sprinkler in a golf course, an electric cart stopped while sprinkling water. [Cause] The noise of the inverter affected the power supply of the electric cart (supplied from the rail).  ...

  • Page 111: Countermeasures Against Noise

    REVIEW OF INSTALLATION ENVIRONMENT 7.2.3 Countermeasures against noise (1) Stance of countermeasures against noise Although there are many noise propagation paths as described in Subsection 7.2.2, the noise source can be classified into the following three types, as shown in Fig. 7.12 and Fig. 7.13. 1) Conduction, induction, or radiation from the input power supply cable 2) Induction or radiation from the motor connection cable 3) Radiation from the inverter...
  • Page 112 REVIEW OF INSTALLATION ENVIRONMENT 2) Line noise filter FR-BSF01, FR-BLF This filter consists of the core. Therefore, it can be used for all models regardless of the power supply voltage or capacity. Wind the all three-phase cables around the filter in the same direction as shown in Fig. 7.19 and insert it to the inverter power input side.
  • Page 113 REVIEW OF INSTALLATION ENVIRONMENT Table 7.2 Cable used and number of pass-through times ●FR-BSF01 ●FR-BLF Number of Number of When the cable is thick Cable Cable When the cable is thick pass-through pass-through (5.5 mm or more) used (mm used (mm times (T) times (T) (30 mm...
  • Page 114 REVIEW OF INSTALLATION ENVIRONMENT (b) Reducing the noise radiated from the wire between the inverter and the motor Although the radiated noise can be reduced by inserting the line noise filter FR-BLF or FR- BSF01 to the inverter output side as described previously, it is usually reduced by using a metallic pipe or shielded cable as shown in Fig.
  • Page 115 REVIEW OF INSTALLATION ENVIRONMENT (2) Specific examples of countermeasures The following figure shows promising countermeasures against the inverter noise. Note: For the radio noise, counter measures may not be effective in the Commercial power mountain area or inside a building where the airwaves are weak. supply line V.
  • Page 116 REVIEW OF INSTALLATION ENVIRONMENT The following table lists the promising effects (estimation) for each item of Meaning of signs countermeasure examples (refer to the previous page). When taking actual : Great effect countermeasures, refer to the list to determine the priorities. : Effective : Small effect —: No effect...

  • Page 117: Leakage Current

    REVIEW OF INSTALLATION ENVIRONMENT 7.2.4 Leakage current The static capacitances exist between the inverter I/O cables and other cables or earth and in the motor, through which a leakage current flows. Since its value depends on the static capacitances or carrier frequency, the low acoustic noise operation at the increased carrier frequency of the inverter will increase the leakage current.
  • Page 118 REVIEW OF INSTALLATION ENVIRONMENT (2) Line-to-line leakage current Table 7.5 Effects and countermeasures of line-to-line leakage current Type Effect and countermeasure • This leakage current flows via a static capacitance between the inverter output cables. • Harmonics of the leakage current may operate the external thermal relay unnecessarily. When the wiring length is long (50 m or more) for the 400 V class small-capacity models (7.5 kW or lower), the external thermal relay is likely to operate unnecessarily because the ratio of the leakage current to the rated motor current increases.

  • Page 119: Earth (Ground)

    REVIEW OF INSTALLATION ENVIRONMENT 7.2.5 Earth (ground) Generally, an electrical apparatus has an earth (ground) terminal, which must be connected to the ground before use. An electrical circuit is usually insulated by an insulating material and encased. However, it is impossible to manufacture an insulating material that can shut off a leakage current completely, and actually, a slight current flows into the case.
  • Page 120 REVIEW OF INSTALLATION ENVIRONMENT (b) This inverter must be earthed (grounded). Earthing (grounding) must conform to the requirements of national and local safety regulations and electrical codes. (NEC section 250, IEC 61140 class 1 and other applicable standards). A neutral-point earthed (grounded) power supply must be used for 400 V class inverter to be compliant with EN standard.

  • Page 121: Problems And Measures When Using Inverter

    REVIEW OF INSTALLATION ENVIRONMENT Problems and measures when using inverter This section explains the reliability and life of the inverter and important precautions depending on the installation environment of the inverter and the operating condition. In addition, the circuit design, precautions on wiring, and operating procedure for using an inverter are explained as well.
  • Page 122 REVIEW OF INSTALLATION ENVIRONMENT Life “Arrhenius equation” The smoothing electrolytic capacitor used in the inverter is one of the components to which the "Arrhenius equation" is applied. It will shorten the life by half for every 10°C increase in surrounding air temperature (double for every 10°C decrease).
  • Page 123 REVIEW OF INSTALLATION ENVIRONMENT Table 7.6 Amount of heat generated by the inverter and reactor (at the rated output) Reactor FR-A800 heat amount (W) Motor Inverter heat amount capacity (kW) FR-HEL FR-HAL 200 V 400 V 200 V 400 V 200 V 400 V 0.75...
  • Page 124 REVIEW OF INSTALLATION ENVIRONMENT (4) Interference of heat inside the enclosure and ventilation The arrangement of the inverter and ventilation fan is one of the important points when they are installed in the enclosure. When installing multiple inverter or a ventilation fan in the enclosure, note that the surrounding air temperature of the inverter increases or the ventilation becomes less effective depending on the installing position.
  • Page 125 REVIEW OF INSTALLATION ENVIRONMENT (5) Arrangement of the discharging resistor When using a discharging resistor or externally installed high-duty brake resistor (FR-ABR), take necessary countermeasures against the heat generated from the resistor. Consider the cooling system regarding the resistor as a heater. It is recommended to install the discharging resistor outside the enclosure.
  • Page 126 REVIEW OF INSTALLATION ENVIRONMENT ● Temperature (a) Countermeasures against high temperature 1) Use a forced ventilation system or similar cooling system. (Refer to (4).) 2) Install the enclosure in an air-conditioned electric chamber. 3) Block direct sunlight. 4) Provide a shielding plate or similar plate to avoid direct exposure to the radiated heat and wind of a heat source.
  • Page 127 REVIEW OF INSTALLATION ENVIRONMENT (8) When driving an explosion-proof motor with an inverter An explosion-proof motor has an authorization system in combination with the driving inverters. Check the following points for installing them. (a) For the existing explosion-proof motor for commercial power supply drive and a safety explosion-proof motor, the inverter operation is not available.

  • Page 128: Connection Of The Inverter

    REVIEW OF INSTALLATION ENVIRONMENT 7.3.2 Connection of the inverter (1) Terminal connection diagram Connection statuses of various terminals to operate an inverter are described in the catalog. The following explains the specifications and usage notes of these terminals when using the FR- A800 series as an example.
  • Page 129 REVIEW OF INSTALLATION ENVIRONMENT Failure example 1: Wiring for the power supply [Failure] Nothing was displayed on the monitor (LED display) when power of the inverter was turned [Cause] The commercial power supply inputs R/L1, S/L2, and T/L3 were connected to the output terminals of the inverter U, V, and W. The display of the power supply itself was incorrect. Three-phase AC power supply It must be within the permissible power supply specifications of the...
  • Page 130 REVIEW OF INSTALLATION ENVIRONMENT Failure example 2: Incorrect connection of the DC reactor [Failure] At a motor test drive, OV was displayed and the DC reactor was burned. [Cause] The DC reactor was connected to terminals P/+ and PR of the brake resistor instead of P/+ and P1. High-duty brake resistor (FR-ABR∗) Improves the braking capability...
  • Page 131 REVIEW OF INSTALLATION ENVIRONMENT (2) Connection of the main circuit Since the main circuit is a power circuit, incorrect connection may not only damage the inverter but also pose a risk to operators. The following figure shows points likely to fail. Do not apply the voltage Do not repeat starting and stopping frequently with this that exceeds the permissible...
  • Page 132 REVIEW OF INSTALLATION ENVIRONMENT (3) Connection of the control circuit The following table lists the formats of the I/O terminals in the inverter and common terminals. Terminal Format Example of terminal Common terminal SD or PC (power Start signal (STF, STR) Contact (or open collector) Selection signal (RH, RM, RL, AU, etc) Input...
  • Page 133 REVIEW OF INSTALLATION ENVIRONMENT 3) How to connect the frequency setting potentiometer correctly Each terminal of the frequency setting potentiometer has a terminal symbol. Incorrect connection causes an inverter failure. The resistance is also important for selection. 2 W 1 kΩ Wire-wound variable resistor type B characteristic Type C characteristics Type B characteristics Type A characteristics...
  • Page 134 REVIEW OF INSTALLATION ENVIRONMENT (4) Wiring distance of I/O cables Restrictions differ depending on the I/O terminal. Although the control signals are isolated at the input by photocoupler to improve noise tolerance, they are not isolated for the analog input. Therefore, pay particular attention to the wiring of the frequency setting signal and shorten the wire length as much as possible or take other countermeasures against the external noise.
  • Page 135 REVIEW OF INSTALLATION ENVIRONMENT (5) Wiring of the FR-BU2 brake unit For the wiring, connect a pair of the FR-BU2 brake unit and discharging resistor or resistor unit to the inverter terminals P/+ and N/-. (a) The FR-BU2 brake unit and the discharging resistor OCR contact ∗2 GRZG type...
  • Page 136 REVIEW OF INSTALLATION ENVIRONMENT (6) Wiring of the high-duty brake resistor (FR-ABR) A built-in brake resistor is connected to terminals P and PX. When the operation is frequently performed, only if the built-in brake resistor has insufficient heat power, remove the jumper across the terminals PR and PX.

  • Page 137: Precautions For Storing An Inverter In The Enclosure

    REVIEW OF INSTALLATION ENVIRONMENT Precautions for storing an inverter in the enclosure Refer to Fig. 7.43 for precautions of enclosure storage. Install a device which generates large heat away from the inverter. 3.7K or lower: 1 cm or more Install it to the best position where 55K or lower: 5 cm or more  ...
  • Page 138 REVIEW OF INSTALLATION ENVIRONMENT Failure example 1: Inverter failure due to leaking [Failure] An inverter in an enclosure installed outside stopped on a rainy day. [Cause] A short-circuit of the internal plate was found on the investigation of the inverter in the enclosure.
  • Page 139 REVIEW OF INSTALLATION ENVIRONMENT ● Dust, dirt, oil mist Dust and dirt will cause such faults as poor contacts, reduced insulation and cooling effect due to the moisture-absorbed accumulated dust and dirt, and in-enclosure temperature rise due to a clogged filter. In an atmosphere where conductive powder floats, dust and dirt will cause such faults as malfunction, deteriorated insulation and short circuit in a short time.

  • Page 140: Chapter 8 Life Of Inverter Parts

    LIFE OF INVERTER PARTS CHAPTER 8 LIFE OF INVERTER PARTS 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 fault of the inverter. For preventive maintenance, the parts must be replaced periodically.
  • Page 141 LIFE OF INVERTER PARTS (3) Relays To prevent a contact fault, relays must be replaced according to the cumulative number of switching times (switching life). The table below shows the replacement criteria of inverter parts. The other parts which have a short life, such as lamps, must be replaced with new ones when performing the periodic inspection.

  • Page 142: Inverter Parts Life Display

    LIFE OF INVERTER PARTS Inverter parts life display The degree of deterioration of the control circuit capacitor, main circuit capacitor, cooling fan, and inrush current limit circuit can be diagnosed on the monitor. When a part approaches the end of its life, a warning can be output by self diagnosis to prevent a fault.
  • Page 143 LIFE OF INVERTER PARTS (1) Life warning display and signal output (Y90 signal, Pr.255) • Whether the parts of the control circuit capacitor, main circuit capacitor, cooling fan, and inrush current limit circuit have reached the life warning output level or not, can be checked with E700 (Pr.255) and the life alarm signal (Y90).
  • Page 144 LIFE OF INVERTER PARTS (2) Life display of the inrush current limit circuit (E701 (Pr.256)) • The life of the inrush current limit circuit (relay, contactor and inrush resistor) is displayed in E701 (Pr.256). • The number of contact (relay, contactor, thyristor) ON times is counted, and it is counted down from 100% (0 time) every 1%/10,000 times.
  • Page 145 Remark When the inverter is mounted with two or more cooling fans, "FN" is displayed with one or more fans. For replacement of each part, contact your local Mitsubishi Electric System & Service Co., Ltd. 8.2 Inverter parts life display...

  • Page 146: Diagnosis Using Fr Configurator2

    LIFE OF INVERTER PARTS Diagnosis using FR Configurator2 "Diagnosis" displays fault information of the inverter. Select [Faults History (A)] in the [Diagnosis (D)] menu to display the "Faults History" window as a sub window. 8.3.1 Explanation of window Symbol Name Function and Description Station Select Select a station for which faults history is to be displayed.

  • Page 147: Chapter 9 Replacement Procedure

    REPLACEMENT PROCEDURE CHAPTER 9 REPLACEMENT PROCEDURE This chapter describes how to replace the Mitsubishi inverter FR-A700 series with FR-A800 series. Saving FR-A700 parameters and replacing with FR-A800 parameters (1) Prepare a personal computer where FR Configurator2 (SW1DND-FRC2-E) is installed and a cable for inverter connection.
  • Page 148 REPLACEMENT PROCEDURE (7) Select [Read from connected inverter]. Check that [Connection type] is "USB", and specify the station number connected to the source inverter in [Target station]. Select [Read from connected inverter] After specifying the station number, click [Detection]. After detection, check the inverter model in the [Model] field, and Click [Detection].

  • Page 149: Setting The Parameter

    REPLACEMENT PROCEDURE Setting the parameter (1) Prepare a personal computer where FR Configurator2 (SW1DND-FRC2-E) is installed and a cable for inverter connection. (2) Turn ON the FR-A800. (3) Connect the personal computer with the FR-A800. USB host (A connector) Communication status LED indicator USB device (mini B connector) (4) Turn ON the computer and start up the FR Configurator2 (SW1DND-FRC2-E).
  • Page 150 REPLACEMENT PROCEDURE (6) Parameters converted for the FR-A800 are listed on the [Setting Value] column. (7) Click [PU] to change the operation mode to PU. (8) Check and write down the setting values of E400 (Pr.77), D000 (Pr.79). When E400 (Pr.77) is "1", change the setting values of E400 (Pr.77) to "0". When D000 (Pr.79) is other than "0 or 1", change the setting values of D000 (Pr.79) to "0".
  • Page 151 REPLACEMENT PROCEDURE (10) Click [Batch Write] to write the parameters on the FR-A800. (11) Turn OFF the personal computer, and then turn OFF the inverter. (Note that some parameter setting values reflect the inverter after turning off or resetting the inverter.) Mount the operation panel.

  • Page 152: Installation Of The Fr-A800

    REPLACEMENT PROCEDURE Installation of the FR-A800 (1) Install the FR-A800 to the enclosure. Since the installation size of 280K model or lower of the FR-A800 inverter is the same as that of the FR-A700, the FR-A800 can be installed as it is in the mounting hole of the FR-A700. (2) Open the wiring cover and route the main circuit wires.
  • Page 153 Memo    ...
  • Page 154 INVERTER SCHOOL TEXT INVERTER TROUBLE SHOOTING COURSE (FR-A800) HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN When exported from Japan, this manual does not require application to the MODEL Ministry of Economy, Trade and Industry for service transaction permission. MODEL CODE SH(NA)-060029ENG-A (2110)MEE Printed in Japan...

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