MlTSUBlSHl

VVVF TRANSISTOR INVERTER

-INSTRUCTION MANUAL-
( 208/230V series I

MlTSUBlSHl
ELECTRIC

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 FORWORD

Thank you for your purchase of Mitsubishi Multi-Purpose Inverter FREQR0L.K .

This is a variable frequency power supply unit to control the speed of squirrel-cage induction motors. This in-
struction manual is intended both to explain the unit and to outline operation procedures.

This unit is not difficult to operate. but incorrect operation may lead to some troubles. so read this instruction
manual carefully before operation. I f you use to unit properly. we are sure it will give you many years of satisfac-
tion .

Please make sure to attach this instruction manual to the unit when the unit is shipped.

CONTENTS

1. UNPACKING 1
2. TRANSPORTING 1
3 . INSTALLATION ......................................................... 1
4 . WIRING AND POWER SUPPLY RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4-1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4-2 Power supply rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
5 . OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5-1 Points to check before operations .......................................... 4
5-2 Preparations before operations ............................................4
5-3 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5-4 Operation's precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 . MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 . CONSTRUCTION AND ARRANGEMENTOF CONTROLLER PARTS . . . . . . . . . . . . . . . . . . . . . 8
8 . TROUBLESHOOTING AND COUNTERMEASURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8-1 Troubleshooting chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8-2 Failures indicated by lighting of alarm indication lamps and how to deal with them . . . . . . . . . 13
8-3 Measuring voltage and current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9. STANDARDSPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10. PROTECTIVEFUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
11. INPUT/OUTPUTTERMINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

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 1. UNPACKING

After unpacking your FREQROL-K, first check the following points.

0 Refer t o the name plate t o confirm that the model and the output rating is indeed the one you ordered.
(See table 1)
0 Check where there has been any damage or breakage t o the FREQROL-K during transportation.
I f you have any doubts about the above, or find any damage t o the unit, please contact your local service
representative.

Table 1 FR-K Series Configuration

Motor output (HP) 112 1 2 3 5 7.5 10

Without operation FR-K- FR-K- FR-K- FR-K- FR-K- FR-K- FR-K-

panel 400-U 750-U 1500-U 2200-U 3700-U 5.5K-U 7.5K-U

With operation FR-K- FR-K- FR-K- FR-K- FR-K- FR-K- FR-K-

panel 400M-U 750M-U 1500M-U 2200M-U 3700M-U 5.5KM-U 7.5KM-U

Note: The operation panel is provided with a frequency setter, a frequency meter and a FWDIREV starting
switch.

2. TRANSPORTING

When transporting the FREQROL-K, handle it gently to prevent damage. There are depressions on both the
top and the bottom where the unit can be grasped, and these should be held when it is moved.
Do not apply too much force t o the fan at the bottom of the unit. The unit is covered with a plastic case,
and care should be taken n o t to apply force only t o this cover during transport.

a 3. INSTALLATION

o Place the inverter in a clean and well ventilated location. Avoid locations exposed t o direct sunlight, or
subject t o high temperatures, humidity, dust or corrosive gases.
0 Install the inverter securely on the wall with volts or screws, vertically so that the letters "FREQROL-K"
appears front.
0 Since the inverter does generate some heat during operations, any other equipment or parts should be
installed at least 10 cm away from up and the bottom t o prevent heat confined.
The brake resistor attached t o the rear of the unit also generates heat, so the unit should not be placed on
a wall with low heat resistance.
0 If your inverter is one equipped with an operation panel, take care t o put it i n a place where it can be
easily operated.

4. WIRING AND POWER SUPPLY RATING

4-1 Wiring

Connect wiring correctly according to following instructions and refer t o Fig. 1, Standard Wiring
Diagram.
Fow wiring of the peripheral devices such as MCCB, refer t o Table 2, Selection of Peripherals.
(1) When the wiring cover located at the bottom of the inverter i s pushed inward and then pulled
toward the operator, the wiring cover alone i s removed thus exposing all terminal blocks. A
corrugated gripping surface has been provided for your convenience. Now perform wiring.

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 (2) The wirings of the frequency setter, FWDIREV start switches, frequency meter and calibration
resistor of meter equipped with an operation panel in Fig. 1 have already connected.
(3) Do not wire the power cable in such a manner that the line source voltage is directly applied to
the output terminals U, V and W.
(4) It is not always necessav to provide wiring to the reset switch, since the circuit can be restored
by cutting off MCCB or Magnetic Contactor (MS) if the output protective circuit has been
activated to stop the controller.
(5) Since terminals P and N have been provided for brake unit and discharge resistor connections,
avoid connecting only discharge resistor, or any other equipment, to these terminals.
(6) It is not necessary to consider the phase sequence when connecting to terminals R, S and T.
(7) Since the frequency setting signal current i s extremely low if it is necessary to use contacts in the
frequency setting circuit, use two pairs of parallel contacts or twin contacts for extremely low
current to prevent poor contact.
(8) Use shielded wires or twisted wires as the wire cable in connections to the control terminals
(terminals marked as in Fig. 1, Standard Wiring Diagram) to prevent the control circuit from
being induced by other equipment, and also connect them away from the main circuit and high
voltage circuit (Relay sequence circuit of 230V. 115V).

Twisted wire . ~ . Shielded wire

Frequency setter Frequency setter

(9)The output wires from the inverter are protected from short-circuiting (i.e., short-circuiting
among terminals U, V and W) by an overcurrent protective circuit. However, there is no pro-
tection against shortcircuit caused by accidental leakage such as grounding. Therefore, care
should be taken to position the wires so as to prevent them from making contact with the chassis,
etc.
(10) Rotation direction of the motor is counterclockwise as seen from the load side with the normal
wiring to the output terminals U, V and W.

4-2 Power supply rating

The FREQROL-K is shipped by the standard power supply rating of AC 230V 60Hz. I f you are going
to install the FREQROL-K where the power supply is AC 208V 60Hz, change the connection for the
transformer T I as shown below.
In this case, take care to check the box on the front cover which indicates that the power supply rating
has been changed.
Transformer T 1

Change form 230V to 208V

or vice verra.

the terminal black

R1 and T 1

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 Table 2 Selection o f Peripherals

Model / Current Ratings

of MCCR a dMS / Wires R, S. T I Wires U, V, w I
F R-K400-U 5A mps #14 AWG #14 AWG
F R-K-7504 10A mps #I4 AWG #14 AWG
F R-K-1500-U 15A m ~ s #14 AWG #14 AWG
FR-K-2200-U 20A mps #14 AWG #14 AWG
FR-K-3700-U 30A mps 2 AWG
#I #12 AWG
FR-K-5.5K-U 50A mps #lo AWG # I 0 AWG
FR-K-7.5K-U 60A mps # 6 AWG # 8 AWG
Note: 1. A wire size of #19 AWG or more i s adequate all circuits other than the main circuit.
2. Select MCCB and MS according t o power supply capacity.
3. I f wiring distance exceeds 30 meters, increase wire size.

--
Fig. 1 Standard Wiring Diagram

NFB
IMCCBI
/L
MS 1'21
9
1 OCR ('11 Motor

FREOROL-K
Inverter I

STF
Reret aw.

STR

SD SD

FM

Calibratiot NOTE:
Frequency meter 1. I f you are running a motor w i t h
moving coil type 1 1 3 1~0 k a different capacity from the
1 mA inverter, or more than one motor.
(Hz indication] ~ r o v i d ethermal overload relay t o
the inverter's output circuit.
2. The purpores of this MS as
follows,
11 I f the n s r t switch is held
meCnanlCB v , tne nverter w I
restart a.tomat'ca v nnon the
Frequency setter m n e r I . O. D. ~ .Y I a . m
. e0 after
2W 1 kSL the momentary power inter-
ruption. For application when
auto.restart must be avoided.
this MS must be inrtalled.
21 I n the case the inverter must
be restarted until the motor
are built into inverters
has sopped coasting, or the
an operation panel. output transinor might be
damaged.

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 5. OPERATIONS

5-1 Points to check before operations

After installation and wiring of FREQROL-K is completed, check the following points before opera-
ting.
If insulation is to be checked with a megger, perform only the test between controller and grounding.
Never perform a megger test between the inverter's terminals.
Also do not perform a megger t e n on the control circuit terminals.
Refer t o section 6 for details on megger insulation tests.
(1) Check whether wiring conforms to the standard wiring diagram.
(2) Check for points short-circuited by broken wire, etc.
(3) Check if any wire is strained.
(4) Check tightness of screws, of terminals and other fasteners.
(5) Check motor load conditions.

5-2 Preparations before operations

When inspection is completed, open the setting panel flap on the inverter front panel and make the
following setting.
5-2-1 Selection of maximum output frequency (set with connector)
By changing the position of the connector on the P.C. board, set the maximum output frequency.
The maximum output frequency is set to 60Hz at shipping. (Don't change the connector while inverter
is operating)

1. 60Hz
(At shipping)

Note: If you are using a general-type motor, do not set the maximum output frequency to 240Hz.
(This setting is for specialdesigned motors.)
5-2-2 Selection of frequency setting signal (set with sleect switch)
The settings O-5V and 0-10V are available for frequency signal. The 0-5V position is set at shipping. If
another setting is required, select as follows:
(1) For 0-5V DC signal: s e t the select switch to the down position. (at shipping)
(2) For 0-10V DC signal: set the select switch to the up position.
5-2-3 Setting of accelerationldeceleration time (set with ACCE LIDECEL dials and select switches)
Set acceleration and deceleration times by setting the ACCEL and DECEL dials and the accelera-
tion and deceleration time magnifying select switches.
(1) Acceleration and deceleration times can be set independantly.
(2) Acceleration and deceleration time refers to the time during which output frequency is
increasing from 0 to maximum frequency or decreasing from maximum frequency to 0.
(3) The relationship between the figures on the notches of the ACCEL and DECEL dials and the
position of the accelerat~onand deceleration time magnifying select switch is shown in the
figure below. Set them a t positions appropriate according to applications and kinds of the
motor load.

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 10 -150 rec. 0.2 - 3 sec.
110 secor~dsincrement) 10.2 second increment1

(4) Both the acceleration and deceleration times are set at 5 seconds at shipping.

5-2-4 Sening of electronic thermal relay (set b y setting dial)

(1) For setting of the electronic thermal relay, the rated output current of the inverter is deter-
mined at 100%. (The setting range i s 50 t o loo%.)
(2) The electronic thermal relay is s e t at 100% at shipping.
(3) Set the setting dial for the electronic thermal relay by calculating the percentage according
t o the following equation.
0 When s single motor is operated by the inverter, the following equation applies:

Rated current of the motor ( A )

Set scale (%) = - x 100
Rated output currentof the inverter ( A )

I f the value of the s e t scale (%) exceeds 100%. then s e t the setting dial t o 100%.
Rated output current i s shown i n the name plate.
(4) I f a multipole motor with eight or more poles, an special-purpose motor, or plural motors
are being operated, the built-in electronic thermal relay will n o t affort sufficient protection
so a thermal overload relay should be added t o the inverter's output circuit.
I f such cases turn the electronic thermal relay setting dial (TH) as far as it will go i n the
clockwise direction.

5-3 Operations

When the preparations have been completed, begin inverter operations in the following procedure:
(1) First close the MCCB, then the magnetic contactor (MS) by pushbutton. The power pilot lamp
on the inverter panel should light in yellow. The motor will not yet rotate in this state. Touch the
motor with your hand t o see that there are no buzzing sounds or vibration.
(2) I f there are no zbnormalities, turn the FWD start switch (or REV start switch) on. Gradually turn
the knob of frequency setter clockwise. When the knob is turned t o "3Hz" position, the motor
will start rotating. And turned farther clockwise, the frequency (rotation of the motor) will in-
crease gradually ap to i t s maximum frequency setting (60Hz. 120Hz or 240Hz)
(3) When the frequency setter has been s e t at the desired frequency, and the FWD start switch (or
REV start switch) has been turned on, motor revolutions will increase to the set value within the
time s e t by the acceleration time setting dial described above, and then continue t o operate at the
setting frequency. I f the motor does not accelerate smoothly and the A L A R M lamp blinks during
the acceieration or the "ALARM" indication lamp lights up, this is because the acceleration time
has been s e t at too short period i n relation t o the motor load, and the acceleration time should
thus be lengthened.

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 (4) When the FWD start switch (or REV start switch) is turned off while the motor is rotating, motor
speed is decelerated in the time'period set by the DECEL dial. When the frequency falls below
3Hz. the DC dynamic brake will be activated and the motor will stop immediately. If the motor
speed does not decelerate smoothly and the ALARM lamp blinks during the deceleration or the
"ALARM" indication lamp lights up, this is because the deceleration time is not sufficient for the
motor load, and the deceleration time should thus be lengthened.
(5) I f the FWD start switch and the REV start switch are turned on simultaneously, the motor will not
rotate. Also, if the FWD start switch and the REV start switch are simultaneously activated while
the motor is rotating, the motor will begin decelerating in the same manner as when the FWD (or
REV) start switch is turned off.
(6) If the FWD start switch is turned off and the REV start switch turned on while the motor is rotat-
ing forward, the motor speed will decelerate t o a frequency of 3Hz. at which point the rotation
direction will automatically be reversed, accelerating gradually tothe frequency that has been set.
The same is also true of movement from reverse to forward rotation.
(7) I f the settings of the acceleration or deceleration times are changed during motor operations, the
previous settings will remain in memory and the changes will not take effect. Note that this
unit is designed for changes in the setting of acceleration and deceleration time to be made at a
inverter frequency below 3Hz.
(8) I f the protective circuits, such as those against overcurrent and regenerative overvoltage are
activated, the alarm indication lamp will light up in red and the shut-off state will continue. To
reset
after a shut-off, perform the following operations:
0 First turn off the power supply with the MCCB or the Magnetic contactor (MS), then turn

it on.
0 Short-circuit the terminals between RES (reset) and SD (common) of the control circuit by the
reset switch, then (after about 0.1 second), re-open.
(9) Use the calibration resistor to adjust the frequency meter so that the frequency i s indicated as 60,
120 or 240Hz when the commanded voltage (across terminals between 2 and 5) is set to 5V DC
or 10V DC by the frequency setting input signal select switch.
Inverters equipped with a frequency meter have already been adjusted at the factory before
shipping.
(10) When the DC dynamic brake activates at below 3Hz during deceleration, it may cause a high-
pitched noise. This noise is common, and does not indicate any abnormalities (The DC dynamic
brake functions for about 0.5 second.)

5.4 Operation's Precautions

When the confirmations described above have been completed you may begin normal operations, but
keep the following points in mind when doing so.
(1) When a general type motor is being driven by the inverter, the temperature, noise and vibrations
will be somewhat higher than they would be with a commercial power supply.
(2) Since cooling efficiency decreases at low speed operations, it is necessary to reduce the torque
from the rated motor torque. (Refer to the catalog for the torque reduction ratio.)
(3) The FREQROL-K is capable of controlling plural motors at the same time. When the inverter is
used to control more than one motor, care should be taken that the total current requirement for
the simultaneously operated motors is within the rated output current of the inverter.
(4) I f the FREQROL-K is being used to control multipole motors with 8 or more poles, submersible
motors. or other special-purpose motors, carefully examine the rated current and other electrical
specification.

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 (5) Do not add a capacitor nor surge absorber t o the output circuit of the inverter. This may activate
the overcurrent protection.
(6) I f you are using a motor with mechanical brakes, the brake exciting circuit should not be con-
nected t o the inverter output, and make certain theat brake action can be affected after turning
off the inverter's power supply.
(7) I f using motors o f different capacity or special-purpose motors, or i f more than one motor is being
used simultaneously, add a thermal overload relay t o the inverter output circuit t o protect the
motor from being burned up. I n this case turn the electronic thermal relay setting dial (TH) on
the operation panel as far as it will go i n the clockwise direction.
(8) Th= FR-K-400 can also be used with a single phase power supply, but when doing so be sure t o
connect the power supply t o terminals R and S.
(9) Since the built-in brake resistor will cause temperature increases, mount it on noninflammable
materials such as metal or concrete.

6. MAINTENANCE AND INSPECTION

The FREQROL-K is the static type, so almost no daily maintenance is required. The following maintenance
practices should, however, be observed.
(1) Since the capacitor i n the inverter remains charged at high voltage for a while after the inverter is turned
off, perform inspections only after charge indication lamp "CHARGE" goes out. Also, the cooling fan
will continue t o run for some time after the power has been turned off, so be careful t o keep hands away
from this area.
(2) From time t o time, inspect the inverter for dust and dirt accumulated inside, and clean it i f there is a
buildup.
(3) Check the tightness of terminal block screws and mounting screws. I f they come any loose, tighten
them securely. Make certain there are no defects i n the wiring parts or components. Replace defective
wiring part i f found, or contact your service representative.
(4) Megger test
a) When performing a megger test on the external equipment, remove all inverter terminals so that the
test voltage will not be applied t o the inverter.
b) Perform megger tests only for the main circuit of the inverter as shown i n Fig. 2. Do not apply the
test voltage t o the control circuit.
c) TO check the FFiEQROL-K control circuit, use a multimeter (set t o high resistance range position).
Do not use a megger or buzzer.

Fig. 2 Megger Test

-
Earth terminal

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 7. CONSTRUCTION AND ARRANGEMENT OF INVERTER PARTS I
As noted above, wiring requires only the removal of the wiring cover at the bottom of the inverter. To
inspect the inverter's interior, however, proceed as follows:
(1) When the wiring cover is removed, the plastic cover's two set screws will be exposed. Remove these
screws and slide the plastic cover upward.
(2) The P.C. board of the control circuit has been attached by set screws (for inverters below class FR-K-
3700-U) or the board support (for FR-K-5.5K-U and FR-K-7.5K-U).

Fig. 3 Type FR-K-400-U to FR-K-3700-U Fig. 4 Type FR-K-5.5K-U and FR-K-7.5K-U

Control circuit terminal arrangement

TR?

Control circuit terminal arrangement

TB4

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 8. TROUBLESHOOTING A N D COUNTERMEASURE

I n the unlikely event that there should,be problems with the inverter or i t s should lose any of its functions,
use the troubleshooting chart below t o identify the cause and apply the appropriate countermeasure. If your
problem i s not described below, the inverter i s out of order, one of the parts has been damaged or i f you have
any other problem not dealt with here, contact with your local service representation.

8-1 Troubleshooting Chart

( 1 ) Motor does not run

i
i START

Note 1.
power supply has been
Are MCCB (ELB), MS. Yes
terminals R and S, S etc. turned on? Defective MCCB (ELBI or
and T . T and S. MS, or wiring trouble

lamp lit up?

pacity transformer?

Inverter trouble

Cooling fan trouble

tion relay of radiation
Ventilation obstruction fan. Remove

Set reret rwitch lbetween terminals

Is reset switch "ON"? RES and SD) t o "OFF"

1s voltage across termi-

nals RES and SD below
14V?
t yes .(
Defective reret switch
Transistor falls t o function when energized.

L No
lcont'd on next right page1

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 (cont'd from left pagel

I No

IAre terminals STF and

STR both ON?
Either STF or STR should be
continuity; not both.

J, No
1s voltage across termi-
nals STF lor STRI and Poor start switch contact
SD greater than 1V7 , Transistor fsilr t o function when energized.

P
Has voltage been applied
Has voltage been applied Yes
to motor terminals U
and V, V and W, and W > to frequency command Inverter trouble
,and U? J terminals 2and 5?
I

I
v

I s voltage across termi- %,-

nalr 5 and 10 5V (or

trouble or wiring
trouble

Note 3.

Is three-phasevoltage Yes Is voltage still unbalan-

out of balance? > ced after disconnecting Inverter trouble
motor terminals.

Motor trouble

.
Motor overload
Magnetic brake does not open.
Motor trouble
Note 0: ELL3 = Earth Leakage Braker
Wiring trouble
Note 1: Out of voltage should be within f10%of rated voltage.
Note 2: Is thermal overload relay IOCRI connected.
Note 3: Imbalanced should be within 1%of maximum output voltage.

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 (2) Motor buzzes and does not run.

Does frequency meter fail

t o change even though Overload causer activation Increase inverter capacity
frequency setter has been of protection againat stalls. and motor capacity.
turned t o increase?

A Note 4.

Is output voltage across

terminals U and V. V
Inverter trouble
and W, and W and U
out of balance?

Motor trouble
Note 4: Examine this w i t h motor disconnected

(3) Motor runs a t constant speed and cannot be controlled.

,
-
/
OV t o 5~ lor from 1~ t o Frequency rener trouble
10Vl across terminals 2
and 5 even after freque-
ncy setter has been t u r -
ned on?

No
Inverter trouble

(4) Motor overheats.

u

Ir motor overloaded? Yes Lighten the load or increase capacity of motor and

No

Does motor run a t l o w

speeds for long periods Lighten the load or ventilate the motor f r o m
of time? or increasecapacity of motor and inverter.

I
& Note. 6
I
IS output voltage among
terminals U and V, V
and W, W a n d U out Of Inverter trouble
balance?

I s there any obstruction

t o motor cooling? Remove obstruction.

Inverter trouble Note 5: Overload should be below 110% of motor rated current l60Hz. 220V ACI.
Note 6: Proper balance i s not more 1%of maximum output voltage.

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 (5) Motor does not run s m o o t h l y
Note 7.
Does problem occur Is accelerationldecele- ngthen acceleration1
during acceleration/ ration time too short? deceleration time.
deceleration?

Load 4 t o o heavy.
Increase capacity of
motor and inverter.

I Does output voltage

fluctuctuate?

\L
Is voltage out o f balance
amaung terminals U and yes
V, V and W. W and U?
NO

Har there been a load Yes Minimize load variation or attach flywheel t o motor.
vibration? Run w i t h load vaciation.

Is there any backlash i n

chain, gear. etc.? Improve mechanical parts.

No

Capacitor for constant

Has inverter been used
output voltage has been
for 5 t 0 10 years?
used beyond service life.

Inverter trouble

Note 7: Anivatlon of protectton function against stalls causes unstable acceleratianldeceleratian

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 8-2 Failures Indicated by Lighting of Alarm Indication Lamps and How to Deal with Them

The protective functions can be activated by various conditions, as shown below. I f an alarm indication
lamp lights up, it i s important t o keep your head and examine the cause of the problem, and then t o
apply the appropriate countermeasure.

Alarm Cause Description Countermeasure

Acceleration time i s too Lengthen acceleration1

short. deceleration time.

Inverter's output circuit i s Check whether the magneti Correct sequence if wrong.
turned on and off. contactor has been turned If it i s necessary to turn on
on after the inverter start and off of inverter's output
signal (ST) went ON. circuit, increase the capacit
of inverter by five times or
more.

Peak load reached Adjust machine so that

nstan-ianeously. peak load i s not reached.
Increase capacity of in-
verter by 1 or 2 class.

Load i s too heavy Even after acceleration timt Since static friction torque
has been lengthened, motor i s larger than the torque of
hardly runs before the alarn motors under 3Hz at start-
indication lamp lights up. up, increase capacity of
(The electronic thermal motor and inverter. Lighter
relay has been activated dut the load or change opera-
t o overload or overheating tions partern.
caused by low speed opera-
tions, thus turning alarm
indication lamp on.)

Built-in brake is being Deceleration may be done Either lengthen the decel-
Uarm lsed too frequently. i n several stages. If the eration time or lessen its
ndication maximum number a l l ~ w a b l ~frequency. Add an exter-
amp "ON' is exceeded, however, this nal brake unit.
will increase the frequency
of use of the brake, and an
alarm indication lamp will
come on.
-.
:Ither a capacitor for There is an overcurrent Remove them. If they
lower factor improvement because impedence of have been factory-set, care
l r a capacitor for surge capacitor is small against should be taken not t o
jbsorber has been inserted high frequency. forget t o remove them.
3 t inverter's output circuit. It is recommended to
insert a reactor into the
input circuit in order to
improve the power factor.

jhort-circuit or ground Ground faults do not alway Locate the short-circuited

'ault i n the output circuit cause an overcurrent trip points and apply the ap-
)f the inverter. (OCT) state. If a ground propriate countermeasure.
fault occurs, i t may lead t o
inverter trouble.

Motor is turned on again Since inverter starts opera- Restart the motor only
luring free running (runnin tion at 3H2, motor runs by after it has stopped com-
sf inertia force after power regenerative operation, pletely.
ias been turned o f f ) . which generates overcurreni I n automatic operation, use
a timer to start the motor
after it has stopped com-
pletely.

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 Alarm Cause I Description Countermeasure

t
Activation of the When the fin for cooling Cooling fan trouble or
temperature detection power modules is over- ventilation obstruction in
relay of the rediation fin. heated, the temperature radiation fin has caused a
sensor activates to stop rise in temperature, so
output remove those troubles.

External noise. Consider the possibility Twisted wire or shield

of external noise when wire are used fo the fre-
the alarm indication lamp quency setting signal cir-
lights up for causes other cuit (10, 2.5). Shield wire
than these described above. should be connected to
terminal " 5 only and do
Alarm
not connect shield wire
indication
with grounding or around
lamp "ON"
terminal of other circuit
(i.e., instrumentation
circuit).

Instantaneous power If there has been an in Reset the inverter and

failure. stantaneous power failure restart it. I f you wish to
for 15 msec or more, and keep the alarm state on
the power supply has been display, use an external
restored before the motor circuit.
has stopped after a free
running, overcurrent may
occur.

Note: If you cannot identify the trouble even after checking all the points listed above, try discon-
necting the motor from the inverter. If the alarm indication lamp still comes on, there has been
a breakdown in the inverter.

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 8-3 Measuring Voltage and Current

Since the primary and secondary voltage and current contain high frequency, data may differ depend-
ing upon the instrument used and the circuit t o be measured.
I f you use a measuring instrument for commercial frequency, select one listed i n Table 3 and measure
the circuit as shown i n Fig. 5
Variation o f the indicated value are shown i n Fig. 6. However, even measuring instruments of the same
accuracy may be inconsistent because of differences i n factors such as manufacturer, model type or
year made, etc.

FR-K Inverter

7
Fig. 5 Points t o be Measured and Examples of Measuring Instruments

Example: Output voltage of inverter

Motor rating: 3.7 kW 4P
FR-K.3700-U Inverter
Take the indicated value of
rectifier type voltmeter as
100%.

4 Rectifier type

k Moving-iron type

Electrothermic type

Fig. 6 Variation of Indicated Value Depending on the Type of the

Measuring Instrument

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 Table 3 Terminals to be Measured and Measuring Instrument

Item Terminals to be measured Measuring instrument Remarks (reference value)

Supply voltage: V1 Across terminals R and S, Moving-iron type Commercial voltage:

Current at power supply:

Sand T, and T and R.
Line current at terminals
9:fi Moving-irontype
230V

I1 R, S and T.
Power at power supply: Terminals R, Sand T and Electro-dynamo- P = WI + Wn
P1 across terminals R and S, meter type
and S and T.
Power factor at power Measure supply voltage (Vl), current at power supply (11) and power at powet
supply: Pfl supply (PI ), and calculate power factor using equation shown below:
PI
Pfl = 100%
fiV1 . I1
Voltage at output: V2 Across terminals U and V, Rectifier type Difference between each
V and W, and Wand U. + (Moving-irontype phase should be within
is not available) 10%
Current at output: 12 Line current at terminals Moving-irontype Below rated current of
U, V and W. inverter
Difference between each
phase should be within
10%.
Power at output: P2 Terminals U, V and W and Electro-dynamo-
across terminals U and V, $ meter type
and V and W.
Power factor at output: Calculate in a similar manner as for power supply, using the following equation:
Pf2

Output of converter Across terminals P and N Moving-coil type Charge lamp lights up
(such as multi- when voltage is 10V DC
meter) or more.
1.35 x v 1
Maximum 380V DC
during regeneration.
Frequency setting signal Across terminals 2 and 5 Movinwcoil tvpe 0 to 5V DC I3
(such i s multi-.
W meter)
(internal resistance
5 0 kCl or more)
Power supply for fre- Across terminals 10 and 5
quency setting
Power supply fot Across terminals FM and About 5 V DC at
frequency SD maximum frequenq
(when frequency
meter is connected.)
Forward operation signal Across terminals STD and Open: 13V DC to
SD 19V DC
ON voltage:
Reverse operation signal Across terminals STR and 1V DC or less
SD OFF voltage:
13V DC or more
Reset Across terminals RES and
SD
Base shut-off (alarm) Across terminals Band C Moving-coil type Measuring continuity
signal (such as multi- Continuity when power
meter) supply is shut off or
during normal operations.

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 9. STANDARD SPECIFICATIONS

I Nominal o u t p u t (HP)

Output capacity ( k V A )
-

-
FR-K-
400-U / FR-K-
750-U
FR-K-
1500-U
FR-K- FR-K-
2200-U 2.700-U / FR-K-
55K-U
FR-K-
7.5K.U

Rated o u t p u t current (A)

Maximum output voltage

Power source requirement ( k V A )

ilVeight (kg)

Construction Totally enclosed type 1 Enclosed t y p e

Voltagelfrequency

Allowable voltage regulation

Allowable frequency regulation

Control method Sinusoidal PWM, Voltage-control

1 : 1 0 ( 6 - 60Hr) or 1 : 2 0 ( 6 - 120Hz) or 1 : 4 0 ( 6 - 240Hz) selectable

Frequency range
(Operation starts at 3Hz)

Frequency resolution
(Hzlmaximum frequency)

Frequency accuracy

VoltagefFrequency ratio is constant until 60Hz.

Voltageifrequency ratio
Voltage i s constant above 60Hz
7
Overcurrent resistance
;
-150% f o r one minute

I Frequency setting signal 0 - 5 V DC, 0 - 1 0 V DC changeable

i 0.2 - 3.0 rec. (in 0.2 sec. increments),

i Acceleration1deceleration time 1 - 1 5 sec. (in 1 sec. increments),
10 - 150 sec. ( i n 10 sec. increments) selectable

Regenerative braking torque Over 70% o f rated motor torque (short t i m e rating)

Protection against stalls caused b y overcurrent, protection against stalls

caused b y regenerative overvoltage, overcurrent protection, regenerativ,
Protective functions overvoltage protection, overload protection (electronic thermal relay),
instantaneous power failure, thermo detect o f the heatsink (*3), alarm
against overload.

-1 0•‹C t o +50•‹C
-1 O•‹C t o +40•‹C
Ambient temperature ( T o be free
( T o be free f r o m freezing)
f r o m freezing)

Ambient h u m i d i t y Below 90% ( T o be free f r o m condensation)

T o be free from
Atmosphere T o be free from corrosive gas corrosive gas
and dust
. --
Altitude Less than 1,000 m

Vibration Less than 0.5G

phase power supply of 200V 50Hz. 2001220V AC 60Hz.
ncy resolution at accelerationldeceleration is one half of table value.
ipped w i t h thermo detect of the heatrink.
17
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 10. PROTECTIVE FUNCTION

The protective functions listed below are built into the FR-K Series inverters.
When the protective circuits are activated, output is stopped by shutting off the base of the transistor so that
the modules are protected. This will cause the motor to stop after a brief free run. To start again, it is neces-
sary to either reset by using the reset terminal "RES", or to turn off and on the power.

Protection against stalls I f an overcurrent more than 150%of the rated current occurs during acceleration,
caused by overcurrent the freauencv increase is stopped and freauencv is keot until the load current has
been reduced, thus preventing the inverte; from the stall. If an overcurrent larger
than 150% of the rated current occurs during normal operations (at constant
speed), the frequency is decreased until the load current has been reduced, thus
preventing the inverter from the stall. When the load current has been decreased
below 156%. frequency will be increased again and acceleration will be continued
to reach the set frequency level.
Protection against stalls This protective circuit detects any regenerative energy during deceleration, so tha
caused by regenerative the frequency decrease will be stopped until the output voltage of the capacitor
overvoltage has been reduced, thus preventing the inverter from the stall. When the regener-
ative energy has been reduced, frequency will be decreased again and deceleration
continued.
Overcurrent protection If an overcurent larue than 200% of rated outout current is detected throuuh the
output current, the-overcurrent protection circuit will be activated to cut i f f the
transistor circuit and keep it off. (When an overcurrent protection circuit has beel
activated, the alarm indication lamp will light up.)
(Activation of the overcurrent protection circuit is caused mainly by a power
supply decrease, extreme load inertial (GDz 1, extremely short preset acceleration
time, or a short-circuit in the inverter secondary circuit, so to remove the trouble
and restore the circuit examine all possible failure.)
Regenerative overvoltage When an overvoltage is caused by regenerative energy at the converter output, the
protection protection circuit is activated to cut off the transistor circuit and keep it off. (An
alarm indication lamp will light up in such cases.)
(Activation of the rGeneratLe overvoltage protection circuit is caused mainly by
an extremely short preset deceleration time, so lengthen the preset deceleration
time or consider using the optional brake unit.)
Instantaneous power failurl If a power failure continues for 15 msec or more, the instantaneous power failure
protection protection circuit is activated to cut off the transistor circuit and keep i t off. (An
alarm indicator will light up in such cases.)
I f the power failure is within 15 msec, the protection circuit will not work and th
control circuit will continue operation.
Overload protection Any overload while the motor is running under its rated condition or overheating
(electronic thermal relay) at low speed running is detected by an electronic thermal relay, which cuts off thl
transistorcircuitand keeps itoff. (Alarm indication lamp will Iightup insuch cases.)
(Check the cause of the overload and either lighten the load, change the opera-
tions pattern or reconsider the capacity of inverter and motor.)
Overload alarm If the motor becomes overloaded, an alarm indication lamp will go on and off. I f
overload increases further. the overcurrent protection function will be activated.
I f the alarm indicator goes on and off during accelerationldeceleration, preset to
longer accelerationldeceleration times. If an alarm indication begins blinking
during fixed speed operation, lighten the load or reconsider the capacity of
inverter and motor.
Thermo defect of the When the heat sink is overheated through a decrease in the cooling effect of the
heatsink semiconductor, the temperature sensor~isactivated to stop the function and
output of the power element and to keep them off. (An alarm indicator will light
up in such cases.)
l~xaminethe cooling fan and the ambient temperature.)
However. inverters below tvoe FR-K-750 are not provided with this function,
A
lote: When the overcurrent P~rotection,regenerative overvoltage protection, or instantaneous power failure pro-
tection i s activated, ;an alarm indicator lamp lights up and that state will be retained. However, when the
magnetic contactor (MZi) is opened by an alarm signal, the alarm display will not be retained. I f you wish
to retain the alarm dislplay, design the circuit so that main circuit and control circuit are configurated
independently. In ord er~to retain the display of an alarm, disconnect control circuit power terminal R1
and Sl,and connect the!separate power.

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 11. INPUT/OUTPUT TERMINAL

Terminal
symbol

R.S.T.
Terminal name

4C powered supply
Rating
7
Description

When FR-K-400 is used with single-phase power

n p u t terminal supply, connect it at terminals R and S.
--

E Sround terminal Be sure t o ground both inverter and the panel box
which encloses inverier.
--
U.V.W. Output terminals for
notor

3utput terminals for

Connection for three-phase induction motor.

Terminals for connection of regenerative brake

I
:onverter unit.
Never connect anything other than brake unit t o
these terminals.

'ower supply ter- 5V DC ? 0.01V DC Use these terminals as power supplies for external
ninal for frequency Allowable load setters such as the variable resistor for frequency
setting current: 6 mA Setting (motor speed setting).

Terminals for inpilt lnput resistor Maximum frequency (60Hz. 120Hz, or 240Hzl
iignal of frequency 11 k a ? 1 kc2 is obtained at 5 V (1OV).

STF-SD lnput terminal for lnput resistor 2.5 kc2 Forward start by closing terminals between STF
forward start signal Open voltage and SD, stoppage by opening them
14 t o 20V DC Reverse start by closing terminals between STR
STR-SD lnput termial for Optoelectronic SD, stoppage by opening them.
-everse start signal isolator Closing terminals between STF and SD, and STR
Controllable by SD simultaneously causes stop command.
means of open-
collector.
~ ~~ -
FM-SD 3utput terminal for Allowable load Appromixately 5 V DC is obtained at maximum
irequency meter current: 1 mA frequencies (60Hz. 120H2, or 240Hz) and output
Optoelectronic iso- voltage is in proportion with the frequencies.
!ator output voltage Connect moving-coil type ampere meter (DC
form i s oulse. 1 mA) with terminals FM and SD. Use calibration
variable resistor 10K 1/3W by inserting it i n series

RES-SD Input terminal fol lnput resistor 4.7 kc2 For resetting emergency stop of the inverter
;ignal Open voltage caused by the activation o f protection circuit.
14 t o 20V DC Resetting initializes each part of the control
Optoelectronic iso- circuit immediately, and the circuit t o inverter and
lator converter i s shut off. T o give this reset command,
Controllable by it is necessav t o short-circuit across terminals RES
means of open- and SD for 0.1 second or more. Initial reset is
controller automatically performed inside the controller
0.2 t o 0.4 seconds later after power up.
-

B-C 3utput terminal for Contact output Normally closed contact that provides alarm signal
alarm 230V AC 0.3A when protective circuit is activated.
cos@= 0.4 When this signal is provided, power t o the con-
30V DC 0.3A verter and inverter are cut o f f and the motor will
stop after free running.

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 symbol
Terminal I Terminal name Rating Description

RUN-SE Output terminal Open-collector of Open-collector:

controller operations transistor L ... when the commanded frequency is above 3H
Allowable load H ... normally
23V DC 0.1A Use power supply 24V DC with ripple voltage
within 10%.

SU-SE Output terminal for Output terminal that indicates whether the actual
correspondence of frequency corresponds to the preset frequency:
frequencies Open-collector:
L ... corresponds
H ... does not correspond

Power supply ter- These terminals are connected internally with

minal for control input terminals R and S. To retain an alarm
circuit display, disconnect from terminals R and S, and
connect external control circuit power supply
with terminals R1 and S1.

Exclusive terminal for

manufacturer check

Fig. 7 Black Diagram

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