Mitsubishi Electronics FR-V540-1.5K to 55K User Manuals

Table of Contents

• FR-V500 INSTRUCTION MANUAL (Detailed)

  1
• This section is specifically about safety matters

  2
• CONTENTS

  4
• 1 WIRING

  10
  • 1.1 Internal block diagram

    11
  • 1.2 Main circuit terminal specifications

    12
  • 1.3 Connection of stand-alone option units

    13
    • 1.3.1 Connection of the dedicated external brake resistor (FR-ABR)

      13
    • 1.3.2 Connection of the brake unit (FR-BU)

      14
    • 1.3.3 Connection of the brake unit (BU type)

      15
    • 1.3.4 Connection of the high power factor converter (FR-HC)

      15
    • 1.3.5 Connection of the power regeneration common converter (FR-CV)

      16
    • 1.3.6 Connection of the DC reactor (FR-HEL/BEL)

      16
  • 1.4 Control circuit terminal specifications

    17
    • 1.4.1 Connecting the control circuit to a power supply separately from the main circuit

      19
  • 1.5 Precautions for use of the vector inverter

    20
  • 1.6 Others

    21
    • 1.6.1 Leakage currents and countermeasures

      21
    • 1.6.2 Power off and magnetic contactor (MC)

      23
    • 1.6.3 Installation of reactor

      24
    • 1.6.4 Notes on earthing (grounding)

      25
    • 1.6.5 Inverter-generated noises and their reduction techniques

      26
    • 1.6.6 Power supply harmonics

      28
    • 1.6.7 Harmonic suppression guidelines

      29
    • 1.6.8 Inverter-driven 400V class motor

      31
    • 1.6.9 Using the PU connector for computer link

      32
  • 1.7 Input terminals

    35
    • 1.7.1 Run (start) and stop (STF, STR, STOP)

      35
    • 1.7.2 External thermal relay input (OH)

      36
    • 1.7.3 Speed setting potentiometer connection (10E, 2 (1), 5)

      36
    • 1.7.4 Torque setting input signal and motor-generated torque (terminals 3, 5)

      37
    • 1.7.5 Meter connection method and adjustment (DA1, DA2)

      37
    • 1.7.6 Common terminals (SD, 5, SE)

      38
    • 1.7.7 Signal inputs by contact-less switches

      38
  • 1.8 How to use the input signals (assigned terminals DI1 to DI4, STR) (Pr. 180 to Pr. 183, Pr. 187)

    39
    • 1.8.1 Multi-speed setting (RL, RM, RH, REX signals): Pr. 180 to Pr. 183, Pr. 187 setting "0, 1, 2, 8" Remote setting (RL, RM, RH signals): Pr. 180 to Pr. 183, Pr. 187 setting "0, 1, 2"

      39
    • 1.8.2 Second function selection/second motor switchover (RT signal) : Pr. 180 to Pr. 183, Pr. 187 setting "3"

      39
    • 1.8.3 Jog operation (jog signal): Pr. 180 to Pr. 183, Pr. 187 setting "5"

      39
    • 1.8.4 Third function selection (X9 signal): Pr. 180 to Pr. 183, Pr. 187 setting "9"

      40
    • 1.8.5 FR-HC, FR-CV connection (X10 signal): Pr. 180 to Pr. 183, Pr. 187 setting "10"

      40
    • 1.8.6 PU operation external interlock signal (X12 signal): Pr. 180 to Pr. 183, Pr. 187 setting "12"

      40
    • 1.8.7 PID control enable terminal: Pr. 180 to Pr. 183, Pr. 187 setting "14"

      40
    • 1.8.8 Brake sequence opening signal (BRI signal): Pr. 180 to Pr. 183, Pr. 187 setting "15"

      40
    • 1.8.9 PU operation/external operation switchover: Pr. 180 to Pr. 183, Pr. 187 setting "16"

      40
    • 1.8.10 S-pattern acceleration/deceleration C switchover terminal (X20 signal) : Pr. 180 to Pr. 183, Pr. 187 setting "20"

      40
    • 1.8.11 Orientation command (X22 signal): Pr. 180 to Pr. 183, Pr. 187 setting "22"

      41
    • 1.8.12 Pre-excitation/servo on (LX signal): Pr. 180 to Pr. 183, Pr. 187 setting "23"

      41
    • 1.8.13 Output stop (MRS signal): Pr. 180 to Pr. 183, Pr. 187 setting "24"

      41
    • 1.8.14 Start self-holding selection (STOP signal): Pr. 180 to Pr. 183, Pr. 187 setting "25"

      41
    • 1.8.15 Control mode changing (MC signal): Pr. 180 to Pr. 183, Pr. 187 setting "26"

      42
    • 1.8.16 Torque limit selection (TL signal): Pr. 180 to Pr. 183, Pr. 187 setting "27"

      42
    • 1.8.17 Start time tuning (X28 signal): Pr. 180 to Pr. 183, Pr. 187 setting "28"

      42
    • 1.8.18 Torque bias selection 1 (X42 signal): Pr. 180 to Pr. 183, Pr. 187 setting "42" Torque bias selection 2 (X43 signal): Pr. 180 to Pr. 183, Pr. 187 setting "43"

      42
    • 1.8.19 P control selection (P/PI control switchover) (X44 signal): Pr. 180 to Pr. 183, Pr. 187 setting "44"

      43
  • 1.9 How to use the output signals (assigned terminals DO1 to DO3, ABC) (Pr. 190 to Pr. 192, Pr. 195)

    44
  • 1.10 Design information to be checked

    46
  • 1.11 Using the second motor

    47
    • 1.11.1 Wiring diagram (second motor)

      47
    • 1.11.2 Second motor setting parameters

      47
  • 1.12 Using the conventional motor and other motors

    48
    • 1.12.1 Conventional motor (SF-VR, SF-JR with encoder)

      48
    • 1.12.2 Precautions for and wiring of the motor with encoder (SF-JR with encoder)

      49
• 2 VECTOR CONTROL

  50
  • 2.1 What is vector control?

    51
  • 2.2 Speed control

    53
    • 2.2.1 Outline of speed control

      53
    • 2.2.2 Easy gain tuning function block diagram

      53
  • 2.3 Fine adjustment of gains for speed control

    54
    • 2.3.1 Control block diagram

      54
    • 2.3.2 Concept of adjustment of manual input speed control gains

      55
    • 2.3.3 Speed control gain adjustment procedure (Pr. 820, Pr. 821)

      55
    • 2.3.4 Troubleshooting

      56
    • 2.3.5 Speed feed forward control, model adaptive speed control (Pr. 828, Pr. 877 to Pr. 881)

      58
  • 2.4 Torque control

    60
    • 2.4.1 Outline of torque control

      60
  • 2.5 Fine adjustment for torque control

    61
    • 2.5.1 Control block diagram

      61
  • 2.6 Gain adjustment for torque control

    62
    • 2.6.1 Concept of torque control gains

      62
    • 2.6.2 Gain adjustment procedure

      62
    • 2.6.3 Troubleshooting

      63
  • 2.7 Position control (Pr. 419 to Pr. 430, Pr. 464 to Pr. 494)

    64
    • 2.7.1 Connection diagram

      64
    • 2.7.2 Position control step

      65
    • 2.7.3 Control block diagram

      66
    • 2.7.4 Parameter

      66
    • 2.7.5 Conditional position feed function by contact input (Pr. 419 = 0)

      68
    • 2.7.6 Setting the electronic gear

      69
    • 2.7.7 In-position width (Pr. 426)

      71
    • 2.7.8 Excessive level error (Pr. 427)

      71
    • 2.7.9 Pulse monitor selection (Pr. 430)

      71
    • 2.7.10 Concept of position control gains

      71
    • 2.7.11 Troubleshooting

      72
    • 2.7.12 Position control is not exercised normally

      73
• 3 PARAMETERS

  74
  • 3.1 Parameter list

    75
  • 3.2 At-a-glance guide to functions

    82
  • 3.3 Basic functions (Pr. 0 to Pr. 9)

    85
    • 3.3.1 Torque boost (Pr. 0)

      85
    • 3.3.2 Maximum and minimum speed settings (Pr. 1 , Pr. 2)

      85
    • 3.3.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19)

      86
    • 3.3.4 Multi-speed operation (Pr. 4 to Pr. 6, Pr. 24 to Pr. 27, Pr. 232 to Pr. 239)

      86
    • 3.3.5 Acceleration and deceleration time (Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45, Pr. 110, Pr. 111)

      87
    • 3.3.6 Motor overheat protection (Pr. 9, Pr. 452, Pr. 876 )

      89
  • 3.4 Standard operation functions (Pr. 10 to Pr. 16)

    91
    • 3.4.1 DC injection brake operation (Pr. 10, Pr.11, Pr. 12, Pr.802)

      91
    • 3.4.2 Starting speed (Pr. 13)

      93
    • 3.4.3 Jog operation (Pr. 15, Pr. 16)

      94
  • 3.5 Operation selection functions 1 (Pr. 17 to Pr. 37)

    95
    • 3.5.1 Inverter output stop (MRS) (Pr. 17)

      95
    • 3.5.2 Torque limit (Pr. 22, Pr. 803, Pr. 810 to Pr. 817)

      96
    • 3.5.3 RH, RM, RL signal input compensation (Pr. 28)

      97
    • 3.5.4 S-pattern acceleration/deceleration curve (Pr. 29, Pr. 140 to Pr. 143, Pr. 380 to Pr. 383)

      98
    • 3.5.5 Regenerative brake duty (Pr. 30, Pr. 70)

      101
    • 3.5.6 Speed jump (Pr. 31 to Pr. 36)

      102
    • 3.5.7 Speed display (Pr. 37, Pr. 144, Pr. 505 )

      102
  • 3.6 Output terminal functions (Pr. 41 to Pr. 50)

    104
    • 3.6.1 Up-to-speed sensitivity (Pr. 41)

      104
    • 3.6.2 Speed detection (Pr. 42, Pr. 43, Pr. 50, Pr. 116)

      104
  • 3.7 Display functions 1 (Pr. 52 to Pr. 56)

    106
    • 3.7.1 Monitor display/DA1, DA2 terminal function selection (Pr. 52 to Pr. 54, Pr. 158)

      106
    • 3.7.2 Monitoring reference (Pr. 55, Pr. 56, Pr. 866)

      109
  • 3.8 Automatic restart (Pr. 57, Pr. 58)

    110
    • 3.8.1 Automatic restart after instantaneous power failure (Pr. 57, Pr. 58, Pr. 162 to Pr. 165)

      110
  • 3.9 Additional functions (Pr. 59)

    112
    • 3.9.1 Remote setting function selection (Pr. 59 )

      112
  • 3.10 Brake sequence (Pr. 60, Pr. 278 to Pr. 285)

    115
    • 3.10.1 Brake sequence function (Pr. 60, Pr. 278 to Pr. 285)

      115
  • 3.11 Operation selection function 2 (Pr. 65 to Pr. 79)

    118
    • 3.11.1 Retry function (Pr. 65, Pr. 67 to Pr. 69)

      118
    • 3.11.2 Applied motor (Pr. 71, Pr. 450)

      120
    • 3.11.3 PWM carrier frequency selection (Pr. 72, Pr. 240)

      121
    • 3.11.4 Speed setting signal on/off selection (Pr. 73)

      122
    • 3.11.5 Reset selection/disconnected PU detection/PU stop selection (Pr. 75)

      124
    • 3.11.6 Parameter write disable selection (Pr. 77)

      125
    • 3.11.7 Reverse rotation prevention selection (Pr. 78 )

      126
    • 3.11.8 Operation mode selection (Pr. 79)

      126
  • 3.12 Offline auto tuning (Pr. 80 to Pr. 96)

    129
    • 3.12.1 Offline auto tuning function (Pr. 9, Pr. 80, Pr. 81, Pr. 83, Pr. 84, Pr. 71, Pr. 96, Pr. 450, Pr. 452)

      129
    • 3.12.2 Parameters

      129
    • 3.12.3 Execution of offline auto tuning

      130
    • 3.12.4 Utilizing or changing offline auto tuning data for use

      132
    • 3.12.5 Setting the motor constants directly

      133
    • 3.12.6 Direct input + offline auto tuning

      134
  • 3.13 Online auto tuning (Pr. 95)

    135
    • 3.13.1 Online auto tuning selection (Pr. 95, Pr. 9, Pr. 71, Pr. 80, Pr. 81 )

      135
  • 3.14 Communication functions (Pr. 117 to Pr. 124, Pr. 342)

    137
    • 3.14.1 Computer link operation (RS-485 communication) (Pr. 117 to Pr. 124)

      137
    • 3.14.2 E2PROM write selection (Pr. 342)

      148
  • 3.15 PID control (Pr. 128 to Pr. 134)

    148
    • 3.15.1 PID control (Pr. 128 to Pr. 134)

      148
  • 3.16 Current detection (Pr. 150 to Pr. 153)

    155
    • 3.16.1 Output current detection function (Pr. 150, Pr. 151)

      155
    • 3.16.2 Zero current detection (Pr. 152, Pr. 153)

      156
  • 3.17 Auxiliary functions (Pr. 156, Pr. 157)

    157
    • 3.17.1 Stall prevention operation selection (Pr. 156)

      157
    • 3.17.2 OL signal output timer (Pr. 157)

      158
  • 3.18 Display function 3 (Pr. 160)

    159
    • 3.18.1 Extended function display selection (Pr. 160)

      159
  • 3.19 Initial monitor (Pr. 171)

    159
    • 3.19.1 Actual operation hour meter clear (Pr. 171)

      159
  • 3.20 Terminal assignment functions (Pr. 180 to Pr. 195)

    159
    • 3.20.1 Input terminal function selection (Pr. 180 to Pr. 183, Pr. 187)

      159
    • 3.20.2 Output terminal function selection (Pr. 190 to Pr. 192, Pr. 195)

      161
  • 3.21 Auxiliary function (Pr. 244)

    163
    • 3.21.1 Cooling fan operation selection (Pr. 244)

      163
  • 3.22 Stop selection function (Pr. 250)

    163
    • 3.22.1 Stop selection (Pr. 250)

      163
  • 3.23 Operation selection function (Pr. 251)

    164
    • 3.23.1 Output phase failure protection selection (Pr. 251)

      164
  • 3.24 Additional function 2 (Pr. 252, Pr. 253)

    165
    • 3.24.1 Override bias, gain (Pr. 252, Pr. 253)

      165
  • 3.25 Power failure stop functions (Pr. 261 to Pr. 266)

    165
    • 3.25.1 Power-failure deceleration stop function (Pr. 261 to Pr. 266)

      165
  • 3.26 Droop (Pr. 286 to Pr. 288)

    167
    • 3.26.1 Droop control (Pr. 286 to Pr. 288)

      167
  • 3.27 Orientation (Pr. 350 to Pr. 362, Pr. 393 to Pr. 399)

    168
    • 3.27.1 Orientation control (Pr. 350, Pr. 351, Pr. 356, Pr. 357, Pr. 360 to Pr. 362, Pr. 393, Pr. 396 to Pr. 399)

      168
  • 3.28 Control system function (Pr. 374)

    175
    • 3.28.1 Overspeed detection (Pr. 374)

      175
  • 3.29 Position control (Pr. 419 to Pr. 430, Pr. 464 to Pr. 494)

    176
    • 3.29.1 Position control (Pr. 419 to Pr. 430, Pr. 464 to Pr. 494)

      176
  • 3.30 Remote output (Pr. 495 to Pr.497)

    177
    • 3.30.1 Remote output function (Pr. 495 to Pr.497)

      177
  • 3.31 Operation selection functions 4 (Pr. 800 to Pr. 809)

    178
    • 3.31.1 Control selection (Pr. 800, Pr. 451)

      178
    • 3.31.2 Torque characteristic selection (Pr. 801)

      178
    • 3.31.3 Torque command source selection (Pr. 804 to Pr. 806)

      180
    • 3.31.4 Speed limit (Pr. 807 to Pr. 809)

      182
  • 3.32 Control system functions (Pr. 818 to Pr. 837)

    184
    • 3.32.1 Easy gain tuning selection (Pr. 818, Pr. 819)

      184
    • 3.32.2 Speed loop proportional gain setting (Pr. 820, Pr. 830)

      184
    • 3.32.3 Speed control integral time setting (Pr. 821, Pr. 831)

      184
    • 3.32.4 Speed setting circuit filter function (Pr. 822, Pr. 832)

      184
    • 3.32.5 Speed detection filter function (Pr. 823, Pr. 833)

      185
    • 3.32.6 Current loop proportional gain setting for vector control (Pr. 824, Pr. 834)

      185
    • 3.32.7 Current control integral time setting for vector control (Pr. 825, Pr. 835)

      185
    • 3.32.8 Torque setting filter function (Pr. 826, Pr. 836)

      185
    • 3.32.9 Torque detection filter function (Pr. 827, Pr. 837)

      186
    • 3.32.10 Model speed control gain (Pr. 828)

      186
  • 3.33 Torque biases (Pr. 840 to Pr. 848)

    186
    • 3.33.1 Torque bias function (Pr. 840 to Pr. 848)

      186
  • 3.34 Additional functions (Pr. 851 to Pr. 865)

    189
    • 3.34.1 Selection of number of encoder pulses (Pr. 851)

      189
    • 3.34.2 Selection of encoder rotation direction (Pr. 852)

      189
    • 3.34.3 Excitation ratio (Pr. 854)

      190
    • 3.34.4 Notch filter (Pr. 862, Pr. 863)

      190
    • 3.34.5 Torque detection (Pr. 864)

      191
    • 3.34.6 Low speed detection (Pr. 865)

      191
  • 3.35 Display function (Pr. 867)

    192
    • 3.35.1 DA1 output response level adjustment (Pr. 867)

      192
  • 3.36 Terminal function assignment (Pr. 868)

    192
    • 3.36.1 Terminal 1 function assignment (Pr. 868)

      192
  • 3.37 Protective functions (Pr. 870 to Pr. 874)

    193
    • 3.37.1 Speed deviation excessive (Pr. 870, Pr. 871)

      193
    • 3.37.2 Speed limit (Pr. 873)

      194
    • 3.37.3 Stop by OLT level prevention (Pr. 874)

      194
  • 3.38 Operation selection functions 5 (Pr. 875)

    195
    • 3.38.1 Fault definition (Pr. 875)

      195
  • 3.39 Control system function 2 (Pr. 877 to Pr. 881)

    195
    • 3.39.1 Speed feed forward control, model adaptive speed control (Pr. 877 to Pr. 881)

      195
  • 3.40 Maintenance function (Pr. 890 to Pr. 892)

    196
    • 3.40.1 Maintenance output function (Pr. 890 to Pr. 892)

      196
  • 3.41 Calibration functions (Pr. 900 to Pr. 920)

    197
    • 3.41.1 DA1/DA2 terminal calibration (Pr. 900, Pr. 901)

      197
    • 3.41.2 Biases and gains of speed setting terminals (speed setting terminal 2, torque command terminal 3, multi function terminal 1) (Pr. 902 to Pr. 905, Pr. 917 to Pr. 920)

      199
  • 3.42 Additional function (Pr. 990)

    202
    • 3.42.1 PU buzzer control (Pr. 990)

      202
• 4 SPECIFICATIONS

  204
  • 4.1 Model specifications

    205
  • 4.2 Common specifications

    208
  • 4.3 Outline dimension drawings

    209
    • 4.3.1 Inverter outline dimension drawings

      209
    • 4.3.2 Control panel (FR-DU04-1) outline dimension drawings

      212
    • 4.3.3 Parameter unit (FR-PU04V) outline dimension drawings

      212
    • 4.3.4 Dedicated encoder cable outline dimension drawings

      213
    • 4.3.5 Dedicated motor outline dimension drawings

      215
• APPENDICES

  220
  • Appendix1 Setting a thermistor of a dedicated motor (SF-V5RU*****T) (when used with the FR-V5AX)

    221
  • Appendix2 Parameter Instruction Code List

    222
  • Appendix3 SERIAL number check

    229
• REVISIONS

  231
• Instruction Supplement (BCN-C22005-642)

  232