SH (Na) 3183 Fatec Inverter Application Course General Manual

INVERTER APPLICATION COURSE
CONTENTS
1. CHARACTERISTICS OF AN INVERTER-DRIVEN MOTOR

1.1 Motor Types ................................................................................................................. 1
1.2 Motor Structure ............................................................................................................ 2
1.3 Basic Characteristics .................................................................................................... 3
1.3.1 Torque-current vs. Speed curve ......................................................................... 3
1.3.2 Motor speed ...................................................................................................... 3
1.3.3 W hat is "slip"? ................................................................................................... 4
1.3.4 Motor current ..................................................................................................... 5
1.3.5 Motor speed fluctuation and motor load current .................................................. 5
1.3.6 W hat is rated motor torque? ............................................................................... 6
1.4 Torque and Current Characteristics of an Inverter-Driven Motor ..................................... 7
1.5 Operation of Standard Induction Motor by an Inverter .................................................... 8
1.5.1 Difference in rated torque between 50Hz and 60Hz operation .............................. 8
1.5.2 Important point about inverter-operated motors................................................... 9
1.5.3 W hy is voltage also varied when motor speed is varied by an inverter? ................ 9
1.5.4 Motor-generated torque.................................................................................... 10
1.5.5 Operation over 50Hz or 60Hz ........................................................................... 10
1.6 Output Characteristics of Inverter-Operated Standard Motors ...................................... 11
1.7 V/f Pattern and Torque Boost ...................................................................................... 12
1.7.1 Fundamental equivalent circuit of a motor......................................................... 12
1.7.2 W hat is torque boost? ...................................................................................... 13
1.7.3 Setting of torque boost ..................................................................................... 14
1.8 Load Torque Types and V/f Patterns ........................................................................... 16
2
1.9 Acceleration/Deceleration Time and GD ..................................................................... 17
1.9.1 Acceleration/deceleration time ......................................................................... 17
2
1.9.2 W hat is GD ? .................................................................................................. 18
2. INVERTER PRINCIPLES AND ACCELERATION/DECELERATION

CHARACTERISTICS
2.1 Inverter Structure ....................................................................................................... 19
2.2 Inverter Circuit Principles ............................................................................................ 20
2.3 Operation of the Converter Circuit ............................................................................... 26
2.4 Inverter Control System and Auto Tuning Function ...................................................... 29
2.4.1 V/F control....................................................................................................... 29
2.4.2 General-purpose magnetic flux vector control ................................................... 30
2.4.3 Advanced magnetic flux vector control.............................................................. 31
2.4.4 Vector control (Closed loop) ............................................................................. 32
2.4.5 Auto tuning function ......................................................................................... 33
2.5 Protective Functions ................................................................................................... 34
2.5.1 Purposes and types of protective functions ....................................................... 34
2.5.2 How protective functions are activated.............................................................. 35
2.5.3 Levels at which protective functions are activated ............................................. 36
2.5.4 Displays and output signals provided on activation of protective functions ......... 37
2.5.5 Resetting method............................................................................................. 38
2.5.6 Retry function .................................................................................................. 38
2.6 Acceleration and Operational Characteristics of an Inverter ......................................... 39
2.6.1 Start ................................................................................................................ 39
2.6.2 Acceleration .................................................................................................... 40
2.6.3 Stall prevention due to overcurrent ................................................................... 41
2.6.4 Constant-speed operation ................................................................................ 41
2.7 Deceleration and Stopping Characteristics of an Inverter ............................................. 42
2.7.1 Deceleration .................................................................................................... 42
2.7.2 Stop ................................................................................................................ 43
2.8 Efficiency and Power Factor of an Inverter .................................................................. 45
2.8.1 Efficiency ........................................................................................................ 45
2.8.2 Power factor .................................................................................................... 46
2.8.3 Inverter input current and power factor improvement ......................................... 46
3. CAPACITY SELECTION AND OPERATION METHODS FOR MOTOR
AND INVERTER
3.1 How to Select Capacity ............................................................................................... 50
3.1.1 W hat is inverter capacity? ................................................................................ 50
3.1.2 Notes about capacity selection ......................................................................... 51
3.2 Selection According to Operation Pattern .................................................................... 55
3.2.1 Start ................................................................................................................ 56
3.2.2 Acceleration .................................................................................................... 56
3.2.3 Deceleration .................................................................................................... 57
3.2.4 Motor temperature rise..................................................................................... 60
3.3 Finding the Machine Reduction Ratio .......................................................................... 61
3.4 Capacity Selection Procedure ..................................................................................... 62
3.4.1 Continuous operation examination procedure.................................................... 64
3.4.2 Cyclic operation examination procedure............................................................ 66
3.4.3 Lifting operation examination procedure ........................................................... 67
3.5 Operation Methods ..................................................................................................... 72
3.5.1 Types of operation methods ............................................................................. 72
3.5.2 Operation procedure overview .......................................................................... 73
3.5.3 How to set the functions ................................................................................... 73
3.5.4 Starting/stopping method ................................................................................. 76
3.5.5 Starting and stopping using the input side magnetic contactor MC ..................... 77
3.5.6 Starting of coasting motor using an inverter ...................................................... 78
3.5.7 How to use a motor fitted with an electromagnetic brake ................................... 78
3.5.8 Frequency setting (selection) signal and output frequency................................. 79
3.5.9 Other operation methods.................................................................................. 82
4. INVERTER POWER SUPPLY

(HARMONICS AND INSTANTANEOUS POWER FAILURE)
4.1 W hat is a Harmonic? .................................................................................................. 85
4.2 Characteristics of the Rectifying Circuit and Harmonics ............................................... 86
4.3 Harmonic Current Branching Routes ........................................................................... 87
4.4 Japanese Harmonic Suppression Guideline ................................................................. 90
4.4.1 Japanese harmonic suppression guideline for household appliances
and general-purpose products .......................................................................... 90
4.4.2 Japanese harmonic suppression guideline for consumers receiving power
of a high voltage .............................................................................................. 90
4.5 Influence of Harmonics on Peripheral Devices and Harmonic Suppression Techniques.......... 96
4.5.1 Power capacitor ............................................................................................... 96
4.5.2 Independent power generator ........................................................................... 97
4.6 Influence of Instantaneous Power Failure on an Inverter .............................................. 98
4.6.1 Operation of an inverter depending on instantaneous power failure time ............ 98
4.6.2 Inverter peripheral circuits and inverter operation at occurrence
of an instantaneous power failure ..................................................................... 99
4.6.3 Automatic restart control after an instantaneous power failure ......................... 100
5. NOISE
5.1 Noise Generation Principles ...................................................................................... 102
5.2 Noise Types and Transmission Routes ...................................................................... 103
5.3 Noise Reduction Techniques..................................................................................... 106
5.3.1 Noise reduction techniques ............................................................................ 106
5.3.2 Specific noise reduction examples.................................................................. 110
5.3.3 Noise filters ................................................................................................... 112
5.4 Leakage Currents ..................................................................................................... 114
5.4.1 Earth leakage current..................................................................................... 114
5.4.2 Line leakage currents..................................................................................... 115
5.5 Grounding (Earthing) ................................................................................................ 116
5.5.1 Grounding method and grounding work........................................................... 116
6. INVERTER OPERATING PROBLEMS AND CORRECTIVE ACTIONS
6.1 Environment and Installation Conditions .................................................................... 118
6.1.1 Inverter reliability and temperature ................................................................. 118
6.1.2 Ambient temperature ..................................................................................... 118
6.1.3 Heat generated by the inverter ....................................................................... 119
6.1.4 Heat interference and ventilation in an enclosure ............................................ 120
6.1.5 Installation of discharge resistors ................................................................... 121
6.1.6 Direction of inverter installation ...................................................................... 121
6.1.7 Standard installation environment specifications ............................................. 121
6.1.8 Dirt-protection structure ................................................................................. 123
6.1.9 Considerations for installing the inverter in an enclosure ................................. 123
6.1.10 Inverter-driven explosion-proof motor ............................................................. 125
6.2 Inverter W iring ......................................................................................................... 126
6.2.1 Terminal connection diagram ......................................................................... 126
6.2.2 Main circuit wiring .......................................................................................... 127
6.2.3 Control circuit wiring ...................................................................................... 128
6.2.4 I/O cable wiring distances .............................................................................. 130
6.2.5 BU brake unit wiring....................................................................................... 131
6.2.6 FR-BU brake unit wiring ................................................................................. 132
6.2.7 High-duty brake resistor (FR-ABR) wiring ....................................................... 133
7. PERIPHERAL DEVICES AND OPTIONS

7.1 Peripheral Devices and Points for Understanding ...................................................... 134
7.2 Inverter Options........................................................................................................ 135
7.3 Power Supply Capacity ............................................................................................. 136
7.4 No-Fuse Breaker (NFB) ............................................................................................ 136
7.5 Earth Leakage Breaker (ELB) ................................................................................... 136
7.6 Input Side Magnetic Contactor (MC) .......................................................................... 137
7.7 Surge Suppression Filter .......................................................................................... 138
7.7.1 Measures ...................................................................................................... 138
7.7.2 Outline dimensions ........................................................................................ 138
7.8 Output Side Magnetic Contactor (MC) ....................................................................... 139
7.9 Thermal Relay (OCR) ............................................................................................... 139
7.10 Main Circuit Cable Size............................................................................................. 140
7.11 Power Factor Improving Reactor (FR-BAL or FR-BEL) ............................................... 140
7.12 Inverter Setup Software (FR-A500 series and FR-E500 series inverters) .................... 141
8. MAINTENANCE AND INSPECTION

8.1 Precautions for Maintenance and Inspection.............................................................. 142
8.2 Check Items ............................................................................................................. 142
8.3 Replacement of Parts ............................................................................................... 145
8.4 Measurement of Main Circuit Voltages, Currents and Powers ..................................... 146
8.5 Checking the Parameter Unit Display at Alarm Occurrence ........................................ 148
8.6 Faults and Check Points ........................................................................................... 149
8.7 Protective Functions ................................................................................................. 150
8.8 Operation of the Training Kit ..................................................................................... 152
8.8.1 Details of demonstration ................................................................................ 152
8.8.2 Structure of the FR-A Training Machine .......................................................... 152
This chapter deals with the basic characteristics of a squirrel-cage, three-phase, induction motor to
be considered for capacity selection and operation when it is driven by an inverter.
Since motors operated with a commercial power supply and operated by an inverter differ in charac-
teristics, it is essential to understand the following points.
POINTS OF UNDERSTANDING
1. Relationships between speed, current and torque.
2. V/f (voltage/frequency ratio) pattern and basic motor characteristics.
3. Differences in characteristics of the motor when operated by inverter and when operated with
commercial power supply, e.g. torque, current, temperature.
4. Definition of torque boost.
1.1 Motor Types
Motors may be classified in various ways. W hen they are divided by the operation principle and
structure, there are the following motor types. Among them, inverter-driven motors are mainly
three-phase squirrel-cage motors.
Classification Classification by Classification
by power supply operation principle by structure
DC motor
Synchronous
Motor
motor
Wound-rotor
AC motor
motor
Split-phase start motor
Single-phase
Induction motor Capacitor motor
motor
Repulsion-start motor
Squirrel-cage
motor
Drip-proof motor
Three-phase
Indoor motor
motor
(Standard motor) Totally-enclosed,
fan-cooled motor
Constant-torque motor
Pressure-resistant, explosion-proof motor
Geared motor
Table 1.1 Mitsubishi Motors

Structure/
Motor Type Model Capacity Application
Specifications
SB-JR 0.4kW to 55kW Drip-proof
Used with inverter for a wide range of
Standard motor Totally-enclosed,
SF-JR 0.2kW to 55kW speed control.
fan-cooled
SF-JRC 0.4kW to 22kW Totally-enclosed,
fan-cooled Most appropriate for applications where
Constant-torque SF-JRCA 0.4kW to 45kW
continuous operation is performed at low
motor SF-JRC-FV 30kW to 45kW Totally-enclosed, speed under rated torque.
SF-JRCA-FV 55kW force-cooled
XE-NE 0.2kW Used in environment of flammable gas
Pressure-resistant, Pressure-
XF-NE 0.75kW to 7.5kW steam, etc.
explosion-proof resistant,
Those accepted by Japanese Labor Ministry
motor XF-E 11kW to 45kW explosion-proof
test.
GM-H 0 .1 k W to 3 .7 k W For uniform load Large torque can be developed at low
GM-LJ 0.4kW to 37kW For medium load speed. Used in a wide range of
Geared motor
GM-LLJ 0.4kW to 22kW For heavy load industrial fields such as conveyors and
GM-AJ 7.5kW to 75kW For medium load food processing machines.
Geared motor GM-H 0.1kW to 0.4kW For uniform load Compact, high torque, low acoustic noise.
(used exclusively
GM-LJZ 0.4kW to 7.5kW For medium load W ide speed control.
with inverter)
–1–
1.2 Motor Structure
Due to its rigid and simple structure, a squirrel-cage motor can be used in a wide variety of environ-
ments such as outdoors, underwater and potentially dangerous circumstances (explosion-proof
motor).
From a structural point of view, motors are largely classified into a totally enclosed, fan-cooled type
and a drip-proof protection type. Fig. 1.1 shows an example of totally enclosed, fan-cooled type motor
structure. W hen roughly divided in structure, the motor consists of a fixed area and a rotary area and
each area is made up of mechanical parts and electrical parts. A fan coupled to the shaft is provided
for cooling as the motor itself will generate heat.
W hen the motor is run by an inverter at low speed, its speed decreases and the cooling effect of the
fan reduces. To suppress the temperature rise of the motor within the specified value, permissible
load torque must be reduced.
Frame Stator core Rotor core
Coil
Fan (for cooling) Bracket
Bearing
End ring fan
Terminal box Shaft Center

height
Fig 1.1 Example of Totally Enclosed, Fan-Cooled Type Motor Structure
–2–
1.3 Basic Characteristics
1.3.1 Torque-current vs. Speed curve

The characteristics of the motor direct-on line started are shown in Fig. 1.2.
Generator region
Current
Point where load torque

and motor-generated
Torque (T) torque are balanced
Starting
current (I S )
Current [A] Maximum

Torque torque Tm
[kgf·m]
{N·m} Starting
torque (T S ) Load
torque (T L )
Motor current at
(I M )
load torque (T L )
N
Speed [r/min]
Synchronous
speed (N 0 )
Slip (S) is expressed as %

Motor rotates at a point where
Slip (S) of Synchronous speed (N o )
load torque and motor-generated
torque are balanced.
Fig. 1.2 Relationships between Speed, Current and Torque of Motor when started direct-on line
1.3.2 Motor speed

Motor speed is determined not only by load torque but also by the number of poles and applied power
supply frequency, as indicated below:
120 × frequency ( f ) [Hz]

Motor speed (N) = × (1 − S) [r / min] ............................................ (1.1)
Number of poles (P)
Determined by motor Determined by load specifications

specifications. (load torque).
This is called
Synchronous Speed (N 0 ).
–3–
As seen in equation (1.1), motor speed can be varied by changing the power supply frequency applied
to the motor or the number of poles. Alternatively, the voltage applied to the motor may be changed.
Frequency is changed .................. Inverter
Number of poles is changed ......... Pole-change motor
Voltage is changed ...................... PS motor (primary voltage control)
Slip is changed ............................ W ound-rotor motor
An eddy-current coupling type variable speed motor (Mitsubishi AS motor) has an eddy-current type
electric coupling between the output shaft and the drive motor which keeps rotating at the rated
speed. As the speed of the output shaft is varied by slip caused by the coupling section, this motor is
similar to a slip (S) changing system.
1.3.3 What is "slip"?

W hen a motor is under load, its speed differs from (is lower than) the synchronous speed (Fig 1⋅2).
"Slip" indicates the degree of a difference between motor speed and synchronous speed.
"Slip" is expressed as in equation (1.2):
Synchronou sspeed(N0 ) − speed(N)

Slip (S) = × 100[%] ............................................................. (1.2)
Synchronou sspeed(N0 )
(1) At start (zero speed), "slip" is 100% (often represented "slip 1"). W hen the frequency is increased
gradually by the inverter (called frequency start), "slip" is about several %.
(2) W hen the motor is run at the rated torque, "slip" is generally about 3 to 5%. W hen load torque
increases (overload), "slip" and motor current also increase.
(3) Slip is negative when the speed is greater than the synchronous speed (N>N 0 ).
Useful Motor Check Points

Torque generated by the motor is not fixed. If the motor capacity is large but the load is small,
motor-generated torque decreases in proportion to the load.
Motor-generated torque always varies to match load torque. Motor speed also varies according to
load variation.
–4–
1.3.4 Motor current

As shown in Fig. 1.2, a larger current flows when speed is low (i.e. slip is larger). The current at the
slip of zero, or a no-load current, is sometimes about 50% of the rated current in a small-capacity
motor. In the negative torque (regenerative brake) region, the regenerative current is larger as slip (its
absolute value) is larger.
1.3.5 Motor speed fluctuation and motor load current

Motor speed is determined by the relationship between load torque (T L ) and motor-generated torque
(T) as shown in Fig. 1.2.
(1) W hen load torque varies (motor torque constant)

As load torque increases, motor speed (N 2 ) decreases. As load torque decreases, motor speed
(N 1 ) increases. Hence, as load torque becomes larger, motor current becomes larger.
Output torque (T)
T L large
T L small
N 2 N 1 Speed [r/min]
Fig. 1.3 Load Fluctuation vs. Speed
(2) W hen motor-applied voltage varies (load torque constant)

Motor torque varies in proportion to the square of the voltage applied. Therefore, when voltage
varies, motor speed also varies. W hen voltage increases, current decreases.
Voltage high
Output torque
Voltage low
TL
N 2 N 1 Speed [r/min]
Fig. 1.4 Voltage Fluctuation vs. Speed
–5–
1.3.6 What is rated motor torque?

"Force" generated by a standard induction motor is called torque. "Force" is generally represented in
{kgf} or [N] in linear motion. However, in the case of a motor in which its shaft rotates to develop
"force", "force in rotary motion" is equal to torque and is represented in {kgf·m} or [N·m].
The value of the rated motor torque can be calculated by equation (1.3) or (1.4).
Rated motor output (P) [kW ]

Rated torque (TM) = 974 × {kgf ⋅ m} ............................................... (1.3)
Rated speed (N) [r / min]
Rated motor output (P) [kW ]

Rated torque (TM) = 9550 × {N ⋅ m} ................................................ (1.4)
Rated speed (N) [r / min]
Indicated on motor name plates and test reports.
Note: The "rated speed" is the speed at the rated motor torque when the rated voltage and frequency
are applied.
Exercise
Find the rated torque (T M ) of a 3.7kW four-pole motor whose rated speed is 1730 [r/min].
3.7
Rated torque (TM) = 974 × = 2.08 {kgf ⋅ m}
1730
3.7
Rated torque (TM) = 9550 × = 20.4 {N ⋅ m}
1730
W hen the motor is inverter-operated, the rated speed may be replaced by synchronous speed (N 0 ) in
the calculation of the rated torque. For exact calculation, use the rated speed.
Useful Motor Check Point

The rated motor torque is not necessarily the torque generated by the motor. It is load torque (T L )
permissible if the motor is run continuously at the rated speed.
–6–
1.4 Torque and Current Characteristics of an Inverter-Driven Motor
Fig. 1.5 shows the comparison results of motor torque and current characteristics between operation
of a motor with a commercial power supply (commercial power supply operation) and operation of a
motor by an inverter (inverter operation). [%] indicates the ratios of torque and current to the rated
torque and rated current, respectively. (Example: 4-pole motor)
Commercial Power Supply Operation Inverter Operation

Speed-
current 600
curve
500
IS
Current
400 (Starting
Current [%] Overcurrent immunity of inverter
current)
[%] 300
200
150
100 100
50Hz 60Hz 15Hz 20Hz 30Hz 50Hz 60Hz
0 0
0 1500 1800 [r/min] 0 450 600 900 1500 1800 [r/min]
Speed-
torque Tm
300 (Maximum
curve torque)
250
Torque
Torque
200 [%]
[%] T S (Starting torque)
150 150
Rated
Rated torque torque
100 100
50
50Hz 60Hz 50
0 15Hz 20Hz 30Hz 50Hz 60Hz
0 1500 1800 [r/min] 0
0 450 600 900 1500 1800 [r/min]
Features • Starting torque (Ts) is large but starting • To suppress the starting current, the motor
current (Is) is also large. is started at low frequency. Starting torque
• Speed is fixed by the power supply is also small.
frequency. • Speed can be set as desired independent
of the power supply frequency.
Fig. 1.5 Comparison of Motor Current and Torque Characteristics

(Example of V/f operation)
Approximate characteristic values of a standard motor operated with a commercial power supply
(1) Starting current, Is = 600 to 700 [%] (2) Starting torque, Ts = 150 to 250 [%]
(3) Maximum torque, Tm = 200 to 300 [%] (4) Slip under rated load, S = 3 to 5 [%]
–7–
1.5 Operation of Standard Induction Motor by an Inverter
1.5.1 Difference in rated torque between 50Hz and 60Hz operation

Induction motors are widely used and have the following standard ratings; 200V 50Hz, 200V 60Hz,
220V 60Hz, 400V 50Hz, 400V 60Hz and 440V 60Hz. Table 1.2 shows the comparison of the rated
current, rated speed and rated torque of the commercial power supply-operated SF-JR 3.7kW 4-pole
motor corresponding to the power supply specifications.
Table 1.2 Comparison of Values for Common Use with Three Ratings
Power Supply Rated Current [A] Rated Speed [r/min] Rated Torque
{kgf·m} [N·m]
200V 50Hz 14.6 1420 2.54 24.9
200V 60Hz 14.2 1710 2.11 20.7
220V 60Hz 13.4 1730 2.08 20.4
Supposing that the rated currents for the corresponding power supply ratings are I 200/50 , I 200/60 and
I 220/60 (I 400/50 , I 400/60 and I 440/60 for 400V power supplies) respectively, the following relationship is
established, the current at 50Hz is maximum current.
I 200/50 > I 200/60 > I 220/60 (I 400/50 > I 400/60 > I 440/60 )
As seen from equation (1.3) in Section 1.3.6, the magnitude of the rated motor torque differs between
50Hz and 60Hz.
P [kW ] P
Torque at 50Hz TM = 974 × = 974 × = 0.649 × P
N [r / min] 1500
20% higher
P [kW ] P
Torque at 60Hz TM = 974 × = 974 × = 0.541 × P
N [r / min] 1800
At 50Hz, torque (force) is large but motor current is also large. Hence, the temperature rise of the
motor is greater than that at 60Hz.
Temperature high
Temperature low
50Hz 60Hz
Large current Smaller current
–8–
1.5.2 Important point about inverter-operated motors

W hen compared to a motor operated with a commercial power supply, an inverter-operated motor
suffers a "motor current increase."
Since the waveform of the voltage applied to the motor is not a sine wave but includes distortion, the
motor current at the rated torque is approximately 10% higher than that of a motor operated with a
commercial power supply. Accordingly, the motor temperature is higher than that of the motor
operated with commercial power supply. This can pose a problem at 50Hz where there is a less
allowance for the standard value.
This is why the inverter catalogs and technical information state, "At 50Hz, reduce the load torque to
85%" for continuous operation. (Note: This only applies to Japanese motors.)
At 60Hz where there is sufficient temperature allowance, the temperature will fall within the standard
value even if the current increases.
Here, "at 50Hz" does not indicate the magnitude of the power supply frequency. Please
CAUTION
understand that it indicates "at the output of the rated torque calculated at 50Hz."
1.5.3 Why is voltage also varied when motor speed is varied by an inverter?
To vary the motor speed, only the frequency may be changed as indicated in equation (1.1). However,
if the output frequency is changed to 50Hz or less with the voltage kept constant (for example, 200V),
the magnetic flux of the motor increases (saturates). Therefore, the current increases and the motor
becomes overheated, then burnt.
To prevent this, the magnetic flux should be kept constant. As the magnetic flux is directly
proportional to the voltage and inversely proportional to the frequency as indicated in equation (1.5),
the application of a voltage which will always establish this relationship will solve this problem.
Voltage (V)
Magnetic flux ∝ = Constant ........................................................................ (1.5)
Frequency (f)
Supposing that the speed is halved (from 60Hz to 30Hz), for example, V/f is as follows:
V 220[V] 110[V]* * Actually, this value is slightly larger to compensate for a

= = = Constant voltage drop in the motor.
f 60[Hz] 30[Hz]
W hen the motor temperature is taken into consideration, the problem can be solved by also varying
the voltage as described above. However, it is also necessary to think of the torque.
–9–
1.5.4 Motor-generated torque

Relationships between the applied voltage (V), frequency (f) and torque (T) of the motor are
represented by formula (1.6):
Voltage ( V )
Torque (T ) = K ⋅ ⋅ I ........................................................................................... (1.6)
Frequency ( f )
K: Constant, I: Current
(1) W hen the ratio of V/f is constant, the torque is Torque

Torque decrease
constant. constant
(constant output)
(2) W hen the voltage (V) is constant and only the
frequency (f) varies, the torque is inversely Voltage
Voltage constant
proportional to the frequency if the motor current Voltage [V] proportional to
frequency
is constant. Torque [T]
• Relationships between the voltage and torque
to the frequency are shown in Fig. 1.6. The
relationship between the output voltage and
output frequency of an inverter is called the Frequency (f)
"V/f pattern" which is an important factor in
controlling a motor. Fig. 1.6 Constant Torque and Constant
Output Ranges
1.5.5 Operation over 50Hz or 60Hz

Since an inverter cannot output a voltage higher than the power supply voltage, the output voltage of
the inverter is constant in a frequency region above 50Hz or 60Hz (base frequency...refer to the
explanation below).
As only the frequency is varied, the torque decreases in inverse proportion to the frequency if the
motor current value is the same, as indicated in equation (1.6). This region is called a "constant
output" region.
Useful Inverter Check Point
W hat is base frequency?

This frequency represents the frequency at the rated torque of 220V
200V
the motor.
Output
Since a standard motor is designed for use at either 50Hz or voltage
60Hz, set the base frequency to 50Hz or 60Hz. In consideration
of the motor temperature rise described in Section 1.5.2, it is
recommended to set the base frequency to 60Hz independently
of the power supply frequency. Even for a machine designed 50Hz 60Hz Output
for use with a motor whose rated torque is 50Hz, the setting of frequency
the base frequency to 60Hz will not pose any problem if the
load current at 50Hz is not more than the rated motor current Fig. 1.7 V/f Pattern and Base
at 60Hz. Frequency
– 10 –
1.6 Output Characteristics of Inverter-Operated Standard Motors
Fig. 1.8 shows the output characteristics of Mitsubishi standard squirrel-cage motors (4 poles) used
with an inverter of the same capacity.
Base frequency setting of inverter. Not power supply frequency.
• 220V 60Hz • 200V 50Hz

Output torque [%] of 100% is the rated Output torque [%] of 100% is the rated
torque of the motor at 60Hz. torque of the motor at 50Hz.
When boost of 3.7kW or less motor is increased
under advanced magnetic flux vector control When boost of 3.7kW or less motor is increased
under advanced magnetic flux vector control
Maximum torque at factory setting
(boost set value) Maximum torque at factory
setting (boost set value)
Advanced magnetic flux vector
control (0.4kW to 1.5kW) Advanced magnetic flux vector
150
140 control (0.4kW to 1.5kW)
Continuous
Short-time 130
operation torque maximum torque 120
Output torque [%]
Output torque [%]
Continuous Short-time
100 operation
maximum torque
90 torque
85
80 75
70 70
65
50
45
35 38
30 30
25
36 20 30 60 120 36 20 30 50 120
Output frequency [Hz] Output frequency [Hz]
Output voltage
V/f pattern
Output voltage
V/f pattern
60Hz 120Hz 50Hz 120Hz

Output frequency Output frequency
Fig. 1.8 Output Characteristics of Standard Motors (under V/f control)
(1) Continuous operation torque is permissible load torque restricted by the temperature rise of the
motor. It is not the maximum value of motor-generated torque.
(2) Short-time maximum torque is maximum torque generated by the motor within the overload
capacity (150%) of the inverter. Accordingly, as the inverter capacity is increased, the maximum
torque also increases.
The short time of the short-time maximum torque indicates the permissible overload current flow
time of the inverter, i.e. within 1 minute.
* There are constant torque motors which can be run continuously at low speed and high torque.
The frame size is increased, and it is designed to suppress heat generated by the winding.

A standard motor can be run at high speeds of up to 120Hz. Note that there are restrictions on the
operating frequency range according to the motor size, e.g. 120Hz or less for 4-pole motors of up
to frame size 132, 100Hz or less for frame sizes 160 and 180 motors, and 65Hz or less for frame
sizes 200 and 225 motors.
These restrictions are made according to the motor size because of such problems as permissible
bearing speed and motor structure strength. Always check with the motor manufacturer.
– 11 –
1.7 V/f Pattern and Torque Boost
1.7.1 Fundamental equivalent circuit of a motor

For ease of understanding torque boost, the fundamental equivalent circuit of a motor will be
described first. Fig. 1.9 shows a generally used equivalent circuit of a motor.
I1 r1 jX 1 jX 2
V : Primary voltage
Im V' : Primary induced electromagnetic voltage
I2
I1 : Primary current
I2 : Secondary current (Converted from primary value)
Im : Excitation current
rm r1 : Primary resistance
V V’ r2 : Secondary resistance (Converted from primary
r 2 /S value)
rm : Core loss resistance
Xm Xm : Excitation reactance
X1 : Primary leakage reactance
X2 : Secondary leakage reactance
S : Slip
Fig. 1.9 Equivalent Circuit of Motor
W hen the motor is run without load in a secondary circuit open state, the equivalent circuit is as shown
in Fig. 1.10.
r1 jx1
Im
Im
∆V
rm
V Im: Excitation current
V’
Xm
Fig. 1.10 Equivalent Circuit

(Secondary circuit open
without load)
This is expressed by a voltage equation as indicated in formula (1.7):
V’ = V – (–jlm) (r 1 + jx 1 )................................................................................................... (1.7)
By replacing (–jlm) (r 1 + jx 1 ) by ∆V, the equation can be simplified as follows:
V’ = V – ∆V .................................................................................................................... (1.8)
– 12 –
1.7.2 What is torque boost?

At the base frequency or lower, the V/f ratio of an inverter must be kept constant as described in
section 1.5.4 (See Fig. 1.11 below). However, there are resistive and reactive components
(collectively called impedance) in the primary winding of the motor as shown in Fig. 1.9 and a voltage
drop caused by this impedance reduces motor-generated torque.
In standard motors, the winding is designed in consideration of a voltage drop at 50Hz or 60Hz.
As the voltage of an inverter-operated standard motor varies in proportion to the output frequency (f),
the voltage drop is especially large in the low-frequency region where the voltage is low, and the
motor-generated torque is much smaller than that of the motor operated with a commercial power
supply. In the low-frequency region, the voltage is increased by ∆V (as in formula (1.8)) to compen-
sate for the voltage drop to suppress the decrease in motor output torque. The compensation for the
voltage of ∆V (as shown in Fig. 1.12) is called torque boost.
V V
220V 220V
Torque
boost
f ∆V f
Base frequency Base frequency
Fig. 1.11 Ideal V/f Pattern of Motor Fig. 1.12 Actual V/f Pattern of Inverter
In magnetic flux vector control, ∆V is automatically controlled according to a voltage drop resulting
from the resistive components (r) and reactive components (x), etc. of the motor.
Manual torque boost is as shown in Fig. 1.13.
V Manual torque boost
∆V
f
Base frequency
Fig. 1.13 Manual Torque Boost
The increase in voltage is kept constant to the frequency (f) (independent of motor current).
– 13 –
1.7.3 Setting of torque boost

W hen large starting torque or acceleration torque is required, a motor torque of about 100% to 150%
can be developed in a low-frequency region by adjusting the torque boost.
(1) Standard torque boost (factory setting) has been matched with the characteristics of Mitsubishi
standard motors.
(W hen a special motor, different in winding specifications is used, the torque boost may have to
be adjusted.)
(2) If the torque boost setting is too large under light load, the current may increase, tripping the
inverter due to overcurrent.
(3) If the motor is always run under light load, motor efficiency is improved by decreasing the torque
boost setting. (Refer to Section 1.8 "Load Torque Types and V/f Patterns".)
(4) The adjustment of torque boost is similarly effective for a voltage drop across cables between the
motor and inverter.
Fig. 1.14 shows relationships between motor torque and current when the voltage is increased by
torque boost.
Since there is a current limit (150% of the rated current) on an inverter, the maximum value of starting
torque is determined within this current range. If the torque boost setting is too large, the motor
current will exceed the current limit, activating overcurrent protection.
100 Current Exceeding the current limit

[%]
Torque 150 Current limit
Torque boost large
[%] of inverter
50 100
Torque boost standard
50
4Hz 6Hz 4Hz 6Hz
0 0
Speed [r/min] Speed [r/min]
Fig. 1.14 Example of Motor Torque and Current at Start
Current
Torque boost large
[%]
100
Torque boost correct
Torque boost small
0
Load factor [%]
Fig. 1.15 Example of Load Factor vs. Motor Current
– 14 –
W hen the torque boost setting is large, the current will vary as described below according to the load
condition:
1) Light load ........... Since the magnetic flux of the motor core saturates, the current will increase and
overcurrent protection is more liable to be activated.
2) Heavy load ......... As torque boost compensates for a voltage drop caused by the primary winding
and cables of the motor to develop large motor torque, motor slip reduces and
the current is smaller than under light load. (Refer to Fig. 1.15 "Example of Load
Factor vs. Motor Current.")

A constant torque motor dedicated to inverter use is designed for continuous operation at 100%
torque even during low speed operation. If it is inevitable that a light load will be used, the motor
current may exceed the rated motor current. To prevent this, lower the manual torque boost set-
ting.
Exercise
W hen the torque boost setting of the inverter is increased, how does the motor current value
change?
Though it depends on the load condition (light or heavy load), increasing the torque boost setting
will increase the motor current, generating large starting torque. During acceleration under heavy
load, torque increases and motor slip decreases. As a result, the average current can be kept
small during acceleration.
If the torque boost setting is too large, the motor current immediately after a start will exceed the
current limit, activating overcurrent protection.
– 15 –
1.8 Load Torque Types and V/f Patterns
Load torque characteristics differ according to application. Their typical examples and applicable V/f
patterns are shown below. W hen a motor is operated by an inverter, a V/f characteristic matching the
load characteristic can be selected.
Load
torque
type
Frequency Frequency Frequency

(speed) (speed) (speed)
Constant torque load Variable torque load Constant output load

Main Conveyor Fan Machine tool (spindle drive)
appli- Trolley Pump W inding machine (center
cations Roll drive Blower drive)
Constant torque pattern Variable torque pattern
Output Output Output

voltage voltage voltage
[V] [V] [V]
Base Base Base

frequency frequency frequency
Output frequency [Hz] Output frequency [Hz] Output frequency [Hz]
2
T = constant: T/N = constant: T × N = constant:
constant torque load squared variable torque constant output load
load
Fig. 1.18 Load Types and V/f Patterns

Although a variable torque load may be operated using a constant torque V/f pattern, operating it
using a variable torque pattern will provide greater efficiency and lead to energy savings and
further reductions in acoustic noise.
– 16 –
2
1.9 Acceleration/Deceleration Time and GD
1.9.1 Acceleration/deceleration time

Acceleration time and deceleration time differ between commercial power supply operation
(operation of a motor with a commercial power supply) and inverter operation (operation of a motor
with an inverter) as indicated below:
Acceleration/
Deceleration
T ime Acceleration Time Deceleration Time
Operation
Commercial 2
Total GD ⋅ N
2
Total GD ⋅ N
power ta = [s] td = [s]
operation 375 × {TM × {15
. to 2} − TL } 375 × TL
N : Rated speed [r/min] N : Rated speed [r/min]
T M : Rated motor torque [kgf·m] T L : Load torque [kgf·m]
T L : Load torque [kgf·m]
2 2
Total GD ⋅ N Total GD ⋅ N
ta = [s] td = [s]
38.2 × {TM × {15
. to 2} − TL } 38.2 × TL
N : Rated speed [r/min] N : Rated speed [r/min]
T M : Rated motor torque [N·m] T L : Load torque [N·m]
T L : Load torque [N·m]
Inverter 2
Total GD ⋅ ∆N 2
TotalGD ⋅ ∆N
operation ta = [s] td = [s]
375 × (TM ⋅ α − TL ) 375 × ( TM ⋅ β + TL )
∆N : Difference between motor speed before and ∆N : Difference between motor speed before and
after acceleration [r/min] after deceleration [r/min]
T L : Maximum load torque [kgf·m] T L : Minimum load torque [kgf·m]
α : Average acceleration torque factor (about β : Average deceleration torque factor
1.1 boost standard) (regenerative braking torque factor)
2
Total GD ⋅ ∆N TotalGD ⋅ ∆N
2
ta = [s] td = [s]
38.2 × (TM ⋅ α − TL ) 38.2 × ( TM ⋅ β + TL )
∆N : Difference between motor speeds before and ∆N : Difference between motor speeds before and
after acceleration [r/min] after deceleration [r/min]
T L : Maximum load torque [N·m] T L : Minimum load torque [N·m]
α : Average acceleration torque factor (about β : Average deceleration torque factor
1.1 boost standard) (regenerative braking torque factor)
2 2 2 2
Total GD = motor GD + load GD [kgf·m ]
(1) Due to a difference in average acceleration torque factor, acceleration time from commercial
power supply operation is shorter than using inverter operation.
(2) Due to regenerative brake operation in inverter operation as opposed to a coasting stop in
commercial power operation, deceleration time in inverter operation is much shorter than in
commercial power operation.
To make a sudden stop in commercial power operation, a mechanical brake is used or a DC
dynamic brake or negative-phase braking system is employed.
– 17 –
2
1.9.2 What is GD ?
2
(1) GD is the inertia of an object converted into a numerical value. A heavy object with a large
diameter has high inertia and a light object has low inertia.
Fast start
Large Slow start Small Fast stop
Slow stop
2
(2) Finding GD of a rotating cylinder
1 π
D [m] GD 2 = × W ⋅ D 2 = × ρ ⋅ L ⋅ D 4 [kgf ⋅ m 2 ]
2 8
Examples of specific gravity

: 2.7 × 10
3
L [m]
W : W eight Aluminum
ρ : Specific gravity Iron : 7.8 × 10
3
: 7.2 × 10
3
Cast iron
2
(3) For the calculation of acceleration/deceleration time, load GD ( GD L2 ) must be converted into the
equivalent value at the motor shaft.
GD converted into the equivalent value at the motor shaft = GD L2 × i (i=reduction ratio)
2 2
2
(4) A load having a large GD takes a long time to accelerate or decelerate. Hence, a large motor
torque is required for acceleration or deceleration in a short time.
– 18 –
CHARACTERISTICS
This chapter describes the operational principles of the fundamental circuits of an inverter which
develop the variable frequency and variable voltage output to control motor speed.
In an inverter, which is a power converter designed for a motor (from constant frequency and voltage
input to variable frequency and voltage output), the input power is a commercial power supply but the
current is different in waveform from a sine wave, and its output waveform is different from the input
waveform.
These characteristic waveforms created due to the inverter's operational principles deeply concern
the selection of a motor, peripheral equipment and measurements of current, voltage, etc. For this
reason, it is important to understand the operation of each circuit of the inverter and their
relationships.
Points for Understanding

1. Principle of creating output waveforms (variable voltage, variable frequency).
2. Operation from start to stop.
3. Definition of inverter power factor.
2.1 Inverter Structure
Fig. 2.1 shows the structure of a transistorized inverter which makes alternating-current power of any
frequency from commercial power (50Hz or 60Hz AC) to run a motor at variable speed. It consists of
a main circuit composed of a converter circuit (which converts commercial power into a direct current
and smooths ripples included in this direct current) and an inverter circuit (which converts the direct
current into an alternating current of variable frequency), and a control circuit which controls these
circuits.
Inverter unit
Main circuit Motor
AC Converter Inverter
IM
power circuit circuit
Control circuit
Fig. 2.1 Inverter Structure
The converter circuit converts an alternating current into a direct current. The inverter circuit then
reconverts the direct current into the alternating current. In the transistorized inverter unit, the whole
unit including the converter circuit is referred to as the inverter.
As described above, the main circuit of the inverter is made up of two power converters which differ
greatly in devices used and characteristics. The operational principles of the inverter and converter
circuits will be described.
– 19 –
CHARACTERISTICS
2.2 Inverter Circuit Principles
(1) Making an alternating current from direct current.

The inverter is a device which makes an alternating current from DC power. Its fundamental
principles will be considered in the case of the simplest single-phase alternating current.
The method of converting a direct current into an alternating current will be described using the
example shown in Fig. 2.2 where a lamp is used instead of a motor as a load.
Four switches S1 to S4 are connected to a DC power supply and are turned on-off alternately to
make an alternating current as shown in Fig. 2.3.
Switch S1 Switch S3
Lamp
+
DC
power E + – S1, S4 ON
supply A L B 0
– + S2, S3 ON Time
–
Switch S2 Switch S4
Fig. 2.2 Making an Alternating Current Fig. 2.3 Current Wavement
• By turning switches S1 and S4 on, a current flows in lamp L in the direction of arrow A.
• By turning switches S2 and S3 on, a current flows in lamp L in the direction of arrow B.
Therefore, turning on-off the S1-S4 and S2-S3 combinations alternately makes an alternating
current in which the direction of the current flowing in lamp L reverses alternately.
(2) Varying the frequency

A frequency is changed by changing the time of turning the switches on-off.
For example, turning S1 and S4 on for 0.5 seconds and then S2 and S3 on for 0.5 seconds
alternately makes an alternating current in which its direction is reversed once during one second,
i.e. an alternating current of 1Hz frequency.
0.5 seconds 0.5 seconds
Time
S1, S4 ON
S2, S3 ON
Fig. 2.4 1Hz AC Waveform
– 20 –
CHARACTERISTICS
Generally, S1-S4 and S2-S3 are turned on for the same duration. Supposing that the sum of
durations in one cycle is t 0 seconds, frequency (f) is as follows:
1
f=
t0
[Hz] Time
t0
Fig. 2.5 Frequency

(3) Three-phase alternating current
The fundamental circuit of a three-phase inverter is shown in Fig. 2.6.
0 60 120 180 240 300 360 420 480 540°

S1
S1 S3 S5 U Motor
S2
DC power
supply S3
E
S4
V W S5
S4 S6 S2
S6
Fig. 2.6 Three-Phase Inverter Fundamental Circuit

U-V
By turning switches S1 to S6 on-off in a sequence as V-W

shown in Fig. 2.7, pulse waveforms of equal interval
are provided across U-V, V-W and W -U and a
rectangular-wave AC voltage is applied to the motor. W-U
By changing this switching on-off period, a desired
frequency is output to the motor. By changing the DC
voltage E, the input voltage to the motor is also made
variable. Fig. 2.7 Making 3-Phase AC
(4) Structure of the inverter circuit 3-phase AC

Instead of the six switches, six transistors are used
to make up a circuit as shown in Fig. 2.8, to which a
three-phase motor is connected. The transistors are
turned on-off alternately to run the motor.
By changing the on-off sequence of the transistors, IM
the rotation direction of the motor can be changed.
Motor
Fig. 2.8 Transistor Inverter
– 21 –
CHARACTERISTICS
(5) Transistor function

A transistor consists of three terminals: a collector (C), Switch Transistor IGBT
an emitter (E) and a base (B) (gate (G) for an IGBT).
W hen the base signal is off, there is no continuity across C C
C-E (switch off). W hen a current flows in the base, there S
is continuity across C-E (switch on). The transistor can B G E
perform the same function (on-off) as switch S rapidly. E
"Transistor base shut-off" in the explanation of the
protective functions of the inverter indicates that this
base signal (gate signal for an IGBT) is switched off. In Fig. 2.9 Transistor
the inverter, the six transistors are switched off
simultaneously to separate the motor from the inverter, i.e. to coast the motor to a stop.
(6) Various methods of varying the AC voltage

As described in the characteristics of an inverter-driven motor, the voltage must be varied in
accordance with the V/f pattern to run a standard motor with an inverter.
As its voltage source is the inverter circuit, the transistorized inverter is a "voltage" source
inverter. There are various inverter types as indicated below according to the voltage varying
methods:
Voltage source type ⋅⋅⋅⋅⋅⋅ Voltage applied to the motor is controlled.
PAM system ⋅⋅⋅⋅⋅⋅ DC voltage is varied.
PWM system ⋅⋅⋅⋅⋅⋅ Transistor's switching pulse width is varied.
Approximate ⋅⋅⋅⋅⋅⋅ Transistor's switching pulse width is varied to make

sine-wave the average output voltage closer to a sine wave.
PWM system
These different control systems provide different motor characteristics (such as vibration, noise,
torque ripple, motor current ripple, torque response). (Refer to Table 2.1.)
– 22 –
CHARACTERISTICS
Table 2.1 Control Systems of the Voltage Source Inverter

(E: DC voltage)
Control Output Frequency Low Output Frequency High
Features
System (Voltage Low) (Voltage High)
PAM system • Small motor noise
E • High efficiency
E
Pulse • Voltage control needed
E
Amplitude E for converter
Modulation • Slow response
Output voltage waveform

Average output
PW M system voltage • Frequency and voltage
can be controlled by the
Pulse inverter circuit only.
W idth E • High-frequency noise is
Modulation generated by the motor.
E
Output voltage waveform

Average output
voltage • Smooth operation at low
speed
Approximate
• Low-degree high
sine-wave E frequency is small.
PW M system
• High-frequency noise is
E generated by the motor.
1 carrier
In the PW M system, several switching pulses are generated during a single cycle and varied in width
to vary the output voltage. The number of switching pulses generated during one second is called the
carrier frequency. In the PW M system, motor vibration and motor noise of frequency components
proportional to this carrier frequency are generated.

Large vibration or noise in only a specific speed range of a machine may be attributable to
resonance with the carrier frequency. In Mitsubishi transistorized inverters, such a problem may
be solved by changing the carrier frequency pattern (i.e. FR-A500, change parameter 72 "PW M
frequency selection"). The tone of motor noise also changes.
– 23 –
CHARACTERISTICS
The carrier frequency of a low acoustic noise inverter is extremely high, 15kHz to 20kHz, and is high
when compared to the human audio-frequency range (approximately 15Hz to 20kHz). Hence, we
hardly hear electromagnetic acoustic noise from a motor and a low acoustic noise inverter has been
achieved. However, since transistors in the inverter circuit are generally limited to about 2kHz, IGBTs
(Insulated Gate Bipolar Transistors) are used.
The FR-A500 series inverters adopt Power modules which use IGBTs as power switching devices.

In a low acoustic noise inverter, the leakage current between the inverter and motor is several
times larger than that of the transistorized inverter and nearly a dozen times larger than that of a
motor operated with a commercial power supply. For this type of inverter, earth leakage breaker
selection, grounding work, etc. should be done correctly.
– 24 –
CHARACTERISTICS
Current waveform
Voltage waveform
10ms/DIV
Fig. 2.10 Measurement Examples of Output Current and Voltage Waveforms
Fig. 2.10 of the FR-A500 Series Inverter (40Hz) (2kHz carrier frequency)
Current waveform
Voltage waveform
2ms/DIV
Fig. 2.11 Measurement Examples of Output Current and Voltage Waveforms
Fig. 2.11 of the FR-A500 Series Inverter (Fig. 2.10 with smaller time base)
(2kHz carrier frequency)
– 25 –
CHARACTERISTICS
2.3 Operation of the Converter Circuit
As described in Section 2.1, the

converter makes DC power to be 3) Inrush current suppression circuit
used in the inverter circuit. As 1) Converter
shown in Fig. 2.12, the converter
R P
circuit consists of: D1 D2 D3
1) Converter; NFB
2) Smoothing capacitor; and 2)
AC power V Smoothing
3) Inrush current suppression supply
C E
capacitor
circuit.
D4 D5 D6
N
Fig. 2.12 Converter Circuit

(1) Converter principle
An AC input current waveform generated when a direct current is made from single-phase AC
power (as shown in Fig. 2.13) will be described.
2V E
Voltage D1 D2
I
Inverter
AC power
V C E circuit
supply
(load)
Current (I)
t1 D3 D4
t2
D1
D4 D2
ON D3
ON Fig. 2.13 Converter Principle
• W hen a sine-wave voltage of effective value (V) (peak value 2 × V ) is input to the converter
from an AC power supply, a current flows only during portion t 1 , where supply voltage is higher
than voltage (E) of the converter DC output section, through diodes D 1 , D 4 .
• In the negative half cycle of the AC voltage, diodes D 2 , D 3 conduct in portion t 2 and a negative
input current flows in the AC side.
Therefore, the AC input current of the converter is not a sine wave but a distorted current wave
including harmonics.
– 26 –
CHARACTERISTICS
(2) AC input current in steady state (during motor running)

W hen AC power is full-wave rectified by a combination of six diodes for three-phase AC input, the
diodes conduct as shown in Fig. 2.14 and the input currents have distorted waveforms similar to
the one in a single-phase power supply.
The smoothing capacitor (C) smooths the three-phase, full-wave-rectified waveforms rectified by
the diodes into a direct current with little ripple.
W hen the inverter is at a stop, the maximum DC voltage is 2 times larger than the AC input
voltage (about 280VDC for 200VAC). W hen the inverter is running, the DC voltage varies slightly
according to the output (torque, speed).
Phase Phase Phase

R S T
DC voltage
Input voltage 0
(3 phase)
Converter output current

D1
D2
Diode D3
current
D4
Output voltage
D5 (without smoothing capacitor)
D6
Current flowing in D1
Phase R
Current flowing in D4 Smoothed DC voltage
Input Current flowing in D2

Phase S Fig. 2.15 Smoothed DC Waveform
current
Phase T
Fig. 2.14 Input Current Principle

W hen the three-phase AC input voltages are unbalanced, the AC input currents may be extremely
unbalanced. This is particularly liable to occur under light load where the DC bus voltage is high,
resulting in an open phase state in an extreme case. However, this is not an inverter fault.
W hen measuring currents, measure and compare across the three phases as the input currents
of the inverter are unbalanced between the three phases. The DC bus voltage can be measured
across terminals P(+)-N(−) of the inverter.
As the maximum DC bus voltage of the inverter is 400VDC (200V series) and is 800VDC (400V
series), measure it carefully.
– 27 –
CHARACTERISTICS
(3) AC input current at power on.

W hen the inverter is switched on, a large inrush
R P
current flows to charge the smoothing capacitor. A
suppression resistor shown in Fig. 2.16 is used to Suppression resistor
I
suppress the peak value of the inrush current.
On completion of smoothing capacitor charging, the Charging current
suppression resistor is shorted by a relay (or C
similar "bypass" device). Smoothing capacitor
N
When there is no inrush When there is an inrush
current suppression circuit current suppression circuit Fig. 2.16 Inrush Current Suppression
Fig. 2.16 Circuit
I
I The peak value is
Peak value large decreased to
prevent converter
module damage.
Time Time
About 50ms
Fig. 2.17 Inrush Current
It is not recommended that this method of Inverter power control is used regularly.
If the inverter is frequently switched on-off with a magnetic contractor (MC) etc, a peak current will
flow in the converter every time the inverter is switched on-off, shortening the life of the diodes.
This will also affect the switching life of the inrush current suppression circuit.
The converter circuit is designed to make DC power. The motor is started by switching on the
transistor base current. (Switch on the control input terminals STF or STR.)

If AC power is applied to the output terminals of the inverter circuit, an inrush current will flow
through the diodes (refer to Fig. 2.8) connected in parallel with the transistors, as described
previously, charging the smoothing capacitor (C). As a suppression resistor is not provided in the
transistor side circuitry, the diodes in the transistor section will be damaged. Power must not be
applied to the inverter output terminals U, V, W .
Charging current
DC voltage Power supply voltage
Inrush
current
Fig. 2.18 Measurement Example of Inverter Input Current and Voltage Waveforms
– 28 –
2. INVERTER PRINCIPLES AND. ACCELERATION/DECELERATION
CHARACTERISTICS
2.4 Inverter Control System and Auto Tuning Function
2.4.1 V/F control

To vary the frequency (f), a conventional transistorized inverter exercises control to keep the output
voltage-to-frequency ratio (V/f) constant as indicated by the dotted line in Fig. 2.19.
Therefore, this system is called V/F control.
In this system, sufficient torque is not always developed Voltage

because the effective voltage is reduced due to a voltage (V)
drop across the wiring and across the primary winding of
the motor.
This phenomenon has greater influence at lower speed.
(Low speed torque shortage.)
Hence, a voltage drop is pre-estimated and the voltage

increased, as indicated by the continuous line in Fig. 2.19 V/f constant
(torque boost*), to compensate for the insufficient torque
Torque
at low speed.
boost
Frequency (f)
Fig. 2.19 V/F Control
* If the torque boost setting is too large, sufficient torque will be developed but an excessive current
will flow, causing the inverter to be more liable to an OCT (overcurrent) trip.
To generate more torque at low speeds without the risk of OCT trip, advanced magnetic flux vector
control and general-purpose magnetic flux vector control are available.
– 29 –
CHARACTERISTICS
2.4.2 General-purpose magnetic flux vector control

In this control system, low speed torque is improved by dividing the output current of the inverter into
‘excitation current’ and ‘torque component current’ by vector arithmetic, then adjusting the voltage to
generate a motor current matching the load torque. Torque as high as 200% can be provided at 6Hz.
If the motor constants vary slightly (such as using another company's motor), this control provides
stable, large, low-speed torque without specific motor constant setting or tuning, achieving high
versatility.
• Vector arithmetic is performed on the output frequency and

phase of each phase current to the output voltage, dividing
Motor current
the output current (motor current) of the inverter into
‘excitation current’ (current needed to generate magnetic
flux) and ‘torque component current’ (current proportional to Excitation
the load torque). (See Fig. 2.20) current
• W hen the motor current varies due to load fluctuation, the
voltage drop on the primary side (including the wiring) of the
motor also varies, affecting the magnitude of the excitation
current.
This voltage drop is found from the motor and primary wiring
constants and torque component current magnitude to
compensate for (increase or decrease) the output voltage of
the inverter so that the primary magnetic flux of the motor is
kept constant.
• The motor constants required for arithmetic are already
stored in the inverter. General-purpose magnetic flux vector
control can be exercised by merely setting the motor Torque component
capacity. current
Fig. 2.20 General-Purpose Magnetic
Flux Vector Control
General-Purpose Magnetic Flux Vector Conventional V/F Control
Load Load
torque 300 torque 300
(%) 200 (%) 200
150
100 Output 100
3 6 10 20 30 40 50 60 frequency
0 (Hz) 0 Output
3 10 30 50 60 frequency
−100 −100 (Hz)
−150
−200 −200
Fig. 2.21 Speed-Torque Curve Comparison between General-Purpose Magnetic Flux

Vector Control and V/f Control
– 30 –
CHARACTERISTICS
2.4.3 Advanced magnetic flux vector control

In this control system, low speed torque and speed accuracy are improved by dividing the output
current of the inverter into ‘excitation current’ and ‘torque component current’ by vector arithmetic and
adjusting the voltage and frequency to generate a motor current matching the load torque. Torque
as high as 150% can be provided at 0.5Hz.
• Vector arithmetic is performed on the output frequency and

phase of each phase current to the output voltage to divide Motor current
the output current (motor current) of the inverter into an Excitation
‘excitation current’ (current needed to generate magnetic current
flux) and a ‘torque component current’ (current proportional
to the load torque). (See Fig. 2.22)
• The actual motor speed is estimated from the torque
component current to compensate for (increase or decrease)
the output frequency to reach the preset speed. <Slip
compensation>
• W hen the motor current varies due to load fluctuation, the
voltage drop on the primary side (including the wiring) of the
motor also varies, affecting the magnitude of the excitation
current.
This voltage drop is found from the motor and primary wiring
constants and torque component current magnitude to
Torque component
compensate for (increase or decrease) the output voltage of current
the inverter so that the primary magnetic flux of the motor is
kept constant. Fig. 2.22 Advanced Magnetic
Flux Vector Control
W ith this control system, the functions in half-tone portions are added to general-purpose magnetic
flux vector control to ensure that high torque can be developed at low speed. Also, the auto tuning
function allows the inverter to measure and store the motor circuit constants, ensuring accurate
arithmetic operation and a wide speed control range.
Advanced Magnetic Flux Vector Control Conventional V/F Control
200% 200%
40 torque 40 torque
50Hz 60Hz
Load 20 100% Load 20 10Hz 30Hz 100%
torque torque
torque 6Hz 30Hz 60Hz torque 3Hz
0 200 400 600 800 1000 1200 1400 1600 1800 2000
0 300 900 1500 1800
(Nxm) (Nxm) 1Hz
Speed Speed
↑ −20 (r/min) ↑ −20 (r/min)
−40
Fig 2.23 Speed-Characteristic Example under Advanced Magnetic Flux Vector Control
Advanced Magnetic Flux General-Purpose Magnetic

No. Item
Vector Control Flux Vector Control
1 Number of motors able to be connected 1 1
Motors that may Standard motor 0.4kW to 55kW , 2, 4, 6 poles 0.1kW to 7.5kW , 2, 4, 6 poles
2
be combined Constant-torque motor 0.4kW to 55kW , 4 poles 0.4kW to 7.5kW , 4 poles
Same as or one rank higher Same as or one rank higher
3 Usable inverter capacity
than motor capacity than motor capacity
4 Inverter model FR-A500 FR-E500, FR-A024/A044
5 Speed control range (in driving mode) 1:120 (60Hz), 1:100 (50Hz) 1:20
– 31 –
CHARACTERISTICS
2.4.4 Vector control (Closed loop)

Motor speed is detected by a PLG and motor slip is found by arithmetic operation to find the magnitude
of the load.
Vector arithmetic is performed on the magnitude of the load to divide the
output current of the inverter into an ‘excitation current’ (current needed Motor current
to generate magnetic flux) and a ‘torque component current' (current Excitation
proportional to the load torque) so that the frequency and voltage are current
controlled to optimise the required currents.
Equipped with a current control loop, vector control can perform

arithmetic on the required excitation current and torque component
current separately.
Control of the torque component current ensures fast response to load

variation, and control of the excitation current enables torque control
(as opposed to speed control).
Torque component
current
To do arithmetic on these accurately, vector control requires a
dedicated motor having little variation of constants to be used with a Fig. 2.24 Vector Control
precision PLG (speed detector).
Though torque accuracy decreases, a

PLG may be mounted to a general-
purpose motor to exercise vector control.
Ñìïîòâ
Short-time rating (1 minute)

150%
100%
Àìëñæëòìòð 75%
áòñö ïÞëäâ 50%
0 1500 3000
Speed r/min
(For 5.5K to 22K)
Fig. 2.25 Output Characteristic Example Fig. 2.26 Appearance of Vector Control-Dedicated
of Vector Control-Dedicated Motor Motor (SF-VR)
Advanced Magnetic Flux

Item Vector Control
Vector Control
Motor General-purpose motor Dedicated motor, general-purpose motor
Speed detector Not needed PLG
Speed accuracy 0.3% 0.01% (with PLG)
Parameter setting Simple Complicated (detailed data needed)
Response High response Ultra high response
– 32 –
CHARACTERISTICS

W hat is advanced magnetic flux vector control?
Vector control is a technique for controlling a dedicated squirrel-cage motor equipped with a
speed detecting encoder (PLG) (or a general-purpose, squirrel-cage motor equipped with a PLG)
as if it is a DC motor.
Advanced magnetic flux vector control is a control technique developed to run a general-purpose,
squirrel-cage motor in a near vector control state. (No PLG is required.)
The features of the advanced magnetic flux vector control system are described below:
(1) In vector control, the speed of a rotor can be detected accurately with a PLG mounted on the
shaft end. In advanced magnetic flux vector control (no PLG), detection accuracy is lower but
a general-purpose motor can be used as the rotor speed is estimated from the motor voltage
and current.
(2) In vector control, any state including a transient state (0 to 100% load) is estimated to ensure
that magnetic flux is always perpendicular to a rotor current. Hence, this control requires the
equivalent circuit constant details of the motor and needs the auto tuning function to measure
the circuit constants to use a general-purpose motor. In advanced magnetic flux vector
control, the rotor current is supposed to be a steady-state sine wave. Therefore, though
response to a transient change is slightly inferior, a wider range of motors may be used
because this control is scarcely influenced by the motor constants.
2.4.5 Auto tuning function

The inverter itself measures and stores offline the motor circuit constants needed for operation under
advanced magnetic flux vector control and vector control.
More specifically, when the auto tuning command is switched on, the inverter provides a motor
excitation output under given conditions, then does calculations to find such values as resistances r1,
r2 and inductances L1, L2, M from the current and other values. The inverter stores the resultant
values into memory.
L1 L2
r1
r1 : Primary resistance
r2 : Secondary resistance
r2
L1 : Primary inductance
L2 : Secondary inductance
M M : Excitation inductance
(1 − S) r2 : Mechanical output equivalent
(1 − S) r2 S ; resistance
S
Fig. 2.27 Equivalent Circuit of Induction Motor
• Since the inverter itself measures the constants of any motor such as a special motor or another
company's motor, advanced magnetic flux vector control and vector control can be used more easily
in a wider range of applications.
• As the motor constants can be measured accurately, starting torque and low-speed torque have
been improved for advanced magnetic flux vector control.
• If the wiring length exceeds 30m, the inverter can be run under advanced magnetic flux vector
control and vector control if autotwring has been performed.
• Either of two tuning modes (FR-A500 series) can be selected to match the machine's state.
• Easier and faster constant measurement without the motor being rotated. (Offline auto tuning)
• Performance of automatic magnetic flux vector control is enhanced by more accurate constant
measurement with the motor being rotated. (Offline auto tuning)
• Advanced magnetic flux vector control
Online auto tuning is designed to make fast tuning of the starting motor conditions to ensure
accurate operation which is unaffected by motor temperature and producing high-torque and steady
operation down to ultra-low speed.
– 33 –
CHARACTERISTICS
2.5 Protective Functions
2.5.1 Purposes and types of protective functions

The inverter has a wide variety of protective functions whose purposes are roughly classified into
"protection of the inverter itself" and "protection of the motor from overheating". In addition to the
protective functions, the inverter has alarm functions which alert the operator to an inappropriate
operation state. The following examples of functions are those of the FR-A500 series inverters.
Protection of
inverter itself Overcurrent shut-off During acceleration OC1
During constant speed OC2
During deceleration OC3
Regenerative overvoltage shut-off OV1 OV2 OV3
Output short circuit (line short) OC1 OC2 OC3

Protection
Output ground fault overcurrent GF
Instantaneous power failure IPF
Undervoltage UVT
Main circuit device overheat OC1 OC2 OC3
Brake transistor fault detection BE
Overload THT
Heat sink overheat FIN

Protection of motor
from overheating Overload THM OLT
External thermal relay operation OHT
Others Inboard option connection fault OPT
Storage device failure PE
Retry count excess RET
CPU error CPU
Heat sink power supply output P24

short-circuit
Operation panel power supply CTE
short-circuit
Brake sequence error MB1 to 7
PU detachment detection PUE
Output phase loss detection LF

Inappropriate operation
Overcurrent stall prevention
state
(during acceleration, during constant speed, during deceleration)
Alarm Overvoltage stall prevention (during deceleration)
Pre-alarm of protective Electronic overcurrent protection pre-alarm
function activation
Regenerative brake duty pre-alarm
Fin overheat prealarm
– 34 –
CHARACTERISTICS
2.5.2 How protective functions are activated

Inverter (FR-A500 series)
Converter circuit Inverter circuit

CT
NFB OCR
CT U
R Motor
C R CT
S V
Power IM
supply
CT W
T
External
thermal
relay
operation
Voltage detection Current detection OH
Regenerative Overcurrent shut-off

overvoltage shut-off Output side short circuit SD
Undervoltage Output side ground fault
Stall prevention overcurrent
Overload (electronic
overcurrent protection)
Stall prevention
Power supply
voltage detection
Brake transistor
Instantaneous power conduction detection
failure protection Parameter unit
Brake transistor fault FR-PU04 PARAMETER UNIT
detection
60.00Hz
STF FWD PU
Temperature
detection MON SET EXT PU
Main circuit HELP SHIFT ESC
device 7 8 9
overhead
4 5 6 FWD
CPU
1 2 3 REV
STOP
0 READ
WRITE
RESET
Connection fault
Inboard Contact output

option
Connector
Open collector output
Fig. 2.29 Protective Function-Related Circuits
– 35 –
CHARACTERISTICS
2.5.3 Levels at which protective functions are activated

The protective functions of the FR-A500 series inverter are activated on detection of currents or
voltages at the following levels:
Values in parentheses are

Current DC voltage those of the 400V series.
About 400V
200% Inverter output shut-off current Inverter output shut-off voltage
(About 800V)
} "Overload" inverse-time
characteristics
About 385V
(About 770V)
"Stall prevention" operation voltage
150% "Stall prevention" operation current (*1)

(Factory setting) About 370V Built-in brake operation voltage
(About 740V) (FR-A500-7.5K or less)
100% Rated inverter output current (*2)

About 215V
(About 430V) "Undervoltage" operation voltage
*1: When the operation current level is *2: About 150V (about 300V) when
changed, the new current (%) applies. converted to AC input voltage.

W hile regenerative overvoltage shut-off (OV1 to OV3) occurs only when power returned from the
motor is large, it rarely occurs due to an overvoltage trip when the motor is stopped. This
phenomenon occurs when a surge voltage from the power supply charges the smoothing
capacitor to reach the output shut-off voltage level and is attributable, for example, to the
switching of a power factor adjusting capacitor into the power supply system (high or low voltage).
To prevent this, use an AC reactor (power factor improving reactor may be used) in the inverter
supply.
– 36 –
CHARACTERISTICS
2.5.4 Displays and output signals provided on activation of protective functions

Protective function Display
activated • Fault definition is shown on the parameter unit display.
Output signal • Fault signal (contact signal) is output. (Note 1)

• For instantaneous power failure, the open collector signal (IPF)
is output. (Note 1)
Alarm function Display

activated • Shown at the right-hand side of the parameter unit display (OL).
Output signal • Alarm signal (contact signal) is not output.

• For stall prevention, the open collector signal (OL) is output.
(Note 1)
• For pre-alarm, the open collector signal can be output by setting
a parameter.
Parameter unit
FR-PU04
FR-PU04 PARAMETER UNIT
Liquid crystal
display
Inverter trip.
OC During Acc
0.00Hz
Fig. 2.31 Fault Display
Note 1: The alarm output signal may depend upon the setting of the inverter parameters. Please
refer to the relevant inverter manual for detailed information.
– 37 –
CHARACTERISTICS
2.5.5 Resetting method

(1) W hen any protective function is activated, the corresponding fault definition is displayed on the
parameter unit, and the inverter outputs the corresponding fault signal and stops the motor
output.
(2) The inverter remains in the fault state. Unless the fault is reset, the inverter cannot be restarted.
Faults may be reset by any of the following methods:
1) After connecting the reset terminal RES-SD of the inverter for more than 0.1 second,
disconnect them. (If they are remain connected, the inverter cannot be restarted.)
2) Switch power (R, S, T) off once, wait for more than 0.1 second, and switch it on again.
3) Activate the inverter reset function from the help functions of the parameter unit.
Protective function
activated
Motor Coast to stop

speed
Time
Output
Inverter shut-off
output
Time
Output stop held 10ms
Fault output signal terminal A-C Time
Reset signal terminal RES-SD Time
Start signal terminal STF-SD Time
Fig. 2.32 Reset Operation Timing Chart
2.5.6 Retry function

W hen an alarm occurs in the inverter, the inverter programmed to automatically reset that alarm and
restart operation. W hen this retry function has been selected, the equipment will start suddenly after
an alarm stop, so stay away from the equipment, warn and protect machine operators.

If a fault is reset in the inverter during the running of a motor, transistor base shut-off causes the
motor to coast. W hen the inverter is restored to normal by resetting, the motor restarts (the
inverter restarts at the starting frequency) and may result in an overcurrent trip due to a start
during coasting. Do not perform reset while the motor is running.
– 38 –
CHARACTERISTICS
2.6 Acceleration and Operational Characteristics of an Inverter
2.6.1 Start
W hen the inverter start signal (terminals STF-SD or 100
Torque
STR-SD) and frequency command signal are input to the 80 TL
(%)
inverter, the inverter outputs the starting frequency, and
the motor generates torque. 50
W hen the starting torque of the motor at the starting
frequency is larger than the starting torque of the load, the 4Hz 6Hz 8Hz
motor begins to rotate. If the load torque is larger, the 0
output frequency is increased gradually with the motor
locked, and when the motor starting torque exceeds the Current 150 Current limit
(%) 100 of inverter
load torque T L as shown in Fig. 2.33, the motor starts.
However, if the frequency at start increases, the motor lock
50
current will also increase and may reach the current limit, 4Hz 6Hz 8Hz
resulting in an overcurrent (OC1) or overload (THT) trip. 0
Speed (r/min)
Fig. 2.33 Starting Torque Example
The starting torque of an inverter-driven (V/F control) motor is different from that of a motor
operated with a commercial power supply and defined as follows:
The starting torque of an inverter is the maximum torque that can be developed within the 150%
overcurrent immunity range of the inverter in a low frequency region. Since the starting torque of the
inverter-driven motor is defined differently from that of the motor operated with a commercial power
supply, this starting torque is called "maximum starting torque".
For example, the maximum output frequency within the current limit of the inverter is 6Hz in Fig. 2.33.
Hence, the maximum torque at 6Hz is the maximum starting torque.
At the frequency of less than 6Hz, the inverter will not result in an overcurrent trip if the motor shaft
is locked. Note that if the motor shaft is locked for a long time, the inverter may result in overload
shut-off (THM).

The FR-A500 series inverter has a function to set the starting frequency (0 to 60Hz).
Increasing the starting frequency will increase not only motor starting torque but also starting
current. Unless the motor is reversed by the load (e.g. vertical lift load) due to insufficient motor
torque at start, keep the starting frequency as the factory setting.
To increase the starting torque, adjust the manual torque boost.
– 39 –
CHARACTERISTICS
2.6.2 Acceleration
After it has started, the inverter increases the output frequency gradually up to the frequency
command value according to the acceleration time setting.
As described in Section 1.3.3 "W hat is "slip" ?", if the motor increases its speed greater than
synchronous speed proportional to output frequency (f), a delay will correspond to the slip.
2
This slip is influenced by the values of load GD , load torque and motor-generated torque. W hen the
acceleration time setting is long enough, output frequency (f) and motor speed (N) rise in proportion
to each other. (Refer to Fig. 2.34.)
However, if the acceleration time setting is too small, a difference between f and N is large and slip
remains large (refer to Fig. 2.35). This will increase motor current and may activate the stall
prevention function or current shut-off protection function due to overcurrent. (If the motor capacity is
unchanged and the inverter capacity is increased, immunity increases relative to overcurrent, and the
protective function is less liable to be activated.)
In a transistorized inverter which suppresses the starting current, acceleration time must be set to
match the load.
Output frequency (f)

Output frequency (f)
N f N f Motor speed (N)
↑ ↑ ↑ ↑
Motor speed (N)
Slip large
Time Time
Overload immunity when inverter

I Overload immunity when inverter I capacity is increased
(%) and motor are same in capacity
Rated Motor Current
(%)
Rated Motor Current
↑ ↑
Rated current Rated current
150 150
100 100
Time Time
Fig. 2.34 Acceleration Characteristic Fig. 2.35 Acceleration Characteristic

(When acceleration time setting is matched) (When acceleration time setting is short)

W hen a motor is direct-on line started from a commercial power supply, a current 6 to 7 times
larger than the rated current generally flows in the motor (refer to Section 1.4) and the motor starts
with an acceleration time determined by load characteristics (refer to Section 1.9.1).
W hen a motor is direct-on line started similarly by an inverter having the same capacity as the
motor (for example, an MC is switched on on the inverter output side), it trips due to starting
current. Therefore, a motor used with an inverter must be started at a low frequency. (A starting
current at about 3 to 6 Hz falls within 150% of the rating.)
The MC on the output side of the inverter must not be switched on-off because of the direct-on line
starting current stated above.
– 40 –
CHARACTERISTICS
2.6.3 Stall prevention due to overcurrent

If the motor current exceeds 150% (overload immunity of Acceleration complete
the inverter) during acceleration, the inverter stops Frequency
increasing the output frequency to make overcurrent (f)
shut-off protection less liable to be activated. ↑
Stall prevention operation
Starting frequency
→ Time
Fig. 2.36 Stall Prevention Operation

Fig. 2.37 during Acceleration
Action to be taken when overcurrent shut-off OC1 is activated during acceleration.

(a) A trip occurs immediately after the start signal is switched on.
• Decrease manual torque boost.
• Increase manual torque boost or starting frequency.
(W hen the motor is rotating in reverse (vertical lift load).)
(b) The motor starts rotating but trips without increasing speed.
• Increase the acceleration time setting.
• Increase manual torque boost.
• Correct machine looseness. (W hen the motor rotates but the machine does not start.)
(c) A trip occurs at more than 10 Hz.
• Increase the acceleration time setting.
* The parameter unit used with the FR-A500 series inverter has a monitoring function. W ith this
function, the inverter output frequency at which a trip occurred can be read.
W hen a trip occurs, the corresponding alarm definition is displayed. Press the SHIFT key until
the frequency, output current or output voltage at which the trip occurred is displayed.
2.6.4 Constant-speed operation

W hen the output frequency matches the frequency command value, acceleration is complete and the
motor runs at constant speed.
Stall prevention due to overcurrent Frequency

If the motor current exceeds 150% (overload immunity of (f)
the inverter) during constant speed operation, the inverter ↑
decreases the output frequency to prevent a trip due to
overcurrent. Stall prevention operation
W hen the motor current falls to 150% or less, the inverter
returns the output frequency to the previous value.
→ Time

Fig. 2.37 during Constant Speed
– 41 –
CHARACTERISTICS
Action to be taken when overcurrent shut-off OC2 is activated during constant speed operation.
(a) During operation at less than the base frequency.
• Increase manual torque boost.
(b) During operation at less than 10 Hz.
• Decrease manual torque boost gradually.
(c) W hen load torque is temporarily larger than 150% of the motor rating, increase the inverter
capacity.
2.7 Deceleration and Stopping Characteristics of an Inverter
2.7.1 Deceleration
By switching off the inverter starting signal (STF, STR) or
setting the frequency setting signal to a value lower than
the output frequency, the output frequency is decreased N f
gradually according to the deceleration time setting. Motor speed (N)
↑ ↑
During deceleration, motor speed is higher than Slip (negative)
synchronous speed equivalent to the output frequency of Frequency (f)
the inverter and the motor acts as a generator to return
energy to the inverter (this operation is called
→ Time
regeneration). Therefore, the DC voltage (voltage of the Deceleration
smoothing capacitor) rises. time setting
W hen the motor is operated with a commercial power
supply, switching off the motor run stopping magnetic Fig. 2.38 Deceleration Characteristic
contactor causes the motor to coast to a stop with only load
torque acting as braking force. (For stopping time, refer to Section 1.9.1.)
W hen the motor is operated with the inverter, switching off the start signal does not cause the motor
to coast to a stop immediately but to decelerate to a stop according to the deceleration time setting.
At this time, the motor state is as indicated below according to the deceleration time setting:
Table 2.2 Relationships between Deceleration Time and Regeneration

Deceleration-to-Stop Time Condition Motor State Motor Slip
Deceleration time setting > coasting-to-stop time Driving (motor) 3 to 5% or less
Deceleration time setting < coasting-to-stop time Regeneration (generator) Negative
In the regenerative mode, the motor operates as a

generator and charges the smoothing capacitor in the Frequency
converter circuit, raising the DC voltage across it (voltage (f) Stall prevention
across P-N). ↑ operation
If the deceleration time setting is too small it will activate
the regenerative overvoltage protection function or
overcurrent (regenerative current) protection function. Set Deceleration
complete
deceleration time to a slightly longer value or install an
optional FR-BU brake unit or FR-RC power return converter →Time
to inverters which do not include a regenerative brake
circuit. (W hen the regenerative function is used frequently,
Fig. 2.39 during Deceleration
use the FR-A201 series inverter with built-in power return
function.)
– 42 –
CHARACTERISTICS
• Stall prevention due to overvoltage

W hen the DC voltage rises further, this function stops the decrease of output frequency to make
regenerative overvoltage shut-off protection less liable to be activated.
• Stall prevention due to overcurrent
W hen the motor current exceeds the specified value during deceleration, this function stops the
decrease of output frequency to make overcurrent protection less liable to be activated.
2.7.2 Stop f
(1) W hen the inverter starting signal (STF, STR) is ↑
DC dynamic brake
switched off, output frequency decreases as shown in Deceleration operation frequency
Fig. 2.40. W hen it falls to or below the DC dynamic
brake operation frequency, a DC voltage is applied to
→ Time
the motor to make it stop. This is called DC dynamic
braking.
A given period after DC dynamic braking, the
transistor base signal is switched off to shut off the DC dynamic braking
output.
Fig. 2.40 DC Dynamic Brake Operation
(2) W hen the magnetic contactor (MC) on the inverter
input side is switched off, the inverter detects a power failure and shuts off the transistor base,
coasting the motor to a stop. W hen the deceleration-to-stopping function of the inverter is to be
used, do not switch off the inverter input power.
DC braking
W hen the DC voltage is applied to the motor which is rotating, brake torque is generated. W hen
the motor comes to a stop, brake torque is stopped.
(For the FR-A500 series, the operation frequency, operation time and operation voltage of this
brake can be changed.)
Useful Inverter Check Points
Actions to be taken when overcurrent shut-off OC3 is activated during deceleration.

(a) Motor with brake trips immediately after deceleration.
Refer to Section 3.5.7.
(b) Motor trips immediately before a stop (during DC dynamic brake operation).
• Decrease the DC dynamic brake voltage.
(c) Increase the deceleration time setting.
– 43 –
CHARACTERISTICS
DC bus voltage
Motor current
Inverter input current
Acceleration time setting 2 seconds
Fig. 2.41 Acceleration Characteristic Measurement Example
DC bus voltage
Motor current
Deceleration time setting 2 seconds
Fig. 2.42 Deceleration Characteristic Measurement Example
– 44 –
CHARACTERISTICS
2.8 Efficiency and Power Factor of an Inverter
2.8.1 Efficiency
As the inverter is a power converter consisting of a converter circuit and an inverter circuit as
described in Section 2.1, losses are produced in these circuits. It is generally said that the use of an
inverter saves power. This reason will be described using related equations.
Motor
Power
supply PIN PM POUT
Inverter IM Load
IINV IM
Loss W M
P: Power
Loss W INV I: Current
Efficiency ηM
Efficiency ηINV
Fig. 2.43 Input/Output Power Relation Diagram
Output Output
Efficiency = = .......................................................................................... (2.1)
Input Output + loss
Inverer output power Inverter output power (PM)
Inverter input power (PIN) = (PM) + Inverter loss ( W INV ) = ........ (2.2)
(Motor input power ) Inverter efficiency(ηINV )
Motor output (POUT )
Motor input power (PM) = Motor output (POUT ) + Motor loss ( W M) = ............................. (2.3)
Motor efficiency(ηM)
Machine power
Motor output (POUT ) = Motor output torque × Motor speed = ...................................... (2.4)
Machine efficiency
Hence, inverter input power is as follows:
Motor output
Inverter input power = Motor output + Motor loss + Inverter loss = .................... (2.5)
Overall efficiency
where, Overall efficiency = Inverter efficiency(ηINV) × Inverter driven motor efficiency (ηM) ................ (2.6)
As seen from formula (2.5), inverter loss is added to motor loss which is larger when a motor is
operated with an inverter than when it is operated with a commercial power supply under the influence
of harmonics, etc. W hen the motor is inverter-operated at the same speed as when it is operated with
a commercial power supply, therefore, the input power of the inverter-operated motor is always larger
than that of the motor operated with a commercial power supply. However, since the reduction in
motor speed by the inverter decreases motor output, input power is smaller as speed is lower if load
torque is constant. (For variable torque load such as a fan or pump, input power becomes much
smaller, leading to energy saving.)
– 45 –
CHARACTERISTICS
2.8.2. Power factor

Voltage
A power factor is generally found from the phase Current
angle φ of the voltage and current as shown in Fig. Commercial power
2.44. However, as the input current of the inverter operation
is a distorted wave including harmonics as Power factor=cos φ
described in Section 2.3, its power factor cannot
be defined by cos φ . (W hen measured with a φ
power-factor indicator, it reads about 1.) On the
Voltage
other hand, since a power factor is equivalent to
the ratio of active power to apparent power, the Current
power factor of the inverter is found by formula
Inverter operation
(2.7).
Fig. 2.44 Input Voltage and Current Waveforms
Active power Active power (PIN)

Power factor = =
Apparent power Active power + Reactive power
Inverter input power (PIN)
= .......................................... (2.7)
3 × Power supply voltage × Inverter input current (IINV)
2.8.3 Inverter input current and power factor improvement

The input current waveform of the inverter changes in distortion factor according to the impedance of
the power supply (reactive components of a transformer, cables, etc.), resulting in variation of the
input current (effective) value. However, since the power supply voltage and inverter input power do
not vary if the motor output is constant, as seen from Section 2.8.1, the power factor is changed
according to formula (2.7). As the power supply reactance is larger, the current is smaller and the
power factor is improved. Conversely, when the inverter is installed near a large capacity power
transformer, smaller reactance will increase the current and worsen the power factor.
To improve the power factor, therefore, install a reactor in the DC circuit of the inverter (a power factor
improving DC reactor improves the power factor to about 95%) or in the AC supply side (a power
factor improving AC reactor improves the power factor to about 90%) in order to increase the power
supply side reactance.
Thus, while the power factor of the inverter varies sharply between about 0.6 and 0.9 according the
conditions of the power supply reactance, the power factor of the motor operated with a commercial
power supply is almost constant between 0.75 and 0.85, and the expression of current ≈ power is
established. For the inverter, the expression of current ≈ power is not established. Hence, the inverter
input current may be smaller than the motor current at the rated torque output.
For details, refer to the exercise and calculations on page 48.
– 46 –
CHARACTERISTICS
1) Power factor improving AC reactor FR-BAL(H)

The power factor improving AC reactor enhances the form factor of the inverter input current,
improves the power factor, and allows power supply capacity to be decreased. It is also effective
for reduction of input harmonic currents.
Improvement effect Power factor of power supply 90% or more (at 100% load)
Operating environment • Ambient temperatures −10 to +50°C
• Ambient humidity 90%RH
• Vibration 0.6G or less
• W ithout dust, dirt, corrosive gas or flammable gas
Operating voltage 200/200/220V 50/60/60Hz (400/400/440V, 50/60/60Hz)
Connection Connect to the input side of the inverter.
Inverter
NFB FR-BAL
R X
R
Power S Y
supply S
T Z
T
Fig. 2.45 FR-BAL Connection Example
2) Power factor improving DC reactor FR-BEL(H)

Producing similar effects as the AC reactor, the power factor improving DC reactor is smaller in
loss, size and weight than the AC reactor.
Improvement effect Power factor of power supply 93 to 95% (at 100% load)
Operating environment • Ambient temperatures −10 to +50°C
• Ambient humidity 90%RH
• Vibration 0.6G or less
• W ithout dust, dirt, corrosive gas or flammable gas
Power factor improving reactor
FR-BEL
P1 P
* The length of the cables
Always disconnect the jumper between the reactor and
across terminals P1-P. the inverter should be as
Wiring distance should be 5m max.
short as possible (5m
max.), and their size should
be equal to or larger than
that of the power supply
NFB N P1 P (PR)
Motor cables.
R U
Power supply S V IM
Inverter
T W
Fig. 2.46 FR-BEL Connection Example
– 47 –
CHARACTERISTICS

W hen the power factor improving reactor is installed, the input current decreases, giving the
following advantages:
• Smaller peripheral devices can be selected on the inverter supply side.
• The harmonic currents will be reduced.
• The inverter is protected against surge voltages from the power supply.
• The peak current can be suppressed at power on of the converter circuit.
The power factor improvement ratio of the power factor improving AC reactor is up to about 90%,
the DC reactor is about 95%.
Exercise
Find the input power, motor current and inverter input current when a conveyor (constant torque
load output 7.5kW ) is operated with a commercial power supply at 30m/min and when the conveyor
is operated by an inverter at 30m/min and 15m/min.
Suppose that the power supply is 200V 60Hz, motor efficiency ( η M ) is 0.9 and motor power factor
(cos φ ) is 0.88.
(1) Commercial power operation (30m/min)

PM = POUT / ηM = 7.5 / 0.9 = 8.33 [kW ]
PM 8.33 × 10 3
IM = = = 27.3 [ A ]
3 × E × cos φ 3 × 200 × 0.88
(2) Inverter operation (30m/min)

PM = POUT / ηM' = 7.5 / 0.85 = 8.82 [kW ] (W here η M ' = 0.85)
PINV = PM / ηINV = 8.82 / 0.95 = 9.29 [kW ] (W here η I NV = 0.95)

PM 8.82 × 10 3
IM = = = 28.9 [ A ]
3 × E × cos φ 3 × 200 × 0.88
PINV 9.29 × 10 3
IINV = =
3 × E × Inverter power factor 3 × 200 × Inverter power factor
W hen the inverter power factor is 0.95, IINV = 28.2 (A)

W hen the inverter power factor is 0.7, IINV = 38.3 (A)
(3) Inverter operation (15m/min) ..... POUT = 7.5 [kW] × 15 / 30 = 3.75 [kW]
PM = POUT / ηM' = 3.75 / 0.8 = 4.69 [kW ] (W here η M ' = 0.8)
PINV = PM / ηINV = 4.69 / 0.9 = 5.21 [kW ] (W here η I NV = 0.9)

PM 4.69 × 10 3
IM = = = 318
. [A ] (W here cos φ = 0.85)
3 × E × cos φ 3 × 100 × 0.85
(W hen V/f is constant, E = 100V)
PINV 5.21 × 10 3
IINV = = = 215
. [A]
3 × E × Inverter power factor 3 × 200 × 0.7
– 48 –
CHARACTERISTICS
DC bus voltage
Motor current
10ms/DIV 10ms/DIV
Fig. 2.47 Input/Output Current Waveform Fig. 2.48 Input/Output Current Waveform
Fig. 2.47 Measurement Example (50Hz) Fig. 2.47 Measurement Example
(50Hz, with power factor improving reactor)
10ms/DIV 10ms/DIV
Fig. 2.49 Input/Output Current Waveform Fig. 2.50 Input/Output Current Waveform
Fig. 2.47 Measurement Example (20Hz) Fig. 2.47 Measurement Example
(20Hz, with power factor improving reactor)
– 49 –
AND INVERTER
This chapter describes points to be considered, such as the capacity of a motor to be driven, the
number of motors, operation status, etc. for selection of an inverter, and corrective actions to be taken
when a fault occurs.
As details about specific capacity selection are given in Technical Notes, this chapter mainly provides
details on how to select the inverter capacity.
POINTS FOR UNDERSTANDING

1. Optimum combination of motor capacity and inverter capacity.
2. Capacity selection for driving two or more motors.
3. Difference between acceleration and deceleration.
3.1 How to Select Capacity
W hen regarded as a motor power supply, an inverter having higher capacity is better and allows a
motor to be direct-on line started (to be switched on/off by the inverter output) like a commercial power
supply. However, in consideration of economy, dimensions, etc., it is not be wise to increase the
capacity unnecessarily.
To select the optimum capacity at which trouble-free operation can be performed, first understand the
following:
3.1.1 What is inverter capacity?

The capability (not a function) of driving a motor can be understood from the flow of energy changing
according to the operation.
(1) During acceleration/constant-speed operation. Energy
The capability of an inverter is current immunity,
i.e. how much current the inverter can supply to
the motor. This immunity is represented by the
rated output current and overload capacity. Current
(2) During deceleration.
Since the motor functions as a generator during
deceleration, energy returns to the inverter the
reverse of during acceleration and constant-
speed operation. The capability of the inverter is
the processing (consumption) of this energy. Energy (regenerative)
Part of the energy returned from the load side is
also consumed by the motor. Hence, the
inverter will consume the remaining energy.
Specifically, as this energy will increase the
terminal voltage of the smoothing capacitor in
the inverter, regenerative energy is consumed
or returned to the power supply side with the
terminal voltage rise within the specified value.
– 50 –
AND INVERTER
3.1.2 Notes about capacity selection

The inverter capacity should match the capacity of the motor to be driven. In addition, it should be
selected according to the load characteristics, operation method, etc.
(1) Motor capacity
To prevent unexpected problems caused by using an inverter (e.g. motor will not start), it should
be understood that under V/F control the output torque of an inverter-driven motor is smaller than
that of a motor operated from a commercial power supply in a low frequency region. This also
applies to a rise in motor temperature. (Refer to Sections 1.5 and 1.6.)
(2) Operation method
To select the inverter capacity according to the capacity of a motor to be driven or the number of
motors, first select it so that the sum of motor currents does not exceed the rated current of the
inverter.
A feature of inverters is that a single inverter can drive two or more motors. However, this may not
be economical because the inverter capacity will be extremely large in some operation methods.
Also, a mistake in capacity selection is liable to occur in this type of operation. Under advanced
magnetic flux vector control, only one motor can be driven by a single inverter. For multiple-motor
operation, select V/F control.
General operation methods are as follows:
1) Driving a single motor with a single inverter.
2) Driving two or more motors with a single inverter at the same time.
3) Starting two or more motors with a single inverter, starting sequentially.
4) Switching a single motor on-off on the output side of an inverter.
5) Switching a motor output shaft on-off with a clutch.
1) Driving a single motor with a single inverter.
Rated output current of inverter ≥ rated current × 1.1.................................... (3.1)
Indicated in specifications Value on motor Increase due to distorted

of inverter. name plate waveform
(a) It is not totally correct to select an inverter according to motor capacity in "kW ". It
CAUTION
is better to select an inverter which will satisfy the condition in formula (3.1) based
on the rated current of a motor.
Reason: If the inverter and motor have the same capacity (kW ), an increase in the
number of motor poles reduces the efficiency and power factor of the motor,
increasing the rated current value.
For standard 2, 4, and 6 pole motors, selection of an inverter based on "kW " will
hardly pose any problems.
(b) A motor having a capacity larger than the inverter cannot be used.
– 51 –
AND INVERTER
2) Driving two or more motors with a single inverter at the same time.
Rated output current of inverter ≥ sum of rated currents × 1.1....................... (3.2)
I1
IM 1
Inverter
I2
IM 2
In
IM n
W hen two or more motors are to be run in parallel, inverter electronic overcurrent
CAUTION
protection cannot be used to protect the motors. Provide a thermal relay for each motor
on the inverter output side. W hen motors are to be run continuously at low speed,
thermal relays cannot adequately protect the motors. Instead, use a temperature
detector in each motor.
3) Starting two or more motors with a single inverter, starting sequentially.
Rated output current of inverter ≥ sum of rated currents running × 1.1

+ starting current of motor being started ............... (3.3)
[Example] Supposing that four motors are started sequentially as shown below, the motor
current is maximum when the last motor (IM 4 ) is started (MC 4 is switched on) while the
other three motors are running. W hen a motor starts, motor current I 4 is 6 to 8 times
larger than the rated current.
MC 1 I1
IM 1
Inverter MC 2 I2
IM 2
MC 3 I3
IM 3
MC 4 I4
IM 4
(a) W hen one motor is switched on-off on the output side of the inverter or when a
CAUTION
motor output shaft is switched on-off by a clutch, select the inverter capacity as in
the above sequential start. Regard the motor currents during running as zero and
use only the starting current of the motor to be switched on-off to select the
inverter capacity.
(b) W hen two or more motors are to be run in parallel, the inverter electronic
overcurrent protection cannot protect the motors, a thermal relay should be
provided for each motor on the inverter output side. W hen the motors are to be run
continuously at low speed, thermal relays cannot adequately protect the motors.
Instead, use a temperature detector in each motor.
– 52 –
AND INVERTER
(c) If the current limit function is activated, the frequency varies suddenly. For
sequential starts, the speeds of motors already started may vary suddenly.
Hence, according to the machine specifications:
• W hen the current limit function of the inverter is utilized to minimize the inverter
capacity
Rated output current of inverter ≥
sum of rated currents of motors (IM1 to 4) × 1.1
• W hen it is not desired to affect the speed of the motors already started
<The point is to make a selection so that the current limit function is
not activated>
Rated output current of inverter ≥
sum of rated currents of motors already started × 1.1
+ starting current of motor started last *
* Starting current of motor: Select an inverter on the assumption that the starting
current is around 6 to 8 times larger than the rated motor current.
[Example] For three motors SF-JR 1.5KW 4P (rated current 6.0A, starting current 48.4A)
• W hen the current limit function of the inverter is utilized to minimize the inverter
capacity
Select the FR-A520-5.5K inverter with current limit function having the rating of
19.8A (= 6.0A × 3 units × 1.1).
• W hen it is not desired to affect the motors already started
Select the FR-A520-18.5K inverter with current limit function having the rating of
61.6A (= 6.0A × 2 units × 1.1 + 48.4A) or more.
(3) Operation pattern

W hen there are restrictions on acceleration and deceleration times, conformity with only the
motor capacity (current-based selection) may not be enough to make a proper selection.
The inverter must be selected to satisfy the predetermined acceleration and deceleration times.
For lifting operation or operation where the acceleration and deceleration alternate during a short
period, the inverter capacity may have to be increased. In such a case, always make a full
examination of the application/conditions before selection.
[Examples] 1) W hen sudden acceleration/deceleration or cyclic operation is to be performed
(such as machine tool, trolley).
2) W hen a lifting operation is to be performed.
[Example situations where factors other than current consumption must be satisfied.]
– 53 –
AND INVERTER
Can a motor be used with an inverter whose capacity is one rank higher?
W hen the inverter capacity is increased, the motor torque (power) increases.
The motor-generated torque is lower in inverter operation than in commercial power supply
operation. Therefore, depending on the load magnitude, the current may increase due to
insufficient torque (power), activating the protective function.
Generally, insufficient torque may be solved by increasing the motor capacity (the inverter
capacity must also be increased) or by increasing the inverter capacity only with the motor
capacity unchanged.
Since the price will be higher and the motor size will be larger using the former method than
in the latter method, the latter method is often used.
As the increased inverter capacity will increase the output current of the inverter, motor-
generated torque can be increased.
If the inverter capacity is increased, motor temperature rise cannot be corrected.

W hen motor temperature rises during low-speed continuous operation, for example, this
problem cannot be solved by increasing the inverter capacity.
Since the motor is cooled by its own cooling fan, the cooling capability is not improved by
increasing the inverter capacity.
W hen the inverter capacity is increased, the motor can be operated beyond its power and
motor overheat must be taken into consideration. At this time, it is important to set the
electronic overcurrent protection of the inverter correctly to match the motor capacity.
– 54 –
AND INVERTER
3.2 Selection According to Operation Pattern
The basic operation pattern of a motor is made up of a start, acceleration, constant speed,
deceleration and a stop. Points of selection in each process will be described below.
[3] Is the motor temperature

correct?
Temperature rise should be
[2] Can the motor be accelerated? within specified values. [4] Can the motor be decelerated?
Motor torque should be not less • There should be enough braking
than torque required for N [r/min] torque required for deceleration.
acceleration (Ta+T L ). • Inverter should have capability to
consume or return energy to the
power supply during deceleration.
[1] Can the motor be started?
Motor starting torque
should be larger than load
starting torque.
Time
ta (s) td (s)
Acceleration Deceleration
time time
Load torque (T L )
Time
Acceleration torque (Ta)

Time
Deceleration torque (Td)
GD ⋅ N
2
Ta =
375 × ta
2
GD ⋅ N
Td =
GD ⋅ N
2
Ta = 375 × td
38.2 × ta
2
GD ⋅ N
Td =
38.2 × td
Ta
Required motor torque
<Ta + T L >
TL
Time
Required brake
The key is the magnitude of motor
torque
output torque. Torque changes
<Td – T L >
according to motor capacity,
inverter capacity, control system The key is the regenerative capability
and boost amount. of inverter. Regenerative capability
changes according to selection of
inverter capacity, brake unit model
and power return converter.
Fig. 3.1 Operation Pattern and Torques
– 55 –
AND INVERTER
3.2.1 Start
A motor starts at a point where motor-generated torque exceeds load torque (point A in Fig. 3.2).
Since the motor is locked while the inverter output frequency is between 0 and point A, the point of
intersection must be less than the maximum starting frequency at which the inverter does not trip due
to locked rotor current. (Refer to Section 2.6.1.)
For magnetic flux vector control
Maximum torque of motor

Torque
(changes according to
boost amount)
Point
A
Load torque (T L )
0 Output frequency
fa’
Motor starts at this frequency.
Fig. 3.2 Motor Start
3.2.2 Acceleration
The output torque of the motor must be not less than torque required for acceleration (T a + T L ).
Acceleration is classified into non-linear acceleration in which speed increases with the stall
prevention (current limit) function activated, and linear acceleration in which speed increases
smoothly without the stall prevention function activated. Non-linear acceleration is generally used for
examination. For fixed-position stop of a lift etc., use linear acceleration to make an examination.

To increase acceleration capability and starting torque:
• Select advanced magnetic flux vector control (FR-A500 series) or general-purpose magnetic
flux vector control (FR-E500, FR-A024 series).
• Increase the amount of torque boost.
• Increase the inverter capacity.
• Increase the motor capacity and inverter capacity.
– 56 –
AND INVERTER
3.2.3 Deceleration
Regenerative braking torque is determined by motor loss and inverter loss. Therefore, the capability
of an inverter with a built-in brake is determined by inverter loss, and that of an inverter without built-in
brake is determined by motor loss. To increase regenerative braking torque, an increase in the
inverter capacity with a built-in brake is effective but not for an inverter without a built-in brake.
Therefore, use the BU brake unit.
If the inverter has satisfied the brake torque requirement, whether the brake resistor is thermally
acceptable during deceleration must be examined. Energy returned to the inverter (W INV ) during
deceleration must be fully consumed within the capability of the brake resistor.
W hen larger brake capability is needed, use a power return option (FR-RC) or an inverter having
built-in power return function (FR-A201 series) which returns regenerative energy (W RC ) to the power
supply to generate braking force.
Inverter without power return converter Inverter with built-in power return function
During
During acceleration
acceleration
NFB Motor
NFB
Motor Power
Power Inverter IM Load
Inverter IM Load supply
supply
WM Overall Power
energy return
Brake c onv ert er
W INV WM Overall
during
resistor energy
regeneration
during
W MECH
regeneration
W MECH
Inverter having built-in
power return function
Fig. 3.3 Flow of Energy during Deceleration
To increase regenerative braking torque:

• Increase the inverter capacity.
This method is effective for inverters which contain a regenerative brake circuit but not for
models without.
Use an inverter having built-in power return function.
• Use a brake unit (FR-BU or BU option).
• If a BU brake unit is already being used, use a larger BU brake unit or increase the number of BU
brake units. Note that if the BU brake unit required is larger than the inverter, the inverter
capacity must also be increased.
– 57 –
AND INVERTER
Regenerative brake function

The inverter consumes returned energy to brake the motor. The consumption circuit is a regenerative
brake circuit.
Brake circuit
The built-in regenerative brake circuit in
Fig. 3.4 will be used as an example to P
describe its operation.
Regenerative energy raises the voltage (E) U
of the smoothing capacitor (C). W hen the
R
voltage exceeds a specified value, the V
transistor (T Rd ) in the regenerative brake C I d
To motor
E T Rd
circuit conducts, current I d flows in the
regenerative brake resistor (R). This W
current causes the regenerative brake
resistor to generate heat and consume
regenerative energy. This operation
N
decreases energy charged in the capacitor,
dropping the voltage (E). W hen the voltage
(E) falls below the specified value, the Fig. 3.4 Brake circuit
regenerative brake transistor (T Rd ) stops
conducting, shutting off the current to the
regenerative brake circuit.
This operation is repeated during deceleration, but the regenerative brake circuit may be reduced in
duty or may not be operated if regenerative energy is small (torque required for deceleration is small).
The duty of the regenerative brake circuit is preset to 2 to 3% due to the thermal capability of the
circuit. Therefore, if it is changed unnecessarily, the regenerative brake resistor may overheat or the
transistors may become faulty.
The optional brake BU unit has an external circuit which is equivalent to the built-in brake circuit.
W hether the BU brake unit is required or not can be judged as described below:
The brake unit is needed if the DC voltage measured across terminals P(+)-N(–) with a meter
immediately after deceleration starts rises to nearly the stall prevention operation voltage
described in Section 2.5.3. Also, if a voltage above the brake operation voltage continues in an
inverter used with the brake unit, the brake capability may be insufficient, the brake unit capacity
should be increased.
– 58 –
AND INVERTER
• Thermal capacity of regenerative brake (temperature rise)

The capability of the regenerative brake unit is determined by regenerative brake torque and power
consumption. Regenerative brake torque is determined by the resistance value (Ω) of the resistor as
it depends on the value of a regenerative current flowing in the brake resistor. If the regenerative
current flows for a long time, the resistor will generate heat which may exceed the permissible
temperature rating. This permissible value is the rated power (W ) of the resistor. Hence, the thermal
capacity of the regenerative brake must be carefully examined for a high-duty operation pattern or
continuous regenerative load (such as a lift).
• Inverter with built-in power return function (FR-A201 series)
An inverter and power return converter have been integrated into an inverter having both large
braking capability and compact size, featuring:
1) Improved braking capability
Continuous rated braking torque is 100% and overload immunity is 150% for 60 seconds.
2) Reduced installation space
Area needed for installation is about 60 to 80% (will differ according to the capacity) of a separate
inverter and power return unit.
3) A large range of models from 5.5K to 55K for both 200V and 400V classes.
4) No need to make brake unit selection.
For lift operation - single-cycle time, lifting height (m), and load torque during negative torque
(especially machine efficiency) are important selection factors because of the generally long
regenerative operation time.
– 59 –
AND INVERTER
3.2.4 Motor temperature rise

(1) Motor temperature rise differs between continuous operation and cyclic operation. Hence, motor
heat must be examined according to the operation method.
Continuous Operation Cycle Time Operation

Frequency of
operation Frequency of operations per hour: Frequency of operations
10 times or less per hour: 10 times or more
Speed
Speed
Forward Time
Time rotation
Reverse
rotation
Motor heat Under magnetic Acceptable if a motor

examination flux vector control Should be within this equivalent current value
(0.4kW to 1.5kW) continuous permissi- Speed found from a current and
ble torque range. cooling coefficient in each
Time running section is less than
100
the rated motor current.
Torque In inverter operation where
[%] 50 the motor starting current is
Current
restricted by the overload
Time capacity of the inverter,
temperature rise is generally
30 60 120 lower than that in
t1 t2 t3
Frequency [Hz] commercial power
operation.
• Acceptable if the torque value of the output
characteristic at running speed is satisfied.
Fig. 3.5 Operation Patterns and Motor Temperature Rises
(2) Motor insulation

The insulation letter indicates the type of insulating material used for a motor and indirectly
represents the permissible value of the motor temperature rise.
Small-capacity standard motors adopt insulation classes E and B, medium and larger capacity
motors use class F. W hen the ambient temperature is high or it is desired to increase torque
without changing the motor size, a special motor having increased insulation can be used.
Table 3.1 Motor Insulation Ranks
Insulation Rank Max. Permissible Temperature [°C] Temperature Rise Limit of Coil [°C]
(Resistance method)
E 120 75
B 125 80
F 155 100
– 60 –
AND INVERTER
3.3 Finding the Machine Reduction Ratio
Small-capacity standard motors (7.5kW 4P or less) can be used up to 120Hz. W hile the reduction
ratio of a machine conventionally determined with the maximum machine speed at 50Hz or 60Hz, the
following advantages are given for increasing the reduction ratio and inverter output frequency
2
(between 60Hz and 120Hz) to reduce load torque and load GD at the motor shaft:
(1) Motor can be started more easily as the reduction ratio is higher.
(2) Continuous duty is enabled even at low speed. (A standard motor may be selected instead of a
constant torque motor exclusively designed for inverter operation).
(3) Variable speed range can be increased.
Relationships between Reduction Ratio (i), Load Torque Converted into Equivalent Value at
2
Motor Shaft (T L ), and Load (GD L )
TL = TLL ⋅ i TLL : Load torque at load shaft
GD 2 L = GD 2 LL ⋅ i 2 GD 2 LL : Load GD 2 at load shaft
Exercise
Select a geared motor for continuous use of a conveyor requiring 1.2kW power (torque constant)
in a 1:5 variable speed range. Calculation examples in International System of Units (SI) are
half-tone screened.
(1) W hen maximum running frequency is 60Hz and gear ratio is 1/30 Motor
Gear ratio 1/30
9550 9550
6.367 [N·m]
974 × P 974 × 1.2
• Load torque (TL ) = = =0.649[kgf ⋅ m]
N 1800
6.367 191.01 [N·m] Conveyor
• Load torque at reduction gear output shaft (TLL ) = 0.649 × 30 = 19.47[kgf ⋅ m]
(5.17 N·m)
• As continuous motor output torque at low speed of 12Hz is 65% (0.53kgf·m) of the
rating, capacity is insufficient for a 1.5kW motor.
9550
7.587 [N·m] 6.367 [N·m]
974 × 2.2
• 60% torque of 2.2kW motor = × 0.65 = 0.774 [kgf ⋅ m] >TL = 0.649 [kgf ⋅ m]
1800
Hence, if a 2.2kW geared motor of 1/30 gear ratio is selected, the conveyor can be used
continuously at 12 to 60Hz.
(2) W hen the reduction ratio of the geared motor is 1/37.5 and the maximum running frequency
is increased to 75Hz.
• Low-speed frequency is 75Hz/5=15Hz (continuous output torque can be up to 70%
of the rating) 191.01
5.094 [N·m]
19.47
• Load torque at motor shaft (TL ) =TLL ⋅ i = =0.519[kgf ⋅ m]
37.5
9550
5.57 [N·m] 5.094 [N·m]
974 × 15
.
• 70% torque of 1.5kW motor = × 0.7 = 0.57 [kgf ⋅ m] > TL = 0.519 [kgf ⋅ m]
1800
Hence, if a 1.5kW geared motor of 1/37.5 gear ratio is selected, the conveyor can be used
between 15 to 75Hz.
– 61 –
AND INVERTER
3.4 Capacity Selection Procedure
Motor Mechanical brake operated

Frequency speed Inverter output stopped
f1 N1
f2 N2
Machine side Time
conditions [s]
Load torque
converted into T LS
equivalent value T L max
at motor shaft T L min
Time
Ta
Acceleration torque
Time
Deceleration torque
–Td
Ta+T L max
Required motor torque

T L max
Examination
items Time
– (Td–T L max)
I1
I2
I4
Motor current Time
I3
C2
Cooling coefficient (c) C3
C1
C4
C5
Time
t1 (=ta) t2 t3 t4 t5
tc (1 cycle)
Fig. 3.6 Typical Speed Patterns and Examination Items
– 62 –
AND INVERTER
Table 3.2 List of Specification Symbols and Units

Gravitational
Specifications Symbol SI System of Units
System of Units
Machine side Required power PL kW kW
specifications
Motor capacity PM kW kW
Number of motor poles P — —
Motor speed N r/min rpm
Frequency f Hz Hz
Moving velocity V m/min m/min
Load weight W kgf kgf
Machine efficiency η — —
Friction coefficient µ — —
Load torque converted into the equiva-
TL N·m kgf·m
lent value at the motor shaft
Load torque at start converted into the
T LS N·m kgf·m
equivalent value at the motor shaft
Load GD 2 converted into the equivalent
GD 2 L kgf·m 2 kgf·m 2
value at the motor shaft
GD 2 of mechanical brake converted into
GD 2 B kgf·m 2 kgf·m 2
the equivalent value at the motor shaft
Cycle time (1 cycle) tc sec sec
Time in each operation zone tn sec sec
Acceleration time ta sec sec
Deceleration time td sec sec
Shortest acceleration time tas sec sec
Shortest deceleration time tds sec sec
Acceleration Acc m/sec 2 m/sec 2
Specifications Rated motor speed NM r/min rpm
used for
Rated motor torque TM N·m kgf·m
examination
Maximum motor starting torque T MS N·m kgf·m
Acceleration torque Ta N·m kgf·m
Deceleration torque Td N·m kgf·m
Load torque factor TF % %
Motor GD 2 GD 2 M kgf·m 2 kgf·m 2
Short-time maximum torque coefficient αm — —
Continuous operation torque coefficient αc — —
Maximum starting torque coefficient αs — —
Linear acceleration torque coefficient αa — —
Non-linear acceleration torque coeffi-
αd — —
cient
Brake torque coefficient (general term) β — —
Hot coefficient δ — —
Cooling coefficient C — —
Motor current I % %
Motor equivalent current value IMC % %
Regenerative Average power absorbed by the motor WM W W
power
Average power returned to the inverter W INV W W
Average power returned from the ma-
W MECH W W
chine
Continuous permissible power of the
W RC W W
brake unit
Short-time permissible power per one
W RS W W
operation of the brake unit
Stopping Stopping time tb sec sec
accuracy
Delay distance S mm mm
Delay distance ∆ε mm mm
– 63 –
AND INVERTER
3.4.1 Continuous operation examination procedure

1 Selection flowchart
Selection Outline Judgment

Required power 1) • Calculate the power required by Required power (P L )
1) Load torque (T L )
calculation the load.
2) • According to the required power, Motor capacity (P M ) ≥ required power (P L )

temporarily select the capacity of Rated motor torque (T M ) ≥ load torque (T L )
2) Temporary selection the motor used.
of motor capacity •
3) • Temporarily select the inverter Inverter capacity (P INV )

capacity corresponding to the ≥ motor capacity (P M )
3) Temporary selection motor capacity temporarily (Rated inverter output current
of inverter capacity selected. > rated motor current)
4) • For operation, the motor must be Motor starting torque (T MS )

at a stop when starting rotation. > load torque at start (T LS )
4)
Can the motor Hence, examine whether the
NO be started? motor can be started or not.
YES
5) • Examine whether or not the Continuous motor operation torque (T MC )
5) magnitude of the load causes the > load torque (T L )
Can continuous permissible temperature of the
NO operation be motor to be exceeded.
performed?
YES 6) • Calculate the minimum value of

6) acceleration time.
Calculation of the • Examine whether the resultant Shortest acceleration time (tas)
NO shortest accelera- value satisfies the planned < planned acceleration time (ta)
tion time. acceleration time. For example: Shortest acceleration time
(tas) ≤ 45 seconds.
YES
Examination of
7) • Calculate the minimum value of Shortest deceleration time (tds)
brake option < planned deceleration time (td)
deceleration time.
• Examine whether the resultant
7) value satisfies the planned
Calculation of the deceleration time.
NO shortest decelera- • From deceleration time during Deceleration torque (Td)
tion time. operation, calculate the torque
needed for deceleration.
YES
8) • Examine the capability to handle Short-time permissible power (W RS )
regenerative power in > regenerative power during deceleration
8) deceleration period. (W INV )
Examination of
NO regenerative power
• Examine the capability to handle Continuous permissible power (W RC )
regenerative power during > regenerative power during continuous
YES continuous regenerative operation (W INV )
operation.
End
– 64 –
AND INVERTER
Calculation Formula, Etc. Data Used/Item Remarks (Note, Etc.)

1) • Load torque (T L ) • Technical Note No. 22 • Since the output torque of the motor
T L = 9550 × P L /N [N·m] [Calculation of Required Power] reduces during operation at 60Hz or
974 [kgf·m] Refer to APPENDICES. higher, take care to ensure that torque
will not be insufficient.
2) • Rated motor torque (T M ) • Motor Catalog, Technical Data • The permissible speed (operating
T M = 9550 × P M /N M [N·m] • Technical Note No. 22 frequency range) varies according to the
974 [kgf·m] Refer to Chapter 4 "MOTOR AND capacity, number of poles and model of
BRAKE CHARACTERISTICS" the motor.
[Characteristic Charts].
3) • Inverter Catalog • Motor-generated torque differs according
(Standard specifications) to the type and control system of the
inverter (magnetic flux vector control >
V/F control).
• Whether the brake circuit is contained or
not depends on the inverter type.
4) • Motor starting torque=maximum • Technical Note No. 22 • Starting torque is larger under magnetic
starting torque Refer to Chapter 2 "DRIVE flux vector control than under V/F control.
Maximum starting torque CAPABILITY DATA" [Data • Starting torque is improved if the inverter
T MS = T M × αs × δ > T LS Classified by Torque Type]. is increased in capacity.
αs : Maximum starting torque
coefficient
δ : Hot coefficient
5) Continuous operation torque • Technical Note No. 22 • Under magnetic flux vector control, the
coefficient αc > load torque factor Refer to Chapter 2 "DRIVE continuous operation torque range
(TF) = T L /T M CAPABILITY DATA" [Continuous increases for some motor capacities.
or Torque].
Continuous operation torque (T M ) × αc αc : Continuous operation torque
> load torque (T L ) coefficient
6) • Short acceleration time (tas) • Technical Note No. 22 • Acceleration torque is larger under
2 2
(GD L × GD M) × N Refer to Chapter 2 "DRIVE magnetic flux vector control than under
tas = [N·m] CAPABILITY DATA" [Torque V/F control.
38.2 × (TM × αh − TL max) Type]. • When the shortest acceleration time is
375 [kgf·m] αh : Non-linear acceleration torque longer than 45 seconds, use the linear
coefficient acceleration torque coefficient and
recalculate.
7) • Short deceleration time (tds) • Technical Note No. 22 • The value of the shortest deceleration
2 2
(GD L × GD M) × N Refer to Chapter 3 "BRAKING time differs according to whether the
tds = [N·m] CAPABILITY DATA" [Braking brake resistor is contained or not.
38.2 × ( TM × β + TL min) Capability Torque Type]. • When the shortest deceleration time is
375 [kgf·m] β : Deceleration torque coefficient longer than the planned, examine the use
• Deceleration torque (Td) of a brake option.
8) • Regenerative power from the load • Technical Note No. 22 • The capability of regenerative power
(W MECH ) Refer to Chapter 3 "BRAKING (permissible power) differs according to
• Motor-absorbed power (W M ) CAPABILITY DATA" [Braking the type and capacity of the inverter.
• Regenerative power to the inverter Capability Torque Type]. • For continuous regeneration, the power
(W INV ) = W MECH – W M [W] W RS : Short-time permissible power return converter may be needed.
W RC : Continuous permissible
power
Note: The half-tone screen indicates the gravitational systems of units.

The unit is in the International System of Units (SI).
– 65 –
AND INVERTER
3.4.2 Cyclic operation examination procedure

Selection Outline Judgment

µW ⋅ V Temporarily selected motor
Power calculation PL = [kW] capacity (P m ) > P L
6120 × η
2
Also calculate load torque and GD .
Temporary selection of (1) Select the motor capacity greater than the Temporarily selected inverter
motor capacity required power. capacity ≥ P M
Temporary selection of (1) Select the inverter corresponding to the motor

inverter capacity capacity.
(2) If necessary, increase the inverter capacity to
Whether the motor can increase acceleration torque.
be started or not. • Make sure that the starting torque and low-speed T MS > T LS
Whether low-speed torque of the motor are larger than the load T M × αm × δ > T LS
operation can be torque.
performed or not δ : Motor hot coefficient
• Calculation of relationship between acceleration Ta + TL max
NO and acceleration time αa >
Can motor be started? • Acceleration torque TM
YES 2
ΣGD × N max
Ta = [N·m]
Calculation of accel- 38.2 × ta
eration torque (Whether 375 [kgf·m]
acceleration is possible • Calculate the torque required for acceleration.
or not) αa : Linear acceleration torque coefficient
NO Can acceleration be
done? • Deceleration torque Td − TL min
YES 2 β min >
ΣGD × N max TM
Temporary selection of Td = [N·m]
38.2 × td
brake unit 375 [kgf·m]
(Simple selection
method available) • Calculate the torque required for deceleration.
Calculation of decel- βmin: Brake torque coefficient
eration torque (Whether
deceleration is possible
or not)
NO (1) Check the short-time permissible power. W INV < W RS
Can deceleration be
(2) Check the average regenerative power. W INV × td/tc < W RC
done? W INV : Power returned to the inverter
YES td: Deceleration time during 1 cycle
Examination of tc: Time in the whole 1 cycle
regenerative power
NO Can brake system be

used thermally?
YES Make sure that the equivalent current value does not exceed 100%.
Determination of brake 2
Σ (In × tn)
system IMC = < 100 [%]
Σ (Cn × tn)
Thermal examina-
tion of motor
Motor, inverter, brake

unit
• Calculate the stopping accuracy provided by the mechanical brake.
Stopping accuracy
Note: The unit is expressed in the SI systems of units. The half-tone screen indi-
cates the conventional gravitational systems of units.
End
– 66 –
AND INVERTER
3.4.3 Lifting operation examination procedure

Examination of machine
side specifications
Selection Outline
W×V
Load power calculation Required power (PL ) = [kW]
6120 × η
Temporary selection of (1) Select the motor capacity which is not less than 1.5 times of the required power.
motor capacity (2) Increase the motor capacity to increase starting torque
(1) Select the inverter equivalent to the motor capacity.
Temporary selection of (2) Increase the inverter capacity to increase acceleration torque.
inverter capacity
Whether motor can be

(1) Motor starting torque (T MS ) > load torque at start (T LS )
started or not Whether
(2) Motor torque at low speed
low-speed operation can
T M × αm × δ > load torque (T L )
be performed or not
(3) Motor torque at high speed
Whether high-speed
T M × αm > load torque (T L )
operation can be
performed or not
Acceleration torque
NO Can the motor be 2
started? ΣGD × N
Ta = [N·m]
YES 38.2 × ta
375 [kgf·m]
Calculation of Ta: Acceleration torque
acceleration torque ta: Acceleration time [s]
(whether acceleration Examination of whether acceleration can be made or not
can be made or not)
Ta max
NO < αa
Can acceleration be TM
done? αa: Acceleration torque coefficient
YES Deceleration torque
2
Calculation of ΣGD × N
deceleration torque Td = [N·m]
38.2 × td
(whether deceleration
375 [kgf·m]
can be made or not)
Td: Deceleration torque
td: Deceleration time [s]
Td max
Temporary selection of <β min
brake unit TM
βmin: Brake torque coefficient
NO Can deceleration be (Temporarily select the brake unit and the inverter having power return function
done? (FR-A201) in accordance with the data.)
YES
Examination of (1) Check the short-time permissible power.

regenerative power W INV < W RS
(2) Check the continuous permissible power.
NO Can brake unit be used W INV × t/tc < W RC
thermally? W INV : Power returned to the inverter
YES t: Time when negative load torque is applied [s]
tc: Time of whole 1 cycle [s]
Determination of brake
system
Motor equivalent current value
Motor, inverter, braking unit
2
Σ (In × tn)
Examination of motor IMC = < 100 [%]
heat Σ (Cn × tn)
End Note: The unit is in the International System of Units (SI).

The half-tone screen indicates the gravitational systems of units.
– 67 –
AND INVERTER
NOTE:
Lift applications are different from other applications in that there are two modes of positive load
torque (generally rising) and negative load torque (generally lowering), also cyclic operation is always
performed with a stop at a fixed position. A transistorized inverter can be used in such applications in
the following cases:
(1) Vertical lift operation

• Control system
For the following reasons, it is desirable to adopt advanced magnetic flux vector control,
general-purpose magnetic flux vector control or vector control. Note that V/F control may be
advantageous for regenerative torque at low speed.
• Since a lift always involves overload operation, starting torque of 150% or more is required.
• As a counterweighted lift may become negatively loaded due to the size of a load even during
lifting, the output voltage must be controlled to prevent overcurrent.
Reduction
Electromagnetic
gear
brake
MC
Motor
NFB
Lift case
Counterweight
(W LS )
Inverter (W C )
Load (W L )
Vertical motion
Brake unit
Fig. 3.7 Counterweighted Lift System Configuration Example
• Mechanical brake releasing timing

• Release:
To prevent a load drop, the mechanical brake is released after the RUN (running) signal from
the inverter is switched on by the start signal.
• Engagement:
To prevent brake lining wear and overcurrent, speed is fully decreased before the mechanical
brake is engaged and the inverter's MRS (output stop) signal is switched on.
• Lowering operation
The lift is often driven by the load, resulting in regenerative operation.
As the inverter itself cannot compensate for regenerative energy, a braking unit (such as a
power return converter or brake unit) is always required.
• Motor selection
If continuous operation at low speed is not performed, a constant torque motor need not be
adopted.
– 68 –
AND INVERTER
(2) Regenerative operation
Flow of energy in
regenerative mode
P
AC reactor
Power IM
supply
N
Regenerative energy is
returned to power supply in
this area.
Fig. 3.8 Regenerative Operation
W hen the motor is rotated by an external force (such as gravity) during lift lowering operation etc.,
energy generated by the motor functioning as a generator is accumulated in the smoothing capacitor
which raises the voltage across the DC-bus capacitor (across terminals P-N).
Such a state is called regenerative operation.
This regenerative energy is compensated for in the following system to generate braking force in the
motor:
Resistor consumption system : W ith regenerative energy converted to heat, this system is low in
initial cost and is suitable for small capacity use.
Power return system : W ith regenerative energy returned to the power supply, this system
provides a large braking force, produces an energy-saving effect,
and is adequate for large capacity applications.
• Note that if the braking unit capacity is low, the voltage across the capacitor (across terminals
P-N) rises, causing the inverter to trip due to OVT (regenerative overvoltage).
Set Pr. 19 (base frequency voltage) of the inverter according to the power supply voltage to
minimize the occurrence of an OCT (overcurrent) alarm in the regenerative mode.
(3) Low speed operation

• Low speed torque
Since the low speed torque of an inverter-driven motor is liable to be low, care should be taken,
e.g. adopt a control system which will provide high torque (such as advanced magnetic flux
vector control) according to machine specifications and/or set the torque boost properly.
• Motor temperature rise

As motor temperature will rise greatly during continuous operation at low speed, full
examination is required, e.g. use a constant torque (force cooled) motor or reconsider the
operation pattern.
Also, setting the optimum torque boost will produce an effect on the suppression of a
temperature rise during low speed operation.
– 69 –
AND INVERTER
• Stable operation
High torque at start/low speed is slightly different from smooth operation at low speed.
A speed control range indicates the lowest speed at which operation can be performed
smoothly. Vector control (speed control range 1:1500) is the most suitable for use in
applications where smooth operation is desired at ultra low speeds.
<Example>
A speed control range of 1:120 (advanced magnetic flux vector control) indicates that when the
maximum speed is 60Hz, the lowest usable low speed range in which smooth operation can be
performed is to 1/120 of 60Hz or 0.5Hz. (Note: speed control range is 1:100 for 50Hz inverters.)

• It should be noted that the PLG speed feedback operation of the FR-A500 series, etc. provides
a large effect on slow load variation, but may become unstable with speed fluctuations due to
torque ripple at low speed and control response delay.
(4) Inverter and mechanical safety brake

A mechanical safety brake must be used with a lift to hold the load. This safety brake, which is
also used in vertical positioning applications, requires an interlock circuit which does not interfere
with deceleration torque developed by the regenerative brake of the inverter.
(5) Selection of fast-response inverter (general-purpose)

During acceleration/deceleration, a lift calls for a response as fast as about 1 to 2 seconds to
reach high speed. For this purpose, the FR-A500 series in advanced magnetic flux vector control
system is the most appropriate Mitsubishi transistorized inverter.
(6) Fail-safe system configuration and safety measures

W hen the protective circuit of the inverter is activated, eg. a power failure occurs, output to the
motor stops, motor torque will be lost and a gravity-drop of the load may occur. In consideration
of such risk, a fail-safe circuit should be designed. To provide for motor stall, it is recommended
to install an overspeed relay or similar safety measure on the machine.
(7) Measures against vibration, shock and cable separation

For installation in a traveling machine such as a crane, full measures must be taken to prevent
faulty operation due to power supply cable separation and to provide protection against shock and
vibration.
– 70 –
AND INVERTER
List for Quick Selection of Mitsubishi Transistorized Inverter Model
Inverter Model
Item
FR-E500 FR-A024S/A044 FR-A500 FR-A100 FR-A201 FR-V200
Ultracompact,
Compact, High For fans/pumps, High
low price, High accuracy,
Features medium performance, low acoustic performance,
medium high functions
functions high functions noise high functions
functions
3-phase, 200V Single phase,
Power supply 3-phase, 200V 3-phase, 200V 3-phase, 200V 3-phase, 200V
Single-phase, 200V
specifications 3-phase, 400V 3-phase, 400V 3-phase, 400V 3-phase, 400V
100/200V 3-phase, 400V
0.1kW to 3.7kW
Capacity 0.1kW to 7.5kW (400V: 0.4kW to 0.4kW to 55kW 0.75kW to 55kW 5.5kW to 55kW 1.5kW to 45kW
3.7kW)
V/F control or V/F control or V/F control or
V/F control or
general-purpose general-purpose advanced
magnetic flux
Control system magnetic flux magnetic flux magnetic flux V/F control Vector control
vector control
vector control vector control vector control
selectable
selectable selectable selectable
Low acoustic
noise
{ { { { { {
Reset/Output
stop
{ { { { { Output stop
selective
Multiple speeds 15 speeds 15 speeds 15 speeds 7 speeds 7 speeds 7 speeds
Brake Built-in — — 7.5K or less — — 5.5K or less
resistor Option 0.4K or more 0.4K or more { — — 5.5K or less
Brake unit
connection
{ { { { — {
0 to 5, 10VDC 0 to 5, 10VDC 0 to 5, 10VDC
0 to 5, 10VDC 0 to 5, 10VDC 0 to 5, 10VDC
Speed command ±5VDC, ±10VDC ±5VDC, ±10VDC ±5VDC, ±10VDC
4 to 20mA 4 to 20mA ±10VDC
4 to 20mA 4 to 20mA 4 to 20mA
1 changeover 1 changeover 1 changeover 1 changeover 1 changeover 1 changeover
Alarm output
contact contact contact contact contact contact
Output signal 2 type 2 types 5 types 5 types 5 types 3 types
Automatic restart
after
instantaneous
{ { { { { {
power failure
1Hz 150% 1Hz 150% 1r/min 100%
Low speed torque 0.5Hz 150% 6Hz 80% 1Hz 150%
3Hz 200% 3Hz 200% continuous
Stall prevention { { { { { —
Fast-response
current limit
{ { { { { —
0.75kW floor
31 55 100 115 — —
space ratio %
0.75kW standard
61 76 100 97 — —
price ratio %
(400V class) (400V class)
EMC (Dedicated noise (Dedicated noise (Dedicated noise (No confor-
(Dedicated noise (Dedicated noise
EC Directive filter available) filter available) filter available) mance)
filter available) filter available)
Direc-
Low
tives
Voltage { { { (400V class
only)
(No confor-
mance)
(400V class
only)
Directive
UL Standard { { { { { {
cUL Standard { { { { { {
For use when For use when For use when For use when low For use when For use when
some degree of compact size high starting acoustic noise is regenerative large torque,
functions are and regenerative torque and required in torque is called high accuracy
called for, e.g. brake are tripless feature fan/pump for in vertical and fast
multi-speed required. are needed or applications. motion response are
Selection point operation and when operating applications. required.
brake motor conditions are
operation. unclear.
Adequate for use
in most
applications.
General Conveyors, Conveyors, Air conditioners. Lifts, Lifts,
industrial General Machine tools, Winding Winding
machines, industrial General machines, machines,
Infinitely machines. industrial Machine tools, Conveyors.
Main applications
variable speed machines, General
Pulleys, Lifts. industrial
Starters, machines.
Conveyor drive.
– 71 –
AND INVERTER
3.5 Operation Methods
3.5.1 Types of operation methods

The great feature of the inverter is that various signals can be used for operation. Inverter operating
methods (start, stop, variable speed) are roughly classified as follows.
Here, the FR-A500 series inverter is used for explanation.
Operation using Start-stop signals

+ Frequency setting signal
external signals (STF, STR)
Frequency setting potentiometer
External 0-5V, 0-10VDC, 4-20mADC analog signal
Digital signal (BCD, binary)
Contact signal (multi-speed setting)
Computer link ....... Operation performed in combination with computer
CC-Link ....... Operation performed in combination with programmable

controller
Operation using Operation performed by merely entering commands through keyboard of parameter
parameter unit unit (FR-PU04)
(option)
Inverter
NFB MC
FR-A500 Motor
R U
Power IM
S V
supply
T R
Start/stop STF (STR)
SD
RH
Running frequency
selected by contact RM
change-over
RL
10
Frequency setting 2
potentiometer
5
External input signal FR-PU04 PARAMETER UNIT
(0 to 5, 0 to 10VDC,
4 60.00Hz
4 to 20mADC) STF FWD PU
Option
MON SET EXT PU
12-bit digital input FR-A5AX HELP SHIFT ESC
(BCD, binary) 9
7 8
Digital output 4 5 6 FWD
(extension analog output) FR-A5AY

1 2 3 REV
CC-Link FR-A5NC 0 WRITE

STOP
READ RESET
Operation using Operation using

external signals parameter unit
Fig. 3.9 Inverter Operating Methods
– 72 –
AND INVERTER
3.5.2 Operation procedure overview

A general "external signal operation" procedure is as follows:
Power on Function setting Start Operation Stop Power off
Switch on the input Set the values of Switch on the start Vary the speed with Switch off the start Shut off the input
side magnetic the required func- signal to start/ the frequency signal to decelerate side magnetic
contactor MC. tions using the accelerate. setting signal. to a stop. contactor MC.
parameter unit. Switch STF (STR) Switch STF (STR)
(For the first op- ON. OFF.
eration)
3.5.3 How to set the functions

The FR-A500 series has a number of functions which have already been factory-set to given values.
Therefore, function setting is not needed to start operation. Set only the necessary functions
according to the operational specifications.
(1) W hen factory setting is acceptable
You need not set the functions.
(2) Generally set functions
Though the functions used depend on the operational specifications, the following are typical
"often set functions."
Acceleration time [Parameter number 7]
Deceleration time [Parameter number 8]
Electronic overcurrent protection [Parameter number 9]
Minimum
Function Parameter Name Screen Setting Range Setting Factory Setting
Number Display Increment
6%/4%/3%/2%
Basic 0 Torque boost Trq.Bst1 0 to 30% 0.1%
(Note 1)
functions 1 Maximum frequency Max.F1 0 to 120Hz 0.01Hz 120Hz
2 Minimum frequency Min.F1 0 to 120Hz Same as above 0Hz
VFbaseF
3 Base frequency 0 to 400Hz Same as above 60Hz
1
Multi-speed setting
4 PresetF1 0 to 400Hz Same as above 60Hz
(high speed)
Multi-speed setting
(middle speed)
Multi-speed setting
(low speed)
0 to 3600 seconds/ 0.1 seconds/ 5 seconds/15
7 Acceleration time Acc.T1
0 to 360 seconds 0.01 seconds seconds (Note 2)
5 seconds/
0 to 3600 seconds/ 0.1 seconds/
8 Deceleration time Dec.T1 15 seconds
0 to 360 seconds 0.01 seconds
(Note 2)
Electronic thermal O/L Rated output
9 Set THM 0 to 500A 0.01A
relay current
DC injection brake
10 DC Br.F 0 to 120Hz, 9999 0.01Hz 3Hz
operation frequency
DC injection brake 0 to 10 seconds,
11 DC Br.T 0.1 seconds 0.5 seconds
operation time 8888
DC injection brake
12 DC Br.V 0 to 30% 0.1% 4%/2% (Note 2)
voltage
13 Starting frequency Start F 0.01 to 60Hz 0.01Hz 0.5Hz
14 Applied load selection Load VF 0 to 5 1 0
Note 1: These set values differ according to the inverter capacity: (0.4K, 0.75K)/(1.5K to 3.7K)/
(5.5K, 7.5K)/(11K or more).
Note 2: These set values differ according to the inverter capacity: 7.5K or less/11K or more.
– 73 –
AND INVERTER
(3) Parameter numbers and their functions

Note: Pr. stands for "parameter."
Pr. 0 Torque boost (manual) setting Pr. 4 Pr. 5 Pr. 6 3-speed setting
• Motor torque in the low-frequency range can be adjusted Pr. 4 3-speed setting (high speed)
according to the load.
Pr. 5 3-speed setting (middle speed)
100%
Pr. 6 3-speed setting (low speed)
• Any speed can be selected by switching the external
Output contact signal (across terminals RH/RM/RL-SD).
voltage • Each speed (frequency) may be specified as appropriate
(V)
between 0 and 400Hz during inverter operation. The [▲]
and [▼] keys may also be used for setting.
Pr. 0 Setting Speed 1
Output
range (high speed)
frequency
Base (Hz)
frequency Speed 2
Output (middle speed)
frequency
Speed 3
Pr. 1 Pr. 2 Upper and lower frequency limit (Hz)
(low speed)
settings
Pr. 1 Maximum frequency Time
Pr. 2 Minimum frequency
ON
• The upper and lower limits of the output frequency can be RH-SD
clamped. ON
RM-SD
ON
RL-SD
100%
Note: 1. These speeds have priority over the main speed

Output signal across terminals 2-5, or 4-5.
frequency Maximum frequency
Pr. 1 2. This setting may also be made during PU operation
(Hz) setting range
or external operation.
Minimum frequency
setting range Pr. 2
Pr. 7 Pr. 8 Acceleration and deceleration
Frequency setting signal 5V time settings
(10V)
(20mA) Pr. 7 Acceleration time
Note: Use Pr. 18 to set the frequency of 120Hz or more. Pr. 8 Deceleration time
Base frequency setting Pr. 20 Acceleration/deceleration reference
Pr. 3
frequency
Pr. 3 Base frequency Pr. 21 Acceleration/deceleration time increments
• The base frequency (reference frequency at rated motor • In Pr. 7 "acceleration time", set the period of time required
torque) can be set as appropriate between 0 and 400Hz to reach the value set in Pr. 20 (reference frequency) from
according to the motor rating. 0Hz. In Pr. 8 "deceleration time", set the period of time
required to reach 0Hz from the value set in Pr. 20.
• Use Pr. 21 "acceleration/deceleration time increments" to
Base frequency setting range
change the setting range and minimum increments.
100% Set value 0: 0 to 3600 seconds (minimum setting
increments: 0.1 seconds)
Output Set value 1: 0 to 360 seconds (minimum setting
voltage increments: 0.01 seconds)
(V)
Pr. 20
Frequency
Pr. 3 Base frequency 400Hz (Hz)
Running
frequency
(Hz)
Time
Acceleration Pr. 7 Deceleration Pr. 8
– 74 –
AND INVERTER
Pr. 9 Electronic overcurrent protection setting Pr. 14 Applied load selection

• The set value for motor overheat protection may be set as • The optimum output characteristic (V/F characteristic) for
a current value (A). Normally set the rated current value of application and load characteristic can be selected.
the motor at 50Hz. This function provides an optimum
Pr. 14
protective characteristic including better motor cooling Output Characteristic
Setting
capability during low-speed operation. 0 Constant torque load
• Setting of 0A makes the motor protective function invalid. 1 Variable torque load
(The inverter's output transistor protective function is 2 For constant- Reverse rotation boost 0%
valid.) torque vertical
3 Forward rotation boost 0%
• When Mitsubishi's constant-torque motor is used, set 1 or lift
any of 13 to 18 in Pr. 71 (applied motor) to select the 100% Signal across Constant torque load
ON
continuous torque characteristic in the low speed range, terminals (Same as in Pr. 14=0)
then set the rated motor current in Pr. 9 (electronic 4 RT-SD Reverse rotation boost for
overcurrent protection). OFF constant-torque vertical lift 0%
(Same as in Pr. 14=2)
• Factory setting = [inverter's rated output current].
Signal across Constant torque load
However, the 0.4K and 0.75K inverters are factory-set to terminals
ON
(Same as in Pr. 14=0)
85% of the rated inverter current. 5 RT-SD Forward rotation boost for
OFF constant-torque vertical lift 0%
Pr. 10 Pr. 11 Pr. 12 DC dynamic brake (Same as in Pr. 14=3)
adjustment Note: This parameter setting is ignored when the advanced magnetic
Pr. 10 flux vector control mode is selected using Pr. 80 and Pr. 81.
DC dynamic brake operation frequency
Pr. 11 DC dynamic brake operation time
Pr. 12 DC dynamic brake voltage Set value 0 Set value 1
(factory setting)
• Setting the stopping DC dynamic brake torque (voltage),
operation time and operation starting frequency allows the Set value 4, 5
stopping accuracy of positioning operation to be adjusted (ON across RT-SD)
according to the load. For constant torque load For variable torque load
(Conveyor, trolley, etc.) (fan/pump )
Output 100% 100%

frequency
Output Output
Pr. 10 Operation voltage voltage
frequency
Pr. 12 Time
DC dynamic
Operation
brake voltage Base frequency Base frequency
voltage
Time
Pr. 11 Operation Set value 2 Set value 3

time
Set value 4 Set value 5
(OFF across RT-SD) (OFF across RT-SD)
Pr. 13 Starting frequency setting
For vertical lift For vertical lift
• The starting frequency can be set between 0 and 60Hz.
Forward rotation boost Forward rotation boost
... Pr. 0 setting ... 0%
Output Reverse rotation boost Reverse rotation boost
frequency ... 0% ... Pr. 0 setting
[%]
60
100% 100%
Setting Forward Reverse

Output Output rotation
range voltage rotation
voltage
Pr. 13 Forward
Reverse
Pr. 0 rotation Pr. 0 rotation
0
Frequency setting signal (V) Time Base frequency Base frequency
Forward
rotation ON
– 75 –
AND INVERTER
3.5.4 Starting/stopping method

Incorrect starting/stopping of the motor will not allow proper operation, possibly leading to inverter
damage.
Correct Method Incorrect Method
Method Terminal (STF, STR) is used to Input side magnetic contactor Output side magnetic contactor
start/stop the inverter. (MC1) is used (MC2) is used
Operation MC1 MC1 MC1
procedure
R R R
Power on Power on
Power on
(MC1 ON) S S (MC1 ON) S
(MC1 ON)
T T T
MC2
remains on.
Start signal on STF

Start signal (ON across
remains on. STF-SD) SD
Start signal on STF
(ON across
SD STF MC2
STF-SD)
U
SD
MC2 OFF V IM
W
MC1 MC2
R
Start signal off STF U
Power off
(OFF across S
SD (MC1 OFF) V IM
STF-SD) MC2 ON
T W
Motor speed/ N N N
Coast to stop
inverter output
Coast to stop
Speed
Speed
Speed
Time Time Time
Inverter trip
f f f
Output Frequency
Output Frequency
Output frequency
Time Time Time
STF ON OFF STF ON STF ON

Time Time Time
MC1 ON MC1 ON OFF MC2 ON OFF
Time Time Time
Remarks Switch on the signal across Frequent ON-OFF of MC1 will When MC2 is on, overcurrent
terminals STF-SD to start, switch cause inverter damage. protection is activated to trip the
off the signal across terminals inverter.
STF-SD to decelerate the motor to
stop.
Fig. 3.10 Starting/Stopping Method
– 76 –
AND INVERTER
3.5.5 Starting and stopping using the input side magnetic contactor MC
(1) The inverter is designed on the assumption that the input side magnetic contactor (MC1) is not
used to start/stop the inverter.
(2) W hen AC power is switched on by the magnetic contactor (MC1), a large inrush current flows in
the large-capacity smoothing capacitor of the inverter. To suppress this current, a current limiting
resistor of short-time duty rating is installed as shown in Fig. 3.11. A relay, magnetic contactor
(MC3) or thyristor is used to short the resistor on completion of charging.
(3) If the input side MC is switched on-off frequently, an inrush current occurs repeatedly and heats
the current limiting resistor, resulting in wire breakage. If the resistor shorting relay or the
magnetic contactor (MC1) switches on in this state, a large inrush current for charging the
smoothing capacitor passes through the converter devices (diodes) and flows into the smoothing
capacitor. This unsuppressed inrush current will damage the converter devices.
MC3
Converter
R
MC1
Current
Power limiting C Smoothing
supply resistor capacitor
Fig. 3.11 Converter Circuit
(4) Such operation must be avoided because it will not only damage the converter devices but also
shorten the lives of the smoothing capacitor, current limiting resistor, shorting relay and magnetic
contactor (MC3).
(5) W hen the magnetic contactor (MC1) is switched off to stop the motor, the regenerative braking
effect of the inverter does not operate. The motor coasts to a stop.
Similarly, at the time of an instantaneous power failure or a power failure accident, the motor
coasts to a stop.
To prevent any electrical hazards, a machine may require the

Inverter
motor (including the inverter) to be separated from the power MC2
Motor
supply at the end of an operation. For this purpose, it is recom- U
mended to use an output side magnetic contactor (MC2) between V IM
the inverter and motor.
W
Note: Open the output side magnetic contactor (MC2) with the
inverter (output) at a stop. (Switch off MC2 after the signal
across terminals MRS-SD has switched on.)
– 77 –
AND INVERTER
3.5.6 Starting a coasting motor using an inverter

A coasting motor cannot be started by an inverter for the following reasons described below:
(1) A residual voltage occurs in a motor which is coasting to a stop. If a voltage is applied to the motor
by the inverter, the phase of the residual voltage in the motor (sine wave) does not match that of
the inverter output voltage (PW M), causing an excessive current to flow.
(Reference: In a star-delta starting system using a commercial power supply, a similar
overcurrent phenomenon occurs at the time of switching from star to delta.)
(2) W hen starting, the inverter always outputs the starting frequency (0.5Hz: variable by parameter
setting). If the motor is coasting at this time, a regenerative overcurrent flows to brake the motor
down to the synchronous speed of the starting frequency.
Alternatively, a regenerative overvoltage trip may occur.
(3) Generally, use a coasting interlock timer to provide a sequence interlock to ensure that the
inverter will not start while the motor is coasting.
To continue operation without stopping the motor after an instantaneous power failure etc.,
selection of automatic restart after instantaneous power failure is effective. (This function is
available as standard for the FR-A500 series.)
3.5.7 How to use a motor fitted with an electromagnetic brake

The following considerations and reference circuit example are given for a motor with a brake which
will be run by an inverter:
BR
BK Electromagnetic
brake
NFB MC INVERTER
Power R U
supply S V IM Motor
T W
Tr
F
C F
Stop Start STF
F B
SD
F
F
Reset
BR
CR
RES
SD
MRS
BR
CR
Fig. 3.12 Circuit Example of Motor with Brake
– 78 –
AND INVERTER
(1) Brake power must be supplied from the input side of the inverter.
(2) W hen bringing a motor with electromagnetic brake to a stop, switch on the signal across inverter
output stop terminal MRS-SD to switch off the inverter output. Otherwise, a locking current may
flow when the brake operates, resulting in overcurrent (OC3).
(3) The brake lining may chatter during continuous operation in the speed range of 30Hz or less,
depending on the brake type. Such motors can be used without fault for short durations such as
positioning at low speed.
(4) W hen the inverter is used with a 400V power supply, the operation circuit voltage is dropped to
400V/100V or 400V/200V by the transformer (Tr).
3.5.8 Frequency setting (selection) signal and output frequency

The output frequency may be varied by using the following methods:
• Vary the frequency setting signal (such as 0-5V, 4-20mA DC) (possible to continuously vary the
signal).
(W hen using the parameter unit, hold down the [▲]/[▼] key.)
• Switch between two or more frequency setting potentiometers or between multi-speed selection
terminals (RH, RM, RL) for step-by-step frequency variation.
(W hen using the parameter unit, directly input the frequency during operation.)
(1) W hen the frequency setting signal is varied continuously
Acceleration/deceleration
Proportional relationship
time (ta) set from parameter
unit
60
Output
frequency
[Hz] 60Hz
30
Output
frequency
[Hz]
0 2.5 5V
0 Time
Frequency setting signal to *
5V
* If the frequency setting signal is raised Frequency

faster than the acceleration/ setting
deceleration time setting (ta), the signal
acceleration/deceleration time will not
be shorter than ta. 0 Time
Fig. 3.13 Variable Time for Frequency Setting Signal
– 79 –
AND INVERTER
(2) W hen multi-speed selection signal is switched

• Switching without delay • Switching with delay
(Speed 2) (Speed 2) NFB
Inverter
FR-A500
Output (Speed 1) Output (Speed 1)
Deceleration
frequency frequency STF
during this
[Hz] [Hz]
period SD
(Speed 2)
RM
(Speed 1)
Time Time
RL
RL-SD ON RL-SD ON
Time Time
to
RM-SD ON RM-SD ON
Time Time
Fig. 3.14 Variation of Output Frequency at Switching

W hen the motor speed does not reach the set value, possible causes are as follows:
Inverter
NFB Motor
FR-PU04 PARAMETER UNIT
R R
60.00Hz
IM
STF FWD PU
S S
MON SET EXT PU
T HELP SHIFT ESC T

9
7
4
8
5 6 FWD
Frequency meter is not
1 2 3 REV
STOP
calibrated.
0
<When meter is used
WRITE
READ RESET
STF to confirm frequency>

FM
SD
SD
10
2
x "Maximum, minimum frequency" set in
[Pr. 1] [Pr. 2] are incorrect.
5 x "Frequency at 5V input" set in [Pr. 73] is
incorrect.
x For "frequency at 20mA input", terminals
The frequency setting
FR-A500 AU-SD are not connected.
signal level is wrong. x "Gain, bias" is not set correctly.
Measure voltage across [Pr. 902] to [Pr. 905].
terminals 2-5.
– 80 –
AND INVERTER
If the motor does not run at all after the start signal is input
(1) Check the areas related to the main circuit.
1) Check the incoming power supply.
2) Check that a power supply phase R, S or T is not open.
3) Check that the motor is securely connected to the inverter.
(2) Check the input signals.

1) Check that the frequency setting signal is input and not set to zero.
2) Check that both the forward and reverse rotation signals are not both on.
3) Check that the "reset" or "output stop" signal is not on.
4) Check that the signal across AU-SD is on when using a 4-20mA input.
(3) Check parameter set values of the following functions.

1) Check that "reverse rotation prevention" is not set. [Pr. 78]
2) Check that the "operation mode" is correct (i.e. not PU OP when using STF-SD
(External) signal)
3) Check that the corresponding operation function is not set to 0.
"Multi-speed setting" [Pr. 4 to Pr. 6, Pr. 24 to Pr. 27 etc.]
"Jog frequency" [Pr. 15]
4) Check that the "starting frequency" is not higher than the running frequency. [Pr. 13]
5) Check that the "bias" setting is correct. [Pr. 902, Pr. 904]
(4) Others
• Check that the alarm lamp is not lit.
– 81 –
AND INVERTER
3.5.9 Other operation methods

(1) Three-wire system (terminals STF, STR, STOP)
Fig. 3.16 shows connections in the three-wire system.
1) The start self-holding function is made valid by connecting terminals STOP-SD. In this case,
the forward/reverse rotation signal functions as the start signal only.
2) If the start signal terminal STF (STR)-SD are connected once and then disconnected, the
starting signal is held and the inverter operates.
3) To stop the inverter, disconnect terminals STOP-SD once to decelerate it to a stop. The
frequency setting signal and stopping DC dynamic braking operation are as described in
Section 2.7.2.
4) W hen terminals JOG/OH-SD are connected, the signal of terminal STOP is invalid and jog
operation has priority.
5) Connect the output stop terminal MRS-SD to reset the self-holding function.
NFB NFB
Power Power
supply supply Forward Inverter
Inverter rotation start
Stop
Forward rotation start STF STF
Reverse rotation start STR Reverse STR

rotation start
SD STOP
SD
Output
Output
frequency
frequency
Time Time
Start Time
Across STF(STR)-SD ON
Time
Stop Time
Fig. 3.15 Two-Wire System Connection Fig. 3.16 Three-Wire System Connection
Example Example
– 82 –
AND INVERTER
(2) For inverter-motor pairs

Inverter No. 1 Inverter No. 2
"Ready"
ON alarm signal alarm signal
OFF
B C B C
MC
MC
NFB T (Note) 3
MC
R U Motor
Inverter
Power No. 1
S V IM
supply
T W
B
Alarm signal (closed for
normal, opened for alarm)
C
(+5V) Start signal
10 STF
Frequency 2
SD
setting
5
potentiometer
2W1kΩ
Grounding
R U Motor
Inverter
S No. 2 V IM
T W
STF
SD
10 B
Alarm signal
2
C
5
Up to three units can

be connected. Grounding
Fig. 3.17 Inverter-Motor Pairs

For ratio control operation
Note: 1. The calibration function of the parameter unit can be

10 used to make adjustment to match the output fre-
Inverter quencies of three inverters corresponding to the
Frequency setting
2 No. 1 common command voltage value from the frequency
potentiometer
2W 1kΩ setting potentiometer.
5 2. When two or more motors are coupled mechanically,
the load may be offset to one motor, resulting in an
Ratio setting overload.
potentiometer 2
Inverter
3. For a 400V power supply, use a transformer.
1/3W 10kΩ
5 No. 2
The ratio setting potentiometer may be omitted by

setting the calibration function "gain/bias" of the pa-
rameter unit.
Fig. 3.18 Ratio Control Operation
– 83 –
AND INVERTER
(3) Motor with brake

BR Brake (Note 3)
Inverter
NFB MC
R U
Power supply S V IM Motor
T W
T (Note 4)
Grounding When FR-BU brake
F unit is used
C
Ready Brake Resistor
“ON” unit unit
“OFF”
PB 1
PB 2 FR-BU FR-BR
MC B
MC HB HC T H1 T H2
PR PR P
P P
HA
Forward TH1
Stop rotation N N HB TH2
MC PB 5 PB 3 R HC
F
F Brake unit Resistor unit
FR-BU FR-BR
Reverse
rotation
PB 4 F When regenerative brake duty is large
R (7.5K or less)
R
P External regenerative brake
discharge resistor
F (Note 5)
BR PX R
R
PR
Hz FM
Moving-oil type
frequency meter 1mA Reset PB 6
SD RES
F
STF SD
R (Note 1) BR
STR MRS
10
Frequency setting
potentiometer 2
2W 1kΩ
5
Fig. 3.19 Motor with Brake
Note: 1. To bring the motor with electromagnetic brake to a stop, use the output stop terminal MRS-SD of the inverter.
Otherwise, when braking is applied to the motor, a locking current may flow in the motor, resulting in OCT.
2. Similar care should also be taken when using a mechanical brake.
3. When a motor with a brake is run continuously at 30Hz or less, the brake disc may chatter. However, the motor may
be used without fault for low speed operation of short duration, e.g. positioning. Also, because of the limitation on
braking capacity, use the motor at 60Hz or less speed.
4. For a 400V power supply, use a control transformer.
5. When an external brake resistor or brake unit is used, disconnect the jumper from across PR-PX.
– 84 –
This chapter describes the influence of inverter-generated harmonics on the power supply and the
power system to which the inverter is connected. The degree of influence on peripheral devices can
be judged from the amount of harmonics generated to make specific examination of measures
against harmonics.
The influence of power fluctuation (such as instantaneous power failure, voltage drop etc.) on the
inverter will be described. It is essential to understand both the operation of the inverter and motor.

1. Differences between harmonics and noise.
2. Incoming routes and levels of harmonic currents.
3. Harmonic suppression guidelines and how to comply with them.
4. Permissible harmonic values of peripheral devices (capacitor, generator).
5. Operation of inverter and motor at the time of instantaneous power failure (including
instantaneous voltage drop).
4.1 What is a Harmonic?
It is defined that a harmonic has a frequency that is an integral multiple of the fundamental frequency
(generally a power supply frequency). The composition of a single fundamental wave and several
harmonics is called a distorted wave. (Refer to Fig. 4.2.)
A distorted wave generally includes harmonics in a high-frequency region (kHz to MHz order), but
harmonics handled as those in a power distribution system are usually of up to 40th to 50th degrees
(up to 3kHz). Generally, harmonics are different in nature from the problem of a high frequency region
noise which assumes a random form. For example, such problems as electromagnetic interference
and noise generated by personal computers (see Chapter 5) are local problems closely associated
with equipment hardware and differ in both influence and corrective actions from harmonics
applicable to power circuit networks. This is an important point which must be understood.
∞
i = i0 + ∑ in ⋅ sin (2 π f n t + φ n) ............................................................................................... (4.1)
n =1
n = 1, 2, 3, ......
f = fundamental frequency
– 85 –
i1 Fundamental i1
wave i3
Time Time
Second degree
i2 Composition
harmonic
Time
Distorted wave
Third degree
Time
i3 harmonic
Time
Fig. 4.1 Fundamental Wave and Harmonics Fig. 4.2 Distorted Wave
Table 4.1 Differences between Harmonic and Noise

Item Harmonic Noise
High frequency (several ten’s-of kHz to MHz
Frequency Normally 40th to 50th degrees, 3kHz max.
order).
Source Converter circuit. Inverter circuit.
Cause Rectifying circuit commutation. Transistor switching.
Environment To-line/power supply impedance. To-space, distance, wiring route.
Quantitative grasp Theoretical calculation possible. Random occurrence, quantitative grasp difficult.
According to current variation ratio
Amount Almost proportional to load capacity.
(larger when switching speed is higher).
Immunity of affected Different according to manufacture's equipment
Specified in standard per equipment.
equipment specifications.
Suppression example Install a reactor. Increase distance between devices.
4.2 Characteristics of Rectifying Circuits and Harmonics
Sources of harmonics include rectifiers, AC power regulators, etc. The converter circuit of a transis-
torized inverter consists of a rectifier circuit and generates many harmonics.
As shown in Table 4.2, there are various rectifier circuits according to the main circuit system. A
three-phase bridge system is most often used in transistorized inverters.
The harmonic degree n is theoretically n = PK ± 1 (P = number of pulses, K = 1, 2, 3, .....) and
harmonics of 5th, 7th, 11th, 13th degrees etc. take place in a transistorized inverter three-phase
bridge system. Its harmonic level (harmonic content) is 1/n, and the amount of harmonics generated
reduces as the harmonic degree increases. In a single-phase power input inverter, 4K ± first degree
(third, fifth, seventh, ninth) harmonics are generated.
– 86 –
Table 4.2 Rectifier Circuit Systems and Harmonics

Circuit Fundamental Harmonic Harmonic Main
Circuit Diagram Degree Content Equipment
Single-phase n = 4K ± 1 Kn = 1/n AC electric railroad

bridge K = 1, 2, ...... vehicle.
Single-phase n = 2K ± 1 Kn × 1/n 

hybrid bridge K = 1, 2, ......
Inverter.
Three-phase n = 6K ± 1 Kn × 1/n DC electric railway.
bridge K = 1, 2, ...... Transformer substation.
Electrochemistry.
Other general devices.
Three-phase n = 3K ± 1 Kn × 1/n 

hybrid bridge K = 1, 2, ......
Kn: Control lagging angle, commutation overlapping angle
4.3 Harmonic Current Branching Routes
W hen harmonics come into question in a power distribution system, the power supply harmonics are
not general commercial power supply harmonics, but refers to the source of harmonics (converter
circuit for a transistorized inverter) and the commercial power supply (low or high voltage power
transformer) acts as part of a load for harmonics. Hence, a harmonic equivalent circuit of a power
distribution system (diagram example as shown in Fig. 4.3) is as shown in Fig 4.4. A harmonic current
In (In = I 2 + I 3 + I 4 + etc. supposing that n is a degree) generated by an inverter branches in proportion
to the reciprocal ratio (1/Z) of the impedance of the power transformer ( ZL = RL + jnXL ) and those
devices connected to that transformer in parallel (motor B and the capacitor in the example of Fig.
4.3), i.e. the impedance of motor B ( ZM = RM + jnXM ) and the impedance of the capacitor
( ZC = jnXr − jXC / n ).
– 87 –
Commercial power supply
Power transformer
XL
RL
ILn ILn IMn I Cn

I Cn
In
nXL nXM nXr 
In   
Xr Z L Z M ZC
IMn RL  RM  XC/n 
Inverter Inverter
Xc
Capacitor
Power Motor B Capacitor
transformer
XM
M M
RM
Motor A Motor B
Fig. 4.3 Power Distribution System Diagram Fig. 4.4 Harmonic Equivalent Circuit
Fig. 4.5 shows an example of a power distribution system diagram including a high-voltage circuit. In
this example, low-voltage side loads (such as motors) are omitted because load impedance ( Z M ) is
generally extremely large compared to the impedance of the power transformer ( Z L ) and most of the
harmonic currents generated by the inverters flow into the power transformer. A high-voltage side
harmonic current (In) is found by dividing the sum of harmonic currents from the low-voltage inverters
by the transformation ratio of the transformer.
Commercial Z C
power supply ILn = In ×
Z S + Z C
XS, RS
Z S
ILn I Cn ICn = In ×
Z S + Z C
m2
In = (In1 + In2) In
m1
XL Transformer Transformer ILn I Cn
Xr
RL Primary m1 [V]
Secondary m2 [V] nXL
Xc
Capacitor RL nXS nXr
In1 + In2
 
Z S Z C
RS 

XC/n 
In1 In2
Inverter
Inverter 1 Inverter 2
Power Capacitor
supply
Fig. 4.5 Power Distribution System Diagram Fig. 4.6 Harmonic Equivalent Circuit
– 88 –
• Impedance ( Z ) of inductive load (motor, transformer, etc.)

Z = R + jωX = R + j2πf X (f = nf0 f0: Fundamenta l frequency, R = Resistance , X = Reactance)
= R + j2πf 0n X = R + n ( j2πf 0 X)
• Impedance ( Z ) of capacitive load (capacitor)
1 1 1 1  1 
Z = − j = −j = −j = ×  − j 
ωC 2 πf C 2πf 0nC n  2πf 0C 
• A current is liable to flow toward smaller impedance. W hen there is a capacitive impedance
element (such as a power capacitor), harmonics may become larger.
W hen examining the harmonic problem, therefore, 1) as the typical power supply side
impedance ( Z S ) is the short-circuit capacity of a power supply system, a larger power supply
capacity has less influence on others, 2) an inductive load has high impedance to harmonics and
can be ignored, and 3) it is necessary to examine only capacitive loads such as a power
capacitor.
(a) The installation of a power factor improving reactor produces the same effect as when the
power supply side impedance of the inverter has increased, decreasing harmonic
components. As compared to the impedance of a power transformer, that of a reactor is much
larger, eliminating a difference due to the capacity of the power transformer.
(b) W hen a power factor improving reactor is not installed, harmonic components are greatly
influenced by the capacity of the power transformer (including line impedance).
(c) W hen the inverter output frequency or motor load factor is low, the harmonic content to the
inverter input current increases. However, since the input current itself is small, the absolute
value of the harmonic current will not be larger than under full load. For a variable torque load
such as a fan or pump, calculate the harmonic current at the maximum operating frequency of
50Hz or 60Hz.
– 89 –
4.4 Japanese Harmonic Suppression Guideline
Power harmonics are generated not only by inverters but also by most electrical devices, posing
social problems. The power harmonic suppression guidelines were published by the Ministry of
International Trade and Industry in September, 1994, and the "harmonic suppression technology
guideline" was further issued by Japan Electric Association in October, 1995.
1) Scope
• <Japanese harmonic suppression guideline for household appliances and general-purpose
products> applies to 200V class 3.7kW or less inverters used with power factor improving
reactors (option).
• <Japanese harmonic suppression guideline for consumers receiving power of high volt-
age/specially high voltage> applies to 200V class 5.5kW or more and 400V class inverters.
4.4.1 Japanese harmonic suppression guideline for household appliances and general-purpose products
For each equipment of 300V 20A or less, the maximum amount of harmonics generated must be
suppressed within the following values.
The maximum harmonic current output of each equipment must be lower than the following values:
Harmonic Degree n 3rd 5th 7th 9th 11th 13th 15th to 39th
Maximum permissible
harmonic current [mA]* 2.30 1.14 0.77 0.40 0.33 0.21 0.15×(15/n)
*Converted into values at the voltage of 230V.
The guidelines apply to the transistorized inverters of 200V class 3.7kW and less models. These
inverters must be used with power-factor improving reactors.
4.4.2 Japanese harmonic suppression guideline for consumers receiving power of a high voltage
The maximum amount of harmonic currents generated must be lower than the following values per
1kW contract power:
Table 4.3 Maximum Outgoing Harmonic Current per 1kW Contract Power
(Unit: mA/kW)
Received Power Voltage 5th 7th 11th 13th 17th 19th 23rd Over 23rd
6.6kV 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70
22. 1.8 1.3 0.82 0.69 0.53 0.47 0.39 0.36
33. 1.2 0.86 0.55 0.46 0.35 0.32 0.26 0.24
66. 0.59 0.42 0.27 0.23 0.17 0.16 0.13 0.12
77. 0.50 0.36 0.23 0.19 0.15 0.13 0.11 0.10
110. 0.35 0.25 0.16 0.13 0.10 0.09 0.07 0.07
154. 0.25 0.18 0.11 0.09 0.07 0.06 0.05 0.05
220. 0.17 0.12 0.08 0.06 0.05 0.04 0.03 0.03
275. 0.14 0.10 0.06 0.05 0.04 0.03 0.03 0.02
The harmonic contents of different circuits are listed below:
Table 4.4 Harmonic Contents

Circuit Type 5 7 11 13 17 19 23 25
Three-phase bridge
• 6-pulse converter 17.5 11.0 4.5 3.0 1.5 1.25 0.75 0.75
• 12-pulse converter 2.0 1.5 4.5 3.0 0.2 0.15 0.75 0.75
• 24-pulse converter 2.0 1.5 1.0 0.75 0.2 0.15 0.75 0.75
Three-phase bridge (capacitor smoothed)
• W ithout reactor 65. 41. 8.5 7.7 4.3 3.1 2.6 1.8
• W ith reactor (AC side) 38. 14.5 7.4 3.4 3.2 1.9 1.7 1.3
• W ith reactor (DC side) 30. 13. 8.4 5.0 4.7 3.2 3.0 2.2
• W ith reactor (AC/DC side) 28. 9.1 7.2 4.1 3.2 2.4 1.6 1.4
Single-phase bridge (capacitor smoothed)
• W ithout reactor 50. 24. 5.1 4.0 1.5 1.4  
• W ith reactor (AC side) 6.0 3.9 1.6 1.2 0.6 0.1  
– 90 –
1) Calculation of outgoing harmonic current

(a) Calculate the rated capacity [kVA]. Table 4.5 Fundamental Wave Currents and
The rated capacity is used to calculate Table 4.5 Rated Capacities
a 6-pulse equivalent capacity in order
Motor Fundamental Rated Capacity
to judge whether the "harmonic Capacity Wave Current [A] [kVA]
suppression guideline for consumers [kW] 200V 400V 200V 400V
receiving power of high voltage/ 0.4 1.6 0.8 0.6 0.6
specially high voltage" applies or not. 0.75 2.9 1.5 1.0 1.0
Independently of whether a reactor is 1.5 5.6 2.8 2.0 2.0
used or not, the rated capacity [kVA] 2.2 8.0 4.0 2.8 2.8
and fundamental wave current (A) are 3.7 13.0 6.5 4.6 4.6
5.5 19.2 9.6 6.8 6.8
standardized according to the motor
7.5 25.7 12.8 9.1 9.1
capacity. 11. 36.9 18.5 13.1 13.1
• It should be fully noted that the above 15. 49.9 24.9 17.7 17.7
rated capacity is used to judge whether 18.5 61.4 30.7 21.8 21.8
the harmonic suppression guideline 22. 73.1 36.6 25.9 25.9
applies to an inverter or not and is 30. 99.7 49.8 34.7 34.7
37. 122. 60.9 42.8 42.8
different from the capacity of the power
45. 147. 73.7 52.1 52.1
supply facility (such as a power 55. 180. 89.9 63.7 63.7
transformer) required for use of an 75. 245. 123. 86.8 86.8
actual inverter. 90. 294. 147. 104. 104.
The power supply facility capacity 110. 359. 180. 127. 127.
required is 1.3 to 1.6 times greater than 132.  216.  153.
the above rated capacity (specific 160.  258.  183.
values are indicated in the inverter 200.  323.  229.
catalogs/manuals). 220.  355.  251.
250.  403.  285.
(b) Find the 6-pulse equivalent capacity
280.  450.  319.
using conversion factor Ki.
• 6-pulse equivalent capacity
= rated capacity × conversion factor (Ki) [kVA]
where, conversion factor (Ki) is:
• 3.4 when a reactor is not used
• 1.8 when an AC reactor is used
• 1.8 when a DC reactor is used
• 1.4 when AC and DC reactors are used
If the equivalent capacity is 50 [kVA] or less at the received power voltage of 6.6kV, the
guideline does not apply to the inverter and the outgoing harmonic current need not be
calculated.
(c) Convert the received power voltage into the rated current.
• Rated current converted from received power voltage
= fundamental wave current × (200V or 400V/received power voltage) [A]
For the fundamental wave current, refer to Table 4.5.
(d) Find the outgoing harmonic current of each degree from the harmonic content.
• Outgoing harmonic current = rated current converted from received power voltage
× operation ratio × harmonic content [A]
– 91 –
2) Specific calculation example

W hen a 30kW 400V motor is driven by a FR-A540-30K inverter
• The fundamental wave current of the motor is 49.8A according to Table 4.5.
• The rated capacity is 34.7 [kVA] according to Table 4.5.
= rated capacity × conversion factor (Ki) = 34.7 = 118 [kVA]
As this value is higher than 50 [kVA] and the guideline applies, find the outgoing harmonic
current in the following procedure:
• Rated current converted from received power voltage = fundamental wave current
× (400V/received power voltage) = 49.8 × 400/6600 = 3.02 [A]
× operation ratio × harmonic content
See the following table. It is assumed that the operation ratio is 50%.
Degree 5th 7th 11th 13th 17th 19th 23rd 25th

Outgoing current
[mA] 982. 619. 128. 116. 64.9 46.8 39.3 27.2
Maximum outgoing current Guideline
[mA/kW ] 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70 ⇐ set value
Hence, if the contact power is 982/3.5 = 281kW or less, harmonic suppression is necessary.
Specific suppression technique

The following techniques are available to suppress harmonics in the inverter:
• High-power factor inverter: Corrects an input current waveform into a sine wave to greatly
reduce harmonics generated by the inverter used in combination.
• AC reactor: Install an AC reactor in the power supply side of the inverter to increase
impedance, suppressing harmonics.
• DC reactor: Install a DC reactor in the DC circuit of the inverter to increase impedance,
suppressing harmonics.
• AC and DC reactors: Install an AC reactor in the power supply side and a DC reactor in the
DC circuit to increase impedance, suppressing harmonics.
Application of each suppression techniques

(A) High-power factor converter
The amount of harmonics generated is
sharply reduced by switching the rectify-
ing circuit (converter circuit) of the in- Motor
External
P
verter by transistors to control the cur- N
box
ACL1 ACL2
rent waveform to be closer to a sine
wave. W ithout any other techniques,
Inverter
this inverter can clear the guideline. High-power factor converter
As the amount of harmonics generated
by the inverter is decreased, this is the most desirable technique.
(B) AC reactor
Install an AC reactor in the power supply • ACL connection example
side of the inverter to increase line im-
pedance, suppressing harmonics.
(a) Features
• As the input power factor is im- Motor
proved to about 0.9, the AC reactor
may also be used as a power factor ACL
improving reactor when the inverter
is used.
• The most typical technique for harmonic suppression.
– 92 –
(b) Selection method

Select the type according to the capacity of the motor connected to the inverter.
F R-BAL-H 22 K
Basic type Capacity ... Motor capacity [kW]
Voltage class ... ⋅ 200V: None

⋅ 400V: H
(c) Note
• A relatively large (about 6%) voltage drop in the power supply side may have an
influence, such as motor torque shortage.
• Since merely installing the AC reactor will not allow the inverter to clear the guideline,
this technique must be used with other techniques.
(d) Specific calculation example
(1) W hen the FR-BAL-H30K is connected to the power supply according to the motor
capacity under the conditions in Section 3), the rated capacity is 34.7 [kVA] according
to Table 4.5.
• 6-pulse equivalent capacity = rated capacity × conversion factor (Ki)
= 34.7 × 1.8 = 62.5 [kVA]
As this value is higher than 50 [kVA] and the guideline applies, find the outgoing
harmonic current using the following procedure:
See the following table. It is assumed that the operation ratio is 50%

Outgoing current
[mA] 574. 219. 112. 51.3 48.3 28.7 25.7 19.6
[mA/kW ] 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70 ⇐ set value
Hence, if the contact power is 574/3.5 = 164kW or less, harmonic suppression is

necessary (for the 5th degree).
(C) DC reactor
Install a DC reactor in the DC circuit of • DCL connection example
the inverter to increase impedance, DCL
suppressing harmonics.
(a) Features P P1
• As the input power factor is im-
proved to about 0.95, the DC reactor Motor
may also be used as a power factor
improving reactor when the inverter
is used.
• Since the DC reactor is connected in
the DC circuit, the voltage drop is only that of the DC resistance (1% or less).
Therefore, the DC reactor scarcely has an influence on such things as motor torque
shortage and gives many advantages.
• The DC reactor is smaller in size and weight and produces a greater power factor
improving effect than the AC rector.
Select the type according to the capacity of the motor connected to the inverter.
F R-BEL-H 22 K
Basic type Capacity ... Motor capacity [kW]
Voltage class ... • 200V: None
• 400V: H
– 93 –
(c) Note
• As the DC reactor is connected in the DC circuit of the inverter, the DC reactor cannot
be used with a model which does not have terminals P and P1. Specifically, the DC
reactor can be used with the following inverter models:
• All models of FR-A500 and FR-E500
• All models of the FR-A100
• Since only the installation of a DC reactor will not allow the inverter to meet the rele-
vant guidelines, this technique must be used with other techniques.
(1) W hen the FR-BEL-H30K is connected across P-P1 according to the motor capacity
under the conditions in Section 3), the rated capacity is 34.7 [kVA] according to Table
4.5.
• 6-pulse equivalent capacity = rated capacity × conversion factor (Ki)
= 34.7 × 1.8 = 62.5 [kVA]
As this value is higher than 50 [kVA] and the guideline applies, find the outgoing
harmonic current in the following procedure:
See the following table. It is assumed that the operation ratio is 50%.

Outgoing current
[mA] 453. 196.3 126.8 75.5 71.0 48.3 45.3 33.2
[mA/kW ] 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70 ⇐ set value
Hence, if the contact power is 453/3.5 = 129kW or less, harmonic suppression is

necessary (for the 5th degree).
(D) AC and DC reactors used together

Install an AC reactor in the power • Example of using the ACL and DCL together
supply side and a DC reactor in the DCL
DC circuit to increase impedance,
suppressing harmonics. P P1
(a) Feature
Using the AC and DC reactors Motor
together increases the
harmonic suppression effect. ACL
Select the AC and DC reactors
individually according to the motor capacity. Specifically, refer to sections (B) and (C).
(c) Note
• A relatively large (about 6%) voltage drop in the power supply side may have an
influence, such as motor torque shortage.
• Since merely installing the AC and DC reactors will not allow the inverter to clear the
guideline, this technique must be used with other techniques.
(1) W hen the FR-BAL-H30K AC reactor and FR-BEL-H30K DC reactor are connected
under the conditions in Section 3)
• The rated capacity is 34.7 [kVA] according to Table 4.5.
= rated capacity × conversion factor (Ki) = 34.7 × 1.4 = 48.6 [kVA]
As this value is lower than 50 [kVA], the guideline does not apply and no harmonic
suppression technique is necessary.
– 94 –
(3) Overview of harmonic suppression techniques

The following table gives an overview of principles, features, etc. of harmonic suppression and
absorption techniques:
No. Item Description Effect, Etc.

1 Reactors for Connect an AC reactor in the power supply Harmonic currents
inverter side of the inverter or a DC reactor in its DC are suppressed by
side or both to increase the circuit about 1/2.
impedance, suppressing harmonic currents.
2 Power A power factor improving capacitor is small An absorbing effect is
factor in impedance to high frequency components. greater in the low
improving W hen used with a series reactor, it has an voltage side.
capacitor effect of absorbing harmonic currents. This
capacitor may be installed in either a high or
low voltage side.
3 Transformer W hen two or more transformers are used, If capacity combina-
multi-phase connecting them with a phase angle tion of Y- , -
operation difference of 30° as in Y- , - differs, an effect
combination will cause a timing shift to corresponding to 12
suppress a peak current, providing an effect pulse bridge can be
corresponding to a 12 pulse bridge. expected for a smaller
one, and harmonic
currents can be
suppressed to about
1/2.
4 AC filter As in a power factor improving capacitor, a Produces a great
capacitor and series reactor are used suppression effect.
together to reduce impedance to a specific (Can clear the
frequency (degree), producing a great effect guideline.)
of absorbing harmonic currents.
5 Active filter This filter detects the current of a circuit Provides a great
generating a harmonic current and suppression effect.
generates a harmonic current equivalent to a (Can meet the
difference between that current and a guideline.)
fundamental wave current to suppress a As this filter corrects a
harmonic current at the point of detection. whole waveform, a
power factor
improving effect is
also expected.
★ The above techniques are more advantageous:
• The suppression effects are in the order of 5, 4, 3, 2, 1.
• The cost is in the order of 1, 2, 3, 4, 5.
– 95 –
4.5 Influence of Harmonics on Peripheral Devices and Harmonic Suppression Techniques
4.5.1 Power capacitor

Harmonics overlapping with the fundamental wave current of a capacitor will promote the thermal
deterioration of conductors or insulating materials due to a temperature rise caused by increased
loss. Overheating caused by an increased current (effective value), etc., can lead to burning or
breakage in the future.
The permissible overvoltage/overcurrent limits of power capacitors are specified in the JIS Standard:
130% of the rated current or less in JIS-C4902 for high-voltage power capacitors and 130% of the
rated current or less in JIS-C4901 for low-voltage power capacitors. W hen the permissible value is
exceeded, a change in capacity or the addition, change, etc. of a series reactor must be examined.
The harmonic current which will flow in the capacitor can be found by the following formula. (Refer to
Fig. 4.6.)
Z S RS + jnXS
Icn = In × = In ×
Z S + Z S RS + jnXS + jnXr − jXc / n
nXS
≈ In × ............................................................................................... (4.2)
n(XS + Xr) − Xc / n
Supposing that a capacitor fundamental wave current is Ic1 , the capacitors effective current (Ic) is:
∞
Ic = Ic 2 + ∑ Icn2 ............................................................................................................. (4.3)
n=2
Reference conditions are:

For a low-voltage power capacitor Ic1 × 13
. > Ic ...................................................... (4.4)
For a high-voltage power capacitor Ic1 × 13
. > Ic ...................................................... (4.5)

The following harmonic current suppression techniques are available for capacitors:
(a) Insert a power factor improving DC reactor in the inverter's DC circuit or a power factor
improving AC reactor in the supply side to suppress harmonics generated.
(b) Use a series reactor with a capacitor. For capacitors with series reactors which are available
in 6%, 8% and 13%, avoid series resonance.
(c) Receive power from a large capacity power supply to reduce the harmonic impedance of the
power supply.
– 96 –
4.5.2 Independent power generator

W hen an "n"th harmonic current flows into a generator, a rotary magnetic field of "n" multiples of the
fundamental wave occur and a positive-phase harmonic interlinks the rotor at the velocity of (n−1)
times and a negative-phase harmonic interlinks it at the velocity of (n+1) times. Hence, an induced
current takes place in the braking winding and field winding. Depending on its level, heat generated
may cause decreased output, shorter life, breakage, etc.
These influences of harmonics can be found as an equivalent negative-phase current supposing that
loss due to a harmonic current is equal to loss due to a negative-phase current.
The permissible negative-phase current value of a generator is specified in various standards: 15%
or less in JEM1354.
2
 n 
Equivalent negative-phase current = ∑  4 × (In − 1 + In + 1) .......................................... (4.6)
 2 
The following harmonic suppression techniques are available for generators:

(a) Insert a power factor improving AC reactor in the inverter's supply side or a power factor
improving DC reactor in the DC side to suppress harmonics generated.
(b) Use a generator having a large permissible negative-phase current value. (As a large capacity
generator is designed to match the specifications of a purchase order, it is advisable to
consult the manufacturer.)
(c) Restrict the inverter load used with a generator.
– 97 –
4.6 Influence of Instantaneous Power Failure on Inverter
W hen an instantaneous power failure occurs, the control circuit of the inverter loses power. To
prevent control misoperation caused by the lost voltage, the instantaneous power failure protection is
activated (if selected) to stop the inverter output, and keep it stopped. The FR-A500 series is used as
an example to describe this protection which differs according to instantaneous power failure
duration.
4.6.1 Operation of inverter depending on instantaneous power failure time

(1) Instantaneous power failure duration of (2) Longer than 15 to 100ms.
less than 15ms. The protective function is activated and the
The protective function is not activated and inverter output stops. (The motor coasts to a
operation continues as it is. stop.)
15ms to 100ms
Within 15ms Power
Power supply
Time
supply
Time
15ms
Motor Inverter f
Motor Inverter speed output Output shut-off
f
speed output (N) frequency N
(N) frequency Motor coasts to a stop.
N (f)
(f)
Operation continues.
Time
Time
Kept on.
Time
Alarm output/display
Fig. 4.7 Instantaneous Power Failure of
Fig. 4.8 Instantaneous Power Failure of
Fig. 4.7 15ms or Less
Fig. 4.7 15 to 100ms
(3) Power failure of 100ms or longer

W hen power restores, an automatic reset is performed to make the inverter ready for restart.
100ms or
[Caution]
Power If the start signal (STF, STR) is on, the inverter
supply longer
Time will restart when power is restored. If the motor
is coasting at this time, overvoltage or
Motor Inverter 15ms overcurrent protection may activate to trip the
speed output f inverter. To restart the inverter automatically
(N) frequency when power is restored, use the automatic
Output
(f) N shut-off restart after instantaneous power failure
Motor coasts function. (This function is available as
to a stop. standard for the FR-A500 series. As the
automatic restart function is not factory-set,
Time
set "0" in parameter Pr. 57.)
For more information on automatic restart
Alarm output/display is not provided. after instantaneous power failure, refer to
Fig. 4.9 Instantaneous Power Failure of Section 4.6.3.
Fig. 4.7 100ms or longer
– 98 –
4.6.2 Inverter peripheral circuits and inverter operation at occurrence of instantaneous power.
failure
(1) W hen there are no magnetic contactors in the primary and secondary circuits of the inverter
NFB
Inverter IM
RA
STF
SD
If instantaneous power failure time is short and the relay RA does not switch off (start signal STF
remains on), operation performed is as described in Section 4.6.1.
If instantaneous power failure protection is activated to stop the inverter output and coast the
motor, the inverter may trip at restart. Therefore, the automatic restart after instantaneous power
failure function must be used or the start signal switched off during inverter output stop.
(2) W hen there is a magnetic contactor (MC) in the inverter supply circuit.
NFB MC
Inverter IM
RA
STF
SD
If instantaneous power failure time is short and the magnetic contactor MC and relay RA do not
switch off, operation performed is as described in above (1).
If only the magnetic contactor MC switches off, the motor coasts to a stop. To restart after power
is restored, switch MC on again after the motor has coasted to a stop (coasting interlock timer is
needed).
(3) W hen there is only a magnetic contactor (MC) in the inverter output circuit.
NFB MC
Inverter IM
RA
STF
SD
If instantaneous power failure time is short and the magnetic contactor MC and relay RA do not
switch off, operation performed is as described in above (1).
If only the magnetic contactor MC switches off, the motor coasts to a stop but the inverter
continues its output depending on the instantaneous power failure time or only the inverter
restarts after an initial reset of the inverter due to power restoration. Hence, when the MC is
switched on again, the motor is direct-on line started at the inverter frequency being output, and
overcurrent may occur to trip the inverter.
– 99 –
(4) W hen there are magnetic contactors (MCs) in the inverter primary and secondary circuits.
NFB MC1 MC2

Inverter IM
RA
STF
SD
Operation is performed as in above (2) and (3).
(a) If an instantaneous power failure occurs on the high voltage power supply, a (complete)
instantaneous power failure rarely occurs at the lower voltage inverter input terminals (R, S,
T) and in most cases only an instantaneous voltage drop takes place.
(b) The inverter has both instantaneous power failure protection and undervoltage protection.
Undervoltage protection is designed to function when the DC circuit voltage of the inverter is
lower than a given value for a given period of time. W hen an instantaneous voltage drop
occurs the inverter will operate differently according to its load output (kW ): the protective
function of an inverter with a large load output will be activated; while an inverter having a
small load will continue operation.
(c) Meanwhile, the magnetic contactors and relays once switched on may not switch off if an
instantaneous voltage drop occurs. They generally switch off at voltages 30 to 50% or less of
the coil rating.
4.6.3 Automatic restart control after instantaneous power failure

(1) Commercial power supply-inverter switch-over, automatic restart after instantaneous power
failure.
Caution These functions are valid when only one motor is connected to the inverter and must
not be used if two or more motors are used.
• Commercial power supply-inverter switch-over.
............ W hen commercial power operation is switched to inverter operation, the inverter can
be started with the motor coasting without stopping of the motor.
• Automatic restart after instantaneous power failure.
............ If a restart is done when power is restored after an instantaneous power failure,
operation can be continued without the motor being stopped.
(2) Activation of automatic restart after instantaneous power failure.

(a) W hen motor power is switched off during operation, the motor coasts.
(b) A DC voltage is applied by the inverter to the coasting motor, a DC current flows in the motor.
(Refer to area (A) in Fig. 4.10.)
This DC current includes ripples of a period proportional to motor speed.
– 100 –
(c) A signal from the current detector is sent to the CPU and the period of ripples is counted to
judge motor speed.
(d) The inverter outputs a frequency matching the motor speed. (Refer to (B) in Fig. 4.10.) By
increasing the output voltage gradually after that, the inverter operation is resumed with the
motor starting current suppressed.
AC220V
Power supply voltage
0 Time
60Hz 60Hz
Output frequency (B)
0 Time
1800r/min 1800r/min
Motor coasting
Motor speed
Time
50A DC voltage
application (A)
Motor current
0 Time
Instantane-
ous power Acceleration
failure time Reset time time
440ms 600ms 520ms
Speed Voltage
detection reduction time
time 300ms
140ms
Fig. 4.10 Example of Automatic Restart after Instantaneous Power Failure
W hen the inverter has the function for automatic restart after instantaneous power failure
(e.g. FR-A500 series).
NFB
Inverter IM
RA
STF CS
SD SD
Fig. 4.11 Wiring for Automatic Restart after Instantaneous Power Failure
To use automatic restart after instantaneous power failure, connect CS-SD.
– 101 –
5. NOISE
W ith the widespread use of electronic equipment, problems attributable to noise are tending to
increase.
As the inverter will generate noise because of its operational principles, it will effect equipment, and
devices around it. The degree of influence is not certain because it is related to the inverter control
system, the affected equipment's noise immunity, wiring conditions, installation distance, grounding
method, etc. W hen the following equipment and devices are to be installed near the inverter, it is
recommended to take the following measures according to the circumstances:
[Equipment requiring noise reduction techniques]
Sensors (proximity switch, etc.), video cameras (ITV, image scanner, etc.), radio transmitters
(including AM radio), acoustic equipment (microphone, video cassette recorder, audio equipment,
etc.), CRT displays, medical equipment
[Equipment recommended for reduction techniques]
Measuring instruments, private telephones
5.1 Noise Generation Principles
As described in Chapter 2, the DC voltage is switched at high speed in the inverter circuit to control
the output voltage waveform. An expanded view of the output waveform is as shown in Fig. 2.10 in
Chapter 2 (page 25). The sharp rise and fall include many high-frequency components, these
components are sources of noise generation.
Noise described here and harmonics described in Chapter 4 are often confused because they both
affect other electronic equipment. However, harmonics are generally 40th to 50th degrees (2⋅4 to
3kHz) and noise are often several to 10kHz or more.
+300V
−300V
Fig. 5.1 Example of Inverter Output Voltage Waveform

(For 200V class power supply)
– 102 –
5. NOISE
5.2 Noise Types and Transmission Routes
Noise generated by the inverter is roughly classified into noise directly radiated by the inverter and
cables connected to the inverter main circuit (I/O), noise induced magnetically and statically into
signal lines of peripheral devices close to the main circuit cables, and noise transmitted through
power supply channels.
Fig. 5.2 indicates noise types and Fig. 5.3 shows noise routes.
Noise transmitted Noise radiated directly

Inverter-generated noise ... Route 1)
in the air from inverter
Noise radiated from

... Route 2)
power supply cables
Noise radiated from cables

... Route 3)
connected to motor
Magnetic induction noise ... Routes 4), 5)
Static induction noise ... Route 6)
Noises transmitted Noise transmitted through

... Route 7)
through electric channels power supply cables
Noise from ground cable

... Route 8)
due to leakage current
Fig. 5.2 Noise Types
5) Telephone
7) 7)
7) 2)
1)
Sensor
2) power supply
Inverter
Instru- Receiver 3)
ment
6)
8)
4)
Sensor
Motor IM 3)
Fig. 5.3 Noise Routes
The noise levels tend to drop as the frequency band rises, and will generally be low enough to be
ignored above 30MHz.
Therefore, they will not affect most televisions and FM radios using 30MHz or higher frequencies, but
will affect AM and other radios in the low frequency band (0.5 to 10MHz). Thus, it will be reasonable
to consider this noise frequency band and examine reduction techniques.
– 103 –
5. NOISE
(1) Noise transmitted in the air ( routes 1), 2) and 3) )

The noise generated by the inverter is radiated and transmitted in the air in the three routes shown
in Fig. 5.4:
1) Radiated by the inverter
2) Radiated by the input cables
3) Radiated by the motor cables
1)
2) 3)
3)
Power IM
Inverter
supply
2)
(Motor frame grounding)
Grounding
Fig. 5.4 Noise Transmitted in Air
(2) Magnetic induction noise ( routes 4), 5) ) Motor

These noises are transmitted to a device when the
power cable and signal cable of a peripheral device Inverter IM
interlink magnetic fields generated by the input and
output side currents of the inverter.
(Refer to Fig. 5.5.)
W hen the cables run closely in parallel or the area Affected
of a loop made by each cable is large, induction device
Signal source
noise will be large. (such as sensor)
Fig. 5.5 Magnetic Induction Noise
(3) Static induction noise ( route 6) ) Motor

Magnetic fields generated by the input and Inverter IM
output side currents of the inverter are
coupled with signal lines through static
capacitances and transmitted to a device. C C (Capacitance)
(Refer to Fig. 5.6.)
Affected
device
Signal source
(such as sensor)
Fig. 5.6 Static Induction Noise
(4) Noise transmitted through electric channels ( route 7) ) Motor

High frequency noise generated in the inverter is Inverter IM
transmitted to a peripheral device via the power supply
cables. (Refer to Fig. 5.7.)
Affected
device
Signal source
Fig. 5.7 Noise Transmitted

Fig. 5.7 through Electric Channels
– 104 –
5. NOISE
The levels of such noise may either be measured by measuring field strength in the air or as a noise
voltage at the power terminals. (Refer to Fig. 5.8 Measurement Example.) Noise transmitted in the air
can be measured by the former method and noise transmitted through electric channels by the latter
method. As there are no ways of accurately measuring magnetic and static induction noise, the
measurement data of the above two noise types are generally used to size the noise.
Noise Noise
field terminal
strength voltage Inverter: FR-A520-3.7K
Running frequency: 30Hz
 dB   dB
   V Measurement distance: 15m
 µV / m µ 
120 Noise terminal voltage
Noise field strength
100
80
60
40
20
0
0.1 0.2 0.4 0.6 0.8 1 2 4 6 8 10 20 30
Frequency (MHz)
AM radio band
Fig. 5.8 Noise Measurement Example
– 105 –
5. NOISE
5.3 Noise Reduction Techniques
5.3.1 Noise reduction techniques

As described in Section 5.2, there are many routes by which noise is transmitted. Sources of noise
can be largely classified into the following three types as indicated in Fig 5.3 and Fig 5.4:
1) Transmission, induction or radiation from input power supply cables
2) Induction or radiation from motor cables
3) Radiation from inverter
The noise level tends to drop as the frequency band rises, and will generally be low enough to be
ignored at 10MHz or higher. (Refer to Fig. 5.8.)
Therefore, this noise will not affect televisions and FM radios using 70MHz or higher frequencies, but
will affect AM and other radios in the low frequency band. Thus, it will be reasonable to consider this
noise frequency band to examine reduction techniques.
(1) Reduction of noise going into power supply cables

Using a filter between the inverter and power supply cables will reduce mains conducted noise.
The usage and effects of the following filters is described.
1) Radio noise filter FR-BIF (200V class), FR-BIF-H (400V class)
This filter is common to all capacities, available in 200V and 400V types.
As shown in Fig. 5.9, connect the filter to the power supply terminals of the inverter. If the
filter-inverter cable is long it will act as an noise radiation antenna and the filter will not be able
to provide enough of an effect. Hence, connect the filter cables, including the filter ground
cable, directly to the inverter terminals and the minimum cable length possible.
If the distance between the inverter ground terminal and the earth point is long, the ground
cable will function as an antenna and the filter may not produce enough of an effect. Therefore,
also make the ground cable as short as possible.
This filter has a large effect upto several MHz as indicated in the noise reduction effect
example (page 114), this filter is effective for reduction of noise interference with AM radios.
This filter contains a capacitor.
Note that this filter will be damaged if it is connected to the output of the inverter.
R
Inverter
Power
S
supply
T
GND
FR-BIF
Radio noise filter

Connect the Grounding
cables directly to
the inverter input
terminals with the
shortest cable
distance possible.
Fig. 5.9 Installation of the FR-BIF Radio Noise Filter
– 106 –
5. NOISE
2) Line noise filter FR-BSF01, FR-BLF

This filter consists of a core and can be used with all models independent of the power supply
voltage and capacity.
As shown in Fig 5.10, wind all the three-phase wires in the same direction and insert the filter
into the power supply side of the inverter. As the effect of the filter becomes greater as the
number of winds is increased, wind the wires four or more times. If the wires are too thick to
wind four or more times, use two or more filters so that the sum of the turns is four or more.
Choose the filter types according to the wire size used.
As shown in the noise reduction effect example (page 113), this filter provides a greater effect
above several 100kHz. This filter may also be used on the output side of the inverter.
<Inverter input side> <Inverter output side>
Minimum
NFB distance
Minimum Inverter Within 3 winds
distance U (4 turns)
Power R Motor
supply V
S W IM
Line noise filter T

FR-BLF Line noise filter
(FR-BSF01 ) FR-BLF
(FR-BSF01 )
Fig. 5.10 Installation of FR-BSF01 and FR-BLF Line Noise Filters
3) Combined use of the FR-BIF(-H), FR-BLF and FR-BSF01

As described above, the FR-BIF has a large effect on the reduction of relatively low-frequency
noise and the FR-BLF on the reduction of high-frequency noise. Using them together will
provide much better results as indicated in the noise reduction effect example (page 113).
In this case, connect them as shown in Fig. 5.11.
Minimum
NFB distance
Inverter
Power R
supply
S
Line noise filter T

FR-BLF
( FR-BSF01 )
GND
FR-BIF
Connect the
cables directly to
the inverter input Grounding
terminals with the
shortest cable
distance possible.
Fig. 5.11 Combined Use of the FR-BIF, FR-BLF and FR-BSF01
– 107 –
5. NOISE
4) EMC Directive-compliant noise filter SF type

This line filter consists of a reactor and a capacitor and is exclusively used on the power supply
side.
As shown in Fig. 5.12, the filter must be installed near the inverter to minimize the wiring
distance between the filter and inverter.
As shown in the outline drawing of the noise filter (page 112), this filter is larger than the
FR-BIF, BLF or BSF01, but it has a wide range of noise reduction effects from low to high
frequencies as indicated in the noise reduction effect example (page 114).
Inverter
Noise filter
1 4 R U Motor
SF type
Power 2 5 S V IM
supply
3 6 T W
Do not bundle
these cables. Make these cables
as short as possible.
Fig. 5.12 Installation of the SF type Noise Filter
5) Noise cutting transformer

The noise cutting transformer is designed to have extremely small magnetic and static
couplings for the primary and secondary coils and provides a great noise reduction effect on
not only release but also entry of noise. (Refer to Table 5.1.)
As this transformer does not require grounding because of its principle, it provides an ideal
noise reduction technique in cases where proper grounding work cannot be done or a ground
cable will be long. However, this transformer requires a transformer of necessary capacity to
be installed in the main circuit and three single-phase transformers to be used in the three-
phase power supply, taking a large space and leading to high costs. Also, due to large internal
impedance, its large voltage drop should be noted.
Table 5.1 Noise Reduction Example of Noise Cutting Transformer

Measured
Frequency 5K 7.5K 10K 25K 50K 75K 100K 250K 500K 750K 1M 2.5M 5M 7.5M 10M 25M 50M 75M 100M
[Hz]
Reduction 85 74 77 72 54 45 37 32 22 28 42 46
ratio 100 or less or or or or or or or or or or or or
− [dB] less less less less less less less less less less less less
Voltage after damping

Note: Damping factor = 20 log 10 [dB]
Voltage before damping
– 108 –
5. NOISE
(2) Reduction of noise radiated from inverter-motor wiring

Though the above-mentioned FR-BLF or FR-BSF01 line noise filter may be inserted in the output
side of the inverter, a metal conduit is generally used as shown in Fig. 5.13 to reduce radiated
noise. Here, it is advisable to ground the motor on the inverter side using a single wire in the
four-core cable and to use a conduit of 2mm or larger wall thickness to produce a greater effect.
The same effect is also produced by running the cables in a concrete pit, or placing them in a
concrete-enclosed chamber.
Metal casing
Metal conduit
Power
Inverter IM
supply
Grounding
Fig. 5.13 Running the Motor Cables in Conduit
(3) Reduction of noise radiated from inverter

Generally, noise radiated from the inverter is relatively small and rarely poses a problem.
However, when the inverter must be installed near equipment which is sensitive to the above-
mentioned noise interference, put the inverter in a metal casing as shown in Fig 5.14, install a
noise filter in the power supply, and run the output wiring in a metal conduit connected to the
casing.
Noise filter
Metal conduit
Power
Inverter IM
supply
Grounding
Fig. 5.14 Reduction of Noise Radiated from Inverter
– 109 –
5. NOISE
5.3.2 Specific noise reduction examples

(1) Reduction techniques and effects
The reduction techniques (see page 111) produce the following levels of
expected effects (estimated values). Use the following table for reference to
~ : Great effect
determine priority.
{ : Effective
∆ : Slight effect
— : No effect
Table 5.2 Effects of Noise Reduction Techniques
Noise Transmission Route
Noises transmit-
Noise transmitted in the air ted through elec-
Magnetic Static tric channels
Sym-
Location Reduction Technique induction induction Leakage
bol Radiated Radiated Radiated
noise noise Power current
by by power by motor from
cables
inverter cables cables ground wire
Inverter
A
Reduce the carrier frequency (Pr. 72)
(for the FR-A series). ~ ~ ~ ~ ~ ~ ~
B
Increase the input filter constant
(Pr. 74) (for the FR-A series). ∆ ∆ ∆ { ∆ — —
C
Install FR-BIF(-H) radio noise filter.
— ~ — — — ~ —
D
Install the FR-BSF01 or FR-BLF line
noise filter. — ~ — — — ~ ∆
Input
side
E
Run the power supply cables in a metal
conduit or use shielded cables. — ~ — — — ~ —
F
Install an insulating transformer or
noise cutting transformer. — ∆ — — — ~ —
G
Separate the power supply system.
— — — — — ~ ~
H
Install FR-BSF01 or FR-BLF line noise
filter. — — ~ ∆ ∆ — ~
Output
side
I
Run the output cables in a metal
conduit or use shielded cables. — — ~ { { — —
J
Use a 4-core motor power cable and
use one wire as a ground wire. — — ∆ ∆ ∆ — ~
K
Use a twisted pair cable for sensor
signals. { { { ~ ~ — —
L
Connect the shield to the common wire
of the sensor signal. — — — ~ ~ — ~
M
Do not ground the sensor power unit
directly to the control box. — — — — — ∆ ~
N
Ground the sensor power unit to the
capacitor. — — — — — ∆ {
Use a shielded cable for signal input
O and connect the shield to the
common (input terminal) SD.
∆ ∆ ∆ { ~ — ∆
Use a twisted pair shielded cable for
Affected
P speed input and connect the shield to
terminal 5.
{ { { ~ ~ — ∆
device Q
Insert a ferrite core into the feed input
cable (output side of affected device). ∆ ∆ ∆ { — — —
R
Decrease the impedance of the
affected device output circuit. ∆ ∆ ∆ { — — —
S
Separate the device from inverter and
power lines more than 30cm ~ ~ ~ ~ ~ — —
T
Do not run cables in parallel, do not
bundle them. ∆ ∆ ∆ ~ ~ — —
U Provide a shield plate. { ∆ ∆ ∆ ∆ — —
V Place the device away from the earth. ∆ { { ∆ ∆ — —
W
Insert a ferrite core into the input
side of the affected device. — — — — — { ∆
– 110 –
5. NOISE
Reduction Technique Examples

The following techniques are expected to produce inverter noise reduction effects:
Note : For radio noise generated in mountains, within buildings or
weak wave areas, technique may not provide enough
Commercial V. effect.
power line Place the device as
far away as possible
from earth.
AM radio H.Install filter (FR-BLF,
Radiated noise A. Reduce carrier frequency. FR-BSF01) in
(Set 0 (0.7kHz) in Pr.72.) inverter output side.
E. Ground metal conduit
or shielded cable to
Receiving machine at one point.
transformer
Mechanical
power FR- FR-
R,S,T U,V,W BLF Motor
supply BLF
3300/200 D. Install filter FR-
V (FR-BLF, FR- BIF Inverter
I. Ground metal conduit or
400/200V BSF01) in inverter shielded cable to control
F. Install insulating
i t id
C.Install FR-BIF
transformer or box.
filter in inverter
noise cutting input side. J. Use 4-core cable as motor
transformer. power cable and use one
O. Use shielded STF wire as ground wire.
Programmable cables and STR 24VDC
controller or connect SD B. Increase parameter Pr.74
G. Separate microcomputer shield to SD. (input filter constant) setting
power system. board Q. Insert a ferrite of FR-A inverter.
core (Note that response will be
Control commercially slower.)
power il bl
supply 0 to 5VDC
400/200V Control box or
W. Insert a ferrite machine enclosure
core P. Use twisted pair
commercially R. Reduce output shielded cables
available. circuit impedance. and connect
shield to
terminal 5. S. Separate inverter and power
line more than 30cm (at least
10cm) away from sensor
i it
K. Use twisted pair

DC power shielded cables.
supply for Sensor
sensor
+
−
L. Do not earth shield but
connect it to common
Fig. 5.15 Inverter Noise Reduction N. Earth to control box wire of signal.
via 0.1µF to 0.01µF Sensor with
Techniques capacitor. high noise
M. Do not earth directly immunity.
to control box.
Wiring in control box
U. Shielding plate
Inverter S. Separate more than 30cm

T. Maximize wiring length (at least 10cm).
and do not run cables in
parallel or bundle them. Microcomputer board
If inevitable, cross them. Programmable controller
Noise filter
Terminal block Terminal block
Power supply Connect

Motor
Control power supply Limit switch sensor
Fig. 5.16 Wiring of Control Board
– 111 –
5. NOISE
5.3.3 Noise filters

(1) Noise filter outline drawings (Unit: mm)
(a) FR-BIF, FR-BIF-H
White
Red Blue Green
E
300
φ5
42
58 29 7
44
The FR-BIF (200V class) and FR-BIF-H (400V class) have the same dimensions.
(b) FR-BLF, FR-BSF01
<FR-BLF> <FR-BSF01>
2− φ 5 hole
31.5
22.5
130
2− φ 7
85 (65)
(33)
80 35 (65)
4.5
2.3 95
160
110
180
(c) SF type
Noise Filter Applicable Inverter
W H D W1 H1 C 2-φC hole
Model Model
SF1258 FR-A520-0.4K/0.75K 112 360 40 85 340 6
SF1259 FR-A520-1.5K to 3.7K 142 410 65 105 386 6
SF1260 FR-A520-5.5K to 11K 222 468 80 190 449 7
200V
SF1261 FR-A520-15K 253 600 86 220 575 10

SF1262 FR-A520-18.5K/22K 303 650 86 270 625 10
SF1263 FR-A520-30K 327 730 86 293 705 10
H1
SF1265 FR-A520-3.7K to 55K 468 913 110 410 768 12

H
SF1197 FR-A540-0.4K to 3.7K 114 360 47.5 117 340 6

SF1147B FR-A540-5.5K/7.5K 213 360 38 180 340 6
SF1175 FR-A540-11K/15K 253 530 60 220 505 10
400V
SF1176 FR-A540-18.5K/22K 303 600 60 260 575 10

SF1177 FR-A540-30K 327 700 80 280 675 10
SF1178 FR-A540-37K/45K 450 770 80 384 735 12
SF1179 FR-A540-55K 467 920 80 410 895 12
C
W1
D
– 112 –
5. NOISE
(2) Noise reduction effect examples

(a) FR-BIF, FR-BLF
Carrier frequency: 14.5kHz Measurement conditions

• FR-A520-3.7K
120
a. Without any noise reduction techniques.
b. FR-BLF (4 turns) installed in input side.
a
c. FR-BIF and FR-BLF (4 turns) installed in
100 input side.
b
Noise 80
terminal
voltage c
(dB)
60
40
20
Noise terminal voltage (average value)

0
0.1 0.2 0.3 0.5 0.7 1 2 3 5 7 10 20 30
Noise frequency (MHz)
Carrier frequency: 2kHz

Measurement conditions
120 • FR-A520-3.7K
a. Without any noise reduction techniques.
b. FR-BLF (4 turns) installed in input side.
c. FR-BIF and FR-BLF (4 turns) installed in
100
input side.
a
Noise 80
terminal
voltage b
(dB)
60 c
40
20
Noise terminal voltage (average value)

0
0.1 0.2 0.3 0.5 0.7 1 2 3 5 7 10 20 30
Noise frequency (MHz)
– 113 –
5. NOISE
(b) SF type filter

Measurement conditions
Inverter: FR-A520-3.7K
Moter: SF-J3.7kW, 4P
Filter: SF1259
80
EN50081-2
70 OP level
Noise
terminal
voltage 60
(dBuV)
50
40
30
Average
20
0.15 1 10 30
Freq (MHz)
5.4 Leakage Currents
Leakage currents flow through capacitances existing in the inverter input/output wiring and the motor.
These values depend on the capacitances, carrier frequency, etc. W hen a low acoustic noise inverter
is used, leakage currents will increase and the following technique should be used.
5.4.1 Earth leakage current

Leakage currents will flow not only into the Inverter
NV1
Power Motor
inverter system but may also flow into other
systems through the ground cable. These supply
C
Earth leakage breaker
leakage currents may make the earth leakage C
breakers or relays trip. NV2 Motor
C
(1) Technique Earth leakage breaker
• Decrease the carrier frequency (Pr.72) of
the inverter. Note that motor noise will
Fig. 5.17 Leakage Current Routes
increase.
• Use harmonic/surge reduction products * For the selection of earth leakage breakers,
(such as Mitsubishi's New Super NV refer to page 136.
series) with the inverter system and other
systems to keep motor noise low (carrier frequency increased).
– 114 –
5. NOISE
(2) Earth leakage current data example
Note that long wiring lengths will result in large leakage Long wiring lengths will result in large leakage currents.
currents. Decrease the inverter carrier frequency to Leakage currents of 400V class are larger than those of
reduce leakage currents. 200V class.
1000
400
Conditions Carrier frequency
Leakage Leakage 700
• Motor : SF-J3.7kW 4P 14.5kHz (FR-A540) current 500
current • Output frequency : 30Hz
(mA)
(mA) 300
10kHz (FR-A540) 300
FR-A540
FR-A520
200
200
2kHz (FR-A540) 100

1kHz (FR-Z240) Conditions
100 70 • Wiring length: 20m
50 • Carrier frequency: 14.5kHz
• Output frequency: 30Hz
0 50 100 Output side 30
0.4 0.75 1.5 2.2 3.7 5.5 7.5 11 15 22 30 37 45 55
wiring length (m)
Motor capacity (kW) 18.5
Fig. 5.18 Differences between Earth Fig. 5.19 Difference between Earth
Fig. 5.18 Leakage Currents according to Fig. 5.18 Leakage Currents according to
Fig. 5.18 Carrier Frequency and Wiring Length Fig. 5.18 Motor Capacity
5.4.2 Line leakage currents

Harmonics of leakage currents flowing in capacitances between the inverter output cables may cause
the external thermal relay to be inoperative. W hen a 400V series small-capacity model (especially
7.5kW or less) is wired over a long distance (50m or more), the ratio of the leakage current to the rated
motor current will increase, causing the external thermal relay to become inoperative more easily.
Table 5.3 Line Leakage Current Data Examples

Thermal Table 5.3 (200V series)
NFB relay Motor
Motor Rated Motor Leakage Currents (mA)
Power
Inverter Capacity Current W iring length W iring length
supply (kW ) (A) 50m 100m
Line 0.4 1.8 310 500
capacitance 0.75 3.2 340 530
1.5 5.8 370 560
2.2 8.1 400 590
Fig. 5.20 Line Leakage Current Routes 3.7 12.8 440 630
5.5 19.4 490 680
7.5 25.6 535 725
(1) Technique • Motor: SF-J 4P • Cable used: 2mm 4-core
2
• Use the electronic overcurrent protection • Carrier frequency: 14.5kHz standard cable
of the inverter. ★ Leakage currents of 400V series will be about twice larger
than those of 200V series.
• Install the reactor (FR-BOL) on the output
side.
• Decrease the carrier frequency. Note that motor noise will increase.
To securely protect the motor from line leakage currents, it is recommended to detect the
temperature of the motor body directly with a temperature sensor.
– 115 –
5. NOISE
5.5 Grounding (Earthing)
An electric device generally has a ground terminal, which must be connected to the earth.
An electrical circuit is usually isolated by an insulating material and contained in a case. However, in
reality it is impossible to manufacture an insulating material which can isolate currents completely, so
slight currents will leak to the case. The ground terminal is primarily designed to ground the case to
prevent someone from getting an electric shock when they touch the case of the electric device.
For devices which handle low-level signals, such as audio equipment, sensors and computers, and
machines operating at extremely high speed, grounding is also important to protect them against
external noise.
As described above, there are two types of grounding (safety and noise reduction) different in nature.
If these two grounding techniques are used without differentiation, problems will occur. Therefore,
grounding must be considered by dividing it into dirty grounding for electric shock prevention and
clean grounding for noise prevention.
W hen the inverter is used, its output voltage does not have a sine wave but a sharp wave as shown
in Fig. 2.10 in Chapter 2 (page 26). Hence, charging/discharging currents to/from capacitances
existing in the isolation section will also flow as leakage currents.
Further, similar charging/discharging currents will flow in the inverter supplied motor. As shown in
Fig. 5.9, larger currents with high frequency components flow during inverter operation than in
commercial power operation. This tendency increases as the carrier frequency of the inverter
increases.
5.5.1 Grounding method and grounding work

As described above, grounding purposes are roughly classified into electric shock prevention and
prevention of faults due to noises. Therefore, these two grounding types must be differentiated clearly
and the following action taken to ensure that leakage currents having high frequency components do
not enter grounding for fault prevention.
(a) W here possible, ground the inverter independently of other devices. (Refer to Fig. 5.21.)
If independent grounding ( (a) in Fig. 5.21 ) is impossible, use the joint grounding technique in
which the inverter is connected with another device at the ground point ( (b) in Fig. 5.21 ). The joint
grounding technique ( (c) in Fig. 5.21 ) in which the same ground cable is used for the inverter and
other device must not be used, especially for a large power device such as a motor or
transformer.
Also, since leakage currents with high frequency components will flow in the ground cables of the
inverter and the motor driven by the inverter, the inverter must be grounded independently of
devices which are sensitive to noise.
– 116 –
5. NOISE
In high buildings, it will be advisable to ground steel frames for noise fault prevention and use the
independent grounding technique for electric shock prevention.
Other Other Other

Inverter Inverter Inverter
device device device
Class 3
Class 3
grounding
grounding
(a) Independent grounding (b) Joint grounding (Good) (c) Joint grounding
(Best) (Not allowed)
Fig. 5.21 Grounding Techniques
(b) Use the class 3 grounding technique (grounding resistance 100Ω or less) for the 200V class
inverters and special class 3 grounding technique (grounding resistance 10Ω or less) for the 400V
class.
(c) Use the largest possible gauge for the ground cable. Use the size indicated in Table 5.4 or larger.
(d) The grounding points should be as near as possible to the inverter to minimize the grounding
cable length.
(e) Run the ground cable as far as possible from the I/O wiring of equipment sensitive to noise and
over the shortest possible parallel distance.
(f) The ground terminal of the motor should be connected to one wire in the four-core cable and
grounded on the inverter side.
Table 5.4 Ground Cable Size

Ground Cable Size
Motor Capacity Note: The sizes indicated in the table are in
200V class 400V class
2 2
accordance with the "Electric Facility
3.7kW or less 3.5mm 2mm Standard" published by the Japanese
2 2
5.5kW , 7.5kW 5.5mm 3.5mm Ministry of International Trade and In-
2 2
11kW to 15kW 14mm 8mm dustry and the "Internal Cable Regula-
2 2
18.5kW to 37kW 22mm 14mm tion" published by Japan Electric Asso-
2 2
45kW , 55kW 38mm 22mm ciation.
If the ground cable of the inverter, ground cable of the inverter-driven motor, or the ground cable of
audio equipment, sensor, computer etc. are connected together, leakage currents will be a source of
noise, affecting the equipment.
To solve this problem, dirty grounding work for the inverter must be done separately from clean
grounding for audio equipment, sensor, computer, etc.
Current 0
Time
0.4ms
Fig. 5.22 Ground Cable Current Example of Motor Driven by Inverter

(Inverter: FR-A520-0.75K, motor: SF-JR 0.75kW 4P)
– 117 –
This chapter deals with inverter reliability and life-span according to the installation environment and
operating conditions.
Also inverter circuit design, wiring instructions and operation procedures will be described.
6.1 Environment and Installation Conditions
6.1.1 Inverter reliability and temperature

Inverter reliability depends greatly upon temperature. A high ambient temperature or a temperature
rise in the inverter due to incorrect installation or unsuitable mounting may cause an unexpected fault
such as failure or damage. This may occur due to the following factors:
Example factors
• Heat build-up in enclosure.

• Low heat dissipation effect of enclosure.
High ambient (Small size, insufficient ventilation, etc.).
temperature • Narrow ventilation path for inverter.
• Incorrect inverter mounting position.
• Heat source installed near the inverter.
High internal • Incorrect inverter mounting direction.

temperature of • Small space above the inverter.
inverter itself • Failure of inverter fan.
6.1.2 Ambient temperature

The ambient temperature of the inverter indicates a temperature in the vicinity of where the inverter
is installed.
1) Measure the temperature at the positions shown in Fig. 6.1.
2) Permissible temperatures are between −10°C and +50°C.
(A too high or too low temperature will result in a fault.)
3) W hen the measured temperature inside the enclosure is +50°C
or less, it may be assumed that the ambient temperature of the
enclosure itself is 40°C or less. 5cm 5cm
5cm
Fig. 6.1 Measurement of

Fig. 6.1 Ambient Temperature
– 118 –
Useful
Useful Inverter
Inverter Check
Check Points
Point "Arrhenius law"
Inverter Life
Life
A 10°C rise in ambient temperature will halve
the inverter life (a 10°C fall will double life).
This is called "Arrhenius law". The
smoothing electrolytic capacitor used in the
inverter is one device to which "Arrhenius
law" applies. Similarly, the lives of the other
devices are also temperature dependent.
Temperature
Relationship between failure rate and
temperature. Premature
failure Random Wearout
The inverter consists of many electronic period failure period failure period
Failure
components including semiconductor
rate
devices. Such devices have a close
relationship between ambient temperature
Ambient
and failure rate. To reduce the failure rate temperatures
use the inverter at the lowest possible 50°C
permissible temperature. 45°C
40°C
Time (Year)
6.1.3 Heat generated by the inverter

Heat generated by the inverter unit varies according to the capacity of the inverter and the load of the
motor.
Also, options such as the power factor improving reactors (FR-BEL, FR-BAL) and brake unit
(including the resistor), contained in an enclosure together with the inverter also generate heat. Such
heat must be considered in enclosure design. Heat generated is indicated in Table 6.1
Heat generated in an enclosure can be reduced sharply by mounting the inverter heat sink outside the
cabinet . For details about using an attachment to place the semiconductor heat sink and built-in
brake resistor outside of the enclosure refer to Fig. 6.2.
– 119 –
Table 6.1 Heat Generated by Inverter and Power Factor Improving Reactors
Heat Generated by Inverter (W) Heat Generated by Power
Motor Inverter Type When outside heat sink mount- Factor Improving Reactors
Capacity ing attachment is used (W)
(kW) 200V series 400V series Heat generated Heat dissipated FR-BEL FR-BAL
in enclosure from enclosure
0.4 FR-A520-0.4K FR-A540-0.4K 55   2 6
0.75 FR-A520-0.75K FR-A540-0.75K 70   3 8
1.5 FR-A520-1.5K FR-A540-1.5K 120 36 84 6 16
2.2 FR-A520-2.2K FR-A540-2.2K 150 45 105 8 15
3.7 FR-A520-3.7K FR-A540-3.7K 240 72 168 14 21
5.5 FR-A520-5.5K FR-A540-5.5K 330 99 231 19 30
7.5 FR-A520-7.5K FR-A540-7.5K 440 132 308 25 30
11 FR-A520-11K FR-A540-11K 670 201 469 31 45
15 FR-A520-15K FR-A540-15K 860 258 602 36 55
18.5 FR-A520-18.5K FR-A540-18.5K 1100 330 770 40 60
22 FR-A520-22K FR-A540-22K 1300 390 910 52 65
30 FR-A520-30K FR-A540-30K 1750 525 1225 60 90
37 FR-A520-37K FR-A540-37K 2100 630 1470 67 110
45 FR-A520-45K FR-A540-45K 2400 720 1680 95 140
55 FR-A520-55K FR-A540-55K 2700 810 1890 100 170
Note: Heat generated by the built-in brake resistor (for the FR-A520 series, 7.5K or less) is not included.
Enclosure
6.1.4 Heat interference and ventilation in an Inside
enclosure Mounting bracket FR-A5CN
enclosure (option)
The position of the inverters and ventilation fans Inverter
must also be noted when installing inverters in an Heat sink
enclosure.
Depending upon the installation positions, two or
more inverters installed in an enclosure or a
ventilation fan incorrectly mounted in an enclosure Cooling fan
may raise the ambient temperature of the inverters,
by reducing the ventilation effect.
Cooling air
Fig. 6.2 Using the Outside Heat Sink

Fig. 6.2 Mounting Attachment
Inverter
Air
Inverter Inverter guide Inverter Inverter
Inverter
Correct Incorrect Correct

Correct Incorrect
Fig. 6.3 Example of Installing Two Inverters Fig. 6.4 Position of Ventilation Fan
Fig. 6.2 in Enclosure
– 120 –
6.1.5 Installation of discharge resistors

W hen the BU brake unit or externally mounted high-duty brake resistor (FR-ABR) is used, measures
must be taken to fully dissipate the heat generated by the resistor. It should be recognized that the
resistor is a heating device and measures should be taken to cool it.
It is recommended to install the discharge resistor on the outside of the enclosure.
Provide a cover which Note: The surface temperature of the resistor may rise up to about
will dissipate heat and Use a 300°C. Also, note the material of the mounting surface and
prevent any hazards cooling fan the positions of resistors when two or more of them are used.
such as a burn. as required.
Discharge resistor
Separation
Discharge resistor 7cm or more.
Fig. 6.6 Resistor Arrangement

Fig. 6.5 Resistor Mounting
6.1.6 Direction of inverter installation

If the inverter is installed in an incorrect position, its heat generated will not be dissipated properly and
will built up in the inverter. (The printed board section of the control circuit is not cooled by the cooling
fan.)
Correct Incorrect Incorrect

Vertical installation Sideaways installation Horizontal installation
Fig. 6.7 Directions of Inverter Installation
6.1.7 Standard installation environmental specifications (for FR-A500 series)

Item Specifications
Ambient temperature −10°C to +50°C (non-freezing)
Ambient humidity Relative humidity 90%RH or less (non-condensing)
Atmosphere Indoors free from corrosive gas, explosive gas, flammable gas, dust, dirt and oil mist.
Altitude Max. 1000m above sea level
2
Vibration 5.9m/s {0.6G} or less (in compliance with JIS C0911)
3-phase 200 to 220V 50Hz, 200 to 240V 60Hz (0.4K to 22K), 3-phase 200V to 220V
AC voltage/frequency
50Hz, 200 to 230V 60Hz (30K to 55K)
170V to 242V 50Hz, 170V to 264V 60Hz (0.4K to 22K), 170V to 242V 50Hz, 170V to
Permissible voltage fluctuation
253V 60Hz (30K to 55K)
Permissible frequency fluctuation ±5%
– 121 –
• Temperature
(1) Measures for high temperature prevention.
(a) Adopt a cooling technique such as forced ventilation.
(b) Install in an air-conditioned electric chamber.
(c) Do not subject direct sunlight.
(d) Shield or avoid direct exposure to radiated heat or warm air.
(e) Provide smooth air flow around the enclosure.
(2) Measures for low temperature prevention.
(a) Install a space heater in the enclosure.
(b) Do not switch off the inverter. (Switch off the inverter start signal only.)
(3) Prevention methods for sudden temperature changes.
(a) Select an installation place where sudden temperature changes will not occur.
(b) Avoid positioning near the inlet/outlet of an air conditioner.
(c) Install the inverter away from a door if the door opening/closing causes sudden temperature
changes.
• Humidity
Operate the inverter at ambient humidity between 45% and 90%. If humidity is too high, reduced
insulation and metal corrosion problems will take place. If humidity is too low, insulation breakdown
may occur.
The insulation distance specified in JEM1103 "Insulators for Control Equipment" has the humidity
condition of 45 to 85%.
(1) Measures for high humidity prevention.
(a) Use an enclosure of dirt-protection structure type and put moisture absorbent in it.
(b) Blow dry air into the enclosure.
(c) Install a space heater in the enclosure.
(2) Measures for low humidity prevention.
Blow air of the correct humidity into the enclosure. In addition, when installing or inspecting the
unit in this state, important points to note are to discharge the inspectors body (static electricity)
first and not to touch the parts.
(3) Measures for condensation prevention.
Condensation may take place if the temperature in the enclosure changes suddenly due to
frequent starting and stopping or if the outside temperature changes suddenly. Condensation
will cause faults such as reduced insulation, corrosion, etc.
(a) Take measures against high humidity as described in point (1).
(b) Do not switch off the inverter. (Switch off the inverter start signal only.)
– 122 –
6.1.8 Dirt-protection structure

For use in places laden with dust and dirt, the dirt-protection structure attachment (FR-A5CV) can be
used to close the ventilation ports of the inverter. This modifies the inverter into a dirt-protection
structure, (0.4kW to 22kW ). Note that the inverter may be operated with a −10°C to +40°C ambient
temperature. Thus, the maximum permissible ambient temperature will be 10°C lower than that of the
standard type.
Even the dirt-protection structure inverter cannot be operated in places where oil mist etc. exists. In
this case, install a standard type inverter in an applicable protection enclosure.
6.1.9 Considerations when installing the inverter in an enclosure

For these considerations, refer to Fig. 6.8.
Leave enough clearance

(5cm or more) between Install the fan in the best position
inverter and equipment where inside temperature and Other equipment installed here
which will generate heat. inverter ambient temperature should not prevent cooling air
will not be high. The fan should from flowing.
provide enough cooling capability. Also, equipment easily affected
by heat should not be mounted
in this position. (10cm or more)
Install in correct direction.
Discharge resistor etc.

which will generate heat
Inverter should be mounted on the
outside.
Leave enough clearance

(10cm or more) so that wiring
conduit etc. will not prevent the
flow of cooling air.
Wire the control signal

cables separately from the
main circuit (power circuit)
cables. Do not bundle wires.
Air filter
Clean and inspect periodically
to prevent clogging.
Power factor improving reactor
Fig. 6.8 Considerations for Installation in Enclosure
– 123 –
• Dust, dirt, oil mist

Dust and dirt will cause faults such as mis-contact, reduced insulation, moisture absorption due to
accumulated dust and dirt, reduced cooling effect, and a temperature rise in the enclosure due to a
clogged filter. Also, in places where conductive powder exists, dust and dirt will cause such faults
as misoperation, deteriorated insulation, and short circuits.
Oil mist will cause similar conditions, adequate measures must be taken.
Countermeasures
(a) Install the inverter in a dust-protection structure enclosure.
If the temperature in the enclosure rises, take appropriate measures.
(b) Force air in.
Force clean air into the enclosure to provide positive pressure from inside the enclosure.
• Corrosive gas, damage from salt

If the inverter is exposed to corrosive gas or salt (sea breeze), its printed board patterns, parts and
its relay switch section will be corroded.
In such places, take the measures against dust, dirt and oil mist (a) and (b).
• Explosive gases, flammable gases

As the inverter is not an explosion-proof structure, it must be contained in an explosion-proof
enclosure. If the inverter to be used in places where explosion may occur due to explosive gas or
dust it must conform to the standard guidelines of the law and pass an examination. The enclosure
itself will be expensive (including examination fees). It will be best to avoid installation in such
places and to install the inverter in non-hazardous place.
• High altitudes
Use the inverter at an altitude of 1000m or less. At a higher altitude the air will be thinner and will
lead to a decrease in the cooling effect.
• Vibration, shock
2
The vibration immunity of the inverter is 10Hz to 55Hz vibration up to 5.9m/s {0.6G} acceleration at
1mm amplitude in conformance with JIS C0911. If vibration or shock is less than the specified value
but is applied for a long time, the mechanical section may become loose or contactors may
misoperate.
Especially when shock is applied repeatedly, the mounting legs may be broken.
Countermeasures
(a) Fit rubber vibration insulators to the enclosure.
(b) Strengthen the structure of the enclosure to prevent resonance.
(c) Install the enclosure away from source of vibration.
– 124 –
6.1.10 Inverter-driven explosion-proof motor

Since the combination of an explosion-proof motor and its driving inverter must pass the specified
examination, install them carefully noting the following points:
(1) The existing pressure-resistant explosion-proof motor and safety-increased explosion-proof

motor designed for commercial power supply drive should not be operated by a standard inverter.
These motors must first pass the Ministry of Labor's (or relevant examaning body) explosion-
proof examination (safety examination) for motor and inverter combined.
An inverter-driven, pressure-resistant explosion-proof motor that has passed the safety
examination can be used with the inverter. However, the inverter that may be used should be of
the same type (including the capacity) as the one that has passed the examination, and the
operating range is limited to the examination conditions.
Inverter-driven pressure-resistant explosion-proof motors and inverters are available from
Mitsubishi Electric.
(2) W hen the operation rating desired is outside the examination conditions or it is desired to use a
model that has not yet passed the safety examination, the motor must pass the safety
examination.
(3) W hen the motor is to be used with any inverter options, refer to the corresponding manuals.
(4) W hen a safety-increased explosion-proof motor is to be used with an inverter, there are severe
restrictions on operating conditions (such as generated loss reduction, cooling effect
improvement) and this motor-inverter combination is not economical. It is recommended to use a
pressure-resistant explosion-proof motor that has passed the safety examination.
(5) The inverter is not designed to be explosion-proof. Therefore, install the inverter in an
explosion-proof place.

W hen an inverter-driven explosion-proof motor for constant torque operation is needed, it will be
economical to use an inverter-driven explosion-proof motor of one or two ranks higher capacity
(that has passed the safety examination).
Note: The above information (Section 6.1.10) only relates to inverters and motors used in Japan.
– 125 –
6.2 Inverter Wiring
6.2.1 Terminal connection diagram

The connections of various terminals for operation of the inverter are indicated in the inverter
manual. The specifications and usage of these terminals will be described using the FR-A500 series
as an example.
Connect after fully con- The input signal The output signal
firming the power supply terminal group is terminal group is If the phase sequence
voltage. Phase sequence on this side. on this side. of the motor is
need not be matched. switched, the direction
of rotation will change.
Inverter
NFB
Motor
R U
Power
supply S V M
T W
Grounding
PU connector Jumper
Control circuit power is (RS-485) Power factor
R1 P1 improving DC
supplied from phases
R and S. S1 P reactor FR-BEL
Jumper R P indicates
Jumper High-duty brake
24VDC power supply and external positive and N
resistor FR-ABR
transistor common control input signals PC PX negative. (DC)
(voltage input is impossible) PR R
If these signals are Forward rotation start STF N

switched on at the
Reverse rotation start STR
same time, the Start self-holding
inverter will stop. selection
STOP A
These dry contact
High outputs should be
Multi-speed speed
RH B Alarm used after
selection
output confirming their
Medium
Up to 7-speed op- (Up to 7
RM C
(Contact specifications.
speed
eration can be speeds) Low RL output)
performed by on- speed
off combinations of Jog mode JOG
three terminals. Second acceleration/
deceleration time RT RUN These open collector
Running
selection outputs require a
SU
Output stop MRS Up-to-frequency power supply (24VDC
IPF or less). Note the
Reset RES Instantaneous power failure polarity.
OL
Current input selection AU Overload
Selection of automatic FU This resistor is not
CS Frequency detection needed when the
restart after
SE parameter unit is
instantaneous power
(Contact input
(Open collector output common)
failure
SD used for setting.
common)
Calibration
resistor
Meter (e.g. frequency meter)
1/2W 10kΩ
It is important not to 10E(+10V)
+ –
connect terminals Frequency setting signals (analog)
FM (Moving coil type,
10 (10E) and 5. 1mA full scale)
3
10(+5V)
Frequency setting
2
SD
(Switching between 0-
potentiometer 2
It is essential to wire 5V and 0-10V)
1/2W 1kΩ
these terminals over 5 (Analog
common) AM (+) Analog signal output
the shortest possible Common
distance (within 30m, (0 to 10VDC)
5 (–)
except terminal 4) Ground securely using
Auxiliary input 1 (Switching between 0-
using shielded cables. ±5VDC and 0-±10VDC) a cable of correct
Current input 4 (DC4 to 20mA) Grounding size.
Do not earth the common
terminal (including SD). Main circuit terminals
Control circuit input terminals
Control circuit output terminals
Fig. 6.9 Terminal Connection Diagram
– 126 –
6.2.2 Main circuit wiring

As the main circuit is a power circuit, incorrect wiring will not only damage the inverter but may also
jeopardize operators. The following areas must be wired carefully:
Do not apply a voltage Do not use this magnetic contactor (MC) to repeat frequent
higher than the permissible starts/stops.
voltage of the inverter. • Basic sequence example without MC
NFB
Power supply 200V R
power S
supply
T
NFB F
Start CR2
CR1 STF(STR)
Stop CR1
CR2 SD
MC
R S T
Inverter
(3) 10
If power is connected to terminals U, V, W, the
(2)
2 inverter will be damaged.
(1) 5
Provide electrical and mechanical interlocks to
U V W ensure that MC C and MC F are not switched on
simultaneously. (Power is applied to terminals
U, V, W.) Otherwise, power will flow incorrectly
(including arc shorting).
MC F MC C Before connection, make sure that the phase

sequence of the commercial power supply is in
order of R, S, T.
If the wiring distance is long, a voltage drop across the

IM cables will take place especially at a low frequency,
reducing motor torque. Use cables of a large size. If the
Motor cables are too thick to directly connect to the inverter
terminals, provide a junction terminal block.
Do not connect terminal 2 of the frequency
setting potentiometer to terminal 10 or 5 of the
inverter.
10 (3) 10
(3)
(2) Fig. 6.10 Main Circuit Wiring
2 2
(2)
(1) 5 (1) 5
Incorrect examples
– 127 –
6.2.3 Control circuit wiring

The following table lists the form of the inverter's input and output terminals and their common
terminals.
Terminal Form Specific Terminal Examples Common Terminal

Contact Start signals (STF, STR) SD or
Input terminals (or open collector) Selection signals (RH, RM, RL, AU, etc.) PC (power (+) common)
Analog Frequency setting signals (2, 1, 4, etc.) 5
Contact Alarm output (A, B) C
Output terminals Open collector Running signals (RUN, SU, OL, IPF, FU) SE
Pulse train For meter (frequency meter) (FM) SD
Analog For analog signal output (AM) 5
(1) Connection to input terminals

1) Contact or open collector input terminals (isolated from the inverter internal circuit)
Each terminal functions when it is connected with common terminal SD. As the current that
flows at this time is at low level (4 to 6mADC), a switch or relay for low-level current (twin
contact, etc.) must be used to prevent poor connections.
Beware of PC, etc.

mis-contact! PC, etc. (transistor output)
RA STF
(STF) (STF) (STF)
Low-level PC
current
SD (common) SD SD
DC
24V
Contact input (switch) Contact input (relay) Open collector Open collector
(External power system)
Fig. 6.11 Input Signal Connections
2) Analog input terminals (not isolated from the inverter internal circuit)
The cables to these terminals must
be fully separated from the 200V Induction noise R
(400V) power circuit cables, etc. so Power supply S
that they are not bundled. Shielded T
cables must also be used to protect
them from external noise.
10
Do not
bundle. 2
5
Shielded cables
External noise
Fig. 6.12 Frequency Setting Input Terminal

Fig. 6.12 Connection Example
– 128 –
3) Correct connection of frequency setting potentiometer

The cables to the frequency setting potentiometer terminals must be connected correctly
according to the terminal symbols. Otherwise, the inverter will not operate correctly.
The resistance value is also an important selection item.
<Specifications> 2W 1kΩ wire-wound variable resistor with characteristic B
2
Characteristic C
Characteristic B
3
10
Resistance Characteristic A
2
value
Inverter
5
Rotary angle <Correct connection>
Fig. 6.13 Connection of Frequency Setting Potentiometer
(2) Connection to output terminals

1) Open collector output terminals
For noise reduction, it is recommended

to use a flywheel diode or capacitor.
Note the polarity!
Relay • Use a DC power supply of

10% or less ripple voltage.
RUN
RA • Connect with correct polarity.
24VDC
SE
Permissible
current is 0.1A.
2) Pulse train output terminal 3) Analog signal output (0 to 10VDC)

Calibration Frequency 10V voltmeter
Pulse train
resistor meter
AM
FM R
10kΩ1/2W
1mA 5
SD
Shielded cables
(Common)
Though a pulse train is output,

the voltage proportional to the
output frequency is output.
Hence, the output state can be
read using a meter (10VDC
Meter range).
Fig. 6.14 Connection of Output Signal Terminal
– 129 –
6.2.4 I/O cable wiring distances

Cable length restrictions differ between I/O terminals. The control signals are photocoupler-isolated
from the input section to improve noise resistance, but analog inputs are not isolated. Hence, the
frequency setting signals should be wired carefully and operational counter-measures should be, e.g.
make the wiring length as short as possible so that signals are not affected by external noise. Fig. 6.15
shows the permissible wiring length guideline for each signal and the action to be taken when this
length is exceeded.
Input side power supply cables Output side motor cables

Determine the cable size with which a
When a voltage drop occurs, the
maximum output voltage of the voltage drop will not be large. (At low
inverter will not be higher than frequency, note that the output voltage is
this voltage. low because of the V/F pattern.) Also, in
consideration of the charging currents of
the stray capacities of the cables, the
cable length should be within 500m.
The length should be within 30m when
advanced magnetic flux vector control is
NFB selected. If the length is longer than 30m
autotuning must be performed.
¥
R U
Power FR A500
supply S V IM Motor
Inverter
T W
Start
STF(STR),etc
SD
Contact input signal
50m or less
For long wiring distance,
RES
it is recommended to
provide a junction relay Reset
SD
near the inverter.
50m or less
Shielded cables
10 Twisted or
shielded cables
Frequency setting
2 FM
potentiometer
Frequency meter
5 SD
AM
5
Analog input signal 30m or less
For remote operation, 30m or less 50m or less

it is recommended to
provide a motorized
speed setter near the
inverter or use a
4 to 20 mADC signal.
Fig. 6.15 I/O Cable Wiring Lengths
– 130 –
6.2.5 BU brake unit wiring

(1) W ire the BU brake unit and resistors are not a single set, connect each set in parallel with
terminals P-N of the inverter.
CAUTION Terminals P and N of the brake unit must not be connected oppositely and must al-
ways be matched with the terminal symbols P and N of the inverter. Otherwise, the
inverter will be damaged.
INVERTER
P P
R R R R
N N
PR
Discharge resistors
Brake unit
P
R R R R
N
PR
Discharge resistors
Brake unit
Fig. 6.16 Brake Unit Wiring
(2) The maximum wiring length between the inverter and BU brake unit and between the BU brake
unit and discharge resistors must be 5m. If less than 5m, but longer than 2m the cables must be
twisted.
INVERTER
P P R R R
Brake
unit
N N
PR
Within 2m Within 2m
INVERTER Twisted Twisted

P P R R R
Brake
unit
N N PR
2m to 5m 2m to 5m
Fig. 6.17 Brake Unit Wiring Lengths
– 131 –
6.2.6 FR-BU brake unit wiring

(1) W ire the FR-BU brake unit and FR-BR resistor unit as a single set, and connect this set to
terminals P-N of the inverter.
CAUTION CAUTION Terminals P and N of the brake unit must not be connected oppositely and
must always be matched with the terminal symbols P and N of the inverter.
Otherwise, the inverter will be damaged.
To ensure safety, configure a circuit which will shut off the primary magnetic
contactor of the inverter when the alarm contact signal of the brake unit or resistor
unit is activated.
No-fuse Transformer (Note 2)

breaker
NFL MC
ON OFF
R U Motor MC
S V IM
MC
T W
INVERTER
Note 1: When the FR-BU is used with PR P
PR P P/+
the 7.5kW (or less) inverter, (Note 1) HA TH1
always disconnect the jumper PX N N/− HB
from across terminals PR-PX. HC THS TH2
Brake unit Resistor unit
Note 2: When the power supply is 400V FR-BU FR-BR
class, provide a control transformer.
Fig. 6.18 Brake Unit Wiring
(2) The maximum wiring length between the inverter and FR-BU brake unit and between the FR-BU
brake unit and FR-BR resistor unit must be 10m. If less than 10m, but longer than 5m the cables
must be twisted.
Inverter Brake Resistor
unit unit
P P P P
N N PR PR
Within 5m Within 5m
Inverter Brake Resistor

unit unit
Twist. Twist.
P P P
PR
N N PR
Within 10m Within 10m
Fig. 6.19 Brake Unit Wiring Lengths
– 132 –
6.2.7 High-duty brake resistor (FR-ABR) wiring

W hen the built-in brake resistor connected across terminals P-PR cannot provide enough thermal
capability for high-duty operation, disconnect the jumper from across terminals PR-PX and connect
the high-duty brake resistor across terminals P-PR.
Note: Do not connect any other device other than the high-duty brake resistor.
Disconnect this jumper when the

Inverter
high-duty brake resistor is used.
PX R
PR
Within 5m (Cables of longer
than 2m should be twisted.)
Fig. 6.20 High-Duty Brake Resistor Wiring
– 133 –
7.1 Peripheral Devices and Points for Understanding
How is the power supply facility

capacity (transformer capacity)
Trans-
determined?
former
What influence does the inverter
TR
1) Why is the ELB more liable to

trip after the inverter is
installed in an existing facility?
2) How is the rated sensitivity Earth
current selected? leakage Power 1) Give clear reasons why the
ELB
breaker capacitor power factor is improved.
2) What effects are produced?
How is the rated current selected? No-fuse
NFB
breaker
1) For what purpose is the MC 1) How is the line noise filter

provided? Magnetic used differently from the
2) How is the capacity selected? MC
contactor radio noise filter?
3) What instructions should be 2) What effects are produced
followed in operation? Power factor
when used in the output
improving reactor
side?
FR-BAL
Line noise filter
Power factor
FR-BLF
1) Give clear reasons why power improving
reactor Radio noise filter
factor is improved.
FR-BEL FR-BIF Frequency setting potentiometer
2) What effects are produced?
(Variable resistor)
Why is a larger cable size used

than in commercial power supply Output side 1) Are there restrictions on
operation? cables resistance value, etc.?
Line noise filter
2) How many inverters can be
FR-BLF
operated from one
1) When should an output side Magnetic potentiometer?
MC be provided? MC
contactor Frequency meter
2) What instructions should be
followed during operation? Surge suppression 1) What is the maximum distance
filter from the inverter?
1) Can a commercially available 2) Can two or more meters be
electronic thermal relay used? connected?
2) How is the thermal relay Thermal 3) Can a digital display be used?
relay OCR
selected?
1) When should a surge

Motor IM suppression filter be used?
Fig. 7.1 Peripheral Devices
– 134 –
7.2 Inverter Options
To ensure effective use of the transistorized inverter, the following options are available for various
applications, and to provide other characteristic improvements.
Table 7.1 FR-A500 Series Inverter Options and Applicable Option Examples
Applicable Option
Use Required Specifications
Examples
• It is desired to set the running frequency with a digital switch. FR-A5AX (12-bit digital input)
• It is desired to set the running frequency from a programmable controller. FR-A5NR
(Computer link RS-485)
FR-A5NC (CC-link)
FR-A5NP (Profibus)
FR-A5ND (Device Net)
FR-A5NM (Modbus Plus)
• It is desired to monitor the output frequency, output voltage and output FR-A5NR
current at the same time. (Computer link RS-485)
• It is desired to operate the inverter from a remote location. FR-A5NC (CC-link)
• It is desired to operate the inverter automatically. FR-A5NP (Profibus)
Operation FR-A5ND (Device Net)
• It is desired to operate the inverter with a personal computer or
FR-A5NM (Modbus Plus)
programmable controller.
• It is desired to change the parameter settings from a remote location.
• It is desired to start the inverter easily. FR-SW 0-SETUP-W J
• It is desired to make parameter settings from a personal computer easily. (inverter setup software)
• It is desired to set parameters by direct input. FR-PU04 (parameter unit)
• It is desired to have a parameter unit which displays English characters.
• It is desired to install the inverter in a control box and mount the parameter FR-CB201, FR-CB203,
unit on the door. FR-CB205
• It is desired to operate the inverter from a short distance from main unit. (connection cables)
Output signal • It is desired to drive an AC relay or contactor with the inverter output signal. FR-A5AR (relay output)
• If the power factor of the inverter is poor, it is necessary to increase the FR-BAL, FR-BEL (power
Power factor
power supply facility. factor improving reactors)
improvement
• Install the inverter near a large capacity power supply.
Harmonic • Harmonics may affect the power supply. FR-HC (high-power factor
suppression converter)
Noise • After installation of the inverter, a radio is affected by noise. FR-BIF (radio noise filter)
reduction FR-BLF (line noise filter)
technique • Leakage current may flow from the inverter. RF-BLF (line noise filter)
•
2
It is desired to decrease speed rapidly though machine GD is large. BU brake unit (brake unit +
Braking force • Enough braking capacity is needed for frequent speed increase and brake resistor)
increase decrease. FR-RC power return
converter
Application • It is desired to make various settings. FR series controller box
operation • It is desired to perform line control and joint operation.
• It is desired to place the inverter's heat generating section outside of the FR-A5CN
Installation enclosure to make inverter size smaller. Outside heat sink mounting
attachment
– 135 –
7.3 Power Supply Capacity
The power supply capacity (transformer capacity) on the inverter input side can be found by formula
(7.1):
Motor output (kW )

Power supply capacity = [kVA ] ....................(7.1)
Overall inverter efficiency × inverter power factor
(Overall inverter efficiency = motor efficiency × inverter efficiency)
The inverter power factor changes according to the load conditions and power supply conditions.
Hence, assuming that inverter power factor is 0.6 to 0.8 and considering the influence of a voltage
drop at power on of the inverter, suppose that the power supply capacity (transformer capacity) is 1.2
to 1.5 times larger the inverter output kVA. W hen the inverter is used with a power factor improving
reactor, set the power factor to 0.95 (FR-BEL) or 0.9 (FR-BAL) for calculations.
The power supply capacity (kVA) is indicated in the inverter manuals.
7.4 No-Fuse Breaker (NFB)
The NFB is used to protect the power supply cables to the inverter from damage by overload and
short-circuit currents.
1) Selection of NFB type
For the selection of the NFB's interrupting capacity, refer to the "Mitsubishi no-fuse breaker
technical information."
2) Selection of rated current
The inverter input current (effective value) varies according to the current form factor and the form
factor is influenced by power impedance.
Therefore, the rated current is set to not less than 1.4 times the input current effective value, with
not only the effective value but also the influence of harmonic components taken into
consideration.
3) For the selection of the NFB type and rated current, refer to "Peripheral Device Selection" in the
relevant catalog to prevent an incorrect trip when the peak value of inrush current occurs at power
on.
7.5 Earth Leakage Breaker (ELB)
1) Leakage currents from electric cables

The output waveform of the inverter includes harmonic components and leakage current from the
motor and from the electric cables between inverter and motor. These are larger than those in
commercial power supply operation.
Therefore, when the inverter is used in an existing facility, the ELB may trip.
2) Selection of rated sensitivity current
The rated sensitivity current is found from the ordinary leakage current of the cables and motor.
The ordinary leakage current differs according to such conditions as the motor capacity, cable
length, insulation class and wiring method.
The output side leakage currents during inverter operation are about three times larger than in
commercial power supply operation.
3) W hen Mitsubishi's New Super NV is used, the same sensitivity current as in commercial power
operation can be selected.
– 136 –
7.6 Input Side Magnetic Contactor (MC)
(1) Necessity of installation

W hen regarded as a power converter, the inverter can be used if a magnetic contactor (MC) is not
provided in its supply.
A magnetic contactor (MC) is installed in the input side in order to:
1) Prevent a restart when power is restored after an instantaneous power failure.
2) Separate the inverter from the power supply when an inverter fault has occurred or before
maintenance and inspection.
3) Stop the inverter for a long time (power saving).
For instructions to be followed when switching on-off the input side magnetic contactor (MC),
refer to Section 3.5.5.
(2) Capacity selection
As the input side magnetic contactor (MC) is not installed to start/stop the inverter, its electrical
life will not pose a problem. Select the MC according to the inverter input current.
For the selection of the input side magnetic contactor (MC), refer to "Peripheral Device Selection"
in the relevant catalog.
Having a large-capacity smoothing electrolytic capacitor in its

Input voltage
converter circuit, the inverter is a capacitor-input rectifier to
the power supply side. To charge the capacitor, therefore, a
pulsed current flows in the inverter input. This current
waveform will be extremely poor in form factor compared
Input
to a sine-wave current in commercial power operation, reducing current
the power factor.
What is an inverter stop?

An inverter stop indicates that the main power circuit output transistors are shut off. If the start
(STF or STR) signal is switched off, the inverter does not come to a stop until deceleration time
elapses. Also, if the output side MC is switched off, the motor comes to a stop but the inverter
continues operation. Hence, switch off the start signal or switch on the output stop (MRS or reset
terminal RES) signal to shut off the main power circuit output transistors.
W hen the inverter is switched off, the main power circuit output transistors are shut off
immediately and the inverter comes to a stop. If the inverter is switched on, its output is at a stop
until the start signal is input.
– 137 –
7.7 Surge Suppression Filter
In a PW M type inverter, a surge voltage occurs at the motor terminals. Especially, a 400V class motor
insulation may deteriorate because of the surge voltage. Therefore, take the following measures
when a 400V class motor is to be driven by an inverter.
7.7.1 Measures
It is recommended to take either of the following measures:
(1) Techniques for enhancing motor insulation
Use an insulation-enhanced 400V class motor.
Specifically:
1) Specify the "inverter-driven, insulation-enhanced 400V class motor."
2) For dedicated motors such as a constant-torque motor and low-vibration motor, use a "motor
dedicated to inverter operation."
(2) Techniques for suppressing surge voltage on the inverter side
On the output side of the inverter, connect a filter designed to suppress a surge voltage so that
the motor terminal voltage is 850V or less.
W hen the motor is driven by a Mitsubishi inverter, connect the optional surge voltage suppression
filter in the output side of the inverter.
7.7.2 Outline dimensions

Dimensions (mm) Approx.
Type Applicable Inverter Terminal Ground Installati- Mass
A B C D E F G H× K
screw J screw K on screw (kg)
FR-ASF-H1.5K FR-A540-0.4K/0.75K/1.5K 220 160 193 2.3 200 134 95 6 × 17 M4 M4 M5 8.0
FR-ASF-H3.7K FR-A540-2.2K/3.7K 220 180 200 3.2 200 155 115 6 × 18 M4 M4 M5 11
FR-ASF-H7.5K FR-A540-5.5K/7.5K 280 215 250 3.2 255 191 125 8 × 24 M6 M4 M6 20
FR-ASF-H15K* FR-A540-11K/15K 335 285 260 6 310 235 200 φ 10 M6 M6 M8 28
FR-ASF-H22K* FR-A540-18.5K/22K 335 349 340 6 310 281 240 φ 10 M8 M6 M8 38
* The shape of H15K (or larger size units) differs slightly.
Ground screw K
Max. C
G F
D
Max. B
Terminal screw J E A
Surge Voltage Suppression Filter FR-ASF-H K
– 138 –
7.8 Output Side Magnetic Contactor (MC)
W hen a magnetic contactor (MC) is provided on the output side of the inverter, do not switch on the
output side magnetic contactor (MC) during inverter operation (in principle). If it is switched on during
inverter operation, a large starting current will trip the inverter due to overcurrent.
The output side magnetic contactor (MC) may be switched off during operation. At this time, the motor
coasts to a stop. The magnetic contactor (MC) is provided in the output side to:
1) Make up a commercial power supply-inverter switch-over circuit.
2) Use a single inverter to switch between two or more motors. (Switching should be made when the
inverter is at a stop.)
3) Separate the motor from the electric supply during a stop in an operation cycle.
For instructions to be followed when switching on-off the output side magnetic contactor MC, refer
to Section 3.5.4.
7.9 Thermal Relay (OCR)
(1) The overcurrent protection of a standard motor provided by electronic overcurrent protection built
into the inverter cannot provide sufficient protection in the following cases. In these cases, install
a thermal relay between the motor and inverter.
1) W hen driving two or more motors by a single inverter
Inverter
NFB OCR Motor
Power
IM
supply
OCR
IM
2) W hen driving a special motor different in thermal characteristic from a standard motor
[Example] Submersible motor, multi-pole motor (8 or more poles)
3) W hen performing commercial power supply-inverter switch-over operation
MC C
Inverter
NFB Motor
MC F OCR
Power
supply IM
(2) Thermal relay set value

Set the thermal relay to the current value at 50Hz as detailed on the motor name plate.
(3) As the inverter output waveform is not a sine wave and includes harmonic components, some
electronic thermal relays available on the market cannot be used.
– 139 –
7.10 Main Circuit Cable Size
Select the size of the main circuit cables according to the voltage, current, ambient temperature and
wiring distance.
(1) Inverter input
Select the cable size matching the input current. (Refer to the sizes in the manual.)
(2) Inverter output
Select the size matching the motor current. W hen the distance between the inverter and motor is
long, a voltage drop may reduce the motor output torque or increase heat generated. Select a
cable size large enough to prevent this occuring. The wire size in the manuals uses a wiring length
of 20m.

The inverter output voltage is almost proportional to the output frequency. In the low-frequency
range, therefore, the output voltage is low, and the actual voltage drop [V] across the cables is the
same as at 50 to 60Hz, but the voltage drop ratio [%] will be larger.
7.11 Power Factor Improving Reactor (FR-BAL or FR-BEL)
(1) Purpose of use

To improve the power factor of inverter input, connect a power factor improving reactor to the
supply side (FR-BAL) or DC circuit (FR-BEL) of the inverter.
(2) Effects
The improvement ratio of the power factor improving AC reactor (FR-BAL) is about 90% and that
of the power factor improving DC reactor (FR-BEL) is about 95%. In addition to power factor
improvement, the reactors have the following effects:
1) Decreases the power supply capacity. <As the power factor is improved>
2) Reduces the rating of a device used in the inverter input side. <As the input current is
decreased>
3) Reduces harmonic components included in the input current.
4) Suppresses the increase of the capacitor terminal voltage caused by a transient rise of the
power supply voltage to prevent an overvoltage trip (OV1 to OV3).
(3) Capacity selection
Select the reactor according to the motor capacity and voltage specifications. Note that the
FR-BEL is applicable to inverters over 5.5kW . As a power factor improving AC reactor (FR-BAL)
will produce a voltage drop of about 6% (for rated load), care should be taken to avoid torque
shortage.
– 140 –
7.12 Inverter Setup Software (FR-A500 series and FR-E500 series inverters)
The inverter setup software is a support tool designed to provide an easy inverter operating
environment from inverter startup to maintenance/checking.
Parameter setting, monitoring, etc. can be made easily and efficiently on the W indows screen of a
personal computer.
(1) Functions
• Parameter setting and editing ......... Four modes are available: all list, function list, individual
list and simple setting modes.
• Monitoring ..................................... Four modes are available: data display, meter display,
oscilloscope display and alarm history modes.
• Test operation ............................... Used to judge whether the inverter may be operated
properly without operation sequence to the inverter.
• Diagnostics .................................... Internal diagnostics for judging the operating status of the
inverter.
• System setting ............................... Setting made to write or read data to or from a
multi-inverter system.
• File................................................ Used to store parameters, operation data, etc. onto hard
disk/floppy disk etc.
• W indow ......................................... Able to show more than one screen.
(2) Screen examples
00
00 00 00 00
FR-Q5000-0000K00
200 200 200 200
0 Max 400 0 Max 400 0 Max 400 0 Max 400

rpm
1800
5 5
(3) System configuration

Motor
NFB
Power Inverter IM
supply
Personal computer
Inverter
Setup software
(Note: For RS-232C communication a standard
converter should be used (RS-485 to RS-232C). )
Note: The FR-E500 series inverter refers only to the Japanese version of the FR-E500.
– 141 –
A transistorized inverter is a static unit consisting mainly of semiconductor devices. Daily inspection
must be performed to prevent any fault from occurring due to adverse influence of the installation
environment, such as temperature, humidity, dust, dirt, vibration, changes in the parts with time,
service life, and other factors.
8.1 Precautions for Maintenance and Inspection
For some time after the power is switched off, the smoothing capacitor remains at a high voltage.
Before accessing the inverter for inspection, make sure that the charge lamp is off and check that the
voltage across the main circuit terminals P-N of the inverter is 30VDC or less using a meter.
8.2 Check Items
(1) Daily inspection.

• Check the following:
(1) Motor operation fault.
(2) Improper installation environment.
(3) Cooling system fault.
(4) Unusual vibration and noise.
(5) Unusual overheating and discoloration.
• During operation, check the inverter I/O voltages using a meter.
(2) Periodic maintenance and inspection.
• Check the areas inaccessible during operation and requiring periodical inspection.
(1) Cooling system:
Clean the air filter, etc.
(2) Screws and bolts:
Check that they are securely tightened and retighten as necessary.
(3) Conductors and insulating materials:
Check for corrosion and damage.
(4) Insulation resistance:
Measure, change if necessary.
(5) Cooling fan, smoothing capacitor, relay:
Check and change if necessary.
Note: Have a good understanding of the definitions of power and alarm indications provided by the
transistorized inverter. Also, have a good understanding of the electronic overcurrent
protection, acceleration/deceleration time and other settings using the parameter unit, and
record the set values.
Refer to the next page for the Inspection List.

(3) Insulation resistance test using megger
Motor
(1) Before performing the insulation resistance Power R Inverter U
test using a megger on the external circuit, supply S V IM
disconnect the cables from all terminals of T W
the inverter so that the test voltage is not
applied to the inverter. 500VDC
(2) For the continuity test of the control circuit, megger
use a tester (high resistance range) and do
Earth terminal
not use the megger or buzzer.
(3) For the inverter, conduct the insulation resistance test on the main circuit only as shown
above and do not perform the test on the control circuit. (Use a 500VDC megger.)
– 142 –
Daily and Periodic Inspection

Interval
Area of Inspection
Description Periodic Method Criterion Instrument
Inspection Item Daily
1 year 2 year
General Surrounding Check ambient Measure temperature and Ambient temperature: Thermometer,
environment temperature, humidity, humidity. –10°C to +50°C, hygrometer,
dust, dirt, etc. Check for dust build-up. non-freezing. recorder
O
Ambient humidity:
90%RH or less,
non-condensing.
Overall unit Check for unusual Visual and auditory No fault.
O
vibration and noise. checks.
Power supply Check that main circuit Measure voltage across W ithin permissible AC Meter, digital
voltage voltage is normal. inverter terminals R-S-T. voltage fluctuation multimeter
O
(Refer to 6.1.7
"Specifications".)
Main circuit General (1) Check with megger (1) Disconnect all cables (1) 5MΩ or more. 500VDC class
(across main circuit from inverter and (2), (3) No fault. megger
O O
terminals and ground measure across
terminal). terminals R, S, T, U, V,
(2) Check for loose W and ground terminal
O with megger.
screws and bolts.
(3) Check for overheating (2) Retighten.
O (3) Visual check.
on each part.
(4) Clean.
Conductors, (1) Check conductors for (1), (2) Visual check. (1), (2) No fault.
O
cables distortion.
(2) Check cable sheaths
O
for breakage.
Terminal block Check for damage. O Visual check. No fault.
Inverter Check resistance across Disconnect cables from (See the next page.) Analog meter
module terminals. inverter and measure
Converter O across terminals R, S, T-P,
module N, and across U, V, W -P, N
with meter × 1MΩ range.
Smoothing (1) Check for liquid (1), (2) Visual check. (1), (2) No fault. Capacity meter
O
capacitor leakage. (3) Measure with capacity (3) 85% or more of rated
(2) Check for safety valve meter. capacity
O
projection and bulge.
(3) Measure electrostatic
O
capacity.
Relay (1) Check for chatter (1) Auditory check. (1) No fault.
O
during operation. (2) Visual check. (2) No fault.
(2) Check for rough
O
surface on contacts.
Resistor (1) Check for crack in (1) Visual check. Cement (1) No fault. Tester, digital
O
resistor insulation. resistor, wire-wound (2) Error should be within multimeter
(2) Check for open cable. O resistor. ±10% of indicated
(2) Disconnect one end resistance value.
and measure with
meter.
Control Operation (1) Check balance of (1) Measure voltage (1) Phase-to-phase Digital
circuit check output voltages across across inverter output voltage balance within multimeter,
Protective phases with inverter O terminals U-V-W . 4V (8V) for 200V rectifier type
circuit operated (2) Simulatively connect (400V). voltmeter
independently. inverter protective (2) Fault must occur
(2) Perform sequence circuit output because of sequence.
protective operation terminals.
test to make sure of no O
fault in protective and
display circuits.
Cooling Cooling fan (1) Check for unusual (1) Turn by hand with (1) Smooth rotation.
O O
system vibration and noise. power off.
(2) Check for loose (2) Visual check. (2) No fault.
connection.
Motor General (1) Check for unusual (1) Auditory, sensory, (1), (2) No fault.
O
vibration and noise. visual checks.
(2) Check for unusual O (2) Check for unusual odor
odor. due to overheating,
damage, etc.
Insulation (1) Check with megger (1) Disconnect cables (1) 5MΩ or more. 500V megger
resistance (across terminals and O from U, V, W , including
ground terminal). motor cables.
Note: The values for the 400V series are indicated in the parentheses.
For periodic inspection, contact your sales representative.
– 143 –
• Checking the inverter and converter modules

<Preparation>
(1) Disconnect the external power supply cables (R, S, T) and motor cables (U, V, W ).
(2) Prepare a tester. (Use 100Ω range.)
<Checking method>
Change the polarity of the tester alternately at the inverter terminals R, S, T, U, V, W , P and N, and
check for continuity.
Note: 1. Before measurement, check that the smoothing capacitor is discharged.

2. At the time of discontinuity, the measured value indicated is nearly an infinite value. Due
to the influence of the smoothing capacitor, continuity may instantaneously be
established and an infinite value not indicated. At the time of continuity, the measured
value is several to several ten's-of-ohms depending on the number of modules, number
of parallel modules, circuit tester type, etc. If all measured values are almost the same,
the modules are without fault.
<Module device numbers and terminals to be checked>

Tester Tester
Polarity Measured Polarity Measured Converter
module P Inverter module
Value Value
Converter D1 R P Discontinuity D4 R N Continuity TR1 TR3 TR5
module P R Continuity N R Discontinuity D1 D2 D3
D2 S P Discontinuity D5 S N Continuity
R U
P S Continuity N S Discontinuity C
D3 T P Discontinuity D6 T N Continuity S V
P T Continuity N T Discontinuity
T W
Inverter TR1 U P Discontinuity TR4 U N Continuity
module P U Continuity N U Discontinuity
TR3 V P Discontinuity TR6 V N Continuity D4 D5 D6
P V Continuity N V Discontinuity TR4 TR6 TR2
TR5 W P Discontinuity TR2 W N Continuity
N
P W Continuity N W Discontinuity
(The above data is for an analog tester.)
– 144 –
8.3 Replacement of Parts
The inverter consists of many electronic parts such as semiconductor devices. The following parts
may deteriorate with age because of their structure or physical characteristics, leading to reduced
performance or failure of the inverter. For preventive maintenance, the following parts must be
changed periodically.
(1) Cooling fan
The cooling fan cools heat-generating parts such as the main circuit semiconductor devices. The
life of the cooling fan bearing is usually 10,000 to 35,000 hours. Hence, the cooling fan must be
changed every 2 to 3 years if the inverter is run continuously. W hen unusual noise and/or vibration
is noticed during inspection, the cooling fan must be changed immediately.
The FR-A500 series has a function to set the ON-OFF control of the cooling fan. W hen ON-OFF
control is set, the cooling fan life can be increased. Also, the cassette system ensures ease of
replacement.
(2) Smoothing capacitors
A large-capacity aluminum electrolytic capacitor is used for smoothing the DC in the main circuit,
and an aluminum electrolytic capacitor is also used for stabilizing the control power in the control
circuit. Their characteristics are adversely affected by ripple current, etc. W hen the inverter is
operated in ordinary, air-conditioned environment, change the capacitors about every 5 years.
W hen a given period has elapsed, the capacitors will deteriorate more rapidly. Check the
capacitors at least every year (less than six months if the life will be expired soon). Check the
following:
1) Case (side faces and bottom face for expansion)
2) Sealing plate (for warping and cracking)
3) Explosion-proof valve (for excessive valve expansion and operation)
4) Appearance, external cracks, discoloration, leakage.
W hen the measured capacitance of the capacitor has reduced below 85% of the rating,
change the capacitor.
(3) Relays
To prevent a contact fault, etc., relays must be changed according to the number of accumulative
switching operations (switching life). See the following table for the inverter parts replacement
guide. Lamps and other short-life parts must also be changed during periodic inspection.
Replacement Parts of the Inverter

Part Name Standard Replacement Interval Description
Cooling fan 2 to 3 years Change (as required)
Smoothing capacitor in main circuit 5 years Change (as required)
Smoothing capacitor on control board 5 years Change the board (as required).
Relays — Change as required.
– 145 –
8.4 Measurement of Main Circuit Voltages, Currents and Powers
• Measurement of voltages and currents

Since the voltages and currents on the inverter power supply side and output side include
harmonics, accurate measurement depends on the instruments used and circuits measured.
W hen instruments for commercial frequency are used for measurement, measure the following
circuits using the instruments given on the next page.
Input Output
voltage voltage
Input Output
current current
Inverter
Ar W11 R U Au W21
3-phase Vr Vu
power As W12 S V Av To motor

supply Vs Vv
At W13 T W Aw W22
Vt Vw
P N
2 5
+ –
Instrument
types
Typical Measuring Points and Instruments
– 146 –
Measuring Points and Instruments

Item Measuring Point Measuring Instrument Remarks (Reference Measured Value) *
Power supply Across R-S, S-T and Moving-iron type AC Commercial power supply
voltage (V 1 ) T-R voltmeter W ithin permissible AC voltage fluctuation
(Refer to 6.1.7 "Specifications".)
Power supply R, S and T line Moving-iron type AC
current (I 1 )
currents ammeter
Power supply At R, S and T, and Electrodynamic type P 1 = W 11 + W 12 + W 13
power (P 1 ) across R-S, S-T and single-phase wattmeter (3-wattmeter method)
T-R
Power supply Calculate after measuring power supply voltage, power supply current and power supply power.
power factor P1
(Pf 1 ) Pf1 = × 100%
3 V1 ⋅ I1
Output Across U-V, V-W and Rectifier type AC voltmeter Difference between phases is within ±1% of maximum
voltage (V 2 ) W-U (Note 1) output voltage.
(Not moving-iron type)
Output U, V and W line Moving-iron type AC Current should be equal to or less than rated inverter
current (I 2 ) currents ammeter current.
Difference between phases less than 10%.
Output At U, V and W, and Electrodynamic type P 2 = W 21 + W 22
power (P 2 ) across U-V and V-W single-phase wattmeter 2-wattmeter method (or 3-wattmeter method)
Output Calculate in similar manner to power supply side power factor.
power factor P2
(Pf 2 ) Pf 2 = × 100%
3 V 2 ⋅ I2
Converter Across P-N Moving-coil type (such as POWER lamp
output analogue meter) 1.35 × V 1
Max. 380V (760V) during regenerative operation
Frequency Across 2(+)-5 Moving-coil type 0 to 5V/0 to 10VDC "5" is
setting signal Across 1(+)-5 (Meter, etc. may be used) 0 to ±5V/0 to ±10VDC comm-
on.
Across 4(+)-5 (Internal resistance: 50kΩ 4 to 20mADC
Frequency Across 10(+)-5 or larger) 5VDC
setting power Across 10E(+)-5 10VDC
supply
Frequency Across FM(+)-SD Approx. 5VDC at maximum frequency (without SD is
meter signal frequency meter) comm-
on.
T1
8VDC
T2
Pulse width T1: Adjust in Pr. 900.

Pulse cycle T2: Set in Pr. 55.
(Valid for frequency monitoring only)
Across AM(+)-5 Approx. 10VDC at maximum frequency
(without frequency meter)
Start signal Across STF, STR, RH, 20 to 30VDC when open.
Select signal RM, RL, JOG, RT, AU, ON voltage: 1V or less
STOP-SD
Reset Across RES(+)-SD
Output stop Across MRS(+)-SD
Alarm signal Across A-C Moving-coil type Continuity check (Note 2)
Across B-C (such as analogue meter) <Normal> <Fault>
Across A-C: Discontinuity Continuity
Across B-C: Continuity Discontinuity
Note 1: Do not use a meter because accurate data will not be obtained.
Note 2: When Pr. 195 "A, B, C terminal function selection" setting is positive logic.
* Values in parentheses indicate those for 400V series.
– 147 –
8.5 Checking the Parameter Unit Display at Alarm Occurrence
The display of the parameter unit is switched as follows to indicate the cause of a faulty operation.
(For the FR-A500 series)
Display
Cause of Fault Check Point Remedy
Parameter unit
OC During Acc Overcurrent Acceleration too fast? Increase acceleration time. Change fan.
Main circuit device Check for output short circuit or ground Remove obstacle to cooling fan. (Note)
overheating fault.
Check for cooling fan stop.
Stedy Spd Oc Sudden load change? Keep load stable.
Check for output short circuit or ground Change fan.
fault. Remove obstacle to cooling fan. (Note)
OC During Dec Deceleration too fast? Increase deceleration time. Change fan.
Check for output short circuit or ground Remove obstacle to cooling fan. (Note)
fault. Check brake operation.
Mechanical brake of motor operate too
fast?
Ov During Acc Overvoltage on DC bus Acceleration too fast? Increase acceleration time.
(terminals P-N)
Stedy Spd Ov Sudden load change? Keep load stable.
Ov During Dec Deceleration too fast? Increase deceleration time.
(Set deceleration time which matches
load GD 2 .)
Reduce braking duty.
Motor Overload Thermal relay for motor Motor used under overload? Reduce load.
Inv. Overload Thermal relay for inverter Increase motor and inverter capacities.
Inst. Pwr. Loss Instantaneous power Check the cause of instantaneous power
failure failure.
Under Voltage Drop of power supply Large-capacity motor started? Check power system equipment such as
voltage power supply capacity.
H/Sink 0/Temp Heat sink overheat Ambient temperature too high? Lower ambient temperature to within
specifications.
Fan Failure • Cooling fan failure • Cooling fan stopped due to failure? • Change fan.
• Incorrect parameter • Operation different from cooling fan • Set correct value.
setting operation selection setting?
Br. Cct. Fault Brake transistor fault Braking duty too high? Reduce load GD 2 .
Reduce braking duty.
Ground Fault Ground fault occurred in Check motor and cables for ground fault. Resolve ground faults.
output circuit.
OH Fault External thermal relay Check motor for overheating. Reduce load and frequency of operation.
operated.
Stll Prev STP Stall prevention or current Motor used under overload? Reduce load.
limit activated too long. Increase motor and inverter size
Option Fault Option and inverter Check for loose connector. Connect securely.
connected improperly.
Corrupt Memry Storage device (E 2 PROM) Number of parameter write times too Change inverter.
faulty. many?
Retry No. Over Operation could not be Check cause of alarm occurrence.
resumed within the
number of retry times set.
CPU Fault CPU malfunction Check for loose connections. Change inverter.
PU Leave Out The PU has been Check that the PU is connected securely. Securely install the PU.
disconnected.
PU to Inverter • Reset signal ON • Check for incorrect wiring to the reset • Turn the reset signal off.
comms. Error • Connection between PU terminal. • Securely connect.
Inv. Reset ON and inverter loose *1 • Check for loose connector. • Change inverter.
• Communication circuit
fault
CPU malfunction *2 • Switch power off, then on.
• Switch reset signal on, then off.
• Change inverter.
Note: This alarm does not occur due to the cooling fan stop, but it will occur to prevent the main circuit devices from
overheating because of the fan failure.
*1: The parameter unit display remains unchanged but operation may be performed in the external operation mode.
*2: If the alarm is still displayed on the parameter unit after corrective action has been taken, the internal circuit may be
faulty. Consult your sales representative.
– 148 –
8.6 Faults and Check Points
Fault Typical Check Point

Motor does not rotate. (1) Check the main circuit
• Check that a power supply voltage is applied (inverter POWER lamp is lit).
• Check that the motor is connected properly.
(2) Check the input signals
• Check that the start signal is present.
• Check that both the forward and reverse rotation start signals are not present
simultaneously.
• Check that the frequency setting signal is not zero.
• Check that the signal across terminals AU-SD is on when the frequency setting signal is
4 to 20mA.
• Check that the output stop signal (across terminals MRS-SD) or reset signal (across
RES-SD) is not on.
(3) Check the parameter set values
• Check that the reverse rotation prevention (Pr. 78) is not set.
• Check that the operation mode (Pr. 79) setting is correct.
• Check that the bias and gain (Pr. 902 to Pr. 905) settings are correct.
• Check that the starting frequency (Pr. 13) set value is not greater than the running
frequency.
• Check that various operational functions (such as three-speed operation), especially the
maximum frequency, are not zero.
(4) Check the load
• Check that the load is not too heavy and the shaft is not locked.
(5) Others
• Check that the inverter ALARM lamp is not lit.
Motor rotates in opposite • Check that the phase sequence of the output terminals U, V and W is correct.
direction. • Check that the start signals (forward rotation, reverse rotation) are connected properly.
Speed greatly differs from • Check that the frequency setting signal is correct. (Measure the input signal level.)
the set value. • Check that the following parameter set values are correct:
Maximum frequency (Pr. 1), acceleration/deceleration reference frequency (Pr. 20),
acceleration / deceleration time increment (Pr. 21), bias, gain (Pr. 902 to Pr. 905), base
frequency voltage (Pr. 19).
• Check that the input signal lines are not affected by external noise. (Use of shielded cables)
Acceleration/deceleration • Check that the acceleration/deceleration time set value is not too short.
is not smooth. • Check that the load is not too heavy.
• Check that the torque boost set value is not too large to activate the current limit function.
Motor current is large. • Check that the load is not too heavy.
• Check that the torque boost (manual) set value is not too large.
Speed does not increase. • Check that the maximum frequency set value is correct, i.e. it is not too small.
• Check that the load is not too heavy.
• Check that the torque boost set value is not too large to activate the current limit function.
Speed varies during (1) Inspection of load
operation. • Check that the load is not varying.
(2) Inspection of input signal
• Check that the frequency setting signal is not varying.
(3) Others
• Check that the settings of the applied motor capacity (Pr. 80) and the number of applied
motor poles (Pr. 81) are correct for the inverter capacity and motor capacity in advanced
magnetic flux vector control.
• Check that the wiring length is within 30m in advanced magnetic flux vector control if the
inverter and motor have not been autotuned.
• Check that the wiring length is correct in V/F control.
"PU to inverter comms. • Check that the reset signal (terminals RES-SD) is not ON.
error" is displayed on the • Check that the PU is connected securely.
PU screen.
Note: Pr. indicates a parameter.
– 149 –
8.7 Protective Functions

W hen any of the protective functions have been activated, switch the power off, then on, or reset the
inverter with the reset terminal (RES). (Inverter reset can also be executed from the PU help menu.)
Display Alarm Alarm
Function Description
Parameter unit Code Output
If a current not less than 150% of the rated inverter current
flows in the motor during acceleration, this function stops the
increase in frequency until the load current reduces to prevent
the inverter from resulting in overcurrent trip. If a current not
Acceleration/
less than 150% of the rated inverter current flows during steady
constant-speed
(constant-speed) operation, this function also lowers the
stall prevention OL is shown
frequency until the load current reduces to prevent the inverter Not
current limit (during motor
from resulting in overcurrent trip. When the load current has provided.
rotation)
reduced below 150%, this function increases the frequency D Provided by
Stll Prev STP
again and accelerates up to the set speed and continues EOLT
(shown at a motor
operation. display.
stop)
If the brake operating level has exceeded the specified value
due to excessive regenerative energy during motor
Deceleration stall deceleration, this function stops the decrease in frequency to
prevention prevent the inverter from resulting in overvoltage trip. As soon
as the regenerative energy has reduced, this function reduces
the frequency again and continues deceleration.
If the inverter output current reaches
During acceleration OC During Acc 1
or exceeds 200% of the rated current,
Overcurrent the protective circuit is activated to
During constant speed Stedy Spd Oc 2 Provided
shut-off stop the inverter. When any main
circuit device is overheated, the
protective circuit is also activated to During deceleration OC During Dec 3
If the converter output voltage is
excessive due to the regenerative During acceleration Ov During Acc
energy from the motor, the
Regenerative
protective circuit is activated to stop
overvoltage During constant speed Stedy Spd Ov 4 Provided
the transistor output.
shut-off
This may also be activated by a surge
voltage generated in the power During deceleration Ov During Dec
supply system.
If an instantaneous power failure has occurred in excess of
15ms (this applies also to inverter input power shut-off), this
function is activated to stop the inverter output in order to
Instantaneous
prevent misoperation. At this time, the alarm output contacts
power failure Inst. Pwr. Loss 7 Provided
are open (across B-C) and closed (across A-C).
protection
(If the power failure is within 15ms, the control circuit operates
without fault. If the power failure persists for more than about
100ms, the protective circuit is reset.)
If the inverter power supply voltage has reduced, the control
circuit cannot operate properly, resulting in the decrease in
Undervoltage motor torque and/or the increase in heat generation. To
Under Voltage 8 Provided
protection prevent this, if the power supply voltage reduces below about
150V (300V for the 400V series), this function stops the
inverter output.
Brake transistor If a brake transistor fault has occurred due to extremely large
alarm regenerative brake duty, etc., this function detects that fault Br. Cct. Fault A Provided
detection and stops the inverter output.
The electronic overcurrent protection in the inverter detects
inverter overload or motor overheat and activates the
protective circuit to stop the inverter output. When a Motor Overload 5
Overload shut-off
multi-pole motor or more than one motor is driven, for
[electronic over-
example, the motor(s) cannot be protected by the electronic Provided
current
overcurrent protection. Provide a thermal relay in the inverter
protection]
output circuit. In this case, setting the electronic overcurrent Inv. Overload 6
protection value to 0A activates the inverter protection only.
(Activated at a current 150% or more of the rated current.)
If the regenerative brake duty from the motor has exceeded the
Brake resistor
specified value, the brake operation is stopped temporarily to
overheating (Not displayed) — Not provided
protect the brake resistor from overheating. When the brake
protection
resistor has cooled, the brake operation is resumed.
Output side If a ground fault current has occured in the output (load) side of
ground fault the inverter, this function stops the inverter output. A ground
Ground Fault B Provided
overcurrent fault occurring at low ground resistance may activate the
protection overcurrent protection (OC1 to OC3).
– 150 –
Display Alarm Alarm

Function Description
Parameter unit Code Output
If the external thermal relay for motor overheating protection or
the internally mounted temperature relay in the motor has been
External thermal switched on (relay contacts open), this function stops the
OH Fault C Provided
relay operation inverter output and keeps it stopped. This protection is
provided only when the "external thermal relay input" function
is selected.
Stops the inverter output if the dedicated option used in the
Inboard option
inverter results in connection (connector) fault during Option Fault E Provided
connection alarm
operation.
2
Parameter Stops the output if the fault of E PROM which stores the
storage device function set values has occurred. Corrupt Memry F Provided
alarm
Retry count If operation cannot be resumed within the number of retry times
Retry No. Over F Provided
exceeded set, this function stops the inverter output.
If the operation of the built-in CPU does not end within a
CPU error predetermined period of time, the inverter self-determines it as CPU Fault F Provided
alarm and stops the output.
Stops the inverter output if the parameter unit is disconnected.
Parameter unit
This protective function is activated only when the "reset PU Leave Out F Provided
disconnection
selection/PU disconnection detection" function is selected.
Heat sink When the heat sink overheats, the temperature sensor is
H/Sink O/Temp 9 Provided
overheat activated to stop the inverter output.
For the inverter containing a cooling fan, FN is displayed on the
operation panel when the cooling fan stops due to a failure or
Fan failure when operation differs from the Pr. 244 (cooling fan operation Fan Failure — Not provided
selection) setting.
At this time, the inverter does not stop output.
* The stall prevention operation current can be set as appropriate. The factory setting is 150%.
– 151 –
8.8 Operation of the Training Kit
The training kit (FR-A training machine) can be used to confirm the capability of the
inverter-driven motor coupled with a load and the controllability and functions of the inverter.
Use this training kit to check the capability and functionality of the inverter.
8.8.1 Details of demonstration
The FR-A training machine may be used to confirm:

(1) Comparison of torques generated at low speeds between advanced magnetic flux vector control
and V/F control.
(2) Load magnitude and acceleration/deceleration capabilities.
(3) Inverter operation and monitoring (terminal I/O states, troubleshooting function, etc.) from the
interactive parameter unit.
(4) Output terminal assignment function.
(5) Override operation.
(6) Switch-over between frequency meter and analog output.
(7) I/O waveforms.
8.8.2 Structure of the FR-A Training Machine
Training machine Operation panel

R R1 S,T U,V,W U U1
Motor
MC1
NFB Tr
Power R U
IM
supply S FR-A500 V
T W
1φ
100V
STF RUN
STR SU
MC1
IPF PG AV
Instantaneous OL
power failure switch Speed
FU
meter
Frequency
setting
FM DV1
Compensation
AM DV2
input
Power brake
DA
MC2
Load ON-OFF Load torque adjusting
variable resistor
– 152 –

SH (Na) 3183 Fatec Inverter Application Course General Manual

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SH (Na) 3183 Fatec Inverter Application Course General Manual

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INVERTER APPLICATION COURSE

1. CHARACTERISTICS OF AN INVERTER-DRIVEN MOTOR

2. INVERTER PRINCIPLES AND ACCELERATION/DECELERATION

4. INVERTER POWER SUPPLY

7. PERIPHERAL DEVICES AND OPTIONS

8. MAINTENANCE AND INSPECTION

1.1 Motor Types

Pressure-resistant, explosion-proof motor

Table 1.1 Mitsubishi Motors

1.2 Motor Structure

Frame Stator core Rotor core

End ring fan

Terminal box Shaft Center

Fig 1.1 Example of Totally Enclosed, Fan-Cooled Type Motor Structure

1.3 Basic Characteristics

1.3.1 Torque-current vs. Speed curve

Point where load torque

Current [A] Maximum

Slip (S) is expressed as %

1.3.2 Motor speed

120 × frequency ( f ) [Hz]

Determined by motor Determined by load specifications

1.3.3 What is "slip"?

Synchronou sspeed(N0 ) − speed(N)

Useful Motor Check Points

1.3.4 Motor current

1.3.5 Motor speed fluctuation and motor load current

(1) W hen load torque varies (motor torque constant)

Fig. 1.3 Load Fluctuation vs. Speed

(2) W hen motor-applied voltage varies (load torque constant)

Fig. 1.4 Voltage Fluctuation vs. Speed

1.3.6 What is rated motor torque?

Rated motor output (P) [kW ]

Rated motor output (P) [kW ]

Indicated on motor name plates and test reports.

Useful Motor Check Point

1.4 Torque and Current Characteristics of an Inverter-Driven Motor

Commercial Power Supply Operation Inverter Operation

Fig. 1.5 Comparison of Motor Current and Torque Characteristics

1.5 Operation of Standard Induction Motor by an Inverter

1.5.1 Difference in rated torque between 50Hz and 60Hz operation

1.5.2 Important point about inverter-operated motors

V 220[V] 110[V]* * Actually, this value is slightly larger to compensate for a

1.5.4 Motor-generated torque

(1) W hen the ratio of V/f is constant, the torque is Torque

1.5.5 Operation over 50Hz or 60Hz

Useful Inverter Check Point

W hat is base frequency?

1.6 Output Characteristics of Inverter-Operated Standard Motors

Base frequency setting of inverter. Not power supply frequency.

• 220V 60Hz • 200V 50Hz

60Hz 120Hz 50Hz 120Hz

Fig. 1.8 Output Characteristics of Standard Motors (under V/f control)

Useful Motor Check Point

1.7 V/f Pattern and Torque Boost

1.7.1 Fundamental equivalent circuit of a motor

Fig. 1.9 Equivalent Circuit of Motor

Fig. 1.10 Equivalent Circuit

1.7.2 What is torque boost?

V Manual torque boost

Fig. 1.13 Manual Torque Boost

1.7.3 Setting of torque boost

100 Current Exceeding the current limit