SB750R3.0 1751complete PDF

FALCON SB CONCENTRATOR
MODEL SB750
OPERATIONS AND
MAINTENANCE MANUAL
(Including support manuals / documentation)
C.I. BALKANES S.A.
Equipment Name: Gravity Concentrator

INTRODUCTION 1
Concentrator Serial Number: SB750-1751
SPECIFICATIONS 2
AutoPac Serial Number: 06027422
Date of Shipping: March 2006

INSTALLATION 3
Falcon Reference Number: 05-2339 AUTOMATION 4
Vendor Manual Number: SB750 R3.0

START-UP 5
Vendor Contact Details: Falcon Concentrators Inc.
9663 – 199A Street MAINTENANCE 6
Langley, British Columbia,
Canada V1M 2X7
SPARE PARTS 7
Contact Person Dave Robertson,
Production Manager DRAWINGS 8
Telephone (+1) (604) 888-5568

SUPPORT MANUALS 9
Fax (+1) (604) 888-5521
MISCELLANEOUS 10
Email production@concentrators.net
This Manual:
• Is written to be used by trained and competent personnel, responsible for
the planning, design, construction, commissioning, operation and
maintenance of the described equipment.
• Gives you an overview of the process
• Contains your guarantee
• Defines the operating limitations
• Shows all the parts of the concentrator
• Provides clear instructions to:
install the concentrator
get the concentrator up and running
operate and maintain the concentrator
troubleshoot
order spare parts
• Contains safety cautions, warnings and operational tips.
Inquiry Information
Before calling one of the engineers at Falcon, make sure this information is on
hand. Most of this is available from the name plate(s) on the equipment.
CLIENT:
CONCENTRATOR SERIAL NUMBER(S):
AUTOPAC SERIAL NUMBER:
DATE OF DELIVERY:
PART NUMBER(S):
Contact Persons: Dave Robertson, Production Manager

Ken Smith, Product Support
Telephone (+1) (604) 888-5568

Fax (+1) (604) 888-5521
Email falcon@concentrators.net
Falcon Concentrators
Safety and Operation Precautions
READ BEFORE OPERATING!
Please observe all safety warnings and important notices contained in this
manual.
Because this equipment contains high speed rotating parts, the same
precautions should be observed as with any machinery of this type, where
carelessness in operation or maintenance is hazardous to personnel. In
addition to the many obvious safety rules that should be followed with this
type of machinery, the additional safety precautions as listed below must be
observed.
1. Read, understand and retain all instructions before operating concentrator.
2. For installation, follow all local electrical and safety codes.
3. Electric motors must be securely and adequately grounded.
4. Protect the power cable from coming in contact with sharp objects. Do not kink
power cable and never allow it to come in contact with oil, grease, hot surfaces, or
chemicals.
5. Make certain that the power source conforms to the requirements of your
equipment.
6. Isolate the concentrator before attempting to work or perform maintenance on it.
“Tag out” or “lock out” appropriate switches.
7. Do not attempt to service any part (except lubrication of the bearings) while
machine is in an operational mode.
Always lock unit out!
8. Do not operate concentrator at speeds in excess of its rating.

9. Be sure no tools, rags, or loose parts are left in the concentrator or drive parts.
10. Inspect the machine and surroundings daily to observe and correct any unsafe
operating conditions.
11. Never operate the equipment without all guards in place.
12. Always wear safety glasses in the area surrounding the machine during operation.
SB750R3.0 Operations and Maintenance Manual
Contents
1. Introduction.........................................................................................1-1
1.1 Who is Falcon Concentrators? ................................................................. 1-1

1.2 The Semi-Batch (SB) Concentrator .......................................................... 1-2
1.3 Description................................................................................................ 1-3
Process (see figure on next page)............................................................................... 1-3
Figure 1.3.1 Process Schematic .............................................................................. 1-4
Figure 1.3-2 Typical Installation of Model SB750 (Grinding Circuit) ........................ 1-5
1.4 Falcon’s Guarantee .................................................................................. 1-6
1. Introduction
1.1 Who is Falcon Concentrators?

FALCON CONCENTRATORS INC. of Langley, B.C., Canada, designs, manufactures
and markets two specialized lines of enhanced centrifugal mineral processing
concentrators:
• Falcon ‘SB’ – semi-continuous concentrators

• Falcon ‘C’ – continuous concentrators
With over 250 installations worldwide and 15 years of experience in gravity

concentration, Falcon has the knowledge to assist with a variety of gravity circuit designs.
The use of high gravitational fields (up to 300 Gs), large capacities and small footprints
enable the units to recover very fine liberated metals and minerals and make efficient
separations, even when other gravity processes are unsuitable.
Falcon offers semi-batch (SB) concentrators (normally operating >99% of availability) for
the recovery of precious metals (Au, Ag and Pt) from process streams with fully
automated concentrate discharge cycles. This series of equipment is used for recovering
a fraction of the feed mass as a high-grade concentrate.
A continuous series, which consumes no additional process water, is used for recovering
fine metals and minerals from tailings (flotation or leach), or pre-concentrating of plant
feed (either fresh ore or old tailing dumps). The continuous concentrators have been
installed for recovering lead, tin, tantalum, gold, silver, coal, iron ore and their associated
minerals.
Significant advantages over competing equipment are lower capital, operating and
maintenance costs. Our advice is to review results in current operations and compare
with the commitment Falcon is able to deliver to you.
Thank you for purchasing your own Falcon Concentrator.
11.5 ft.
(3.5 m)
The Falcon C4000 Continuous Concentrator The Falcon SB5200 Semi-Batch Concentrator
Falcon Concentrators 1-1
1.2 The Semi-Batch (SB) Concentrator

In the typical Falcon tradition, the Falcon Model ‘SB’ series of concentrators have been
engineered with simplicity of design, efficiency of use and maximization of results.
Even when other gravity recovery processes prove unsuitable, these Falcon
Concentrators are able to recover ultra fine liberated particles and make high quality
separations by utilizing a high gravitation field. In some instances, a Falcon circuit can
achieve as high as 80% of the overall plant production depending on the percentage of
native metal present.
The Falcon ‘SB’ series of concentrators produces high-grade concentrates while

requiring little, or no operator intervention. The two-stage bowl design yields superior
separations and easy wear part replacement.
The Falcon Model ‘SB’ units work best for:
• Free gold, silver and platinum recovery.

• Grinding circuit cyclone u/f or feed.
• Cleaning concentrates.
• Tails scavenging.
• Placer and alluvial gold.
How it works:
Building on the pioneering work done by MacNicol in the 1930’s, the SB concentrator
employs an elutriated retention zone at the top of the rotor, requiring the addition of a
small volume of process water.
The feed stream particles are subjected to gravitational forces of up to 200 G’s and are
segregated according to effective specific gravity along the smooth spinning rotor wall.
The heaviest layers pass over the concentrate bed retained in the riffles at the top of the
rotor bowl.
The addition of fluidization (back-pressure) water from behind the riffle beds enable
heavy target particles to migrate to the bottom or outside of the bed and be retained in
preference to the lighter particles.
The high G’s permit effective recovery of even very fine particles (below 10 microns) and
the depth of the concentrate bed allows coarser particles in the feed stream to be safely
recovered. When the bed has built up to a sufficient grade, the feed is stopped (for as
little as 30 seconds) the rotor slowed and the built in spray manifold rinses the
concentrate under the rotor baffle and out the rotor discharge ports into a concentrate
launder.
Feed capacity 5 sizes to 433 USt/h

Feed density 70% solids maximum
Feed particle size 6mm maximum

1.3 Description
Frame All-welded construction, mild steel with epoxy paints to ensure
long life of the unit. The design and construction minimize
normal operating vibrations.
Launders / Lid All-welded construction, mild steel with natural rubber and epoxy
paint to ensure long life of the unit.
Rotating Assembly Consists of machined shaft, rotor base, and rotor bowl. All
components contacting slurry are lined with natural rubber. This
assembly is effectively the only moving part.
Drive Consists of the VFD, motor, belts and sheaves.
Process (see figure on next page)
Feed is screened at approximately 2mm. depending on the application and is introduced

as slurry through the central vertical feed pipe and is accelerated by the impeller. Rapid
stratification according to specific gravity occurs as the material is driven up the
stratification zone under the influence of an immense gravity field. No water is added in
this zone.
In the retention zone, which is immediately above the migration zone, fluidization water
(backpressure) is injected through the rotor wall to create a dilated or fluidized bed. The
high specific gravity gold particles become embedded in this zone and are retained here
until the machine is slowed or stopped, which allows the concentrate to be rinsed down
through the concentrate discharge ports.
During the rinse, a centrally located rinse manifold directs jets of water into the retention
zone to thoroughly clean the rotor. The rinsing process can normally be accomplished in
less than 60 seconds. A typical mass recovery to concentrate is normally less than 0.1%.
An example of this is a solids throughput of 20 tonnes per hour and a 2-hour run cycle,
which would yield a concentrate of approximately 20 kg. Dividing 20 into 20,000 equals
0.1%.
All this is done through the Automation Package or AutoPac, available on all production
units. The AutoPAC includes a programmable variable frequency drive (VFD), PLC
control, dynamic braking, and solenoids. These are to control various operating
parameters including acceleration ramp, centrifugal field, deceleration ramp, automatic
rinsing, and others. An external operator interface display screen enables the user to
program many of these operating parameters without opening the enclosure.

Figure 1.3.1 Process Schematic

RINSE MANIFOLD FEED
LIP FEED PIPE

RINSE
RING NOZZLES TAILINGS
W FLUIDIZATION CONCENTRATE
A / RETENTION WATER
T ZONE JACKET
E
R
STRATIFICATION
ZONE IMPELLER
BAFFLE
CONCENTRATE FLUIDIZATION
DISCHARGE PORTS (4) ROTOR HOSES
(2)
THE ROTOR BASKET
FLUIDIZATION FLUIDIZED
WATER BED
CENTRIFUGAL
FORCE

Figure 1.3-2 Typical Installation of Model SB750 (Grinding Circuit)

CYCLONE OVERFLOW TO:
FALCON CONTINUOUS CONCENTRATOR,
LEACH, FLOTATION OR OTHER.
(OPTIONAL)
CYCLONE
CLUSTER
(OPTIONAL)
FRACTION OF CYCLONE UNDERFLOW

(±15% OF CIRCULATING LOAD)
±35 TPH @ ±65% SOLIDS
SPRAY BARS
OVERSIZE (IF NECESSARY)
±5 TPH SIEVE BEND OR
VIBRATING SCREEN
DILUTE TO
45-55% SOLIDS
IN LAUNDER
±30 TPH
FALCON AUTOPAC
RUN TIME: ±2 HOURS
RINSE TIME: ± 60 SEC
FEED PINCH
VALVE
BYPASS LINE
FOR RINSE CYCLE
AUTOMATED
MODEL SB750
FALCON CONCENTRATOR
TAILS ±30 TPH
PLUS FLUIDIZATION
WATER
FLUIDIZATION WATER
CONCENTRATE @ 25-40 USgpm
±240 kg/DAY
@ ±1% Au
OVERFLOW
48 HR
STORAGE
TANK
SHAKING
CONCENTRATE TABLE
TAILS
BULLION FURNACE
FEED TO PRIMARY MILL
GRINDING
COMMON
PUMP BOX
SLURRY PUMP

1.4 Falcon’s Guarantee

Falcon Satisfaction Guarantee
If any Falcon is returned in good condition for any reason, the purchase price will be
refunded less applicable rent.
Falcon Two-Year or 5000 Hour Warranty
Falcon concentrators are tested and inspected before leaving the factory. They are
warranted to be free from defects in material or workmanship for a period of Two Years
from the date of shipment or 5000 Operating Hours, whichever comes first. This warranty
is limited to the repair or replacement of parts other than designated wear parts when
operated and maintained properly in accordance with the Operations and Maintenance
Manual. In no event shall Falcon be liable for any direct, indirect, incidental or
consequential damages resulting from the sale or use of the product during or after the
term of this warranty.
Falcon Warranty Return Policy
Should any trouble develop during the warranty period, return parts (freight prepaid) to
Falcon for inspection. If trouble is caused by defects in material or workmanship then
Falcon will repair (or at our option, replace) the defective part without charge.
It is suggested that critical parts be carried as spares by the customer as per the
Operations and Maintenance Manual. In emergency situations where no suitable spare
parts are on site, a replacement part may be ordered from Falcon and shipped
immediately to avoid downtime while failed parts are being returned to Falcon for
possible warranty repair or replacement.
SB750
The bearing design for the SB750 is engineered specifically for this application, and
Falcon Concentrators will guarantee a L10 bearing life of 20,000 hours. Replacement
bearings and related parts must be replaced with Falcon approved alternatives or the
warranty is void. Further, installation must be according to the instructions in this manual.
Falcon is willing to guarantee an operational availability of the equipment to be in excess

of 95%, resulting from proper operation of the equipment according to the Operations
and Maintenance manual.
Falcon guarantees that each Falcon SB750 will treat 52 tons/h (47 tonnes/h).

Contents
2. Specifications / Requirements ..........................................................2-1
2.1 Specifications ........................................................................................... 2-1

Feed............................................................................................................................. 2-1
Table 2.1-1 Tons Per Hour ................................................................................... 2-1
Concentrate ................................................................................................................. 2-2
Table 2.1-2 SB750 Specifications......................................................................... 2-2
2.2 Electrical ................................................................................................... 2-2

2.3 Compressed Air ........................................................................................ 2-3
2.4 Options ..................................................................................................... 2-3
Installation.................................................................................................................... 2-3
Feed Pinch Valve......................................................................................................... 2-3
2. Specifications / Requirements
2.1 Specifications
Feed
Particle size of less than 2.0 mm. (nominal) to minus #400 mesh (38 microns). Up to 45%
solids by weight recommended 70% maximum. The maximum solids throughput is 52
tons/h (47 tonnes/h) solids, or 350 USgpm (1325 l/min.) slurry, depending on feed
characteristics. See section 5.1 Slurry Feed for more details.
Optimum results may not be obtained at maximum values.
MINIMUM RECOMMENDED MAXIMUM

PARTICLE SIZE (mm) 0 1.0 6.0
SOLIDS THROUGHPUT (Mt/h) 0 25.0 – 40.0 52
PULP DENSITY (% solids) 0 45 70
Table 2.1-1 will help in determining operating limitations. It shows the relationship
between a volumetric pulp flow rate and % solids content of the feed, and how this
affects the solids throughput. The shaded area represents conditions approaching the
recommended capacity limit in tons per hour solids, pulp density or volumetric flow.
Table 2.1-1 Tons Per Hour
S.G. Solids 2.9
PULP
PULP FLOW IN USGPM
DENSITY
(% SOLIDS) 100 150 200 225 250 275 300 325 350 375 400 425
5 1.3 1.9 2.6 2.9 3.2 3.6 3.9 4.2 4.5 4.8 5.2 5.5
10 2.7 4.0 5.4 6.0 6.7 7.4 8.0 8.7 9.4 10.0 10.7 11.4
15 4.2 6.2 8.3 9.4 10.4 11.4 12.5 13.5 14.6 15.6 16.6 17.7
20 5.8 8.6 11.5 12.9 14.4 15.8 17.3 18.7 20.1 21.6 23.0 24.5
25 7.5 11.2 14.9 16.8 18.7 20.6 22.4 24.3 26.2 28.0 29.9 31.8
30 9.3 14.0 18.7 21.0 23.3 25.7 28.0 30.3 32.7 35.0 37.3 39.7
35 11.4 17.0 22.7 25.5 28.4 31.2 34.1 36.9 39.7 42.6 45.4 48.3
40 13.6 20.3 27.1 30.5 33.9 37.3 40.7 44.0 47.4 50.8 54.2 57.6
45 16.0 23.9 31.9 35.9 39.9 43.9 47.9 51.8 55.8 59.8 63.8 67.8
50 18.6 27.9 37.2 41.8 46.5 51.1 55.8 60.4 65.1 69.7 74.4 79.0
55 21.5 32.2 43.0 48.4 53.7 59.1 64.5 69.9 75.2 80.6 86.0 91.4
60 24.7 37.1 49.4 55.6 61.8 68.0 74.1 80.3 86.5 92.7 98.9 105.0
The specific gravity of the feed material may vary slightly, if it is higher than 2.9 kg/l the
tons per hour solids in the feed will be slightly higher for the given pulp density and
volumetric flows shown.

Concentrate
Total concentrate weight is typically less than 90 lbs (40 kg), depending on feed material
characteristics. A heavy gangue material may be much heavier, and conversely a light
gangue material may be much lighter. The volume is relatively constant and cleanup is
typically less than 40 seconds total off-line time.
Table 2.1-2 SB750 Specifications
ITEM SPECIFICATION
Concentrator Weight 2550 lbs, 1160 kg
Dimensions 48½ x 48½ x 67 in high (1232 x 1232 x 1688 mm)
Motor Power 10.0 hp, 7.5 kw
Max. Particle Size 1 mm, #16 mesh recommended, 4mm maximum
Max. Feed Pulp Density 45% recommended, 70% solids by weight maximum
Max. Solids Capacity 47 tons/h, 52 tonnes/h
Max. Pulp Capacity 350 USgpm, 1325 l/min
Max. Rotor RPM 900 ( @ 75 Hz. = 200 G’s)
Concentrate Weight 50 lbs or 22 kg
2.5 gallons or 9.5 liters (approximate wet solids)
Concentrate Volume
25 gallons or 95 liters (approximate with rinse water)
G-Force Range 50 - 200
50 psi differential @ 14 scfm (340 kPa @ 6.6 l/s)
Compressed Air
for feed pinch valve.
Fluidization Water 50 USgpm @ 20 psi
(backpressure) (190 l/m @ 140 kPa)
2.2 Electrical
The automation package or AutoPac requires voltage and frequency as requested by the
customer. Supply conditioners and in-line reactors are installed to avoid damage to the
AutoPAC. The power supply must be constant as specified, spikes in the voltage /
current are not acceptable.
IMPORTANT: Damage caused by voltage spikes or dips are not covered under
Falcon’s warranty policy.
The AutoPac is not supplied with the necessary electrical cables to connect to the
machine mounted junction box. All connections from the junction box to the
instrumentation and solenoids are done and tested at the factory. See AutoPac
Schematic Drawings for power supply and/or cable specifications.

2.3 Compressed Air

Compressed air is required for the optional feed pinch valve (see below). A maximum of
50 psi (340 kPa) above feed line pressure is required. For example: If the feed is pumped
under 20 psi pressure, then 70 psi compressed air supply is required. A regulator is
supplied with this option.
See 3.4 Slurry Connections, 3.7 Air Connection and Installation Drawings for more
details.
2.4 Options
Contact Falcon for additional options, descriptions and current prices.
Installation
All of the slurry piping connections for the Falcon Concentrator are grooved for victaulic
fittings. Falcon recommends that victaulic-flange adapters be used here to isolate
vibration.
INSTALLATION
QTY DESCRIPTION REFERENCE PART NO.
1 FEED PINCH VALVE / REGULATOR S/A FALCON C201604
1 2" VIC 150# GROOVE-GROOVE NIPPLE STYLE 43 301021
1 2" VIC - 150# COUPLING STYLE 75 320001
1 2" VIC - 150# FLANGE ADAPTER STYLE 741 301009
1 2" EXPANSION JOINT - 150# FLANGE STYLE 101 346004
Feed Pinch Valve
The optional pinch valve (see above) is useful if an AutoPac is ordered. This valve will
control the introduction of feed according to the control philosophy (4.10).
An air pressure regulator and all necessary piping come with the pinch valve and it can
be mounted either directly in the feed line or as a bypass. See 3.4 Slurry Connections.

Contents
3. Installing the Equipment ....................................................................3-1
3.1 Lifting ........................................................................................................ 3-1

Overhead Crane .......................................................................................................... 3-1
Forklift .......................................................................................................................... 3-1
3.2 Location .................................................................................................... 3-1

Concentrator ................................................................................................................ 3-1
AutoPac ....................................................................................................................... 3-2
3.3 Mounting................................................................................................... 3-2

3.4 Slurry Connections ................................................................................... 3-3
Feed Inlet ..................................................................................................................... 3-3
Figure 3.4-1 Feed Pinch Valve Configuration .......................................................... 3-3
Tailings Outlet .............................................................................................................. 3-4
Concentrate Discharge ................................................................................................ 3-4
3.5 Water System ........................................................................................... 3-4

Process Water Inlet ..................................................................................................... 3-4
Process Water Requirements...................................................................................... 3-5
Figure 3.5-1 Basic Water Manifold ........................................................................... 3-5
Water Filter .................................................................................................................. 3-5
Fluidization Water ........................................................................................................ 3-6
Rinse Manifold Water .................................................................................................. 3-6
Concentrate Flush Line Water ..................................................................................... 3-6
Pressure Control Valve (PCV) ..................................................................................... 3-6
3.6 Electrical Connections (see drawings and support manuals) ................... 3-7
Motor............................................................................................................................ 3-7
Rinse and Concentrate Flush Solenoids ..................................................................... 3-7
Vibration Monitor.......................................................................................................... 3-7
Pressure Control Valve Solenoids ............................................................................... 3-7
Feed Pinch Valve Solenoid (optional) ......................................................................... 3-7
3.7 Air Connections ........................................................................................ 3-8

Feed Pinch Valve (optional)......................................................................................... 3-8
Figure 3.7-1 4-way Feed Solenoid............................................................................... 3-8
3. Installing the Equipment
3.1 Lifting
Overhead Crane
This equipment can be lifted by overhead crane by using the lifting eyes provided on the
lid or by using lifting straps securely placed around all four vertical frame members. Make
certain lid is connected to machine with the correct number and size of fasteners before
lifting this way. The machine weight is approximately 2550 lbs (1160 kg).
WARNING!
USE EXTREME CAUTION IF LIFTING MACHINE
BY THE LOWER FRAME MEMBERS!
THE UPPER SECTION OF THE MACHINE IS HEAVIER THAN THE

LOWER SECTION, AND IT MAY TIP OR FALL CAUSING INJURY
AND/OR DAMAGE TO THE MACHINE.
Forklift
A forklift can be used to lift the machine provided that the forks are placed under the
lower horizontal frame members. Be extremely careful not to damage any of the
machine components mounted beneath the machine.
IMPORTANT: Do not place forks anywhere near the center of the machine.
The machine weight is approximately 2550 lbs. or 1160 kg.
3.2 Location
Concentrator
The concentrator should be located in a position where it can be disassembled with an

overhead crane. The machine should be protected from constant exposure to water or
other falling material.
There should be space conveniently available for operators and maintenance personnel
to perform various maintenance duties. This includes visually inspecting the rotor,
lubrication and maintenance.

The rotor basket, impeller / baffle and lip ring are wear items requiring the removal of the
lid assembly to replace. Allow approximately 3’ (0.9m) of overhead clearance. Major
overhauls requiring the removal of the rotor may require moving the concentrator to allow
for sufficient access space. The removal of the rotor bowl and shaft requires over 6’
(1.9m) overhead clearance.
IMPORTANT: For best availability, do not mount screens or other equipment so that they
interfere with the lid removal. A crane or lifting apparatus should be available for quick
removal of the lid, rotor components, etc.
See General Arrangement Drawing and section 6. Maintenance for more details.
AutoPac
The AutoPac should be located in a clean, dry location within site as near as possible to
the concentrator. The mounting frame or wall should be free of plant vibration, and the
bottom of the AutoPac should always be off the floor to prevent moisture and/or dust
from entering the enclosure.
IMPORTANT: Exposure to excessive spray, vibration, slurry, or hose down or power

input beyond the specified range may cause Falcon AutoPac drives to fail. These drives
were designed to be “drip proof” (NEMA 12) only and have limited protection against
voltage spikes, etc. Warranty will not be applied to failure due to these causes. In some
cases it may be necessary to move the panel if the environment has changed since
commissioning, or put a protecting enclosure around the AutoPac and install further line
protection devices prior to the drive.
For more information see section 4. AutoPac and drawings.
3.3 Mounting
The supporting structure or floor on which this machine is to be mounted must be
capable of supporting well over the machine weight of about 10,000 lbs or 4,400 kg and
vibrations that may be produced during operation. A reinforced solid concrete foundation
is recommended. Consult the General Arrangement Drawing for information regarding
dynamic loading and unbalance specifications.
For standard installations, the typical foot bolt pattern consists of one 7/8" (22mm) hole
for 3/4" (19mm) mounting bolts on each of the four square mounting pads. Refer to
installation drawing for configuration. Use all four bolts to ensure the machine does
not move around during operation. All four legs should contact and support evenly
and the machine should be reasonably level.
The Concentrator installation drawings and AutoPac layout dimensions can be found in
Drawings.

3.4 Slurry Connections

IMPORTANT: All connections should be flexible to isolate vibration during operation. For
best availability, do not mount screens or other equipment where they interfere with the
removal of the concentrator lid.
Feed Inlet
The feed inlet connection is in the center of the machine at the top and is a 3” (75mm)
pipe grooved for a victaulic fitting. A victaulic coupling and hose nipple can be used here
to connect to rubber hose or a victaulic - flange adapter can be used to connect to an
expansion joint (available from Falcon at extra cost). The high-density polyethylene
(HDPE) feed pipe is considered a wear item and requires about 3' (0.9m) of overhead
clearance to change. Flexible connections and/or lines should be used to isolate machine
vibration during operation.
A 3” (75mm) air-actuated pinch valve can be purchased from Falcon at extra cost (see
2.4 Options) to control the introduction of feed to the machine. This pinch valve would
come complete with a 4-way solenoid, regulator and all necessary piping. When
energized, the solenoid either allows air to exhaust from the pinch valve sleeve to open it
or allows air in to close it, depending on the installation configuration. See 3.7 Air
Connections and contact Falcon for additional design details.
Whichever feed valve is selected, it is recommended that the valve be installed in a

bypass configuration that does not allow feed to the machine when in the default,
normally open state. Installing the feed valve in this manner will lengthen the life of the
valve and minimize the chance of plugging the bypass line. See figure below and
Drawings.
Alternatively, the valve can be located in the feed line with a bypass allowing re-direction
of the feed away from the machine during rinse and shut down, when the valve is closed.
Figure 3.4-1 Feed Pinch Valve Configuration
FEED FEED
Normally- Normally-
Closed Open
during during
operation operation
SB750 SB750
TAILINGS TAILINGS
Recommended Alternative

Tailings Outlet
The tailings outlet connection is the 6" (150mm) pipe on the outside of the shroud and is
at an angle of about 6° below horizontal and grooved for a victaulic fitting. A victaulic-
flange adapter can be used here for a connection to an expansion joint (available from
Falcon at extra cost).
The tailings piping should have a fall adequate to direct slurry away from the machine
without a chance of blockage. This could cause a backup of solids into the machine
causing severe damage. The connection must be flexible as to isolate tailings line from
machine vibration.
Concentrate Discharge
During the concentrate rinse cycle the concentrate combined with the rinse water exits
the rotor through four holes located directly under the rotor baffle. Since the rotor and
impeller/baffle assembly rotate during operation, material cannot exit the rotor until
rotation has ceased or slowed dramatically. After exiting the rotor, the concentrate is
collected in a stationary concentrate launder directly underneath the rotor.
From the concentrate launder the concentrate is flushed through a drain outlet which is a
3” (75mm) vertical pipe grooved for a victaulic fitting, and from there can be directed into
a storage container or pumped to a desired location. A victaulic-flange connection can be
used here to connect (available from Falcon at extra cost).
There is a programmable concentrate launder flush water solenoid fixed to the

concentrate launder, allowing flushing to continue even after the rinse cycle is over.
There should be less than 25 gallons (95 liters) of concentrate/rinse water per rinse
cycle, depending on the nature of the process material, length of the rinse cycle and
launder flushing requirements.
The concentrate discharge connection must be flexible so as to isolate the concentrate

line from machine vibration. The piping should incorporate an adequate slope (+ 20°) to
enable unrestricted gravity flow.
3.5 Water System

Only one process water connection is required. A water distribution system is included on
the machine connection.
Process Water Inlet
Other than the inlet connection no field connections will be necessary to complete this
sytem. Only one process water connection is required, a water distribution system is
included and pre-piped from the pipe string. The inlet piping connection is a 2” (50 mm)
flange. See Drawings for a full description.
The connection must be flexible so as to isolate the water line from machine vibration.
Process Water Requirements
Process water is necessary for fluidizing the retention zone, rinsing of the rotor bowl
during a rinse cycle, and flushing the concentrate launder. The supply requirement can
vary, but 80 USgpm (300 l/m) at 20 psi (140 kPa) should be available.
Figure 3.5-1 Basic Water Manifold
Low Pressure Regulator
Con Flush Valve High Pressure Regulator
Rinse Valve
Pressure Gauges (3)
High/Low Solenoid
On/Off Solenoid
Flow / Pressure Control Valve
“Y” Filter
Screen Flush Valve
Water Inlet
Water Filter
Immediately following the inlet connection is a self-cleaning “Y” filter. This filter comes
complete with a 0.25mm (40 mesh) screen and will prevent oversize material from
entering the water system within the machine.
There are two manual pressure gauges to measure pressure drop across the screen,
indicating a plugged or partially blocked screen if a there is a > 5 psi difference in
pressures.
If the screen becomes plugged, flush the oversize material by intermittently opening the
ball valve attached. Don’t allow prolonged flushing to cause large fluctuations in the
fluidization water flow to the machine. It is acceptable to attach a hose to this flushing
valve to redirect the water and material discharged from the screen.

Fluidization Water
Other than the inlet connection, no field connections are necessary to complete this
system. The machine is pressure tested at the factory and. For initial setup the operating
(high) pressure should be 15 psi, and the rinse (low) pressure 5 psi. Field adjustments
may be necessary for optimum performance.
For additional information regarding fluidization water, rinsing water, and flushing water
see relating sections:
1.3 Description
5.4 Optimizing
5.5 Rinsing
5.6 Shut Down
Rinse Manifold Water
Water for the concentrate rinse manifold is pre-piped directly from the main water
manifold. The water is piped through a manual ball valve to a 2-way normally closed
solenoid valve and directed through a 1/2” flexible hose to the rinse manifold mounted
near the center of the lid. All connections here are made at the factory but the hose may
be disconnected for shipping. Use the ball valve to adjust rinse flow.
Concentrate Flush Line Water
Concentrate launder flushing water is pre-piped directly from the main water manifold.
The water is piped through a manual ball valve and directed through a 1/2” flexible hose
to a 2-way normally closed solenoid attached directly to the concentrate discharge
launder.
This flush line is to be used to keep material from building up in the concentrate launder,
and it may be helpful to add water to the concentrate to aid in pumping. All connections
here are made at the factory. Use the ball valve to adjust flow.
This solenoid is attached directly to the maintenance access port cover in the
concentrate launder. The cover can be removed without disconnecting the solenoid.
Pressure Control Valve (PCV)
The piping connections for the SINGER Pressure Reducing Valve (PCV) are done at the
factory.
For a more complete PCV description, including operation, installation, service and
maintenance see section 6.1 Maintenance, Drawings and the PCV manual in Support
Manuals.

3.6 Electrical Connections (see drawings and support manuals)

IMPORTANT: Only trained, competent personnel should perform all electrical work.
Always replace worn, damaged, or faulty electrical or AutoPac (or automation package)
components with factory specified replacements. Using parts not supplied by Falcon will
void warranty.
For AutoPac installation and electrical connections see section 3.2 Location and AutoPac
drawings. Follow local codes / standards when installing. The AutoPac should be located
in a clean, dry location as near as possible to the concentrator.
The solenoids and vibration monitor connections have been terminated in the electrical
enclosure mounted beneath the deck of the machine. Terminals inside of this enclosure
will be marked in accordance with the schematic drawings. All other connections are to
be made by the customer.
Motor
The drive motor is 10 hp (7.0 kW), 3 phase with voltage and frequency as ordered by the
customer. The motor should be wired to turn the rotor in a counter clock-wise (CCW)
direction when viewed from above. See arrow on machine for direction of rotation. The
motor cable is not supplied.
Rinse and Concentrate Flush Solenoids
For most applications these solenoids are 2-way, 120v. All electrical connections from
the solenoids to the machine-mounted junction box are made at the factory. Connections
from the AutoPac to the junction box are to be done by the customer.
Vibration Monitor
All connections to the machine-mounted junction box are made at the factory.
Pressure Control Valve Solenoids
All connections to the machine-mounted junction box are made at the factory.
Feed Pinch Valve Solenoid (optional)
See General Arrangement drawings. The standard feed pinch valve solenoid is 4-way,
normally closed, 120v. This solenoid is mounted directly under the deck of the machine
with a flexible line protruding upwards to the feed pinch valve.
This cable is separate to allow the option of moving the feed pinch valve and connecting
the solenoid directly to the valve.

3.7 Air Connections

Feed Pinch Valve (optional)
An air-actuated pinch valve can be purchased from Falcon at extra cost (see 2.4
Options) to control the introduction of feed to the machine. This pinch valve would come
complete with a 4-way solenoid, regulator and all necessary piping. When energized, the
solenoid either allows air to exhaust from the pinch valve sleeve to open it, or allows air
in to close it, depending on the installation configuration. See Figure 3.4-1 Feed Pinch
Valve Configuration.
Compressed air is to be connected to the 4-way solenoid. For the pinch valve to operate
correctly there should be a maximum of 50-psi (340 kPa) differential between supplied air
pressure and internal line pressure.
The pinch valve is normally installed in a bypass configuration that does not allow feed to
the machine when in the default, normally open state (solenoid normally closed). When
the solenoid is energized allowing air into the feed pinch valve sleeve, the valve closes
and the feed is re-directed to the machine.
Alternatively, the solenoid can be changed to allow air into the feed pinch valve and
causing it to close when de-energized. In this case, the pinch valve should be located in
the feed line with a bypass allowing re-direction of the feed away from the machine
during rinse and shut down, when the valve is closed.
For the normal or standard configuration, the supply air pressure is connected to the
PRESSURE port, and the pinch valve is connected to the CYLINDER B port. The
CYLINDER A port should be plugged, so that when the solenoid is de-energized the air
from the pinch valve exhausts, opening it fully. When energized, the pressure closes the
pinch valve, directing feed to the machine.
Figure 3.7-1 4-way Feed Solenoid
CYLINDER B CYLINDER A CYLINDER B CYLINDER A
PRESSURE EXHAUST PRESSURE EXHAUST
De-energized Energized

For an alternate configuration, where the feed pinch valve is installed in the feed line,
with a bypass to redirect feed away from the machine, the pinch valve needs to be
closed when the solenoid is de-energized. To do this, switch the pinch valve connection
to CYLINDER A port and plug CYLINDER B port.
If properly connected and wired in either configuration, the AutoPac, solenoid, and the
pinch valve prevent feed slurry from entering the machine in the event of a power failure.
To test, energize the AutoPac and see if any material is allowed to enter the machine.
There should not be any material entering the machine until it reaches run or operating
speed, with the AutoPac either energized or de-energized.

Contents
4. AutoPac ...............................................................................................4-1
4.1 Introduction................................................................................................ 4-1

4.2 Instrumentation .......................................................................................... 4-2
Vibration Switch ........................................................................................................... 4-2
Pressure Control Valve Solenoids ............................................................................... 4-2
Feed Solenoid (optional).............................................................................................. 4-2
Rinse and Flush Solenoids .......................................................................................... 4-2
Options......................................................................................................................... 4-2
4.3 Powering Up .............................................................................................. 4-2
4.4 Programming ............................................................................................. 4-3
VFD.............................................................................................................................. 4-3
Figure 4.4-1 FR-PU04 Parameter Unit:.................................................................... 4-3
Table 4.4-1 VFD Parameter Unit Keys Functions .................................................... 4-4
VFD Parameters .......................................................................................................... 4-5
Figure 4.4-2 E200 Operator Interface ...................................................................... 4-6
Table 4.4-2 LED Indicator Lights ................................................................................ 4-7
4.5 Switch / Button Functions .......................................................................... 4-8
Rinse Selector Switch .................................................................................................. 4-8
Rinse ON (manual rinse) ............................................................................................. 4-8
Rinse OFF.................................................................................................................... 4-8
Rinse AUTO................................................................................................................. 4-8
Normal STOP Button ................................................................................................... 4-9
EMERGENCY STOP Button ....................................................................................... 4-9
Maintenance Timer ...................................................................................................... 4-9
Hour Meter ................................................................................................................... 4-9
4.6 Control Logic ............................................................................................. 4-9
4.7 Start-Up Procedure.................................................................................... 4-9
4.8 Common Faults ....................................................................................... 4-10
Accel / Decel (VFD trip) ............................................................................................. 4-10
Vibration Shutdown.................................................................................................... 4-10
Does not energize...................................................................................................... 4-11
Does not start............................................................................................................. 4-11
4.9 External Communication.......................................................................... 4-11
4.10 Control Philosophy................................................................................... 4-12
4. AutoPac
Note: The standard AutoPac uses a Mitsubishi PLC, Variable Frequency Drive and
Operator Interface. If the customer is supplying their own automation this section can be
used for reference purposes. Contact Falcon for additional automation documentation
and references that may be purchased at extra cost.
4.1 Introduction
Falcon Programmable Automation Controllers or AutoPacs are designed to allow
maximum flexibility for a variety of applications.
Falcon Concentrators guarantees each AutoPac being fully capable of complete stand-
alone operation, and will commission each installation as such. For more information see
section 4.9. External Communication.
The SB750 AutoPac consists of an enclosure complete with a Mitsubishi Variable

Frequency Drive (VFD), Mitsubishi PLC, Mitsubishi E200 Operator Interface (OI),
switches and push buttons. These are used to control the operation through timers,
motor speed, and solenoid actuation.
The control switches, buttons and OI are located on the outside of the AutoPac cabinet,
and access to these only are required for normal operations. These are:
POWER ON AutoPac energized.
START Push button to start the concentrator. When pressed the

green indictor light within the button illuminates, indicating
normal operation.
STOP (Normal) Push button to shut down the concentrator, initiating a rinse
cycle (except in RINSE OFF) before stopping the rotor.
EMERGENCY STOP Large red push button to shut the concentrator down
immediately with no rinsing.
RINSE Selector switch to select rinse function ON, OFF, or AUTO.
OPERATOR INTERFACE Displays all the important operating parameters.
The VFD display screen and the VFD FR-PU04 parameter unit are mounted inside the
enclosure. The VFD parameter unit can be used to select different operating parameters
such as run speed, rinse speed, acceleration and deceleration time, etc.

4.2 Instrumentation
Vibration Switch
A vibration switch supplied by the manufacturer is mounted to the frame of the machine
to monitor the concentrator for excessive vibration. If excessive vibration is detected the
switch sends a signal to the PLC and initiates either a Rinse Cycle or Shut Down
depending on the severity of the vibration. The E200 display will show that a fault has
occurred.
If vibration shut down occurs where little or no vibration is observed adjust the settings
inside the switch and with the E-200 OI - Vibration menu accordingly. See Vibration
Switch Manual in Support Manuals, and also Programming – E-200 in the following
pages.
Pressure Control Valve Solenoids
The automatic valve assembly applies the correct fluidization pressure to the rotor bowl
using two built-in solenoids according to the Control Philosophy (4.10). See also SINGER
manual in Support Manuals.
Feed Solenoid (optional)
The AutoPac actuates this according to the Control Philosophy (4.10).
Rinse and Flush Solenoids
The AutoPac actuates these according to the Control Philosophy (4.10).
Options
Contact Falcon regarding optional instrumentation such as digital flow meters, pressure
transmitters, etc.
4.3 Powering Up
Before energizing the AutoPac, check the following:
1. The input voltage is correct.

2. The wiring is correct.
3. No hazards are present.
4. Feed will not enter the machine until test is complete.
5. All installation instructions stated in the Operator’s Manual have been completed.
The three-phase disconnect handle will only energize the AutoPac if the door of the
cabinet is closed. Turn to the ON position. See section 4.8 Common Faults and the
Mitsubishi VFD manual in Support Manuals if the AutoPac fails to energize.

WARNING:
The cabinet door will need to be opened with the AutoPac energized in order to make
VFD parameter changes. Do this by turning the small flat screw located at the bottom
of the disconnect handle.
Use extreme caution to avoid electrical shock and close and latch the door
immediately after changes are made. Never leave door open and unattended!
4.4 Programming
The following instructions are not intended to be complete, but are enough to allow the
operator to become familiar with the equipment. For complete instructions refer to the
VFD manual in Support Manuals.
VFD
CAUTION: Do not change VFD parameter settings outside given ranges. Changing
some settings may adversely affect machine operation and void warranty.
The VFD Parameter programming procedure is detailed in the Mitsubishi Manual. The
drive has been programmed at the factory with a custom program for Concentrator
applications. Refer to the VFD Instruction Manual before changing parameters.
Figure 4.4-1 FR-PU04 Parameter Unit:
FR-PU04
LCD Display 00.00 Hz

STF FWD EXT
[SET] key [EXT] key
[MON] key [PU] key

[ESC] key
[UP] and [DOWN] keys
[HELP] key
[FWD] key
[SHIFT] key
[REV] key
Number keys
[STOP/RESET] key
[READ] Key [WRITE] key

Table 4.4-1 VFD Parameter Unit Keys Functions
Key Description
[SET] key Used to select the parameter setting mode.
[MON] key Used to select the monitoring mode.
[ESC] key Operation cancel key.
[HELP] key Used to select the help mode.
[SHIFT] key Used to shift to the next item in the setting or monitoring mode.
Number keys Used to enter a frequency, parameter number or set value.
[EXT] key Used to select the external operation mode.
[PU] key Used to select the PU (local) operation mode
• Used to keep on increasing or decreasing the running frequency.
Hold down to vary the frequency.
• Press either of these keys on the setting mode screen to change
the parameter setting sequentially.
[UP] and • On the monitoring, parameter or help menu screen, these keys
[DOWN] keys are used to move the cursor.
• Hold down the [SHIFT] key and press either of these keys to
advance or return the display screen one page.
• In the parameter copy or verify mode, the [DOWN] key is used as
a verify key.
[FWD] key Forward rotation command key.
[REV] key Reverse rotation command key.
[STOP/RESET] • Stop command key.
key • Used as a reset key when an alarm occurs.
[WRITE] key • Used to write a set value in the setting mode.
• Used as a clear key in the all parameter clear or alarm history
clear mode.
• Used as a parameter number read key in the setting mode.
• Used as an item select key on the menu screen such as
[READ] key parameter list or monitoring list.
• Used as an alarm definition display key in the alarm history display
mode.
• Used as a command voltage read key in the calibration mode.
Display Shows monitoring data such as frequency, motor current and I/O
states, as well as troubleshooting guidance and other information.
Note: 1. Do not use a sharp-pointed tool to push the keys.

2. The display is a liquid crystal display. Do not press your fingers
against the display.

VFD Parameters
The following is a list of the parameters changed at the Falcon factory from the default
settings. These can be further changed during commissioning, but should remain fixed
unless the machine is moved or feed characteristics change. For a complete list of the
default settings refer to the VFD manual.
Par # Name (authorized range in parentheses) Default Falcon Setting

0. Torque Boost 6% 2%
1. Maximum frequency (0 – 60) 120 Hz. 70 Hz
2. Minimum frequency 0 Hz. 0 Hz
3. Base frequency 60 Hz. See motor nameplate
4. Multi-speed setting - Run speed (30 – 60) 60 Hz. 45 Hz
5. Multi-speed setting - Rinse speed (1 – 5) 30 Hz. 1.0 Hz
7. Acceleration time (15 – 60) 5s 15 seconds
8. Deceleration time (15 – 60) 5s 15 seconds
9. Electronic thermal O/L relay N/a See motor nameplate
19. Base Frequency Voltage 9999 See motor nameplate
20. Accel / Decel reference frequency 60 Hz. 70 Hz
30. Regenerative function selection 0 1
41. Up to frequency sensitivity 10% 5%
42. Output frequency detection (15 – 60) 6 Hz. 30 Hz
44. Second deceleration time - E-Stop (15 – 60) 5s 10 seconds
70. Special regenerative brake duty 0% 10%
75. Reset selection/PU disconnection detection 14 15
78. Reverse rotation prevention selection 0 1
180. RL terminal function selection 0 3
192. A, B, C, terminal function selection 99 1
Example for changing Run Speed (parameter 4 above):
1. Press [SET] key

2. Press Number key(s) for parameter number (parameter 4, press 4)
3. Press [READ] key
4. Enter desired number using Number keys (parameter 4, for 50 Hz. press 5 then 0)
5. Press [WRITE] key
6. Press [MON] key
To scroll through all the parameters:
1. Press [SET] key once

2. Press [SHIFT] key and the parameters will scroll sequentially
3. To change a parameter, press [PU] key and start at 3. above
This is just a basic instruction. It is highly recommended that the operator(s) consult
the VFD and Parameter Unit manuals before setting or changing parameters. With
the parameter unit it is also possible to monitor current and voltage, review alarms,
operate the concentrator locally (using the parameter unit instead of the panel controls),
and perform other functions.

Figure 4.4-2 E200 Operator Interface
IMPORTANT: These are the only items that need to be altered after commissioning.
E 200 Display Screen

Function Keys label (5)
Time Set Act. Units
Run 2 1.5 hrs LED Indicator Lights (5)
Delay 5 0 sec
Rinse 15 0 sec
[Function] Keys [F1 – F5]
MENU RUN RINSE VIB PREV
[List] key used to bring up the fault list
[Main] – Main View screen (default)
[Scroll] or [Cursor] buttons (4)

[Delete] Key used to delete the
character to the left of the cursor
[Confirm] Key to confirm settings made
and go on to the next line / level
Numerical keys (12)
The function keys [F1-F5] have the following functions:
F1 – MENU Timer, maintenance and alarm menus

F2 – RUN Run time, run time units.
F3 – RINSE Rinse delay, rinse time.
F4 – VIB Vibration settings. Also used as a RESET.
F5 – PREV Previous, will move the display back one screen
With the E200 Operator Display the following parameters can be viewed or set. These
menus and procedures may change slightly. If there are any problems or questions
contact Falcon Concentrators Inc for instructions.
Operating Timers Menu Range Factory Setting

Run Cycle Run 0 – 9,999.9 hours 120 minutes
Rinse Cycle Delay Rinse 0 – 999.9 seconds 5 seconds
Rinse Cycle Rinse 0 – 999.9 seconds 30 seconds
Concentrate Launder Flush Timers 0 – 9,999.9 seconds 20 seconds
2nd Vibration Warning Vibration 0 – 9,999 seconds 30 seconds
Maintenance Timers Timers 0 – 999,999 hours 2,500 hours

Resets (will display when applicable)
VIBRATION SHUTDOWNS – press [F4] to clear.

EMERGENCY STOP BUTTON IS PRESSED – pull E-Stop button to clear.
MAINTENANCE INTERVAL HAS BEEN REACHED – press [F4] to clear.
REMOTE SHUTDOWN HAS OCCURED – remedy fault and press [Main] to clear
screen.
Display
A typical view of the Main Display Screen (default) on the E200:
Time Set Act. Units

Run 2 1.5 hrs
Delay 5 0 sec
Rinse 30 0 sec
This indicates run cycle time of 2 hours, of which 1.5 hours has transpired, a rinse cycle
delay of 5 seconds and a rinse cycle of 30 seconds. The rinse cycle delay and rinse
cycle will not be activated until the run time has expired.
Table 4.4-2 LED Indicator Lights
LED Flashing Green Green Flashing Red Red

Menu not used
Run not used
Rinse rinse delay rinsing not used not used
Vibration not used vibration warning vibration shutdown
Previous not used
Examples of programming the E200 Operator Interface for standard operation:
Set the Run Time and Run Time Units
1. Press [F2], then [scroll] down to run time.

2. Input a number with the numerical keys
3. Press the [confirm] key.
4. [Scroll] down to UNITS, then [scroll] right to unit displayed (minutes or hours).
5. Press the [confirm] key to change.
Set the Delay Time and Rinse Time.
1. Press [F3], then scroll down to delay time.

2. Input a number with the numerical keys.
3. Press the [confirm] key
4. [Scroll] to rinse time and repeat 2. and 3. above.

4.5 Switch / Button Functions

Rinse Selector Switch
RINSE
ON OFF AUTO
Rinse ON (manual rinse)
The machine will initiate a rinse cycle. From a stop, when the START button is pressed,
the VFD accelerates the rotor to the rinse speed with no feed entering the machine. If at
run speed, the VFD decelerates the rotor. Once at rinse speed the rinse water comes on.
No timers are activated, meaning the machine will stay in this state until the operator
selects a different operating mode or stops the machine.
CAUTION: Avoid running the rotor at slow rinsing speed for extended periods. This may
cause motor over heating.
Rinse OFF
When the START button is pressed, the VFD accelerates the rotor to the run speed and
feed is introduced. The machine will process feed continuously without rinsing, and will
stay in this state until the operator selects a different operating mode, stops the machine,
or if a shut down fault is initiated.
The machine will stay in this state until the operator selects a different operating mode or
stops the machine.
Pressing normal STOP will initiate a rinse cycle before the machine stops.
Rinse AUTO
When the START button is pressed, the VFD accelerates the rotor to the run speed and
feed is introduced. The machine will process feed semi-continuously, and will rinse
automatically according to the pre-set run and rinse cycles.
In this mode, the machine can either be accelerating, processing feed, at run speed with
no feed (rinse cycle delay), decelerating, or rinsing.
Pressing normal STOP will initiate a rinse cycle before the machine stops.
RINSE AUTO is the standard operating mode for most applications.

Normal STOP Button
The normal STOP button should always be used for normal shutdowns. This will initiate a
rinse cycle (in Rinse OFF or AUTO) before stopping the machine.
EMERGENCY STOP Button
The EMERGENCY STOP button should only be used in emergencies. The deceleration
time is very short, and no rinse cycle will be initiated. Also, there will be no rinse delay
cycle to allow feed material to empty from the feed piping so there may be a large
amount of material left in the rotor bowl after the machine is stopped.
Maintenance Timer
There is a Maintenance Timer that measures the Concentrator’s running time. When the
Maintenance Timer reaches the programmed set point (hours), the display is activated
on the E200 and the timer will need to be reset [F4].
See section 6. Maintenance for maintenance instructions.
Hour Meter
This is a timer that logs operating hours only. This can’t be reset or changed.
4.6 Control Logic

See Falcon SB Concentrator Control Philosophy (4.10) and PLC Ladder Logic (if
requested this can be supplied by Falcon).
4.7 Start-Up Procedure

This is a procedure for the machine only and must be integrated with plant procedures.
1. Be familiar with the circuit.

2. Make sure the machine and AutoPac are properly fastened or mounted.
3. Use qualified personnel in making electrical connections.
4. Check all piping connections and slopes (if gravity fed).
5. Check that water pressure requirements are met.
6. Energize the AutoPac.
7. Set the VFD parameters.
8. Set the E200 parameters.
9. Go to main display screen.
10. Select Rinse AUTO.
11. Press START button.
For manual operation see section 5. Start-Up and Operation.

4.8 Common Faults
CAUTION: Read entire AutoPac section before troubleshooting. Refer to the schematic
drawings and consult a qualified electrical technician.
Accel / Decel (VFD trip)
If the VFD should trip during acceleration or deceleration, reset the VFD and extend the
corresponding ramp time (parameters 7. or 8.).
There are numerous other possible causes of a VFD trip, see VFD Manual for complete
list of faults and related parameters.
Vibration Shutdown
The vibration switch monitors vibration levels, and the AutoPac attempts to correct the
vibration and if unable to do so shuts the concentrator down.
There are three settings in the Vibration Menu [F4], Warning Level, Danger Level and 2nd
Vibration. If a 1st vibration warning level is detected a rinse cycle is initiated (except if in
RINSE OFF) and the 2nd Vibration timer begins.
If a 2nd vibration warning level is detected a normal stop is initiated and a control panel
warning LED light will illuminate showing that the unit has shut down due to vibration. If a
Vibration Danger level is detected the concentrator will also shut down.
The display will register this fault and will display a “RESET”. The display will read:
“CONCENTRATOR HAS SHUT DOWN ON VIBRATION WARNING” or
“CONCENTRATOR HAS SHUT DOWN ON VIBRATION DANGER”.
In this case, press the [F4] Function Key directly under “RESET” and investigate the
cause of the vibration shut down. Some causes can be found in section 5.8 Vibration. If
not in the Vibration Alarm screen, press [Main] to return to the fault screen.
If the display reads:
“CONCENTRATOR HAS SHUT DOWN ON EXTERNAL VIBRATION SWITCH”,
remove the cover from the vibration switch and reset. Refer to BALMAC Model 550
Vibration Switch Operation Manual in Support Manuals.

Does not energize
Three-phase power is supplied to a switch inside the AutoPac cabinet. This switch has a
handle and interlock mounted on the cabinet door. From the switch, power is applied to
the line contactor and the primary of the control transformer.
The line contactor supplies three-phase power to the VFD and the control transformer
supplies 120VAC power for the PLC, solenoid valves and control switches. A 24 VDC
supply from the PLC supplies power to the E200.
If there is a fault, electrical short circuit, or damage to the motor, solenoids, switches or
other electrical devices this may cause breakers to trip. Investigation of the cause(s)
must be performed by qualified electrical personnel.
Does not start
The START command will not begin if the normal STOP or EMERGENCY STOP buttons
are depressed, if a Vibration Shutdown or other remote shutdown has occurred, or if
there is a VFD fault. Check the E200 screen. These faults must first be corrected and/or
RESET.
If the green START button is flashing this indicates a VFD, brake or other internal fault.
Have an electrician open the AutoPac cabinet door and investigate.
The VFD display should show [EXT] mode, not [PU]. If in the [PU] mode the unit can be
started using the VFD parameter unit, but the AutoPac panel controls will not be
functional.
Always use a qualified electrician to investigate.
4.9 External Communication

Falcon Concentrators Inc. guarantees each AutoPac fully capable of complete stand-
alone operation, and will commission each installation as such.
The PLC and Operator Interface Ladder Logic Programs can only be accessed using a
MAC-PROG/9-CAB cable connected between the RS 232 port on the OI and a laptop
computer, PC or compatible hand-held device. Software must be loaded into the
computer first, which can be purchased from Falcon Concentrators Inc.
Different types of communication/control links between the AutoPac and plant control
systems are possible, the most common being Profibus, Devicenet, and Ethernet. For
quotations on further control requirements please contact Falcon Concentrators Inc.

4.10 Control Philosophy

► START SEQUENCE (with RINSE AUTO or OFF selected)
SPEED (Hz.) and WATER PRE SSURE
Energize Push START

AutoPac button with RINSE
AUTO or OFF Timed Run Cycle (AUTO only)
selected
Accel Run Speed
Time
AutoPac AutoPac
Operating (high) Fluidization Pressure
De-energized Energized
Output Frequency Detection
Feed Off (solenoid de-energized) Feed On (solenoid energized)
Rinse (low) Fluidization Pressure
Water flow zero when machine idle
► MANUAL RINSE SEQUENCE Push Normal STOP button, or to

resume processing feed select
Select RINSE ON RINSE AUTO or OFF.
Timed Run cycle Transition mode Timed Con Launder Flush
Run Speed Decel Rinse Water On

Time
High Pressure
Feed On Feed Off
Low Pressure
Rinse Delay Time Rinse Speed
► MANUAL RINSE from STOP ► then process feed in RINSE AUTO or RINSE OFF
Timed Con Launder Flush
Press START button Select RINSE
in RINSE ON AUTO or OFF Timed Run Cycle (AUTO only)
Accel Run Speed

Rinse Water On Time
High Pressure
Feed Off Feed On
Low Pressure
Rinse Speed
Water Pressure controlled by PRV Programmed Set Points Speed in Hz.

► AUTOMATIC RINSE SEQUENCE (in RINSE AUTO)
Automatic Rinse Cycle,

st
or 1 Vibration Warning Limit
Timed Run Cycle Transition mode Timed Rinse Cycle Timed Run Cycle
Run Speed Decel Accel

Rinse Water On Time
Time
High Pressure
Feed On Feed Off Feed On

nd
Low Pressure 2 Vibration
Warning
Rinse Cycle Delay Rinse Speed Timer begins
► NORMAL STOP SEQUENCE (with RINSE AUTO selected)
nd
Push Normal STOP Button, 2 Vibration Warning
st
or 1 Vibration Danger Limit reached.
Timed Run Cycle Transition mode Timed Rinse Cycle
Run Speed Decel Rinse Water On

Time
High Pressure
Feed On Feed Off
Low Pressure
Rinse Cycle Delay Rinse Speed
► EMERGENCY STOP SEQUENCE (RINSE AUTO or RINSE OFF selected) - and Power Loss
Push EMERGENCY STOP Button Water flow will default to zero in either case.
or Remote Shutdown Device tripped
If power is lost, the machine will coast to a stop with

Run Speed feed shut off. Machine will not automatically restart.
High Pressure
Feed On Feed Off
Decel Time absolute minimum without tripping VFD
Water Pressure controlled by PRV Programmed Set Points Speed in Hz.

Contents
5. Start-up and Operation.......................................................................5-1
5.1 Pre-Start Checks ...................................................................................... 5-1

5.2 Slurry Feed ............................................................................................... 5-2
Table 5.2-1 Tons Per Hour ....................................................................................... 5-3
Oversize Particles / Excess Density ............................................................................ 5-3
High and Low S.G. Gangues ....................................................................................... 5-4
5.3 Starting the Concentrator.......................................................................... 5-4

Automatic Operation (AutoPac) ................................................................................... 5-4
5.4 Optimization.............................................................................................. 5-6

Fluidization Pressure ................................................................................................... 5-6
Figure 5.4-1 The Rotor Basket .................................................................................... 5-7
Procedure to Determine Optimum Run Time .............................................................. 5-7
Rotational Speed ......................................................................................................... 5-8
5.5 Rinsing...................................................................................................... 5-8

Figure 5.5-1 Automatic Rinse Cycle ........................................................................... 5-9
5.6 Shut Down .............................................................................................. 5-10

Figure 5.6-1 Shut Down............................................................................................ 5-11
Vibration Shut Down .................................................................................................. 5-11
5.7 Vibration ................................................................................................. 5-11

Figure 5.7-1 Rotor Basket Imbalance..................................................................... 5-12
Table 5.7-1 RPM vs. G’s ........................................................................................ 5-13
5. Start-up and Operation
It is strongly recommended to use a Falcon Programmable Automation Control, or

AutoPac, to achieve best recovery and eliminate frequent operator attention. With the
Falcon AutoPac most operating functions will be performed automatically. Refer to the
AutoPac manual for additional programming and operational instructions.
Although this manual provides general operating guidelines, it is important that

qualified factory personnel commission the equipment. Incorrect installation
and/or operation causing failure will not be covered under warranty. The following
operating instructions assume that equipment has been correctly installed and
commissioned.
WARNING!
USE SAFETY PRECAUTIONS WHEN WORKING WITH, ON OR
AROUND ROTATING MACHINERY AND ELECTRICAL EQUIPMENT.
Each installation is unique, therefore it is not possible to specify exact procedures for
start up, operating, rinsing, and shut downs. The procedures mentioned in the following
sections are only meant to give the operating personnel general guidelines to help
optimize the performance of the machine, and minimize downtime.
Falcon has a highly qualified staff to help with installation optimization. Please do not
hesitate to ask for assistance.
5.1 Pre-Start Checks

Check the following before starting the machine:
1. Voltage to the AutoPac is correct and constant.

2. All electrical connections comply with local standards.
3. Feed stream is within recommended limits.
4. Feed valve is functioning correctly.
5. Machine rotor is free of debris, and the rotor turns freely.
6. Pressure Control Valve has been tested.
7. Water system does not leak.
8. Water supply is flushed and free of suspended solids (sand, etc.).

WARNING!
DO NOT OPERATE OR ENERGIZE THE MACHINE WITHOUT ALL
GUARDS IN PLACE.
DOING SO COULD RESULT IN INJURY.
5.2 Slurry Feed

IMPORTANT: It is extremely important to make sure the process water supply and
fluidization water pressure are constant before introducing any feed into the machine.
Insufficient fluidization will result in finer material migrating through the rotor wall into the
water jacket causing a build-up of material and creating imbalance and other problems.
Remove filter cover and screen and thoroughly flush entire water supply line before
putting machine into service the first time.
Feed material must only be introduced when the rotor has reached operating or run
speed, otherwise the unit may flood. Before starting the concentrator it is recommended
that the feed be tested using a bypass system to see if it is within design limitations.
Optimum feed volumetric rates and pulp densities will vary greatly with different materials
There is no minimum density for the feed stream but the maximum is 70%. For low-
density feed the throughput may be governed by the maximum slurry capacity of about
350 USgpm or1325 l/m.
For estimating and set up purposes begin with the nominal values given in section 2.
Specifications and the table on the following page.
IMPORTANT: The Shaded area in the following table represents solids throughputs
exceeding the recommended limits. Operating at or above these limits may adversely
affect performance and may significantly increase wear.
If the feed characteristics are within the recommended limits the film of slurry moving up
the migration zone should be relatively thin, and the impeller and the bottom portion of
the rotor should be visible during operation. If there is a large amount of slurry “swirling”
around near the base of the rotor walls this indicates exceeding the feed limits, a worn
impeller, or unsuitable rotational speed.
The following table is provided to aid in determining feed rates. It shows the relationship
between a volumetric pulp flow rate and % solids content of the feed, and how they
determine the solids throughput.

Table 5.2-1 Tons Per Hour
S.G. Solids 2.9
PULP
PULP FLOW IN USGPM
DENSITY
(% SOLIDS) 100 150 200 225 250 275 300 325 350 375 400 425
5 1.3 1.9 2.6 2.9 3.2 3.6 3.9 4.2 4.5 4.8 5.2 5.5
10 2.7 4.0 5.4 6.0 6.7 7.4 8.0 8.7 9.4 10.0 10.7 11.4
15 4.2 6.2 8.3 9.4 10.4 11.4 12.5 13.5 14.6 15.6 16.6 17.7
20 5.8 8.6 11.5 12.9 14.4 15.8 17.3 18.7 20.1 21.6 23.0 24.5
25 7.5 11.2 14.9 16.8 18.7 20.6 22.4 24.3 26.2 28.0 29.9 31.8
30 9.3 14.0 18.7 21.0 23.3 25.7 28.0 30.3 32.7 35.0 37.3 39.7
35 11.4 17.0 22.7 25.5 28.4 31.2 34.1 36.9 39.7 42.6 45.4 48.3
40 13.6 20.3 27.1 30.5 33.9 37.3 40.7 44.0 47.4 50.8 54.2 57.6
45 16.0 23.9 31.9 35.9 39.9 43.9 47.9 51.8 55.8 59.8 63.8 67.8
50 18.6 27.9 37.2 41.8 46.5 51.1 55.8 60.4 65.1 69.7 74.4 79.0
55 21.5 32.2 43.0 48.4 53.7 59.1 64.5 69.9 75.2 80.6 86.0 91.4
60 24.7 37.1 49.4 55.6 61.8 68.0 74.1 80.3 86.5 92.7 98.9 105.0
The specific gravity of the feed pulp material may also vary. If it is higher than 2.9 kg/l,
the tons per hour solids in the feed will be slightly higher for the given pulp density and
volumetric flows shown.
When no solids are fed into the unit, clear water may be left running in most cases
without substantial loss of target minerals, if the concentrator is operating at speed and
target mineral capacity has not been exceeded.
Oversize Particles / Excess Density
Oversize particles will adversely affect the performance of the machine. To prevent
problems and maximize performance it will usually be necessary to install a screen
ahead of the machine. This can be of either static or vibrating type, and should not be
installed directly on top of the machine impeding easy removal of the lid.
If oversize is allowed to enter the machine it is likely to be captured in the retention zone,
or rotor basket, during the run cycle. During the rinse cycle this oversize will be rinsed
from the rotor basket down into the base of the rotor bowl, and may obstruct or even plug
the gap between the rotor baffle and the rotor bowl wall. If this happens it will restrict the
flow of concentrate out of the machine, subsequently decreasing metallurgical recovery.
Other problems created by oversize are imbalance, reduced concentrate volume (less
recovery volume for target mineral), and increased maintenance requirements.
In addition to eliminating problems, classifying the feed will improve metallurgical

performance. Sharper separations can be accomplished between gangue and target
minerals.

High and Low S.G. Gangues
Solids throughput is partially dependent on particle size and specific gravity. Generally,
coarser and denser particle streams reduce the maximum throughput, and require more
water in the feed combined with higher fluidization pressure.
Where a high specific gravity gangue is present, increasing the volume/pressure of the
fluidization water will prevent ‘packing’ of solids throughout the retention zone or rotor
basket. See Fluidization Flow in section 5.4 Optimization. Conversely, finer and lighter
particle streams generally increase the maximum throughput and require less water in
the feed and lower fluidization flow.
Optimum operating conditions for a given material are usually determined and
established during a commissioning visit. Continuing laboratory analysis of the feed,
concentrate and tailings will be necessary to maintain the optimum conditions.
5.3 Starting the Concentrator
IMPORTANT: Test the feed system before starting to make sure the feed valve
operation conforms to the control philosophy in 4.10.
WARNING!
DO NOT OPERATE OR ENERGIZE THE MACHINE WITHOUT ALL
GUARDS IN PLACE.
DOING SO COULD RESULT IN INJURY.
Automatic Operation (AutoPac)
Before starting the machine study the AutoPac functions and control philosophy and be
familiar with the operating parameters such as run speed, rinse speed, acceleration time,
deceleration time, run cycle, rinse cycle, fluidization flow/pressure etc. It is recommended
that a qualified factory representative be present during start up.
Before slurry feed is allowed to enter the machine make certain there is sufficient
fluidization flow/pressure (to be determined during the commissioning). This will eliminate
build-up of solids in the water jacket. A manual gauge is installed immediately prior to the
rotating union to indicate whether sufficient pressure is being applied.
It is recommended that a water test be done first. Once the user is familiar with the
machine and the operating conditions and parameters are established, press Start with
the Rinse status in Auto. This will bring the machine to operating speed.

If the machine does not reach operating speed within the time set for the acceleration
ramp, shut the machine down and determine the cause of the problem. If no mechanical
problem is apparent and the rotor spins freely, an electrical or programming problem is
likely.
Check the machine before the introduction of any feed material for any abnormal
vibration. If vibration is excessive or a problem is observed immediately shut off
the concentrator and investigate cause. See section 5.7 Vibration.
WARNING!
VIBRATION MEANS THAT THERE IS SOMETHING OUT OF
BALANCE. RECTIFY BEFORE RECOMMENCING OPERATION.
The following is a procedure for a typical machine start-up to be integrated with other
plant procedures.
1. Rinse switch in Auto.

2. Press Start, machine accelerates to run speed and feed is introduced.
3. During acceleration, fluidization pressure changes from low (rinse) to high
(operating).
4. If speed is changed, feed is stopped during acceleration or deceleration and does
not resume until speed is constant.
5. Run operation will continue until a rinse function is activated and/or a shut down
occurs either automatically or manually.
6. To initiate a manual rinse cycle, set Rinse switch to On.
The Emergency Stop button should only be pressed in emergencies, for normal shut
down always use the normal stop key.
IMPORTANT: Observe the following cautions during operation:
• Operate the machine only with correct fluidization flow/pressure set-points.

• Do not allow the machine to be decelerated and stopped unless the feed is stopped
first (this should be automatic).
• Do not set acceleration or deceleration time below the recommended safe limits or
the VFD may fault.
• Set the rinse time to make sure the rotor is thoroughly clean after each rinse.
• Do not start the machine until first checking to see that the rotor is clean.

5.4 Optimization
To determine the optimum operating parameters for the desired concentrate
grade/recovery, some experimentation and sampling may be required.
Falcon recommends that a thorough sampling program be followed for the first two
weeks of operation and periodically thereafter to correctly determine the best
grade/recovery.
Fluidization Pressure
In addition to determining optimum operating conditions the commissioning

representative can recommend an optimum fluidization flow/pressure. There are two
adjustable pressures, concentrating or “high” and rinsing or “low”.
When the machine is stopped the backpressure solenoid defaults is normally closed, not
allowing any fluidization water into the machine. As soon as the START button is pressed
the backpressure solenoid opens and remains open until the machine is stopped. The
operating pressure solenoid defaults to a normally open state when the machine reaches
output detection speed (VFD parameter 42).
During operation, fluidization water is injected through the rotor basket wall to create a
dilated or fluidized bed. The high specific gravity target minerals become embedded in
the zone and are retained here until the machine is stopped and the concentrate is rinsed
out of the rotor.
To fully determine if the water fluidization flow/pressure is set correctly for maximum
possible recovery it will be necessary to do laboratory analyses of the feed, concentrate
and tailings.
It may also be necessary to investigate different operating conditions, such as speed,

feed density and run cycle time. However, a good indication that the machine is
functioning effectively is when there is sufficient material collected in the fluidization zone
and it is not ‘packed’.
To determine this
1. Operate the machine for >10 minutes.

2. Shut off feed.
3. Shut off all supply water (fluidization, rinse).
4. Stop the machine.
Observe the texture of the material concentrated in the retention zone, or rotor basket,
noting whether it is packed hard or if it ‘slumps’ out of the riffles. If the material is packed
hard, increase the fluidization water and continue this procedure until the material
slumps. This indicates that the pressure is sufficient to keep the bed of material in the
retention zone properly fluidized during operation.

If the fluidization flow/pressure is too high, however, there will be very little material left in
the retention zone. The amount of concentrate collected after each run cycle should be
approximately 50 lbs (22 kg), depending on various factors. If the amount is significantly
lower than this, this may indicate that the fluidization flow/pressure has been set too high.
Laboratory analysis of the feed, concentrate and tailings should indicate whether
recovery in the fine fraction is as expected. A low recovery here may also indicate that
the fluidization flow/pressure may be set too high.
This should only be determined after following a thorough sampling program, as it may
be that the very fine recovery is affected by other causes, and may not be dependent
solely on fluidization water.
Figure 5.4-1 The Rotor Basket
FLUIDIZATION WATER FLUIDIZED BED
CENTRIFUGAL FORCE
Procedure to Determine Optimum Run Time
During commissioning a run cycle time will be recommended based on the application,
objective, and visible analysis of the concentrate and tailings. A typical run cycle would
be two hours in duration, producing a mass recovery of less than 0.1% to concentrate.
To more accurately determine the optimum run time for the desired concentrate grade
and/or recovery some experimentation, sampling, and laboratory analysis may be
required. Falcon recommends that a thorough sampling program be followed for the first
two weeks of operation and periodically thereafter.
The following procedure can be used as a guide to determine the optimum run time for
any particular material:
1. Operate the concentrator for two hours at approximately constant operating

conditions such as feed rate and pulp density, fluidization backpressure, etc.
2. Collect tailings samples for each of twelve ten-minute operating periods during the
two-hour period (i.e.: Sample #1 = 0-10 minutes, Sample #2 = 10-20 minutes, etc.).
The samples can be collected by taking 3 second cuts every 30 seconds using a
sampling system.

3. Analyze these samples to determine when there was a significant change in tailings
grade over the course of the run period. If no change was evident then repeat
the test using a 4-hour run and sample every half-hour.
4. Use the information from 3. above to determine optimum or 'safe' running time.
In some near capacity situations and when processing some types of feed, depending on
its characteristics, it may be advantageous and convenient to reduce the run time
dramatically and re-process the small volume of rougher concentrate in a clean-up cycle.
An additional SB concentrator or the original concentrator, when off line, can be used for
this clean-up operation to produce a primary high-grade concentrate when lower volumes
can allow optimum feed parameters. The tails from the clean-up operation should be
reprocessed through the rougher cycle feed. This is usually the best way to achieve
higher-grade final concentrates without sacrificing high recovery.
Rotational Speed
The rotational speed of the rotor bowl determines the ‘G’ forces impacted on the material
moving through the machine. This is calculated by the formula:
G-FORCE = Rotor ø (inches) x r.p.m.2

70471
Generally, the fine streams (< 50 microns) require higher G’s for optimal recovery and
coarser streams lower G’s. The rotational speed can be set in Hz. See also Table 5.7-2
RPM vs. G’s.
5.5 Rinsing
The AutoPac automatically controls fluidization flow, acceleration, feed valve operation,
deceleration, rotor rinse speed, rinse water and flush water introduction, and duration of
the rinse cycle. See 4. AutoPac for programming details.
Typical rinsing cycle procedure with an AutoPac:
1. Run Cycle times out.

2. Rinse Delay begins, feed piping empties.
3. The machine decelerates to rinse speed.
4. Fluidization pressure switched from high (run) to low (rinse) at FSSP*.
5. At rinse speed, the rinsing manifold / spray nozzles turn on, cleaning the rotor.
6. Rinse Cycle times out and rinse manifold water turns off.
7. The machine accelerates to run speed.
8. Fluidization pressure returns to high (run) pressure at FSSP.
9. Feed is re-introduced and cycle repeats.
* FSSP Flow State Set-point (Hz.)

The control philosophy below describes a typical run cycle. The rinse cycle is the term
describing the time of operation when the machine decelerates and rinses the target
mineral from the machine. The run cycle begins again once acceleration has begun.
Figure 5.5-1 Automatic Rinse Cycle
Automatic Rinse or
st
1 Vibration Warning
Transition
Run Cycle mode Rinse Cycle Run Cycle
60 Hz
Run
Speed Decel Accel
Time Time
Operating
Fluidization
Rinse Water On
Pressure
30 Hz Output Frequency Threshold
Feed On Feed Off Feed On
Rinse
Fluidization
Rinse Pressure
0 Hz Rinse Delay Speed
The rinse cycle begins with the rinse delay, which stops the feed a pre-set time before
initiating the deceleration. This feature is necessary when the feed valve is located some
distance from the machine, as feed material downstream may still slump into the rotor
during deceleration and rinsing even after the feed stops.
This could cause the grade of the concentrate to be compromised and possible plugging
in the bottom of the rotor. The rinse delay is usually less than 5 seconds. After the rinse
delay times out the machine begins to decelerate, and the fluidization pressure
decreases to the low setting.
When the rotor reaches the rinse speed (usually 1-2 Hz.) the rinse manifold solenoid
opens allowing water to the rinse manifold, and the spray nozzles rinse the concentrate
out of the retention zone or rotor basket. This material then flows out through the
discharge holes located under the impeller/baffle assembly into the concentrate launder
to be directed away from the machine.
A concentrate launder flush line c/w an automatic solenoid is installed to flush out the
concentrate launder following each rinse. This is site specific based on specific
requirements such as pumping the concentrate, tendency for build-ups, etc.
A normal rinse cycle normally takes less than two minutes from start to finish, or off-line
to on-line again. During the first few days of operation observe the concentrate rinsing
from the rotor during the rinse speed, and determine the time it takes to effectively clean
the rotor. Normally this is between 20 and 60 seconds.

If more than one minute is required for the concentrate to be completely removed from
the rotor during the rinse cycle, check for the following:
1. Spray nozzles are not blocked or plugged.

2. Fluidization holes in the rotor basket are not blocked or plugged.
3. Fluidization holes in the rotor basket are not enlarged, causing inconsistencies of
rinse water (this usually is a result of improper fluidization pressure control and/or
inadequate maintenance practices).
4. The exit area around the baffle is not blocked, preventing the contents of the rotor to
freely drain.
5. The discharge ports beneath the baffle are not clear (it will be necessary to remove
the baffle to investigate this).
The complete rinse cycle should be witnessed periodically to insure the rotor is
completely clear of concentrate at the end of the cycle.
5.6 Shut Down

The AutoPac controls the feed valve, rinse delay, deceleration, fluidization water
flow/pressure, and rinse time. Pressing the EMERGENCY STOP should only be done in
an emergency; this will stop the feed and decelerate the machine to a stop without
rinsing the rotor bowl.
Using normal STOP initiates a controlled shut down which includes a rinse delay,
deceleration, and timed rinse cycle before stopping the machine. This allows the
machine to always stop clean.
The following describes what happens when Normal Stop is used:
1. Feed stops (feed solenoid energizes)

2. Rinse Delay activates, times out.
3. Machine decelerates to rinse speed; fluidization water adjusts to low pressure
during deceleration.
4. Rinse solenoid opens allowing water to rinse manifold / spray nozzles.
5. Concentrate exits the rotor through holes underneath the rotor baffle.
6. Rinse Time times out and rinse water turns off.
7. Machine stops and concentrate flush water turns on for set time.
After each shut down inspect the machine for wear. It is important to implement a
preventative maintenance procedure to optimize performance and extend the life of the
machine.
For shut downs of more than one day, drain the water from the machine by opening the
flushing valve attached to the rotating union at the bottom of the machine. This will help
prevent scale or rust build-up within the machine

The control philosophy below also describes a normal shut down.
Figure 5.6-1 Shut Down

Normal STOP or
vibration shut down.
Transition
Run Cycle mode Rinse Cycle
60 Hz
Decel
Time
Rinse Water
ON
30 Hz Output Frequency Threshold
Feed On Feed Off
Rinse Fluidization Flow

Rinse Delay Rinse Speed
0 Hz
Vibration Shut Down
If the machine reaches a vibration level above the set Vibration Warning limit a rinse
cycle or controlled shut down will be initiated, depending on the severity of the vibration.
If Vibration Danger limit or a 2nd Vibration Warning is detected the machine rinses first
and then stops. A message will appear on the E200.
If a vibration shut down occurs it will be necessary for operating or maintenance

personnel to investigate the cause and remedy. For more information regarding the
vibration switch operation see sections 4. AutoPac, 5.7 Vibration and vibration monitor
manual in Support Manuals.
IMPORTANT: If vibration shut down occurs, never re-start without checking the cause.
5.7 Vibration
Prior to leaving the factory all machines are run at full speed, balanced, and run
repeatedly to check for any abnormal vibrations. Upon installation, some vibration of the
unit during operation is normal and safe as the feed material causes varying degrees of
imbalance in the rotor. If excessive vibration is observed, investigate the cause. The
AutoPac employs a machine mounted vibration switch to monitor vibration and effect a
controlled shut down if vibration becomes excessive.
IMPORTANT: Do not override or bypass the vibration switch, operating with excessive
vibration may cause premature bearing failure and will void warranty.

Excess vibration indicates a severe imbalance, possibly caused by
1. Improper feed conditions causing excessive or uneven concentrate distribution

within the rotor. Adjusting the feed characteristics (density, particle size, etc.) to
specifications will eliminate the problem.
2. Improper operating conditions, rotational speed too high for given application.
3. Foreign matter in the rotor, such as grinding balls, oversize, dropped tools, etc.
4. Structural damage to the rotor basket, rotor, shaft, lining, etc.
5. Fluidization water injection holes in rotor basket plugged. This could cause uneven
concentration in the retention zone and also cause premature wear of the rotor
basket and/or wear ring. This problem should be investigated immediately to
determine the cause(s) of the plugging.
6. Insufficient or inconsistent fluidization water, allowing finer particles to migrate into
and build up in the water jacket outside of the rotor basket.
7. Worn, damaged or mis-aligned bearings.
8. Improper maintenance practices. During maintenance, make every effort to
maintain the balance of the machine. For example; when relining, apply new lining
evenly, and repair worn or damaged surfaces to be consistent with surrounding
material.
Figure 5.7-1 Rotor Basket Imbalance
Small particles migrating

Enlarged through basket
fluidization holes Uneven wear of
rings.
Particle plugging
Material buildup
water inlet hole.
O/S, Grinding Do not attach any weight to the

Balls, etc. basket here if field balanced.
This will displace concentrate
during operation.
In many cases vibration can be minimized by changing feed and/or operating conditions,
such as increasing feed throughput, decreasing feed pulp density, and reducing speed.

Table 5.7-1 RPM vs. G’s
This chart relates Hz. to rotational speed and G’s imparted on the feed material.
FALCON DATA SHEET: SEPARATION 'G' FORCE

Concentrator Model: SB750
Rotor Diameter: 16.50 INCHES
Motor Frequency: 60 Hz
Motor Speed: 1760 RPM
Motor Sheave PD: 4.10 INCHES
Rotor Sheave PD: 8.20 INCHES
Max. Rotor Speed: 920 RPM
AUTOPAC MOTOR ROTOR ACCELERATION

Hz RPM RPM "G"
20 587 293 20
25 733 367 32
30 880 440 46
35 1027 513 63
40 1173 587 82
45 1320 660 103
50 1467 733 128
55 1613 807 155
60 1760 880 184
44.23 1297 649 100

49.45 1451 725 125
54.17 1589 795 150
58.51 1716 858 175
62.55 1835 917 200
Note: Values for a 50 Hz. 1450 rpm motor are equal.
Speeds given are theoretical calculated values and do not take into account possible
slippage of motor or belts.
For a more accurate determination measure actual rotor speed.
Running motor at excessively low speeds for long periods may cause overheating and
premature failure.

Contents
6. Maintenance ........................................................................................6-1
6.1 General Maintenance ............................................................................... 6-1

Wear Surfaces ............................................................................................................. 6-1
Fluidization Water System ........................................................................................... 6-2
Rinse and Flush Water Systems ................................................................................. 6-4
Lid Removal ................................................................................................................. 6-4
Rotor Lip Ring .............................................................................................................. 6-4
Figure 6.1-1. Rotor Lip Ring, Top Plate, Basket......................................................... 6-5
Rotor Top Plate............................................................................................................ 6-5
Rotor Basket ................................................................................................................ 6-5
Impeller/Baffle .............................................................................................................. 6-6
Belt Tension ................................................................................................................. 6-6
6.2 Lubrication ................................................................................................ 6-6

Greasing Rotor Bearings ............................................................................................. 6-6
Figure 6.2-1 Grease Manifold................................................................................... 6-7
Table 6.2-1 Lubrication Schedule ................................................................................ 6-7
Greasing Motor Bearings............................................................................................. 6-8
6.3 Rotating Union .......................................................................................... 6-8

6.4 Drive Belt / Sprockets ............................................................................... 6-9
EAGLE Belt.................................................................................................................. 6-9
Sprockets ..................................................................................................................... 6-9
6.5 Rotor Bowl / Shaft..................................................................................... 6-9

Rotor Bowl Removal .................................................................................................. 6-10
Rotor Bowl Repair...................................................................................................... 6-10
Drive Shaft removal ................................................................................................... 6-10
6.6 Bearing Replacement ............................................................................. 6-11

Upper Bearing............................................................................................................ 6-11
Lower Bearing............................................................................................................ 6-11
Re-Assembly.............................................................................................................. 6-11
6.7 Motor Removal ....................................................................................... 6-13

6.8 Rubber Lining ......................................................................................... 6-13
6.9 Disassembly / Shipping .......................................................................... 6-13
6.10 Storage Instructions................................................................................ 6-14
6.11 Service Record ....................................................................................... 6-15
6.12 Maintenance Schedule ........................................................................... 6-16
6. Maintenance
6.1 General Maintenance

This section describes normal, regular maintenance that is necessary to insure optimum
performance and prolong the life of the machine. All maintenance and service performed
should be recorded on the chart in section 6.12 Service Record. Always use anti-seize
compounds or grease on assembly of threaded fasteners and shafts to allow for
subsequent disassembly.
When performing service and maintenance functions that require the machine to be
stopped always LOCK THE MACHINE OUT at the AutoPac or suitable place to avoid
inadvertent starting.
WARNING!
OBSERVE SAFETY PRECAUTIONS WHEN WORKING WITH,
ON OR AROUND ROTATING MACHINERY AND
ELECTRICAL EQUIPMENT.
Wear Surfaces
IMPORTANT: Always re-line rubber surfaces before allowing steel to be exposed.
The following components are designated wear items and their condition should be
periodically checked. In addition to maintaining optimum performance, a preventative
maintenance schedule will extend the overall life of the machine. Wear of one component
may subsequently cause premature wear of another if not repaired or replaced. The
following expected life is based on 24/7/365 operations.
To minimize downtime some of these items should be stocked as spare parts. For a
complete list see section 7. Recommended Spares.
Item Expected Life Remedy

Feed Pipe 6-12months Replace
Lid 6-12 months Re-line
Rotor Lip Ring 6-12 months Replace
Impeller 3-12 months Replace
Baffle 6-12 months Replace
Rotor Bowl Lining 6-12 months Re-line
Rotor Basket 12-36 months Replace
Launder Ring 1-2 years Re-line
Tailings Launder > 2 years Re-line

Fluidization Water System
IMPORTANT: The water system needs to be kept in good working order to maintain
optimum recovery.
During the commissioning visit, a qualified representative will recommend an optimum

operating fluidization flow/pressure and will instruct personnel on all aspects of the water
system(s).
In order to maintain the correct pressure it is important that regular inspection and
maintenance of the water system is performed. If fluctuations occur it may be evidence of
damage and/or blockage in the water filter/screen, rotating union, rotor hose(s), rotor
basket, PCV, or scale build-up. See the following sections for more details.
Water Filter
The filter is a canister type screen which allows for self-cleaning during operation. The
standard screen aperture size is 40 mesh (0.25mm). There are two pressure gauges
attached to the filter, one before the screen and one after.
A significant pressure difference between the two (>5 psi) indicates some blockage of the
screen. This can be cleaned by opening the attached flushing valve while there is inlet
water pressure but it may also be necessary to shut down the machine to open the cover
and remove the filter.
Rotating Union
The rotating union is the device that allows water to enter the rotating shaft from a
stationary pipe string. The union contains a brass seal that can be easily damaged if
there are fine solids or chemicals in the water supply. Damage can also occur if the union
is allowed to run dry.
Water leaking from the union indicates a worn seal, which should be replaced before
complete failure occurs. If cyanide is present in the water supply, it is highly
recommended that a stainless steel union or kit be installed. Rotating union rebuild kits
and/or a complete rotating union should be stocked as spare parts.
Rotor Hoses
There are two rotor hoses made up of hydraulic hose and hydraulic fittings to direct the
fluidization water from the rotor shaft flange to the rotor bowl water jacket. If material is
allowed to build up in the concentrate launder this may cause wear of the bottom hose
fittings.
To inspect the bottom hose fittings remove the access plate bolted to the concentrate
launder.

These hoses must not be allowed to plug with solids to maintain optimum metallurgical
performance and the balance of the machine. Even a small amount of solids in one of
these hoses may cause a severe imbalance at operating speed, as the mass is multiplied
by the force of gravity effected by the rotation (50-200 G’s).
Use only hoses supplied by Falcon.
Check for blockage each time the rotor basket is removed. Do this by opening the FCV
and checking that water is coming through both inlet holes in the water jacket.
Replacement rotor hoses from Falcon should be stocked as spare parts.
Water System Flushing Valve
Attached to the rotating union, this manual ball valve is used to flush all of the water from
the machine. This will be necessary if the machine is to remain idle.
This valve can also be used to flush material from the water jacket. See following
sections regarding Scale and Rotor Basket for more details.
Scale
The presence of scalants (such as calcium carbonate, etc) or particulate matter in the
process water may lead to an increase in maintenance on the water system. If an anti-
scalant system is installed in the process water prior to the machine, it will minimize or
eliminate the problem.
There are several different systems available and most are inexpensive and require
minimal time to install. Falcon Concentrators would be pleased to assist in
recommending a system suitable for specific conditions. Contact Falcon for details.
Pressure Gauges
Pressure gauges are used to back up and verify the Pressure Transmitters. If the water
supply is kept free of slimes and/or scale, they will remain reliable. If the face of the
gauges begins to cloud or if the needle does not register, they should be replaced with
gauges with a range of 0-100 psi. The cause of the failure should be investigated and
steps taken to prevent re-occurrences.
To clean, remove the gauges and blow compressed air into the small inlet hole in the
base of the gauge. Some gauges come with a removable cap in the top; these can be
drained and re-filled with lightweight oil.
Replacement gauges from Falcon should be stocked as spare parts.
IMPORTANT: To ensure continued problem-free operation spare parts should always be

purchased from Falcon.

Rinse and Flush Water Systems
The rinse water system is only operational during the rinse cycle. Watch for wear or
plugging of the rinse nozzles. For maintenance it is necessary to remove the rinse
manifold by removing the two bolts holding the manifold retainer and lifting the assembly
out. Replacement nozzles should be stocked as spare parts.
Should the rinse solenoid fail it is possible (but not recommended) to eliminate the
solenoid and use the manual valve to continue operation. In this case, the manual valve
should remain open at all times (leaving the water on during the run cycle will not
significantly affect performance). It is recommended that solenoids be stocked as spare
parts.
The flush water system is only operational immediately following a rinse cycle. Watch
that this is functioning correctly to avoid build-ups within the concentrate launder.
Lid Removal
The lid is considered a wear item and should be inspected for rubber wear upon each
removal. The lid will need to be removed to repair or replace the rotor basket, impeller,
baffle, lip ring, or to re-line the rotor or lid itself.
First remove the piping above, then remove the bolts through the lid and tailings launder
flange. Using the lifting eyes provided on the lid the lid assembly can be lifted straight up
and off the tailings launder. Be careful to lift straight up to avoid damaging the rubber
lining inside the rotor with the feed pipe or spray nozzles.
Store safely while removed making sure not to damage any attached components or the
rubber lining.
Rotor Lip Ring
With the lid removed, replace the rubber-lined lip ring by removing the bolts and
separating the ring from the rotor top plate. Examine the lip ring for excessive wear that
could be a result of improper operating of the rotor basket or other component. The lip
ring should be stocked as spare parts and can be re-lined by qualified personnel.
When re-installing, snug the bolts in an opposite pattern and tighten in a circular pattern
starting with the inner most row. Torque to 15 ft. lbs.
See figure on next page.

Figure 6.1-1. Rotor Lip Ring, Top Plate, Basket
TOP PLATE
LIP RING
NON-
ROTATING FLUIDIZED BED
CENTRIFUGAL FORCE
ROTOR BASKET
WATER JACKET
ROTATING
FLUIDIZATION WATER
Rotor Top Plate
First remove the lid and lip ring, then remove the top plate bolts. To free the plate from
the rotor it may be necessary to use the jacking holes provided. Use caution not to
damage the o-ring cord under the rotor top plate. The top plate should be stocked as
spare parts.
Rotor Basket
Inspection of the rotor basket should be done on a regular basis (weekly) according to
the severity of conditions present. The basket will undergo varying forms of wear
depending on which specific conditions are present; such as coarseness of feed material,
the presence of scale or particulates in the process water, etc. See Figure 5.7-1 Rotor
Imbalance.
To inspect the basket for wear put the machine through a rinse cycle making sure the
basket is completely free of material. With the machine stopped, use backpressure
bypass valve (see drawings) to allow for water to enter the rotor from all of the water
injection holes. Visually inspect (through the inspection ports in lid) each hole to
determine if any seem enlarged or blocked.
A periodic (at least twice per year) removal of the lid should be done to thoroughly
inspect the rotor basket and replace if necessary. Remove the lip ring, launder cover and
clamp ring using caution not to damage the o-ring cords.

The rotor basket should lift straight up without difficulty using the holes provided for the
insertion of lifting eyebolts. Once the basket is removed inspect the water jacket for
excess material build-up and flush if necessary using the flushing valve attached to the
rotating union.
The rotor basket will remain functional with some of the holes enlarged or plugged, but it
is recommended that an additional basket be stocked as spare parts in order to allow for
a regularly scheduled change-out allowing for optimum performance. Re-assemble in the
reverse order of above with a generous amount of grease in the o-ring depression.
After re-assembly, check to make certain there are no water leaks. Water should only be
entering the rotor through the rotor basket holes.
Impeller/Baffle
The impeller and baffle are wear items. Remove the impeller by holding the rotor
stationary and using a wrench or socket to remove the impeller bolt. The impeller and
baffle should be stocked as spare parts.
Belt Tension
Belt tension is important to minimize slip and to prolong the life of the belts. In order to
insure proper tensioning of the EAGLE drive belt, the belt guard should be removed.
To adjust the tension of the drive belt, loosen the four motor mounting bolts and adjust
the two motor position SQ HD bolts until the drive belt is tensioned correctly. See 9.
Support Manuals for complete instructions. After following instructions, tighten the motor
position bolts and motor mounting bolts and re-check the belt tension. Check that belts or
sprockets do not rub on the belt guard. Replacement belts should be stocked.
See EAGLE specifications in Support Manuals.
6.2 Lubrication
Greasing Rotor Bearings
Bearings may heat up, particularly during the first few hours of operation and after
greasing. This is normal as the lubricants adjust to correct levels. The bearings may also
expel excess lubricant. Operating temperature range should not exceed 100° C.
The machine is equipped with a grease manifold where all lubrications other than the
rotating union can be performed.
See figure on next page.

Figure 6.2-1 Grease Manifold
TACONITE SEAL
UPPER BEARING
LOWER BEARING (1 of 3)
Grease the two rotor bearings while the unit is operating (rotating) as per the following
lubrication chart. For applications where the unit is exposed to severe splashing,
contamination, temperatures or other adverse environmental conditions, the bearings
must be lubricated more often.
Table 6.2-1 Lubrication Schedule
LUBRICATION POINT LUBRICATION QUANTITY FREQUENCY

1. Taconite Seal 3 grams (3 grease gun pumps) Weekly
2. Top Bearing (1 fitting) 6 grams Weekly
3. Bottom Bearing (3 fittings) 2 grams per fitting Weekly
4. Bottom Bearing 2 grams Weekly
5. Bottom Bearing 2 grams Weekly
These maintenance frequencies are assuming the machine is operating 24 hours per day
and 7 days per week. For other usage, the maintenance frequencies should be adjusted
accordingly.
Always lubricate with bearing turning, and do not mix greases. The only approved
grease is Mobil Mobilith SHC – 100. This is a super premium grease combining a
synthetic base fluid with a lithium complex thickener. It is NLGI 2 Grade with an operating
temperature range of -50ºC to 180ºC (-60ºF to 350ºF).
Do not allow contamination to enter housings. If the grease is contaminated or mixed

with different type grease(s), the bearings should be removed and cleaned or replaced
(as detailed in Operations Manual). Check that bearings and seals rotate freely before
starting concentrator.

Greasing Motor Bearings
The standard motor for a Falcon concentrator is a BALDOR. The voltage, frequency,
frame size, RPM, and application for each machine may vary and lubrication
recommendations are tied to these.
For more information see section 3. of the BALDOR Installation and Operating Manual,
Maintenance & Troubleshooting, in Support Manuals.
BALDOR recommends the following greases for standard service conditions:
Shell Dolium R (Factory Installed)

Chevron SRI
If other greases are preferred, check with a local BALDOR Service Center for
recommendations.
6.3 Rotating Union

The rotating union is the device that allows the process water to enter the rotating
shaft/bowl from the static pipe string. This is lubricated at the factory and does not
require additional lubrication.
Should the union develop a leak or seize due to bearing failure, rebuild kits are available
and should be stocked as spare parts. If significant wear occurs due to the presence of
cyanide or other chemicals, a stainless steel rotating union can be supplied by the
manufacturer or distributor.
To remove, make certain the water system pressure is bled to zero pressure. Remove
the supply hose, and then remove the six bolts that attach the union adapter to the
bottom of the shaft. Note the position of the o-ring during removal, this should be placed
inside the rotor shaft and up against the first outer shoulder.
Note: During disassembly of the rotating union, note any conditions that may have
caused premature failure of the union in order to eliminate further occurrences.
With the union assembly on the bench, the union adapter and the UHMW union guard
can be removed. The shaft of the union has two flat opposing surfaces to accept a
wrench, and by holding the shaft, the union adapter can be turned out. The UHMW union
guard may need to be heated slightly to allow easier separation from the shaft.
Upon re-assembly use caution to keep the union clean of contamination. Re-assemble in
the reverse order of disassembly. Turn water system back on and check for leaks prior to
resuming operation.

6.4 Drive Belt / Sprockets

EAGLE Belt
The EAGLE drive belt must be replaced with the correct belt to insure proper contact with
the accompanying sprockets. See 9. Support Manuals for complete details.
To replace the drive belt, first disconnect and remove the rotating union and then the belt
guard. Use caution in preventing any contamination or damage of the union during
disassembly. Next, loosen the belt tension by loosing the motor mounting bolts and the
motor positioning bolts, and remove the belts. Before installing new belts, inspect the
sprockets for alignment, wear or damage. In some cases material falling down onto the
sprockets may cause wear.
After following the instructions in the Eagle Manual to tension the belt, tighten the motor
position bolts and motor mounting bolts and re-check the tension. Check that belts or
sprockets do not rub on the belt guard.
Replace and fasten the belt guard and rotating union.
Sprockets
Do not change the rotor or motor sprocket size. To replace the rotor or motor sprockets,
first remove the rotating union, belt guard, and drive belt as described in previous
sections. Use caution in preventing any contamination or damage of the union during
disassembly.
To remove the rotor sprocket and bushing, first remove the three bolts holding the
tapered bushing into the sprocket. Then insert two or more of these bolts into the
threaded holes in the bushing flange (to act as jacking screws) and tighten to push the
bushing out of the sprocket.
Remove the motor sprocket with bushing similarly.
Upon re-assembly of the sprocket to the rotor shaft or motor shaft use grease or an anti-
seize compound on the bushing ID, shaft, and bolts but not on the taper between the
bushing and the sprocket. Position the sprocket on the shaft so that the belts are in line
and tighten the three 3/8" bushing/sprocket draw bolts evenly and progressively, to about
30 ft/lbs.
6.5 Rotor Bowl / Shaft

Eventually, the bottom portion of the rotor bowl wall will need re-lining, which will involve
removing the rotor bowl. This usually occurs after a year of so of continuous operation. It
is recommended that the concentrator be moved to a suitable area where there is access
to an overhead crane.

Rotor Bowl Removal
To remove the rotor bowl first remove the lid, lip ring, top plate, rotor basket, and impeller
/ baffle.
Attach a lifting eye bolt to the threaded ¾” hole vacated by the impeller/baffle. Next,
remove the four ¾” bolts in the bottom of the rotor bowl fastening the bowl to the rotor
base plate. Lifting gently, separate the bowl from the base plate.
Rotor Bowl Repair
The rotor bowl surface should be prepared by sand blasting before re-lining. First,
separate the rotor bowl from the rotor base by removing the bolts and using these same
bolts to jack the bowl and base apart.
With all the rotor bowl components now separated, repair as necessary. In addition to
rubber, linatex is also an excellent liner. This product is readily available in most areas of
the world.
For installations using two or more machines, it is recommended that a spare rotor bowl
be stocked as a spare part, to minimize off-line time. An exchange program for rubber
lining the rotor bowl can be set up with the manufacturer or nearest distributor to
minimize cost. For more information see section 6.8 Rubber Lining or contact the nearest
representative or the factory.
Prior to re-assembling, prepare mating surfaces with an anti-seize compound to make

subsequent disassembly easier.
Drive Shaft removal
It is recommended that a complete bearing cartridge be stocked as spares,

utilizing a core exchange program set up by the manufacturer. If the cartridge is to
be shipped or stored the bearing and seal surfaces must be greased to prevent rust and
wrapped to prevent damage.
Removing the rotor drive shaft will be necessary for bearing changes, and may include
the removal of the bearing cartridge itself. However, it should be much easier to remove
the drive shaft from the bearing cartridge with the cartridge remaining attached to the
machine.
After separating the rotor bowl from the drive shaft, remove the tailings launder if still
attached. Next disconnect all piping to the concentrate launder, and remove. Also
remove the rotating union, drive belt guard and guard plate, rotor sprocket, and the seal
protecting ring around the drive shaft flange.
Disconnect the grease fittings, and remove the eight bolts and washers holding the upper
bearing cap. Next, slide the L.E.R. sub assembly off by removing the bolts attaching it to
the lower bearing cap.

Now insert a jack directly under the drive shaft, with a block of wood between. Gently
apply pressure to the drive shaft until it is obvious that there is free movement upwards.
The drive shaft can now be lifted by using the holes in the flange to install eyebolts, or
other approved lifting devices. Observe the location and condition of the o-ring, and
replace if necessary.
Use caution in lifting and moving the drive shaft; do not allow the machined bearing
surfaces to contact any metal surfaces. Lay the drive shaft assembly upside down, with
the shaft pointing upwards.
6.6 Bearing Replacement

IMPORTANT: It is recommended that all bearings and related parts be stocked before
proceeding. Refer to drawings and parts list for part descriptions.
Upper Bearing
To remove the bearings, first remove the drive shaft from the machine as instructed in
the previous sections, and place in a clean location with the flange end down.
Next, remove the external circlip. Then heat the inner race of the lower cylindrical roller
bearing and slide off the shaft. Try to heat the race without heating the shaft by moving
quickly around the race with a cutting / heating torch. Use caution to avoid damaging the
shaft. The lower bearing outer race should remain in the bearing cartridge.
Next, remove the bearing locknut followed by the bearing lock washer. The bearing
spacer can then be heated and slid off the shaft. If the spacer remains locked on the
shaft, use a cutting torch to remove this without damaging the shaft.
Then cut off the outer race from the upper four-point bearing, and heat the inner race
halves (the inner race is split into two pieces) and remove. Again, use caution in heating
the inner races, and only cut if necessary.
It is recommended that the taconite seal be replaced each time the upper bearing is
removed.
Lower Bearing
It will be necessary to remove the bearing cartridge to better access the lower bearing.
First remove the lower bearing cap, then cut the bearing out of the cartridge using great
care not to damage any machined surface. The grease distributor should be replaced.
Re-Assembly
Inspect all machined surfaces and repair, prepare and clean as necessary. Anti-seize
compound should only be used on slide fit components such as the upper outer bearing
race, L.E.R. sub-assembly, bearing canister caps, etc.

Do not use any anti-seize compound on any press fit components such as bearing inner
races or bearing surfaces on the drive shaft.
Use an oil bath or similar method to heat bearing inner races and the inner bearing
spacer. Heat to 80° C or 180° F for approximately 20 minutes.
Insert the lower bearing grease distributor and the outer race portion of the lower bearing
into the bearing cartridge as shown, and attach the lower bearing cap. Next, insert the
outer bearing spacer – housing into the bearing cartridge.
With the drive shaft standing with the flange down, mount the taconite seal with the three
setscrews loose. A new taconite seal may come complete with an outer housing, but this
should be discarded as the mating housing needed is incorporated into the bearing cap.
Apply a generous amount of grease before mounting the upper bearing cap. The seal
and cap should be loose. See section 6.2 Lubrication.
Next, mount the heated upper bearing inner race half, the outer race, and other inner
race half on the drive shaft, sliding these tight against the shoulder. The upper bearing
key slots should be facing the drive shaft flange. Then mount the heated bearing spacer
next to the bearing, followed by the bearing lock washer and locknut.
Turn the locknut until tight, and bend a tab of the lock washer to hold in place. Next,
mount the heated lower bearing inner race and circlip. Apply a generous amount of
grease to all areas of the bearings (approximately three tubes).
The drive shaft is now ready to insert into the bearing cartridge. It might be easiest to
mount the bearing cartridge on the machine for this assembly. Locate the o-ring in the
groove with a covering of grease.
As the drive shaft is lowered into the bearing cartridge guide the bottom through the
lower bearing outer race carefully to avoid nicking any surfaces. Before the drive shaft
bottoms out, insert and start the bolts to attach the upper bearing cap and locate the
bearing key slots. Once the drive shaft settles solidly spin the shaft to detect any “burrs”
or flat spots.
Tighten the upper bearing cap, raise the taconite seal approximately 1/16” above the
lowest position, and tighten the three setscrews in the seal. Next, slide the L.E.R. by
assembly on the shaft and bolt to the lower bearing cap.
Re-assemble the remainder of the machine in the reverse order of its disassembly.
Check that the rotor spins freely before starting, and that the rotor is centered inside the
tailings launder. Some adjustment is possible in the location of the bearing cartridge.
Start the machine and run at a moderately slow speed (20 Hz.) for approximately 10
minutes, checking the bearing temperature. Grease the bearings while the unit is rotating
as per section 6.2 Lubrication.

6.7 Motor Removal

The motor can be removed without disconnecting the concentrator piping or moving the
machine as long as there is sufficient space available. Start by first disconnecting the
electrical wires to the motor.
Next, remove the belt guard, belts and motor sprocket and bushing as described in
previous sections. Then remove three of the four motor plate mounting bolts, and use
one of the lower mounting bolts as a swivel point to swing the motor out from under the
frame.
The motor can be lifted using lifting straps attached to the lifting eye shaft. See BALDOR
Manual for more information.
6.8 Rubber Lining

See related instructions for disassembly of rubber lined components. This should only be
required after extensive hours of operation and excessive rubber wear are apparent or if
damage of some description has occurred.
IMPORTANT: Always re-line surfaces prior to allowing steel to be exposed.
It is recommended that re-lining the rotor, rotor baffle and lid with rubber be performed by
Factory Authorized Personnel and is usually best accomplished by shipping the
component to be re-lined back to the factory or the nearest suitable distributor.
Besides rubber, linatex also serves as a good liner. This product is readily available in
most areas of the world. Use care when using imitation materials, as these do not seem
to last as long as linatex.
6.9 Disassembly / Shipping

Disassemble this equipment in the reverse order of the installation instructions. When
shipping, all loose components should be bolted down. The machine should be cleaned
and crated or securely blocked in a shipping container. When shipping, all loose
components should be bolted down.
IMPORTANT: Do not lay the machine down horizontally unless the bowl is first removed
as instructed in this manual.

6.10 Storage Instructions

When the concentrator is to be idle or stored for extended periods, some precautions and
maintenance functions should be performed. This will help to ensure that the equipment
and its service life does not deteriorate, and it can be brought back into service in top
condition.
Clean the machine inside and out and touch up paint all rust spots prior to lay-up and as
required thereafter.
The machine and AutoPac should be stored in a clean, dry and warm location to prevent
condensation and deterioration.
Motor and rotor bearings should be greased as per the maintenance instructions prior to
lay-up.

6.11 Service Record
DATE SERVICE MAINTENANCE PERFORMED COMMENTS
Photocopy additional pages if required.

6.12 Maintenance Schedule
FUNCTION SECTION FREQUENCY

Inspect water pressure gauges for pre-set values 5.4 Daily
Check for water leaks Daily
Bleed process water system (through rotating union
6.1
flushing valve and Y filter.) Weekly
Grease rotor bearings 6.2 Weekly
Inspect rotor basket and wear ring for wear 6.1 Weekly
Inspect rinse water manifold and spray nozzles 6.1 Weekly
Inspect/clean water line filter 6.1 Weekly
Inspect air pressure lines, solenoid and pinch valve
3.6,5.3 Weekly
operation
Inspect drive belt tension and condition 6.4 Monthly
Clean/replace AutoPac air filter Monthly
Inspect impeller, baffle, rotor and linings for wear or
6.1 Monthly
damage
Grease motor bearings 6.2 Semi-Annually
Inspect motor bearings and wiring Annually
Inspect rotor bearings for wear and contamination 6.1 Annually
Check all fasteners are tight (particularly rotor
Annually
shaft/bowl)
Clean entire machine of grease and dirt and touch
up paint to avoid rust Annually
The preceding maintenance frequencies are assuming the machine is operating 24 hours
per day and 7 days per week. For other usage and under adverse conditions the
maintenance frequencies should be adjusted accordingly.
Maintenance should be scheduled at listed frequencies or sooner to coincide with routine

shutdowns, or according to site specific wear conditions. It is highly recommended that a
preventative maintenance program be implemented to minimize downtime.

7. Recommended Spares
The following is a list of recommended spares that should be stocked in order to support
the production operation of a model SB750 concentrator in a location where factory
shipping of spare parts from stock is not acceptable or timely.
This list may be custom for this particular equipment, please use the part numbers when
ordering.
For contact information see the front of the manual.
Contact manufacturer or nearest distributor for current prices.

Falcon Concentrators Inc.
Page 1
FALCON SPARES - MODEL 750-1751
LEASING COLUMBIA SB750
Kitting Items (ICKITBASEPRICE Rev1) Currency: USD 03/04/2006 3:08:00PM

Qty. UOM Item Number Description Reference Unit Price Selling Price
INSTALLATION KIT# 1
1 EA 301004 FITTING VICTALIC-FLANGE ADAPTER 4 in. STYLE 741 121 121
1 EA 301007 FITTING VICTALIIC-FLANGE ADAPTER 6 in. STYLE 741 160 160
1 EA 301021 FITTING VICTAULIC NIPPLE Grv x Grv 2 in. STYLE 43 11 11
1 EA 320001 COUPLING GROOVED FLEXIBLE 2 in STYLE 75 13 13
1 EA 346001 JOINT EXPANSION 4 in. STYLE 101 159 159
1 EA S121610 SB750 4" FEED PINCH VALVE S/A 2,496 2,496
Total: 3,580
Comment:
COMMISSIONING KIT# 2
1 EA 311021 HOSE SUCTION RUBBER 1¼ in. NL2119-125 1 1
4 EA 317001 NOZZLE VEEJET 1/4 NPT CONNECTOR 1/4U1540 36 145
2 EA 323013 SB750 ROTOR HOSE ASS'Y FALCON 53 107
1 EA 326004 KIT REBUILD VALVE PRESS REDUCING 1-1/4" FLOTECH 65 65
1 EA 337008 SLEEVE VALVE PINCH 4 in. JACO - TYPE RT LINATEX 4" 698 698
1 EA 351001 VALVE SOLENOID 2 WAY N/C 3/4 NPT BRASS JKF8210G9 198 198
1 EA 351002 VALVE SOLENOID 2 WAY N/C 1/2 NPT BRASS JKF8210G2 172 172
1 EA 351010 VALVE SOLENOID 2 WAY N/C BRASS JKF8210G93 195 195
1 EA 351011 VALVE SOLENOID 2 WAY N/O BRASS JKF8210G33 269 269
1 EA 359002 VALVE SOLENOID 4 WAY 2 POS 3/8 NPT BRASS JKF8342G3 384 384
1 EA 408005 BELT DRIVE EAGLE PD W-1200 W-1200 108 108
1 EA 441003 BEARING ROLLER CYLINDRICAL 80 mm I.D. NU1016M1 151 151
1 EA 444004 BEARING FOUR-POINT 90 mm I.D. QJ218N2MPA 315 315
1 EA 532011 KIT UNION ROTATING RH 1 1/4 NPT STD 525-097B-043 392 392
1 EA 821022 SB750 400 V AUTOPAC SPARES KIT ARROW 353 353
1 EA 910001 Grease Mobilith SHC 100 MOBILITH SHC 100 82 82
1 EA S211152 SB750 IMPELLER KIT 168 168
Total: 3,803
Comment:
2 YEAR OPERATING KIT# 3

1 EA 531012 UNION ROTATING RH 1 1/4 NPT STD 525-097-043 672 672
1 EA S210102 SB750 LIP RING 841 841
4 EA S211152 SB750 IMPELLER KIT 168 672
1 EA S211611 SB750 FEED PIPE S/A 4" Diameter 194 194
1 EA S212107 SB750 CONCENTRATE BASKET 12,065 12,065
Total: 14,444
Comment:
CAPITAL KIT# 4
1 EA 813002 E200 PANEL with SB Program E200 1,940 1,940
1 EA 816002 CONTROLLER PROGRAMMABLE FXON-24MR-ES FXON-24 1,116 1,116
1 EA S210101 SB750 ROTOR BOWL w/LINING 11,164 11,164
1 EA S210320 SB750 LAUNDER LID W/LINING 4" FEED PIPE 4,990 4,990
1 EA S210403 SB750 ROTOR TOP PLATE W/LINING 3,444 3,444
1 EA S211602 SB750 RINSING MANIFOLD S/A 1,078 1,078
1 EA S212107 SB750 CONCENTRATE BASKET 12,065 12,065
Total: 35,796
Falcon Concentrators Inc.
Page 2
FALCON SPARES - MODEL 750-1751
LEASING COLUMBIA SB750
Qty. UOM Item Number Description Reference Unit Price Selling Price
Comment:
ALL SPARE PARTS PRICES SUBJECT TOP CHANGE WITHOUT NOTICE

ALL PRICES QUOTED EXW, LANGLEY b.c. CANADA INCO TERMS 2000
PACKING , CRATING AND SHIPPING CHARGES EXTRA AND CAN BE QUOTED BY FALCON IF REQUIRED
8. Drawings
The following is a list of drawings that may be included in this manual.
• General Arrangement
• General Assembly
• Load Specifications
• P&ID
• Electrical Schematics
• Electrical Terminals
• Water Manifold
• Bearing Cartridge
• Rotor
• Flushing Manifold

8 7 6 5 4 3 2 1
ITEM DESCRIPTION QTY PART # REV ITEM DESCRIPTION QTY PART # REV ITEM DESCRIPTION QTY PART # REV REVISION HISTORY
ECO # REV DESCRIPTION DATE APPROVED

1 GR 8 1/4-20 UNC x 1½" Lg. 2 204005 N/A 26 BULKHEAD CONNECTOR - 1/8 NPT BRASS 5 305001 N/A 51 BUSHING QD SF-2 7/8" Dia. BORE 1 422015 N/A 04-021 B FEED PIPE CHANGED FROM 3" TO 4"; HOSE KEEPER AND UNION GUARD ADDED 7/26/2004 TR
2 GR 8 HHCS 1/4-20 UNC x 1¾" Lg 4 204006 N/A 27 FITTING CONNECTOR 90º MALE 1/4 TUBE x 1/8 NPT-M 5 305003 N/A 52 SPROCKET EAGLE DRIVE W-40S-SH 1 427016 N/A
3 GR 8 HHCS 3/8-16 UNC x 3/4" Lg. 13 204012 N/A 28 FITTING NIPPLE CLOSE 1/2 NPT 1 308001 N/A 53 SPROCKET EAGLE DRIVE W-80S-SF 1 427017 N/A 11
8 22
44
4 GR 8 HHCS 3/8-16 UNC x 1" Lg. 10 204014 N/A 29 FITTING NIPPLE CLOSE ¾" NPT 1 308002 N/A 54 UNION ROTATING RH 1-1/4" NPT 1 531012 N/A 2
2
5 GR8 HHCS 3/8-16 UNC x 2" Lg. 4 204018 N/A 30 FITTING NIPPLE CLOSE 1-1/4 NPT 1 308013 N/A 55 MOTOR TEFC 10 HP 230/460 V 3 PHASE 1760 RPM 1 805004 N/A 43
6 GR 8 HHCS 1/2-13 UNC x 1 3/4 Lg. 18 204037 N/A 31 FITTING NIPPLE ¾" NPT x 3" Lg. 1 308014 N/A 56 LAUNDER LID w/LINING 1 S210320 - 2
D 7 GR 8 HHCS 3/4-10 UNC x 2½" Lg. 4 204059 N/A 32 HOSE PUSH-LOK 3/4" ID x 24"LG 1 311002 N/A 57 LIGHTS LAUNDER w/LINING 1 S210401 - B D
15
8 GR8 HHCS 3/8-16 UNC x 4" Lg. 2 204095 N/A 33 HOSE PUSH-LOK 3/4" ID x 40" Lg 1 311002 N/A 58 ROTOR S/A 1 S211101 - 21
9 GR 8 HHCS 3/4-10 UNC x 3 1/4" Lg. 4 204106 N/A 34 HOSE PUSH-LOK 1/2" ID x 24"LG 1 311007 N/A 59 BEARING CARTRIDGE S/A 1 S211201 B 4
10
10 SHSS 1/2-13 UNC x 3" Lg. 2 212010 N/A 35 HOSE SUCTION RUBBER 1-1/4" x 24"LG 1 311021 N/A 60 WATER MANIFOLD S/A 1 S211601 C
66
11 GR 8 NUT HEX 3/8-16 UNC 8 244003 N/A 36 CLAMP PIPE 1-1/4" WELDABLE BASE 1 313023 N/A 61 SS RINSING MANIFOLD S/A 1 S211602 A 1
12 GR 8 NUT HEX 1/2-13 UNC 18 244005 N/A 37 CLAMP PIPE 2" WELDABLE BASE 1 313025 N/A 62 FEED PIPE S/A 1 S211611 -
B
13 GR 8 NUT HEX 3/4-10 UNC 4 244007 N/A 38 CLAMP HOSE T-BOLT 1.57" - 1.69" 2 313028 N/A 63 MAIN FRAME 1 S212301 A B 72
14 WASHER LOCK ¼" 6 252001 N/A 39 COUPLING COMBO NIPPLE ¾" NPT - ¾" HOSE BARB 2 318004 N/A 64 JUNCTION BOX SPACER 2 S212302 - 1
15 WASHER LOCK 3/8" 21 252003 N/A 40 COUPLING 2-LUG UNIVERSAL HOSE END 3/4" 1 318005 N/A 65 MOTOR TENSIONER 1 S212315 -
16 WASHER LOCK ½" 18 252005 N/A 41 COUPLING COMBO NIPPLE 1/2" NPT - HOSE BARB 1 318011 N/A 66 LAUDER PORT COVER 1 S212404 -
17 WASHER LOCK ¾" 8 252007 N/A 42 COUPLING COMBO NIPPLE 1 1/4"NPT 1 318029 N/A 67 HEAVIES LDR PORT COVER 1 S212405 -
23
18 WASHER FLAT 3/8" SAE METALLOY 6 262003 N/A 43 COUPLING VICTAULIC STD FLEXIBLE 4" 2 320009 N/A 68 HEAVIES LAUNDER 1 S212408 - 5
19 WASHER FLAT ½" SAE METALLOY 16 262005 N/A 44 CAP GROOVED END COUPLING 4" 2 320010 N/A 69 DRIVE GUARD PLATE 1 S212501 -
26
20 WASHER FLAT 3/8" USS METALLOY 14 262012 N/A 45 GREASE LINE 1/4" x 48" LG 5 321001 N/A 70 DRIVE GUARD 1 S212502 - 5
21 WASHER FLAT ½" USS METALLOY 16 262014 N/A 46 VALVE BALL FULL PORT BRASS ¾" NPT 1 331004 N/A 71 1-1/4" UNION GUARD 1 S212620 -
C C
22 SHSS 3/8-16 UNC x 1½" Lg. 2 271002 N/A 47 VALVE SOLENOID 2 WAY N/C ¾" NPT BRASS 1 351001 N/A 72 HOSE KEEPER 1 S272315 - B
23 FITTING GREASE NIPPLE 1/8 NPT-M 5 302003 N/A 48 VALVE SOLENOID 2 WAY N/C 1/2" NPT BRASS 1 351002 N/A 73 GREASE LINE GUIDE BLOCK 1 S382701 - B
24 FITTING 150# ELBOW 90° STREET 1/2 NPT 2 304009 N/A 49 BELT DRIVE EAGLE PD W-1200 1 408005 N/A 74 ELECTRICAL JUNCTION BOX 10"x8"x4" 1 SEE NOTE -
25 FITTING 150# TEE REDUCING 1 1/4 x 3/4 NPT 1 304049 N/A 50 BUSHING QD SH-1 3/8 Dia. BORE 1 422014 N/A
21
61
1 62 62
A 40
1 33 JUNCTION BOX BUILT TO
36
1
16 1 B 1
43 1
12 2 SB210012-1751
18 58 56
1 1 39
16 B 2
18 59 37
1 1
21
16 ISO VIEW
6
18 64 2 14 74
2 4 6 1
31
17 9 1
8 4
B 67 47 B
1 57 11
16 1 1
8
28 24 18
1 2
12 32 15
18 3 18 1 21
6 13 6
18 20
14
24 41 19
2 1 16 10 5
2 4
48
1 8 45
2 5 38
34 2
1 20 55 27
14 1 5
60 73
1 1 54 30 25 42 38 35
1 46 1 2 1
68 1 1 1
65 1 14
1 1 2 6
A 59 12 7 REAR VIEW - WATER MANIFOLD A

1 18 4
6
CONFIDENTIAL TOLERANCE TABLE 9663 - 199A STREET, LANGLEY, B.C., CANADA, V1M 2X7
PH: (604) 888-5568 FAX: (604) 888-5521
THIS DRAWING CONTAINS (TOLERANCES UNLESS OTHERWISE SPECIFIED)
18 ONLINE @ http://www.concentrators.net/
13 17 71 50 69 CONFIDENTIAL PROPRIETARY X.X ± 0.1 FRACTION ± 1/32 DWG BY DATE
4 8 1 16 1 1 INFORMATION. NO UNAUTHORIZED X.XX ± 0.01 ANGULAR ± 0.5 DEG
B
54
1
70
1
69
1
18
52 51 15
DISCLOSURE, REPRODUCTION
OR DUPLICATION IS TO BE MADE.
X.XXX ± 0.005 SURFACE FIN. 63 MV 09/01/2006
SB750 CONCENTRATOR
GEN. ASSEMBLY - LEASING COLUMBIA
UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS
1 49 3 29 1 21 CHK BY DATE
53 ARE IN INCHES. DCR
SECTION A-A 1 13
15
1 1
A 3
13
63
1
ALL DIAMETERS TO BE CONCENTRIC WITHIN
0.005 T.I.R. OR AS SPECIFIED.
REMOVE BURRS AND BREAK SHARP CORNERS MATL
09/01/2006
SIZE DWG NO. REV SCALE
21 ASME Y14.5M-1994
0.010 OR AS SPECIFIED.
REMOVE GREASE AND MACHINING OILS.
SEE LIST 1163.5 kg D S210002-175 B 1:10
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISION HISTORY
1 1/2 ZONE REV DESCRIPTION DATE APPROVED
9 5/16 38mm MASS CENTER

237mm 0 ROTOR -FC
D D
NOTES:
MASS CENTER MASS CENTER
IMBALANCE-FA MACHINE-FD 1. ARROW LENGTH INDICATES DIRECTION OF FORCE NOT MAGNITUDE OF FORCE.
2. LOAD CALCULATIONS BASED ON MACHINE TREATING SLURRY ONLY WITH A

TOP PARTICLE SIZE OF 4mm.
ROTATION
FA 3. LOADS ARE ACTUAL MAXIMUMS WITH NO FACTOR OF SAFETY APPLIED.
4. MACHINE MUST BE OPERATED ACCORDING TO FALCON'S MANUAL
C C
9 5/16
237mm
A
MASS CENTER
IMBALANCE-FA
ISO VIEW
FA
MASS CENTER
MACHINE-FD
MASS CENTER
TECHNICAL DATA
B ROTOR-FC B
SB750 CENTRIFUGAL GRAVITY CONCENTRATOR - SEMI-BATCH
1716mm
67 9/16
ITEM DESCRIPTION SIZE / DESCRIPTION / DETAILS

1361mm
1 STATIC LOADS
53 9/16
Mass of Concentrator FD, lbm 2550

1146mm
Mass of Concentrator Sanded FD, lbm 3630

45 1/8
Mass of Rotor FC, lbm 648

870mm
Mass Moment of Inertia of Rotor, lbm-ft^2 319

34 1/4
Mass of Imbalance - Maximum FB, lbm 2
2 DYNAMIC LOADS
Type of Load Rotating (Harmonic)
Direction of Rotation Top View Counterclockwise
Mass of Imbalance in Centrifugal Field FA, lbm
50 g's ( 459 rpm / 7.65 Hz ) 100
100 g's ( 649 rpm / 1081 Hz ) 200
1 1/2
38mm 150 g's ( 795 rpm / 13.25 Hz ) 300
A A 200 g's ( 917 rpm / 15.28 Hz ) 400 A
FD FB FC SECTION A-A CONFIDENTIAL TOLERANCE TABLE 9663 - 199A STREET, LANGLEY, B.C., CANADA, V1M 2X7
(TOLERANCES UNLESS OTHERWISE SPECIFIED)
PH: (604) 888-5568 FAX: (604) 888-5521
THIS DRAWING CONTAINS ONLINE @ http://www.concentrators.net/
CONFIDENTIAL PROPRIETARY X.X ± 0.1 FRACTION ± 1/32 DWG BY DATE
INFORMATION. NO UNAUTHORIZED
X.XX ± 0.01
X.XXX ± 0.005
ANGULAR
SURFACE FIN.
± 0.5 DEG
63 MV 14/07/2005 SB750 CONCENTRATOR
ARE IN INCHES.
CHK BY
DCR
DATE
14/07/2005 LOAD SPECIFICATION

S210109
REMOVE BURRS AND BREAK SHARP CORNERS MATL SIZE DWG NO. REV SCALE
ASME Y14.5M-1994
SEE LIST 1163.5 kg D B NTS
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISION HISTORY
ZONE REV DESCRIPTION DATE APPROVED
C CHANGED 2ND 1/2" BALL VALVE TO BRASS PER ECO 05-006 7/14/05 GV
19
1
12
D 21 D
1 2
9
1
16
1 22
1
23 23
2 2
5
1
15
1
4
1
C C
18
1
13 6
8 1 1
1
18
14 1
10 1
2 11
2
3
2
3
20 2
2 C
B 17 B
1
10
21 2 ITEM DESCRIPTION QTY PART N0 REV
1 2
2 1 FITTING 150# PLUG PIPE ¾" NPT 1 304003 N/A
2 FITTING 150# ELBOW STREET 90° ¾" NPT 2 304007 N/A
3 FITTING 150# ELBOW 90° STREET 1/2 NPT 2 304009 N/A ITEM DESCRIPTION QTY PART N0 REV
4 FITTING 150# ELBOW STREET 90° 1-1/4" NPT 1 304030 N/A 14 FITTING NIPPLE 1-1/4" NPT x 2" Lg. 1 308031 N/A
5 FITTING 150# BUSHING 3/4 x 1/4 1 304043 N/A 15 FILTER "Y" ALUMINUM 2" - 40MESH 1 315008 N/A
6 FITTING 150# TEE REDUCING 1 1/4 x 3/4 NPT 1 304049 N/A 16 COUPLING NIPPLE 360° SWIVEL ¾ NPT - ¾ HOSE BARB 1 318003 N/A
7 FITTING 150# CROSS 3/4 NPT 1 304052 N/A 17 COUPLING SWIVEL COMBO NIPPLE 1/2" NPT - HOSE BARB 1 318024 N/A
8 FITTING 150# REDUCING TEE 2x3/4"BRANCH 1 304053 N/A 18 COUPLING COMBO NIPPLE 1 1/4"NPT 1 318029 N/A
9 FITTING 150# COUPLING REDUCER 2 NPT x 1-1/4 NPT 1 304054 N/A 19 VALVE PRESSURE REDUCING 1-1/4" W/SOL 1 327004 N/A
10 FITTING 150# COUPLING REDUCER 3/4 NPT x 1/2 NPT 2 304061 N/A 20 VALVE BALL FULL PORT BRASS 1/2" NPT 2 331003 N/A
11 FITTING NIPPLE CLOSE 1/2 NPT 2 308001 N/A 21 VALVE BALL FULL PORT BRASS ¾" NPT 1 331004 N/A
12 FITTING NIPPLE CLOSE ¾" NPT 2 308002 N/A 22 GAUGE PRESSURE 0 - 30 p.s.i. BOTTOM MOUNT 1 601001 N/A
A A
13 FITTING 150# NIPPLE 1-1/4" NPT x 6" Lg. 1 308029 N/A 23 GAUGE PRESSURE 0 - 100 p.s.i. BOTTOM MOUNT 2 601005 N/A
PH: (604) 888-5568 FAX: (604) 888-5521
(TOLERANCES UNLESS OTHERWISE SPECIFIED)
7 8 1 THIS DRAWING CONTAINS ONLINE @ http://www.concentrators.net/
CONFIDENTIAL PROPRIETARY
1 1 1 INFORMATION. NO UNAUTHORIZED
X.X ± 0.1
X.XX ± 0.01
FRACTION
ANGULAR
± 1/32
± 0.5 DEG
DWG BY DATE
X.XXX ± 0.005 SURFACE FIN. 63 MV 30/10/2002 SB750 CONCENTRATOR
ARE IN INCHES.
CHK BY
DCR
DATE
30/10/2002
WATER MANIFOLD S/A
REMOVE BURRS AND BREAK SHARP CORNERS MATL WT(lbs.) SIZE DWG NO. REV SCALE
ASME Y14.5M-1994
SEE LIST 15.2 kg D S211601 C 1:2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
REVISION HISTORY
7 16 21 ZONE REV DESCRIPTION DATE APPROVED

4 1A A UPDATED REVISED PARTS 7/7/02 MV
A 22
B ECO 04-013: BEARING UPGRADE 7/7/04 MV
12 12
22 1
D D
2 5
9 20
17
B
20
B 8 11
B 11
8
C
19 B
A 24 GRIND 1/4" DOWEL PIN

TO MATCH NOTCH IN
BEARING
DETAIL C
C 14 15 25 C
19 ISO VIEW
1:4
ITEM DESCRIPTION QTY PART NO. REV

1 GR 8 HHCS 3/8-16 UNC x ½" Lg. 2 204011 N/A
2 GR 8 HHCS 3/8-16 UNC x 1 1/4" Lg. 6 204015 N/A
3 SHCS 3/8-16 UNC x 1 1/4" Lg. 6 212006 N/A
4 FHCS 5/16-18 UNC x 1" Lg. 4 232001 N/A
5 WASHER LOCK 3/8" 8 252003 N/A
6 WASHER LOCK HI COLLAR 3/8 6 254003 N/A
7 PIN DOWEL Ø3/8 x 1 Lg. 3 281004 N/A
23 B 8 PIN DOWEL Ø1/4" x 1" Lg. 2 281007 N/A

B 9 FITTING CONNECTOR 90º MALE 1/4 TUBE x 1/8 NPT-M 5 305003 N/A B
B 10 BEARING ROLLER CYLINDRICAL 80 mm I.D. 1 441003 N/A
B 11 4 POINT ANGULAR CONTACT QJ 218 N2MA 1 444004 N/A
9
12 SEAL TACONITE - TA400 1 451008 N/A
13 SEAL FEY LAMINAR RING - FK6 1 451009 N/A
14 NUT LOCK BEARING KM18 1 454007 N/A
15 WASHER LOCK BEARING MB18A 1 454008 N/A
16 O-RING STANDARD .139 CS x 1.984 I.D. 1 511226 N/A
17 O-RING CUSTOM .070 CS x 6.50 I.D. 1 516024 N/A
26
23 18 CIRCLIP EXTERNAL STANDARD - 3 1/8 SHAFT 1 541005 N/A
6 3 19 BEARING HOUSING 1 S212201 A
B
10 20 BEARING CAP - UPPER 1 S212202 A
B 21 DRIVE SHAFT 1 S212204 B
18 22 SEAL PROTECTION RING 1 S212206 -

23 GREASE DIST. - LWR BEARING 1 S212208 -
21 A 24 BEARING SPACER - SHAFT 1 S212211 A
13
25 BEARING SPACER - HOUSING 1 S212212 A
A 26 A
26 BEARING CAP - LOWER 1 S212214 C
SECTION A-A
PH: (604) 888-5568 FAX: (604) 888-5521
THIS DRAWING CONTAINS (TOLERANCES UNLESS OTHERWISE SPECIFIED)
ONLINE @ http://www.concentrators.net/
CONFIDENTIAL PROPRIETARY X.X ± 0.1 FRACTION ± 1/32 DWG BY DATE
INFORMATION. NO UNAUTHORIZED X.XX ± 0.01 ANGULAR ± 0.5 DEG
A DISCLOSURE, REPRODUCTION
X.XXX ± 0.005 SURFACE FIN. 63 MV 06/07/2004 SB750 CONCENTRATOR
ARE IN INCHES.
CHK BY
DCR
DATE
06/07/2004
BEARING CARTRIDGE S/A
DETAIL B REMOVE BURRS AND BREAK SHARP CORNERS MATL WT(lbs.) SIZE DWG NO. REV SCALE
ASME Y14.5M-1994
SEE LIST 101.5 kg D S211201 B 1:2
8 7 6 5 4 3 2 1
4 3 2 1
REVISION HISTORY
20 15 11 18 10
7
ASSEMBLE WITH PIPE DOPE 2
7 4
D D
17 7 1
14
21
C C
16 ITEM DESCRIPTION QTY PART NO. REV

13
1 GR 8 HHCS 3/8-16 UNC x ½" Lg. 4 204011 N/A
2 GR 8 HHCS 3/8-16 UNC x 1" Lg. 12 204014 N/A
6
3 HHCS 3/4-10 UNC x 1" Lg. 2 204054 N/A
4 GR 8 HHCS 3/8-16 UNC x 5/8" Lg. 12 204089 N/A
5 GR 8 HHCS 3/4-10 UNC x 3 1/2" Lg. 4 204097 N/A
9 6 SHCS 3/4-10 UNC x 4" Lg. 1 212021 N/A
7 WASHER LOCK 3/8" 28 252003 N/A
22 8 WASHER LOCK ¾" 6 252007 N/A
B 9 WASHER LOCK HI COLLAR 3/4 1 254007 N/A B
10 HSSS 1/2-13 UNC x 3/8" Lg. 2 272001 N/A
11 PIN DOWEL Ø3/8 x 1 Lg. 3 281004 N/A
12 3/4" M JIC x 3/4" M ORB 90 FITTING 2 309004 N/A
13 3/4" M JIC x 3/4" M ORB STRAIGHT FITTING 2 309005 N/A
14 ROTOR HOSE 2 323013 -
15 O-RING CUSTOM .139 CS x 21.75 I.D. 1 516023 N/A
16 RUBBER STOPPER SIZE 1 1 522001 N/A
17 ROTOR BOWL w/LINING 1 S210101 -
18 LIP RING w/LINING 1 S210102 -
12
19 ROTOR BASE W/LINING 1 S210103 -
20 ROTOR TOP PLATE w/LINING 1 S210403 -
19
21 ROTOR BASKET 1 S212107 -
A A
22 IMPELLER BAFFLE 1 S212115 -
5 3 CONFIDENTIAL TOLERANCE TABLE 9663 - 199A STREET, LANGLEY, B.C., CANADA, V1M 2X7
8 (TOLERANCES UNLESS OTHERWISE SPECIFIED) PH: (604) 888-5568 FAX: (604) 888-5521
8 THIS DRAWING CONTAINS
INFORMATION. NO UNAUTHORIZED X.X ± 0.1 FRACTION ± 1/32 ONLINE @ http://www.concentrators.net/
X.XX ± 0.01 ANGULAR ± 0.5 DEG
SB750 CONCENTRATOR
DISCLOSURE, REPRODUCTION X.XXX ± 0.005 SURFACE FIN. 63 DWG BY DATE
MV 30/10/2002
ARE IN INCHES.
CHK BY
DCR
DATE
30/10/2002 ROTOR S/A
S211101
REMOVE BURRS AND BREAK SHARP CORNERS
ASME Y14.5M-1994
MATL
SEE LIST
WT(lbs.)
256.8 kg
SIZE
C DWG NO.
-
REV SCALE
1:8
4 3 2 1
REVISION HISTORY
A1 A CHANGED TO SS 7/29/2005 GV
D 1 D
C C
ISO VIEW
1:2
B B
4
3
ITEM DESCRIPTION QTY PART NO. REV

1 GR 8 HHCS 3/8-16 UNC x 1" Lg. 2 204014 N/A
2 WASHER LOCK 3/8" 2 252003 N/A
A 3 FITTING 150# ELBOW 90 deg. 3/4 NPT SS 1 304073 N/A
4 NOZZLE VEEJET 1/4 NPT CONNECTOR 3 317001 N/A
5 COUPLING 2-LUG UNIVERSAL MALE END 3/4" NPT 1 318001 N/A
6 FLUSHING MANIFOLD RETAINER 1 C202450 -
A A 7 SS PIPE PLUG 1 S212602 A

A
7 A 8 SS FLUSHING MANIFOLD 1 S212603 A
THIS DRAWING CONTAINS (TOLERANCES UNLESS OTHERWISE SPECIFIED) PH: (604) 888-5568 FAX: (604) 888-5521
INFORMATION. NO UNAUTHORIZED X.X ± 0.1 FRACTION ± 1/32 ONLINE @ http://www.concentrators.net/
X.XX ± 0.01 ANGULAR ± 0.5 DEG
SB750 CONCENTRATOR
DISCLOSURE, REPRODUCTION X.XXX ± 0.005 SURFACE FIN. 63 DWG BY DATE
OR DUPLICATION IS TO BE MADE. MV 30/10/2002
UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS A
ARE IN INCHES.
CHK BY
DCR
DATE
30/10/2002 SS RINSING MANIFOLD S/A
S211602
REMOVE BURRS AND BREAK SHARP CORNERS
ASME Y14.5M-1994
MATL
SEE LIST
WT(lbs.)
1.8 kg
SIZE
C DWG NO.
A
REV SCALE
1:2
9. Support Manuals
The following is a list of support Manuals that may be included in this manual.
• VFD (or AFD)

• Operator Interface
• Pressure / Flow Control Valve
• Pressure Transmitter
• Solenoids
• Motor
• Vibration
• Eagle Drive
• Rotating Union
• Air Regulator
• Communication Module
TRANSISTORIZED INVERTER
FR-E500
FR-E500-NA
INSTRUCTION MANUAL
HIGH PERFORMANCE
&
HIGH FUNCTION
FR-E520-0.1K to 7.5K-NA
FR-E540-0.4K to 7.5K-NA OUTLINE Chapter 1
FR-E510W-0.1K to 0.75K-NA INSTALLATION

AND WIRING Chapter 2
OPERATION/
CONTROL Chapter 3
PARAMETERS Chapter 4
INSTRUCTION MANUAL
HEAD OFFICE:MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100-8310
PROTECTIVE Chapter 5
FUNCTIONS
SPECIFICATIONS Chapter 6
IB (NA) 66866-C (9905) ROD Printed in Japan Specifications subject to change without notice.
Thank you for choosing the Mitsubishi Transistorized inverter.
This instruction manual gives handling information and precautions for use of this
equipment.
Incorrect handling might cause an unexpected fault. Before using the inverter, please
read this manual carefully to use the equipment to its optimum.
Please forward this manual to the end user.
This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have read
through this instruction manual and appended documents carefully and can use the
equipment correctly.
Do not use the inverter until you have a full knowledge of the equipment, safety
information and instructions.
In this manual, the safety instruction levels are classified into "WARNING" and
"CAUTION".
Assumes that incorrect handling may cause hazardous

WARNING conditions, resulting in death or severe injury.

CAUTION conditions, resulting in medium or slight injury, or may
cause physical damage only.
Note that even the CAUTION level may lead to a serious consequence according to
conditions. Please follow the instructions of both levels because they are important
to personnel safety.
A-1
SAFETY INSTRUCTIONS
1. Electric Shock Prevention
WARNING
z While power is on or when the inverter is running, do not open the front cover.
You may get an electric shock.
z Do not run the inverter with the front cover removed. Otherwise, you may access
the exposed high-voltage terminals or the charging part of the circuitry and get
an electric shock.
z If power is off, do not remove the front cover except for wiring or periodic
inspection. You may access the charged inverter circuits and get an electric
shock.
z Before starting wiring or inspection, switch power off, wait for more than 10
minutes, and check for residual voltage with a meter (refer to chapter 2 for
further details) etc.
z Earth the inverter.
z Any person who is involved in the wiring or inspection of this equipment should
be fully competent to do the work.
z Always install the inverter before wiring. Otherwise, you may get an electric
shock or be injured.
z Operate the switches and potentiometers with dry hands to prevent an electric
shock.
z Do not subject the cables to scratches, excessive stress, heavy loads or
pinching. Otherwise, you may get an electric shock.
z Do not change the cooling fan while power is on.
It is dangerous to change the cooling fan while power is on.
2. Fire Prevention
CAUTION
z Mount the inverter and brake resistor on an incombustible surface. Installing the
inverter directly on or near a combustible surface could lead to a fire.
z If the inverter has become faulty, switch off the inverter power. A continuous
flow of large current could cause a fire.
z When a brake resistor is used, use an alarm signal to switch power off.
Otherwise, the brake resistor will overheat abnormally due a brake transistor or
other fault, resulting in a fire.
z Do not connect a resistor directly to the DC terminals P(+), N(−). This could
cause a fire.
A-2
3. Injury Prevention
CAUTION
z Apply only the voltage specified in the instruction manual to each terminal to
prevent damage etc.
z Ensure that the cables are connected to the correct terminals. Otherwise,
damage etc. may occur.
z Always make sure that polarity is correct to prevent damage etc.
z While power is on and for some time after power-off, do not touch the inverter or
brake resistor as they are hot and you may get burnt.
4. Additional instructions
Also note the following points to prevent an accidental failure, injury, electric shock, etc.
(1) Transportation and installation
CAUTION
z When carrying products, use correct lifting gear to prevent injury.
z Do not stack the inverter boxes higher than the number recommended.
z Ensure that installation position and material can withstand the weight of the
inverter. Install according to the information in the Instruction Manual.
z Do not operate if the inverter is damaged or has parts missing.
z Do not hold the inverter by the front cover or operation panel; it may fall off.
z Do not stand or rest heavy objects on the inverter.
z Check the inverter mounting orientation is correct.
z Prevent screws, wire fragments or other conductive bodies or oil or other
flammable substance from entering the inverter.
z Do not drop the inverter, or subject it to impact.
z Use the inverter under the following environmental conditions:
Ambient Constant torque : -10°C to +50°C (14°F to 122 °F)
temperature (non-freezing)
Ambient humidity 90%RH or less (non-condensing)
Environment
Storage
-20°C to +65°C * (-4°F to 149 °F)
temperature
Indoors (free from corrosive gas, flammable gas, oil mist, dust
Ambience
and dirt)
Maximum 1000m (3280.80 feet) above sea level for standard
Altitude, vibration operation. After that derate by 3% for every extra 500m
(1640.40 feet) up to 2500m (8202.00 feet) (91%).
*Temperatures applicable for a short time, e.g. in transit.
A-3
(2) Wiring
CAUTION
z Do not fit capacitive equipment such as a power factor correction capacitor,
radio noise filter or surge suppressor to the output of the inverter.
z The connection orientation of the output cables U, V, W to the motor will affect
the direction of rotation of the motor.
(3) Trial run
CAUTION
z Check all parameters, and ensure that the machine will not be damaged by a
sudden start-up.
(4) Operation
WARNING
z When you have chosen the retry function, stay away from the equipment as it
will restart suddenly after an alarm stop.
z The [STOP] key is valid only when the appropriate function setting has been
made. Prepare an emergency stop switch separately.
z Make sure that the start signal is off before resetting the inverter alarm. A failure
to do so may restart the motor suddenly.
z The load used should be a three-phase induction motor only. Connection of any
other electrical equipment to the inverter output may damage the equipment.
z Do not modify the equipment.
CAUTION
z The electronic overcurrent protection does not guarantee protection of the
motor from overheating.
z Do not use a magnetic contactor on the inverter input for frequent
starting/stopping of the inverter.
z Use a noise filter to reduce the effect of electromagnetic interference. Otherwise
nearby electronic equipment may be affected.
z Take measures to suppress harmonics. Otherwise power harmonics from the
inverter may heat/damage the power capacitor and generator.
A-4
CAUTION
z When a 400V class motor is inverter-driven, it should be insulation-enhanced or
surge voltages suppressed. Surge voltages attributale to the wiring constants
may occur at the motor terminals, deteriorating the insulation of the motor.
z When parameter clear or all clear is performed, each parameter returns to the
factory setting. Re-set the required parameters before starting operation.
z The inverter can be easily set for high-speed operation. Before changing its
setting, fully examine the performances of the motor and machine.
z In addition to the inverter's holding function, install a holding device to ensure
safety.
z Before running an inverter which had been stored for a long period, always
perform inspection and test operation.
(5) Emergency stop
CAUTION
z Provide a safety backup such as an emergency brake which will prevent the
machine and equipment from hazardous conditions if the inverter fails.
(6) Maintenance, inspection and parts replacement
CAUTION
z Do not carry out a megger (insulation resistance) test on the control circuit of
the inverter.
(7) Disposing of the inverter
CAUTION
z Treat as industrial waste.
(8) General instructions

Many of the diagrams and drawings in this instruction manual show the inverter
without a cover, or partially open. Never operate the inverter like this. Always
replace the cover and follow this instruction manual when operating the inverter.
A-5
CONTENTS
Contents
1 OUTLINE 1
1.1 Pre-Operation Information.......................................................................................... 1

1.1.1 Precautions for operation..................................................................................... 1
1.2 Basic Configuration .................................................................................................... 3
1.2.1 Basic configuration .............................................................................................. 3
1.3 Structure..................................................................................................................... 4
1.3.1 Appearance and structure ................................................................................... 4
1.3.2 Removal and reinstallation of the front cover ...................................................... 5
1.3.3 Removal and reinstallation of the wiring cover .................................................... 7
1.3.4 Removal and reinstallation of the accessory cover.............................................. 8
1.3.5 Reinstallation and removal of the control panel................................................... 9
1.3.6 Removal of the control panel (FR-PA02-02) front cover..................................... 10
1.3.7 Exploded view.................................................................................................... 11
2 INSTALLATION AND WIRING 12
2.1 Installation ................................................................................................................ 12

2.1.1 Instructions for installation ................................................................................. 12
2.2 Wiring ....................................................................................................................... 14
2.2.1 Terminal connection diagram ............................................................................ 14
2.2.2 Wiring of the main circuit ................................................................................... 18
2.2.3 Wiring of the control circuit ................................................................................ 23
2.2.4 Connection to the PU connector........................................................................ 28
2.2.5 Connection of stand-alone option units ............................................................. 31
2.2.6 Design information............................................................................................. 34
2.3 Other Wiring ............................................................................................................. 35
2.3.1 Power supply harmonics.................................................................................... 35
2.3.2 Japanese harmonic suppression guideline........................................................ 36
2.3.3 Inverter-generated noise and reduction techniques........................................... 36
2.3.4 Leakage currents and countermeasures ........................................................... 40
2.3.5 Inverter-driven 400V class motor ....................................................................... 41
2.3.6 Peripheral devices ............................................................................................. 42
2.3.7 Instructions for compliance with the UL and CSA standards ............................. 46
2.3.8 Instructions for compliance with the European standards ................................. 47
I
3 OPERATION/CONTROL 49
3.1 Pre-Operation Information........................................................................................ 49

3.1.1 Types of operation modes ................................................................................. 49
3.1.2 Power on............................................................................................................ 51
3.2 About the Control Panel ........................................................................................... 52
3.2.1 Names and functions of the control panel (FR-PA02- 02)................................... 52
3.2.2 Control panel mode is changed by pressing the MODE key ................................ 53
3.2.3 Monitoring .......................................................................................................... 53
3.2.4 Frequency setting .............................................................................................. 54
3.2.5 Parameter setting method ................................................................................. 54
3.2.6 Operation mode ................................................................................................. 56
3.2.7 Help mode ......................................................................................................... 56
3.3 Operation ................................................................................................................. 59
3.3.1 Pre-operation checks......................................................................................... 59
3.3.2 External operation mode (Operation using the external
frequency setting potentiometer and external start signal) ................................ 60
3.3.3 PU operation mode (Operation using the control panel).................................... 61
3.3.4 Combined operation mode 1
(Operation using both external start signal and control panel).......................... 62
3.3.5 Combined operation mode 2 ............................................................................. 63
4 PARAMETERS 64
4.1 Parameter List .......................................................................................................... 64

4.1.1 Parameter list..................................................................................................... 64
4.1.2 List of parameters classified by purpose of use................................................. 70
4.1.3 Parameters recommended to be set by the user............................................... 72
4.2 Parameter Function Details...................................................................................... 73
4.2.1 Torque boost (Pr. 0, Pr. 46) ............................................................................... 73
4.2.2 Output frequency range (Pr. 1, Pr. 2, Pr. 18) ..................................................... 74
4.2.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19, Pr. 47)......................... 75
4.2.4 Multi-speed operation (Pr. 4, Pr. 5, Pr. 6, Pr. 24 to Pr. 27, Pr. 232 to Pr. 239). 76
4.2.5 Acceleration/deceleration time (Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45)....... 77
4.2.6 Electronic overcurrent protection (Pr. 9, Pr. 48)................................................. 79
4.2.7 DC dynamic brake (Pr. 10 to Pr. 12).................................................................. 80
II
4.2.8 Starting frequency (Pr. 13)................................................................................. 81
Contents
4.2.9 Load pattern selection (Pr. 14) .......................................................................... 82
4.2.10 Jog operation (Pr. 15, Pr. 16) .......................................................................... 83
4.2.11 Stall prevention (Pr. 22, Pr. 23, Pr. 66) ............................................................ 84
4.2.12 Acceleration/deceleration pattern (Pr. 29) ....................................................... 86
4.2.13 Regenerative brake duty (Pr. 30, Pr. 70) ......................................................... 87
4.2.14 Frequency jump (Pr. 31 to Pr. 36).................................................................... 88
4.2.15 Speed display (Pr. 37) ..................................................................................... 89
4.2.16 Frequency at 5V (10V) input (Pr. 38) ............................................................... 90
4.2.17 Frequency at 20mA input (Pr. 39).................................................................... 90
4.2.18 Up-to-frequency sensitivity (Pr. 41).................................................................. 91
4.2.19 Output frequency detection (Pr. 42, Pr. 43) ..................................................... 91
4.2.20 Monitor display (Pr. 52, Pr. 54, Pr. 158)........................................................... 93
4.2.21 Monitoring reference (Pr. 55, Pr. 56) ............................................................... 95
4.2.22 Automatic restart after instantaneous power failure
(Pr. 57, Pr. 58).................................................................................................. 96
4.2.23 Remote setting function selection (Pr. 59)....................................................... 97
4.2.24 Shortest acceleration/deceleration mode (Pr. 60 to Pr. 63) ............................. 98
4.2.25 Retry function (Pr. 65, Pr. 67 to Pr. 69) ......................................................... 100
4.2.26 Applied motor (Pr. 71).................................................................................... 102
4.2.27 PWM carrier frequency (Pr. 72, Pr. 240) ....................................................... 103
4.2.28 Voltage input (Pr. 73)..................................................................................... 104
4.2.29 Input filter time constant (Pr. 74).................................................................... 105
4.2.30 Reset selection/PU disconnection detection/PU stop
selection (Pr. 75)............................................................................................ 105
4.2.31 Parameter write inhibit selection (Pr. 77) ....................................................... 107
4.2.32 Reverse rotation prevention selection (Pr. 78)............................................... 108
4.2.33 Operation mode selection (Pr. 79)................................................................. 109
4.2.34 General-purpose magnetic flux vector control selection (Pr. 80) ........................ 112
4.2.35 Offline auto tuning function (Pr. 82 to Pr. 84, Pr. 90, Pr. 96) ......................... 114
4.2.36 Computer link operation (Pr. 117 to Pr. 124) ................................................. 120
4.2.37 PID control (Pr. 128 to Pr. 134) ..................................................................... 131
4.2.38 Output current detection function (Pr. 150, Pr.151) ....................................... 139
4.2.39 Zero current detection (Pr. 152, Pr.153) ........................................................ 140
4.2.40 Stall prevention function and current limit function (Pr. 156) ......................... 141
III
4.2.41 User group selection (Pr. 160, Pr. 173 to Pr. 176)......................................... 143
4.2.42 Actual operation hour meter clear (Pr. 171)................................................... 145
4.2.43 Input terminal function selection (Pr. 180 to Pr. 183)..................................... 145
4.2.44 Output terminal function selection (Pr. 190 to Pr. 192).................................. 147
4.2.45 Cooling fan operation selection (Pr. 244) ...................................................... 148
4.2.46 Slip compensation (Pr. 245 to Pr. 247).......................................................... 149
4.2.47 Ground fault detection at start (Pr. 249)
(400V class does not have this function) ....................................................... 150
4.2.48 Stop selection (Pr. 250) ................................................................................. 151
4.2.49 Meter (frequency meter) calibration (Pr. 900) (200V class, 100V class)....... 153
4.2.50 Meter (frequency meter) calibration (Pr. 901) (400V class) ........................... 155
4.2.51 Biases and gains of the frequency setting voltage (current)
(Pr. 902 to Pr. 905) ........................................................................................ 157
5 PROTECTIVE FUNCTIONS 163
5.1 Errors (Alarms) ....................................................................................................... 163

5.1.1 Error (alarm) definitions ................................................................................... 163
5.1.2 To know the operating status at the occurrence of alarm ................................ 171
5.1.3 Correspondence between digital and actual characters .................................. 171
5.1.4 Resetting the inverter....................................................................................... 171
5.2 Troubleshooting ..................................................................................................... 172
5.2.1 Motor remains stopped .................................................................................... 172
5.2.2 Motor rotates in opposite direction................................................................... 172
5.2.3 Speed greatly differs from the setting .............................................................. 173
5.2.4 Acceleration/deceleration is not smooth .......................................................... 173
5.2.5 Motor current is large ....................................................................................... 173
5.2.6 Speed does not increase ................................................................................. 173
5.2.7 Speed varies during operation ......................................................................... 173
5.2.8 Operation mode is not changed properly......................................................... 174
5.2.9 Control panel display is not operating.............................................................. 174
5.2.10 POWER lamp is not lit ................................................................................... 174
5.2.11 Parameter write cannot be performed ........................................................... 174
5.3 Precautions for Maintenance and Inspection ......................................................... 175
5.3.1 Precautions for maintenance and inspection................................................... 175
5.3.2 Check items ..................................................................................................... 175
IV
5.3.3 Periodic inspection........................................................................................... 175
Contents
5.3.4 Insulation resistance test using megger........................................................... 176
5.3.5 Pressure test.................................................................................................... 176
5.3.6 Daily and Periodic Inspection .......................................................................... 177
5.3.7 Replacement of parts....................................................................................... 180
5.3.8 Measurement of main circuit voltages, currents and powers........................... 185
6 SPECIFICATIONS 188
6.1 Standard Specifications ......................................................................................... 188

6.1.1 Model specifications ........................................................................................ 188
6.1.2 Common specifications.................................................................................... 191
6.1.3 Outline drawings .............................................................................................. 193
APPENDIX 199
Appendix 1 Data Code List........................................................................................... 199
V
C CHAPTER
H A P T E R 11
O OUTLINE
U T L IN E
This chapter gives information on the basic "outline" of this
product.
Always read the instructions before using the equipment.
1.1 Pre-Operation Information .......................................... 1 Chapter 1

1.2 Basic Configuration..................................................... 3
1.3 Structure ..................................................................... 4
Chapter 2
<Abbreviations>
y PU
Control panel and parameter
Chapter 3
unit (FR-PU04)
y Inverter
Mitsubishi transistorized inverter
FR-E500 series
y Pr. Chapter 4
Parameter number
Chapter 5
Chapter 6
1.1 Pre-Operation Information
OUTLINE
1 OUTLINE
1.1.1 Precautions for operation

This manual is written for the FR-E500 series transistorized inverters.
Incorrect handling may cause the inverter to operate incorrectly, causing its life to be
reduced considerably, or at the worst, the inverter to be damaged. Handle the inverter
properly in accordance with the information in each section as well as the precautions
and instructions of this manual to use it correctly.
For handling information on the parameter unit (FR-PU04), stand-alone options, etc.,
refer to the corresponding manuals.
(1) Unpacking and product check
Unpack the inverter and check the capacity plate on the front cover and the rating plate
on the inverter side face to ensure that the product agrees with your order and the
inverter is intact.
1) Inverter type
Capacity plate Rating plate

MITSUBISHI INVERTER
Capacity plate Rating plate MODEL

FR-E520-0.1K-NA Inverter type
Input rating INPUT : XXXXX
FR-E520-0.1K-NA/ Output rating OUTPUT : XXXXX
Serial number SERIAL :
Inverter type Serial number PASSED
z Inverter type
FR - E520 - 0.1 K - NA
Symbol Voltage Class
Represents the
Three-phase
E520 inverter capacity
200V class
"kW ".
Three-phase
E540
400V class
Single-phase
E510W
100V class
2) Accessory
Instruction manual
If you have found any discrepancy, damage, etc., please contact your sales
representative.
1
OUTLINE
(2) Preparation of instruments and parts required for operation

Instruments and parts to be prepared depend on how the inverter is operated. Prepare
equipment and parts as necessary. (Refer to page 49.)
(3) Installation
To operate the inverter with high performance for a long time, install the inverter in a
proper place, in the correct direction, with proper clearances. (Refer to page 12.)
(4) Wiring
Connect the power supply, motor and operation signals (control signals) to the terminal
block. Note that incorrect connection may damage the inverter and peripheral devices.
(See page 14.)
2
1.2 Basic Configuration
OUTLINE
1.2 Basic Configuration
1.2.1 Basic configuration

The following devices are required to operate the inverter. Proper peripheral devices
must be selected and correct connections made to ensure proper operation. Incorrect
system configuration and connections can cause the inverter to operate improperly, its
life to be reduced considerably, and in the worst case, the inverter to be damaged.
Please handle the inverter properly in accordance with the information in each section
as well as the precautions and instructions of this manual. (For connections of the
peripheral devices, refer to the corresponding manuals.)
Name Description
Use the power supply within the
Power
permissible power supply specifications
supply
of the inverter. (Refer to page 188.)
(NFB) E arth leakage The breaker should be selected with
or circuit breaker care since a large inrush current flows
(ELB) or no-fuse in the inverter at power on. (Refer to
breaker page 42.)
Do not use this magnetic contactor to
Magnetic
start or stop the inverter. It might reduce
contactor
(MC) the inverter life. (Refer to page 42.)
The reactors must be used when the
power factor is to be improved or the
inverter is installed near a large power
AC reactor Reactors
supply system (1000KVA or more and
(FR-BAL)
wiring distance within 10m (32.81 feet)).
Make selection carefully.
DC reactor •The inverter life is influenced by
(FR-BEL)
ambient temperature. The ambient
temperature should be as low as
possible within the permissible range.
This must be noted especially when
the inverter is installed in an enclosure.
Inverter
(Refer to page 12.)
•Wrong wiring might lead to inverter
Ground damage. The control signal lines should
be kept away from the main circuit to
protect them from noise. (Refer to page
14.)
Devices Do not connect a power capacitor,
connected surge suppressor or radio noise
to the output filter to the output side.
Ground To prevent an electric shock, always
Ground
ground the motor and inverter.
Japanese Harmonic Suppression Guideline

The "harmonic suppression guideline for household appliances and general-purpose
products" was issued by the Ministry of International Trade and Industry in September,
1994. This guideline applies to the 3.7K* and less models of three-phase 200V classes.
By installing the power factor improving reactor (FR-BEL or FR-BAL), inverters comply
with the "harmonic suppression techniques for transistorized inverters (input current 20A
or less)" established by the Japan Electrical Manufacturers' Association.
* For the single-phase 100V class, the guideline applies to 0.75kW and less models.
3
1.3 Structure
OUTLINE
1.3 Structure
1.3.1 Appearance and structure
(1) Front view
(100V class, 200V class) (400V class)

POWER lamp
(yellow)
Accessory cover
ALARM lamp (red)
Capacity plate
Rating plate
Front cover
Wiring port cover

for option
(2) Without accessory cover and front cover

1
(100V class, 200V class) (400V class)
Inboard option
mounting position
PU conector*
POWER lamp (yellow)
ALARM lamp (red)
Connector for connection
of inboard option
(400V class only)
Control circuit
terminal block
Control logic changing
connector
Main circuit
terminal block
Wiring cover
*Use the PU connector for the FR-PA02-02 or FR-PU04 option and RS-485
communication.
4
OUTLINE
1.3.2 Removal and reinstallation of the front cover
z Removal
(For the FR-E520-0.1K to 3.7K-NA, FR-E510W-0.1K to 0.75K-NA)

The front cover is secured by catches in positions A and B as shown below.
Push either A or B in the direction of arrows, and using the other end as a
support, pull the front cover toward you to remove.
1) 2) 3)
A
B
(For the FR-E520-5.5K, 7.5K-NA)

The front cover is fixed with catches in positions A, B and C.
Push A and B in the directions of arrows at the same time and remove the
cover using C as supporting points.
1) 2) 3)
A B
C C
5
OUTLINE
(For the FR-E540-0.4K to 7.5K-NA)

The front cover is fixed with catches in positions A, B and C.
Push A and B in the directions of arrows at the same time and remove the
cover using C as supporting points.
1) 2) 3)
A B
C C
z Reinstallation
When reinstalling the front cover after wiring, fix the catches securely. 1
With the front cover removed, do not switch power on.
Note: 1. Make sure that the front cover has been reinstalled securely.
2. The same serial number is printed on the capacity plate of the front cover
and the rating plate of the inverter. Before reinstalling the front cover, check
the serial numbers to ensure that the cover removed is reinstalled to the
inverter from where it was removed.
6
OUTLINE
1.3.3 Removal and reinstallation of the wiring cover
z Removal
(For the FR-E520-0.1K to 7.5K-NA, FR-E510W-0.1K to 0.75K-NA)

The wiring cover is fixed by catches in positions 1) and 2).
Push either 1) or 2) in the direction of arrows and pull the wiring cover
downward to remove.
1) 2)
Wiring hole

Remove the wiring cover by pulling it in the direction of arrow A.
Wiring hole
z Reinstallation
Pass the cables through the wiring hole and reinstall the cover in the original
position.
7
OUTLINE
1.3.4 Removal and reinstallation of the accessory cover
z Removal of the accessory cover

Hold down the portion A indicated by the arrow and lift the right hand side using
the portion B indicated by the arrow as a support, and pull out the accessory
cover to the right.
B
1) 2) 3)
z Reinstallation of the accessory cover 1

Insert the mounting catch (left hand side) of the accessory cover into the
mounting position of the inverter and push in the right hand side mounting
catch to install the accessory cover.
Mounting position
Accessory cover
Catch
A
1) 2) 3)
8
OUTLINE
1.3.5 Reinstallation and removal of the control panel

To ensure safety, reinstall and removal the optional control panel (FR-PA02-02) after
switching power off.
The charging area and control printed board are exposed on the rear surface of the
control panel. When removing the control panel, always fit the rear cover option
FR-E5P. Never touch the control printed board because touching it can cause the
inverter to fail.
z Reinstallation of the control panel
Insert the mounting catch (left hand side) of the control panel into the
mounting position of the inverter and push in the right hand side mounting
catch to install the control panel.
B
1) 2) 3)
z Removal of the control panel

Hold down the portion A indicated by the arrow and lift the right hand side
using the portion B indicated by the arrow as a support, and pull out the
control panel to the right.
Mounting position
FR-PA02-02
Catch
A
1) 2) 3)
(If the above procedure is not used for removal, the internal connector may be
damaged by the force applied.)
9
OUTLINE
z Using the connection cable for operation

1) Fit the rear cover option FR-E5P to the back surface of the optional control
panel.
2) Securely plug one end of the connection cable into the PU connector of the
inverter and the other end into the adaptor of the FR-E5P option to connect it
to the control panel. (For the connection cable of the FR-E5P, refer to page
28.)
PU connector
(RS-485 cable specifications)
z Mounting the control panel on an enclosure

When you open the control panel front cover, the screw mounting guides for
fixing the control panel to an enclosure appear on the top left and bottom right. 1
Fit the rear cover of the FR-E5P option, drill holes in the control panel mounting
guides, and securely mount the control panel on the enclosure with screws.
1.3.6 Removal of the control panel (FR-PA02-02) front cover

1) Open the control panel front cover to 90 degrees.
2) Pull out the control panel front cover to the left to remove it.
90 degrees
10
OUTLINE
1.3.7 Exploded view

z FR-E520-0.1K to 7.5K-NA
z FR-E510W-0.1K to 0.75K-NA
Control panel (FR-PA02 -02 )
Accessory cover
Wiring cover
Front cover
z FR-E540-0.4K to 7.5K-NA
Control panel (FR-PA02-02)
Accessory
Front cover cover
Wiring port cover

for option
Wiring cover
11
C CHAPTER
H A P T E R 22
INSTALLATION AND
INSTALLATIONAND
WIRINNG
WIRING
This chapter gives information on the basic "installation and
wiring" for use of this product.
Always read the instructions in this chapter before using the
equipment.
2.1 Installation ....................................................................12 Chapter 1
2.2 Wiring ...........................................................................14

2.3 Other Wiring .................................................................35
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
2.1 Installation
INSTALLATION AND WIRING
2 INSTALLATION
2.1 Installation AND WIRING
2.1.1 Instructions for installation

For the FR-E520-0.1K to 0.75K-NA and FR-E510W-0.1K to 0.4K-NA, install the
inverter with the accessory cover or control panel (FR-PA02-02) front cover open.
<For the accessory cover> <For the control panel (FR-PA02 -02 )>
1) Handle the unit carefully.

The inverter uses plastic parts. Handle it gently to protect it from damage.
Also, hold the unit with even strength and do not apply too much strength to the front
cover alone.
2) Install the inverter in a place where it is not affected by vibration easily (5.9m/s2
{0.6G} maximum).
Note the vibration of a cart, press, etc.
3) Note on ambient temperature.

The inverter life is under great influence of ambient temperature. In the place of
installation, the ambient temperature must be within the permissible range -10°C to
+50°C (14°F to 122°F). Check that the ambient temperature is within that range in
the positions shown in figure 3).
4) Install the inverter on a non-combustible surface.

The inverter will be very hot (maximum about 150°C (302°F)). Install it on a non-
combustible surface (e.g. metal). Also leave sufficient clearances around the
inverter.
5) Avoid high temperatures and high humidity.

Avoid direct sunlight and places of high temperature and high humidity.
6) Avoid places where the inverter is exposed to oil mist, flammable gases, fluff, dust,
dirt etc.
Install the inverter in a clean place or inside a "totally enclosed" panel which does
not accept any suspended matter.
12
7) Note the cooling method when the inverter is installed in an enclosure.

When two or more inverters are installed or a ventilation fan is mounted in an
enclosure, the inverters and ventilation fan must be installed in proper positions with
extreme care taken to keep the ambient temperatures of the inverters with the
permissible values. If they are installed in improper positions, the ambient
temperatures of the inverters will rise and ventilation effect will be reduced.
8) Install the inverter on an installation surface securely and vertically with screws or
bolts.
3) Note on ambient 4) Clearances around the inverter

temperatures 10cm (3.94inch) Leave sufficient
or more clearances above Cooling air
Measurement and under the
position inverter to ensure
adequate ventilation.
5cm FR-E500 5cm
(1.97inch) (1.97inch) 1cm (0.39inch) 1cm (0.39inch) Cooling fan
or more* FR-E500 or more* built in the
5cm
(1.97inch) Measurement position inverter
10cm (3.94inch)
or more
*5cm (1.97inch) or more for 5.5K and 7.5K
7) For installation in an enclosure

Ventilation
fan
Inverter
Inverter Inverter Inverter Inverter
Inverter
2
(Correct example) (Incorrect example) Built-in cooling fan
Position of Ventilation Fan
(Correct example) (Incorrect example)
When more than one inverter is contained
8) Vertical mounting
13
2.2 Wiring
2.2 Wiring
2.2.1 Terminal connection diagram

z 3-phase 200V power input
z 3-phase 400V power input
NFB MC
Motor
3-phase AC R(L1) U
power supply S(L2) V IM
T(L3) W
24VDC power output and Ground
external transistor common PC P1 Jumper
Note 5
Remove this jumper when
(+)P
using the optional power-factor
PR improving DC reactor.
Forward rotation start STF (-)N
Note 2 Brake resistor connection
Reverse rotation start STR
High RH
A
Multi-speed selection Middle RM
B Alarm
Low RL
detection
C
Output stop MRS
Reset RES
Contact input common SD RUN Running
Note 4
FU Frequency detection Open
Control input signals
(no voltage input allowed) SE Open collector collector outputs
Note 3 output common)
Frequency setting signals (analog)
(Note 1) 3 10(+5V) Meter

Frequency 2 (e.g. frequency meter) For 200V and
2 0 to 5VDC Selected
setting 0 to 10VDC + - 100V class
potentiometer1 5(Common) FM Moving-coil type inverters
1/2W1kΩ Current input(-) Note 4 SD 1mA full-scale
Note 3
AM (+) Analog signal output For 400V
4 to 20mADC(+) 4(4 to 20mADC) class inverter
5 (−) (0 to 10VDC)
Ground
PU connector
(RS-485)
Main circuit terminal
Control circuit input terminal
Control circuit output terminal
Note: 1. If the potentiometer is to be operated often, use a 2W1kΩ potentiometer.

2. 0.1K and 0.2K do not contain a transistor.
3. Terminals SD and SE are isolated.
4. Terminals SD and 5 are common terminals. Do not earth them to the
ground. Terminals SD and 5 are not isolated. (Those of the 400V class are
isolated.)
5. When terminals PC-SD are used as a 24VDC power supply, be careful not
to short these terminals. If they are shorted, the inverter will be damaged.
14
z Single-phase 100V power input

NFB MC
Motor
R (L1) U
Power supply V IM
S (L2)
W
Ground
Note: 1. To ensure safety, connect the power input to the inverter via a magnetic
contactor and earth leakage circuit breaker or no-fuse breaker, and use the
magnetic contactor to switch power on-off.
2. The output is three-phase 200V.
(1) Description of the main circuit terminals
Symbol Terminal Name Description

R, S, T Connect to the commercial power supply. Keep these
(L1, L2, L3) AC power input terminals unconnected when using the high power factor
(Note) converter.
U, V, W Inverter output Connect a three-phase squirrel-cage motor.
Brake resistor Connect the optional brake resistor across terminals P-PR
P (+), PR
connection (+ - PR) (not for 0.1K and 0.2K).
Brake unit Connect the optional brake unit or high power factor
P (+), N (−)
connection converter.
Power factor
Disconnect the jumper from terminals P-P1 (+ - P1) and 2
P (+), P1 improving DC
connect the optional power factor improving DC reactor.
reactor connection
Ground For grounding the inverter chassis. Must be earthed.
Note: R, S (L1, L2) terminals for single-phase power input.
15
(2) Description of the control circuit terminals
Terminal
Type Symbol Description
Name
When the STF
Forward Turn on the STF signal to start forward and STR signals
STF
rotation start rotation and turn it off to stop. are turned on
simultaneously,
Reverse Turn on the STR signal to start reverse the stop
STR command is
Contacts, e.g. start (STF), stop (STOP) etc
rotation start rotation and turn it off to stop.

given.
Combine the RH, RM and RL signals
RH, RM, Multi-speed
as appropriate to select multiple
RL selection Input terminal
speeds.
function choices
Turn on the MRS signal (20ms or
(Pr. 180 to
Input signals
longer) to stop the inverter output.

Pr. 183) change
MRS Output stop Used to shut off the inverter output to
terminal functions.
bring the motor to a stop by the
electromagnetic brake.
Used to reset the protective circuit activated. Turn on the
RES Reset
RES signal for more than 0.1 second then turn it off.
Contact input Common to the contact input terminals and terminal FM.
SD common Common output terminal for 24VDC 0.1A power output
(sink*) (PC terminal).
Power output
and external When transistor output (open collector output), such as a
transistor programmable controller (PC), is connected, connect the
PC common external power supply common for transistor output to this
Contact input terminal to prevent a fault caused by leakage current. This
common terminal can be used as a 24VDC, 0.1A power output.
(source*)
Frequency
10 setting power 5VDC, permissible load current 10mA
supply
By entering 0 to 5VDC (0 to 10VDC), the maximum output
Frequency setting
Frequency frequency is reached at 5V (or 10V) and I/O are

2 setting proportional. Use Pr. 73 to switch between input 0 to
(voltage) 5VDC (factory setting) and 0 to 10VDC. Input resistance
Analog
10kΩ. Maximum permissible voltage 20V.

By entering 4 to 20mADC, the maximum output frequency
Frequency
is reached at 20mA and I/O are proportional. This input
4 setting
signal is valid only when the AU signal is on. Input
(current)
resistance 250Ω. Maximum permissible current 30mA.
Frequency
Common to the frequency setting signals (terminal 2, 1 or 4).
5 setting input
Do not connect to the earth.
common
Note: Assign the AU signal to any of the terminals using the input terminal function
selection (Pr. 180 to Pr. 183).
* Used as a contact input signal common terminal for the 400V class by switching
between sink logic and source logic. (Refer to page 24).
16
Terminal
Type Symbol Description
Name
Contact output indicating that the output has
been stopped by the inverter protective
Contact
function activated. 230VAC 0.3A, 30VDC

A, B, C Alarm output
0.3A. Alarm: discontinuity across B-C
(continuity across A-C), normal: continuity Output
across B-C (discontinuity across A-C). terminal
Switched low when the inverter output function
frequency is equal to or higher than the choices
Inverter starting frequency (factory set to 0.5Hz, (Pr. 190 to
RUN
running variable). Switched high during stop or DC Pr. 192)
dynamic brake operation (*1). change
Open collector
Permissible load 24VDC 0.1A. terminal

Switched low when the output frequency has functions.
Output signals
reached or exceeded the detection frequency

Frequency
FU set as appropriate. Switched high when below
detection
the detection frequency (*1).
Permissible load 24VDC 0.1A
Open collector
SE output Common to the RUN and FU terminals.
common
FM
(200V Factory setting of output item:
One selected from output
Pulse
and Frequency
For meter frequency, motor current
100V Permissible load current 1mA 2
class and output voltage is 1440 pulses/second at 60Hz
inverters) output (*2). The output
signal is proportional to
AM Factory setting of output item:
the magnitude of each
Analog
(400V Analog signal Frequency

monitoring item.
class output Output signal 0 to 10 VDC
only) Permissible load current 1mA
With the control panel connector, communication can be
Communication
made using the RS-485 protocol.

RS-485
y Conforming Standard : EIA Standard RS-485

 PU connector
y Transmission format : Multi-drop link
y Communication speed : Maximum 19200 baud rate
y Overall length : 500m (1640.40 feet)
*1: Low indicates that the open collector output transistor is on (conducts). High
indicates that the transistor is off (does not conduct).
*2: Not output during inverter resetting.
17
2.2.2 Wiring of the main circuit
(1) Wiring instructions

1) It is recommended to use insulation-sleeved solderless terminals for power supply
and motor wiring.
2) Power must not be applied to the output terminals (U, V, W) of the inverter.
Otherwise the inverter will be damaged.
3) After wiring, wire off-cuts must not be left in the inverter.
Wire off-cuts can cause an alarm, failure or malfunction. Always keep the inverter
clean.
When drilling mounting holes in a control box or the like, be careful so that chips and
others do not enter the inverter.
4) Use thick cables to make the voltage drop 2% or less.
If the wiring distance is long between the inverter and motor, a main circuit cable
voltage drop will cause the motor torque to decrease, especially at the output of a
low frequency. (A selection example for the wiring length of 20m (65.62 feet) is
shown on page 22.)
5) For long distance wiring, the overcurrent protection may be activated improperly or
the devices connected to the output side may misoperate or become faulty under
the influence of a charging current due to the stray capacitance of the wiring.
Therefore, the maximum overall wiring length should be as indicated in the following
table. If the wiring length exceeds the value, it is recommended to set "1" in Pr. 156 to
make the fast-response current limit function invalid. (When two or more motors are
connected to the inverter, the total wiring length should be within the indicated value.)
3.7K or
Inverter Capacity 0.1K 0.2K 0.4K 0.75K 1.5K 2.2K
more
100V
200m 200m 300m 500m 500m 500m 500m
class,
(656.16 (656.16 (984.24 (1640.40 (1640.40 (1640.40 (1640.40
Non-low 200V
feet) feet) feet) feet) feet) feet) feet)
acoustic noise class
mode 200m 200m 300m 500m 500m
400V
— — (656.16 (656.16 (984.24 (1640.40 (1640.40
class
feet) feet) feet) feet) feet)
100V
30m 100m 200m 300m 500m 500m 500m
class,
(98.42 (328.08 (656.16 (984.24 (1640.40 (1640.40 (1640.40
200V
Low acoustic feet) feet) feet) feet) feet) feet) feet)
class
noise mode
30m 100m 200m 300m 500m
400V
— — (98.42 (328.08 (656.16 (984.24 (1640.40
class
feet) feet) feet) feet) feet)
18
Overall wiring length (3.7K or more)
500m (1640.40 feet)

maximum
300m
(984.24 feet)
300m
(984.24 feet)
300m (984.24 feet)+300m (984.24 feet)=600m (1968.48 feet)
6) Connect only the recommended optional brake resistor between the terminals P-PR
(+ - PR). Keep terminals P-PR (+ - PR) of 0.1K or 0.2K open.
These terminals must not be shorted.
0.1K and 0.2K do not accept the brake resistor. Keep terminals P-PR (+ - PR) open.
Also, never short these terminals.
7) Electromagnetic wave interference
The input/output (main circuit) of the inverter includes harmonic components, which
may interfere with the communication devices (such as AM radios) used near the
inverter. In this case, install the FR-BIF optional radio noise filter (for use in the input
side only) or FR-BSF01 or FR-BLF line noise filter to minimize interference.
8) Do not install a power capacitor, surge suppressor or radio noise filter (FR-BIF 2
option) in the output side of the inverter.
This will cause the inverter to trip or the capacitor and surge suppressor to be
damaged. If any of the above devices are installed, immediately remove them.
(When using the FR-BIF radio noise filter with a single-phase power supply, connect
it to the input side of the inverter after isolating the T phase securely.)
9) When rewiring after operation, make sure that the POWER lamp has gone off, and
when more than 10 minutes has elapsed after power-off, check with a meter etc.
that the voltage is zero. After that, start rewiring work. For some time after power-off,
there is a dangerous voltage in the capacitor.
19
Notes on Grounding
z Leakage currents flow in the inverter. To prevent an electric shock, the inverter
and motor must be grounded.
z Use the dedicated ground terminal to ground the inverter. (Do not use the screw
in the case, chassis, etc.) For the earth connection avoid direct contact between
aluminium and copper. Tin-plated cable lugs can be used if the plating does not
contain zinc. When tightening the screws take care not to damage the thread in
the aluminium frame.
z The ground cable should be as thick as possible. Use the cable whose gauge is
equal to or larger than those indicated in the following table, and make its length
as short as possible. The grounding point should be as near as possible to the
inverter to minimize the ground cable length.
(Unit: mm2)
Ground Cable Gauge
Motor Capacity
100V class 200V class 400V class
2.2kW (3HP) or less 2 2 (2.5) 2 (2.5)
3.7kW (5HP)  3.5 (4) 2 (4)
5.5kW (7.5HP), 7.5kW (10HP)  5.5 (6) 3.5 (4)
To meet the Low Voltage Directive, use PVC insulated cables larger than
specified size in brackets ( ).
z Ground the motor on the inverter side using one wire of the 4-core cable.
20
(2) Terminal block layout
FR-E520-0.1K-NA, 0.2K-NA, 0.4K-NA, FR-E520-1.5K-NA, 2.2K-NA, 3.7K-NA

0.75K-NA
N/- P/+
N/- P1 P/+ PR
PR P1
R/L1 S/L2 T/L3 U V W
TB2
TB1 Screw size (M4) TB1
Screw size (M3.5) Screw size (M4)
Screw size (M3.5) Screw size (M4)
FR-E520-5.5K-NA, 7.5K-NA
R/L1 S/L2 T/L3 N/- P1 P/+ PR U V W
TB1
Screw size
Screw size (M5) (M5)
FR-E540-0.4K to 7.5K-NA
N/- P1 P/+ PR

TB1
Screw size (M4)
Screw size (M4)
FR-E510W-0.1K-NA, 0.2K-NA, 0.4K-NA FR-E510W-0.75K-NA
N/- P1 P/+ PR N/- P/+ 2
R/L1 S/L2 U V W PR P1
R/L1 S/L2 U V W
TB1 TB2
Screw size (M3.5) Screw size (M4) TB1
Screw size (M4)
Screw size (M3.5)
Screw size (M4)
21
(3) Cables, crimping terminals, etc.

The following table lists the cables and crimping terminals used with the inputs (R (L1),
S (L2), T (L3)) and outputs (U, V, W) of the inverter and the torques for tightening the
screws:
1) FR-E520-0.1K-NA to 7.5K-NA
PVC insulated
Tight- Crimping Cables
Terminal Cables
Applicable ening Terminals 2
Screw mm2 AWG mm
Inverter Type Torque
Size R, S, T R, S, T R, S, T R, S, T
N⋅m U, V, W U, V, W U, V, W U, V, W
(L1 , L2 , L3 ) (L1 , L2 , L3 ) (L1 , L2 , L3 ) (L1 , L2 , L3 )
FR-E520-0.1K-NA
M3.5 1.2 2-3.5 2-3.5 2 2 14 14 2.5 2.5
to 0.75K-NA
FR-E520-1.5K-NA,
M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
2.2K-NA
FR-E520-3.7K-NA M4 1.5 5.5-4 5.5-4 3.5 3.5 12 12 4 2.5
FR-E520-5.5K-NA M5 2.5 5.5-5 5.5-5 5.5 5.5 10 10 6 4
FR-E520-7.5K-NA M5 2.5 14-5 8-5 14 8 6 8 16 6
2) FR-E540-0.4K-NA to 7.5K-NA
PVC insulated
Terminal Cables
Applicable ening Terminals 2 2
Screw mm AWG mm
Inverter Type Torque
Size R, S, T R, S, T R, S, T R, S, T
N⋅m U, V, W U, V, W U, V, W U, V, W
(L1 , L2 , L3 ) (L1 , L2 , L3 ) (L1 , L2 , L3 ) (L1 , L2 , L3 )
FR-E540-0.4K-NA M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
FR-E540-0.75K-NA M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
FR-E540-1.5K-NA M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
FR-E540-2.2K-NA M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
FR-E540-3.7K-NA M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
FR-E540-5.5K-NA M4 1.5 5.5-4 2-4 3.5 2 12 14 4 2.5
FR-E540-7.5K-NA M4 1.5 5.5-4 5.5-4 3.5 3.5 12 12 4 4
3) FR-E510W-0.1K-NA to 0.75K-NA
Terminal
Applicable ening Terminals mm2 AWG
Screw
Inverter Type Torque R, S R, S R, S
Size U, V, W U, V, W U, V, W
N⋅m (L1 , L2 ) (L1 , L2 ) (L1 , L2 )
FR-E510W-0.1K
M3.5 1.2 2-3.5 2-3.5 2 2 14 14
-NA to 0.4K-NA
FR-E510W-0.75K
M4 1.5 2-4 2-4 2 2 14 14
-NA
Note: 1. The cables used should be 75°C (167°F) copper cables.

2. Tighten the terminal screws to the specified torques.
Undertightening can cause a short or misoperation.
Overtightening can cause the screws and unit to be damaged, resulting in a
short or misoperation.
22
(4) Connection of the power supply and motor

z Three-phase power input
Three-phase
power supply 200V R S T
Three-phase U V W
(L1) (L2) (L3)
power supply 400V
R S T U V W
Motor
Ground Ground
No-fuse terminal (L1) (L2) (L3)
breaker
Ground
The power supply cables must be connected Connect the motor to U, V, W. In the above
to R, S, T (L 1 , L 2 , L 3 ). If they are connected to connection, turning on the forward rotation switch (signal)
U, V, W, the inverter will be damaged. (Phase rotates the motor in the counterclockwise (arrow) direction
sequence need not be matched.) when viewed from the load shaft.
z Single-phase power input

Single-phase power
supply 100V
R S
U V W
(L1) (L2)
Motor
Ground R S U V W
(L1) (L2)
Ground
No-fuse terminal
breaker Ground
Note: 1. To ensure safety, connect the power input to the inverter via a
2
magnetic contactor and earth leakage circuit breaker or no-fuse
breaker, and use the magnetic contactor to switch power on-off.
2. The output is three-phase 200V.
2.2.3 Wiring of the control circuit

(1) Wiring instructions
1) Terminals SD, SE and 5 are common to the I/O signals. These common terminals
must not be earthed to the ground.
Terminals SD and 5 are not isolated. (Those of the 400V class are isolated.)
2) Use shielded or twisted cables for connection to the control circuit terminals and run
them away from the main and power circuits (including the 200V relay sequence
circuit).
3) The frequency input signals to the control circuit are micro currents. When contacts
are required, use two or more parallel micro signal contacts or a twin contact to
prevent a contact fault.
4) It is recommended to use the cables of 0.3mm2 to 0.75mm2 gauge for connection to
the control circuit terminals.
5) When bar terminals and solid wires are used for wiring, their diameters should be
0.9mm (0.04 inches) maximum If they are larger, the screw threads may be
damaged during tightening.
23
(2) Terminal block layout

In the control circuit of the inverter, the terminals are arranged as shown below:
Terminal screw size: M2.5
(200V class, 100V class) Terminal layout of control circuit (400V class)
RH A
RM B
RL C
MRS 10
RES 2
SD 5
FM* 4
PC SD
SE STF
RUN STR
FU SD
*AM for the 400V class inverter.
(3) Wiring method

1) For wiring the control circuit, use cables after stripping their sheaths.
Refer to the gauge printed on the inverter and strip the sheaths to the following
dimensions. If the sheath is stripped too much, its cable may be shorted with the
adjoining cable. If the sheath is stripped too little, the cable may come off.
7mm±1mm (0.28inches ± 0.04inches)
2) When using bar terminals and solid wires for wiring, their diameters should be
0.9mm maximum. If they are larger, the threads may be damaged during tightening.
3) Loosen the terminal screw and insert the cable into the terminal.
4) Tighten the screw to the specified torque.
Undertightening can cause cable disconnection or misoperation. Overtightening can
cause damage to the screw or unit, leading to short circuit or misoperation.
Tightening torque: 0.2N⋅m
Note: When routing the stripped cables, twist them so that they do not become loose.
(4) Control logic changing (400V class only)

For the 200V and 100V class inverters, the logic cannot be changed.
The input signal logic is factory-set to the sink mode.
To change the control logic, the position of the connector beside the control circuit
terminal block must be changed.
24
1) Use tweezers etc. to remove the connector in the sink logic position and fit it in the
source logic position.
Do this position changing before switching power on.
Note: 1. Make sure that the front cover has been installed securely.
2. The front cover has a capacity plate and the inverter a rating plate on it.
Since these plates have the same serial numbers, always reinstall the
removed cover to the inverter from where it was removed.
3. Always install the sink-source logic changing connector in either of the
positions. If two connectors are installed in these positions at the same time,
the inverter may be damaged.
2) Sink logic type

• In this logic, a signal switches on when a current flows out of the corresponding 2
signal input terminal.
Terminal SD is common to the contact input signals. Terminal SE common to the
open collector output signals.
Current R A current flows out of
the corresponding signal RUN
STF
R
STR RUN
SD
SE
25
• When using an external power supply for transistor output, use terminal PC as a
common to prevent misoperation caused by leakage current.
(Do not connect terminal SD of the inverter with terminal 0V of the external power
supply. When terminals PC-SD are used as a 24VDC power supply, you cannot
prevent misoperation caused by leakage current.)
AY40 type
transistor
output module Inverter
1 DC24V
STF (SD)
2
STR
3
RH
4
RM
5
RL
6
RES
9
PC
10 DC24V
SD
3) Source logic type

• In this logic, a signal switches on when a current flows into the corresponding signal
input terminal.
Terminal PC is common to the contact input signals. Terminal SE common to the
open collector output signals.
PC A current flows out of
the corresponding signal RUN
Current
STF
RUN
R
STR
R SE
26
• When using an external power supply for transistor output, use terminal SD as a
common to prevent misoperation caused by leakage current.
AY-80 Inverter
9 PC
STF DC24V
1
(SD)
2 STR
DC24V
10 SD
(5) How to use the STOP signal

The following connection example shows how to self-hold the start signals (forward
rotation, reverse rotation).
Use Pr. 180 to Pr. 183 (input terminal function selection) to assign the STOP signal.
RL
(STOP)
MRS
Stop
RES
SD
Forward
rotation
STF
Reverse
STR 2
rotation (Wiring example for sink logic)
27
2.2.4 Connection to the PU connector
(1) When connecting the control panel or parameter unit using a cable
Use the option FR-CB2 or the following connector and commercially available cable:
<Connection cable>
y Connector : RJ45 connector
Example: 5-554720-3, Nippon AMP
y Cable : Cable conforming to EIA568 (e.g. 10BASE-T cable)
Example: SGLPEV 0.5mm×4P, MITSUBISHI CABLE INDUSTRIES,
LTD.
<When using the control panel>
Note: The rear cover and junction adaptor are required since the circuit board is
exposed in the back of the control panel.
Use the FR-E5P option (cover and adaptor available as a set).
<Maximum wiring length>
y Control panel (FR-PA02-02): 20m (65.62 feet)
y Parameter unit (FR-PU04): 20m (65.62 feet)
(2) For RS-485 communication

The PU connector can be used for communication
operation from a personal computer etc. 1) SG 5) SDA
When the PU connector is connected with a 2) P5S 6) RDB
personal, FA or other computer by a 3) RDA 7) SG
4) SDB 8) P5S
communication cable, a user program allows the 8) to 1)
inverter to be run and monitored and the parameter
values to be read and written.
<PU connector pin-outs>
Viewed from the inverter (receptacle side) front
Note: 1. Do not connect the PU connector to a computer's LAN board, FAX modem
socket or telephone modular connector. Otherwise, the product may be
damaged due to electrical specification differences.
2. Pins 2) and 8) (P5S) provide power to the control panel or parameter unit.
Do not use these pins for RS-485 communication.
28
<System configuration examples>
1) When a computer having a RS-485 interface is used with several inverters
Computer Station 1 Station 2 Station n
Inverter Inverter Inverter

PU connector PU connector PU connector
RS-485 (Note1) (Note1) (Note1)
interface/terminal
Computer
Distribution
terminal Termination
resistor
10BASE-T cable (Note 2)
Use the connectors and cables which are available on the market.
Note: 1. Connector: RJ45 connector
Example: 5-554720-3, Nippon AMP Co., Ltd.
2. Cable : Cable conforming to EIA568 (such as 10BASE-T cable)
Example: SGLPEV 0.5mm × 4P, Mitsubishi Cable Industries, Ltd.
2) When a computer having a RS-232C interface is used with inverters
Computer Station 1 Station 2 Station n

RS-232C PU connector PU connector PU connector 2
connector Max. 15m (Note1) (Note1) (Note1)
RS-232C (49.21 feet)
cable Converter*
RS-485 Distribution
terminal terminal Termination
resistor
10BASE-T cable (Note 2)
*Commercially available converter is required. (Note 3)
Use the connectors, cables and converter which are available on the market.
Note: 1. Connector: RJ45 connector
Example: 5-554720-3, Nippon AMP Co., Ltd.
2. Cable : Cable conforming to EIA568 (such as 10BASE-T cable)
Example: SGLPEV 0.5mm × 4P, Mitsubishi Cable Industries, Ltd.
3.*Commercially available converter examples
Model: FA-T-RS40
Converter
Industrial System Division Mitsubishi Electric Engineering Co., Ltd.
29
<Wiring methods>
1) Wiring of one RS-485 computer and one inverter
Computer Side Terminals Cable connection and signal direction Inverter
Signal name Description PU connector
10 BASE-T Cable
RDA Receive data SDA
RDB Receive data SDB
SDA Send data RDA
SDB Send data RDB
RSA Request to send
RSB Request to send
(Note 2)
CSA Clear to send
CSB Clear to send
0.3mm2 or more
SG Signal ground SG
FG Frame ground
2) Wiring of one RS-485 computer and "n" inverters (several inverters)

Cable connection and signal direction
Computer 10 BASE-T Cable

RDA
RDB
Termination
SDA
resistor
SDB (Note 1)
RSA
RDB
RDA
RDB
RDA
RDB
RDA
SDB
SDA
SDB
SDA
SDB
RSB SDA
(Note 2) Termination
CSA
resistor
CSB
jumper
SG SG SG (Note 1) SG
FG Station 1 Station 2 Station 3
Note: 1. There may be the influence of reflection depending on the transmission

speed and/or transmission distance. If this reflection hinders
communication, provide a termination resistor. If the PU connector is used
to make a connection, use the distributor as a termination resistor cannot be
fitted.
Connect the termination resistor to only the inverter remotest from the
computer. (Termination resistor: 100Ω)
2. Make connections in accordance with the instruction manual of the
computer used.
Fully check the terminal numbers of the computer as they differ between
models.
30
2.2.5 Connection of stand-alone option units

The inverter accepts a variety of stand-alone option units as required.
Incorrect connection will cause inverter damage or an accident. Connect and operate
the option unit carefully in accordance with the corresponding option unit manual.
(1) Connection of the dedicated external brake resistor (option)

(Cannot be connected to 0.1K and 0.2K)
Connect a brake resistor across terminals P (+) and PR. Connect a dedicated brake
resistor only.
(For the positions of terminals P (+) and PR, refer to the terminal block layout (page 21).)
⋅ FR-E520-0.4K to 0.75K, 5.5K, 7.5K-NA ⋅ FR-E520-1.5K to 3.7K-NA
⋅ FR-E540-0.4K to 7.5K-NA ⋅ FR-E510W-0.75K-NA
⋅ FR-E510W-0.4K-NA
N P1 P PR P
Brake resister
PR
Brake resister
31
(2) Connection of the BU brake unit (option)
Connect the BU brake unit correctly NFB MC Inverter Motor

as shown on the right. Incorrect R (L1) U
S (L2) V IM
connection will damage the inverter. T (L3) W
Remove jumpers.
P (+) N (-) Discharge resistor
T (Note 3)
P HA HB HC TB PR
PC OCR
OCR
Constant-
voltage
power -
+
supply
BU brake unit N
Brake unit
Comparator
HC HB OFF ON
MC
MC
Note: 1. The wiring distance between the inverter, brake unit and discharge resistor
should be within 2m (6.56 feet). If twisted wires are used, the distance
should be within 5m (16.40 feet).
2. If the transistors in the brake unit should fail, the resistor will be extremely
hot, causing a fire. Therefore, install a magnetic contactor on the inverter's
power supply side to shut off current in case of failure.
3. When the power supply is 400V class, install a step-down transformer.
32
(3) Connection of the FR-HC high power factor converter (option unit)
When connecting the high power factor converter (FR-HC) to suppress power
harmonics, wire as shown below. Wrong connection will damage the high power factor
converter and inverter.
High power
External box factor converter Inverter
(FR-HCB) (FR-HC) (FR-E500)
MC1 MC1
Resistor MC2
R (L1)
Reactor 1 Reactor 2 MC2 S (L2)
(FR-HCL01) (FR-HCL02) T (L3)
NFB MC R3
R2 Motor
Power R R2 R3 R4 R4 P P (+)
S2 U
supply S S2 T2 MC S3
T3
S3 S4 S4 N N (-) V IM
T T2 T3 T4 T4 RDY MRS W
RSO RES
R SE SD
Filter S Phase
capacitor Resistor T detection
Note: 1. The power input terminals R, S, T (L1, L2, L3) must be open.
Incorrect connection will damage the inverter. Reverse polarity of terminals
N (−), P (+) will damage the inverter.
2. The voltage phases of terminals R, S, T (L1, L2, L3) and terminals R4, S4,
T4 must be matched before connection.
3. If the load capacity is less than half of the high power factor converter
2
capacity, satisfactory harmonic suppression effects cannot be produced.
(4) Connection of the power factor improving DC reactor (option)
Connect the FR-BEL power <Connection method>
factor improving DC reactor FR-E520-0.1K-NA to 0.75K-NA, FR-E520-1.5K-NA to 3.7K-NA

5.5K-NA, 7.5K-NA
between terminals P1-P (+). In FR-E540-0.4K-NA to 7.5K-NA
this case, the jumper

N P PR
P1 (+) P Remove
connected across terminals FR-BEL
(+)
the jumper.
P1-P (+) must be removed. P1
FR-BEL
Otherwise, the reactor will not
function. Remove the jumper.
Note: 1. The wiring distance should be within 5m (16.40 feet).

2. The size of the cables used should be equal to or larger than that of the
power supply cables (R (L1), S (L2), T (L3)).
33
2.2.6 Design information

1) Provide electrical and mechanical interlocks for MC1 and MC2 which are used for
commercial power supply-inverter switch-over.
When there is a commercial power supply-inverter switch-over circuit as shown
below, the inverter will be damaged by leakage current from the power supply due to
arcs generated at the time of switch-over or chattering caused by a sequence error.
2) If the machine must not be restarted when power is restored after a power failure,
provide a magnetic contactor in the inverter's primary circuit and also make up a
sequence which will not switch on the start signal.
If the start signal (start switch) remains on after a power failure, the inverter will
automatically restart as soon as the power is restored.
3) Since the input signals to the control circuit are on a low level, use two or more
parallel micro signal contacts or a twin contact for contact inputs to prevent a contact
fault.
4) Do not apply a large voltage to the contact input terminals (e.g. STF) of the control
circuit.
5) Do not apply a voltage directly to the alarm output signal terminals (A, B, C).
Always apply a voltage to these terminals via a relay coil, lamp, etc.
6) Make sure that the specifications and rating match the system requirements.
1) Commercial power supply-inverter 3) Low-level signal contacts

switch-over
MC1
Interlock
Power R (L1) U
IM
supply S (L2) V MC2
T (L3) W Leakage current
Inverter Low-level signal contacts Twin contact
34
2.3 Other Wiring
2.3 Other Wiring
2.3.1 Power supply harmonics

Power supply harmonics may be generated from the converter section of the inverter,
affecting the power supply equipment, power capacitor, etc. Power supply harmonics
are different in generation source, frequency band and transmission path from radio
frequency (RF) noise and leakage currents. Take the following measures.
z The differences between harmonics and RF noises are indicated below:
Item Harmonics RF Noise

Normally 40 to 50th degrees, High frequency (several 10kHz to MHz
Frequency
3kHz or less order)
To wire paths, power
Environment Across spaces, distance, laying paths
impedance
Quantitative Logical computation is Occurs randomly, quantitative
understanding possible understanding is difficult.
Approximately proportional According to current fluctuation rate
Generated amount
to load capacity (larger with faster switching)
Immunity of affected Specified in standards for Differs according to maker's device
device each device. specifications.
Examples of
Install a reactor. Increase the distance.
safeguard
z Countermeasures
The harmonic current generated from the 2
inverter to the power supply differs Power factor
improving DC
according to various conditions such as the reactor
NFB
wiring impedance, whether a power factor Motor
Inverter
improving reactor is used or not, and output IM

frequency and output current on load side.
For the output frequency and output current,
the adequate method is to obtain them Power factor Do not insert power
improving AC factor improving capacitor
under rated load at the maximum operating
reactor
frequency.
Note: A power factor improving capacitor and surge suppressor on the inverter's
output side may overheat or be damaged due to the harmonics of the inverter
output. Also, when an overcurrent flows in the inverter, the overcurrent
protection is activated. Hence, when the motor is driven by the inverter, do
not install a capacitor or surge suppressor on the inverter's output side. To
improve the power factor, insert a power factor improving reactor in the
inverter's input or DC circuit. For details, refer to the FR-A500/E500 series
technical information
35
2.3.2 Japanese harmonic suppression guideline

Harmonic currents flow from the inverter to a power receiving point via a power
transformer. The harmonic suppression guideline was established to protect other
consumers from these outgoing harmonic currents.
1) "Harmonic suppression guideline for household appliances and general-purpose
products"
This guideline was issued by the Ministry of International Trade and Industries in
September, 1994 and applies to 200V class inverters of 3.7kW (5HP) or less*. By
installing the FR-BEL or FR-BAL power factor improving reactor, inverters comply
with the "harmonic suppression techniques for transistorized inverters (input current
20A or less)" established by the Japan Electrical Manufacturers' Association.
Therefore install the optional reactor for the 200V class, 3.7kW (5HP) or less
inverter.
* For the single-phase 100V class, the guideline applies to 0.75kW and less models.
2.3.3 Inverter-generated noise and reduction techniques

Some noises enter the inverter causing it to incorrectly operate, and others are
radiated by the inverter causing misoperation of peripheral devices. Though the
inverter is designed to be insusceptible to noise, it handles low-level signals, so it
requires the following basic measures to be taken. Also, since the inverter chops the
output at high carrier frequencies, it could generate noise. If these noises cause
peripheral devices to misoperate, measures should be taken to suppress noise. The
measures differ slightly depending on noise propagation paths.
1) Basic measures
y Do not run the power cables (I/O cables) and signal cables of the inverter in
parallel with each other and do not bundle them.
y Use twisted shield cables for the detector connecting and control signal cables
and connect the sheathes of the shield cables to terminal SD.
y Ground the inverter, motor, etc. at one point.
2) Measures against noise which enters and causes misoperation of the inverter
When devices which generate noise (devices which use magnetic contactors,
magnetic brakes, many relays, for example) are installed near the inverter, the
inverter may misoperate due to noise. The following measures must be taken:
y Provide surge suppressors for devices that generate noise to suppress noise.
y Fit data line filters (refer to page 39) to signal cables.
y Ground the shields of the detector connection and control signal cables with cable
clamp metal.
36
3) Measures against noises which are radiated by the inverter causing misoperation of
peripheral devices.
Inverter-generated noises are largely classified into those radiated by the cables
connected to the inverter and inverter main circuit (I/O), those electromagnetically
and electrostatically inducted to the signal cables of the peripheral devices close to
the main circuit power supply, and those transmitted through the power supply
cables.
Inverter-generated Air-propagated Noise directly radiated by

noise xxxPath 1)
noise inverter
Noise radiated by power
xxxPath 2)
cables
Noise radiated by motor
xxxPath 3)
cables
Magnetic induc-
xxxPath 4), 5)
tion noise
Static induction
xxxPath 6)
noise
Cable Propaga- Noise propagated through
xxxPath 7)
ted noise power cables
Leakage noise from ground
xxxPath 8)
cable due to leakage current
2
Telephone
5)
7) Sensor power
7) 2) supply
1)
Receiver 2)
Inve-
6)
rter
3)
4) 8)
Instrument
Sensor
Motor IM 3)
37
Noise Path Measures

When devices which handle low-level signals and are susceptible to
misoperation due to noise (such as instruments, receivers and sensors)
are installed near the inverter and their signal cables are contained in the
same panel as the inverter or are run near the inverter, the devices may
be misoperated by air-propagated noise and the following measures must
be taken:
(1) Install easily affected devices as far away as possible from the
inverter.
1), 2), 3)
(2) Run easily affected signal cables as far away as possible from the
inverter.
(3) Do not run the signal cables and power cables (inverter I/O cables) in
(4) Insert line noise filters onto I/O and radio noise filters into inputs to
suppress cable-radiated noises.
(5) Use shielded cables for signal cables and power cables and run them
in individual metal conduits to further reduce effects.
When the signal cables are run in parallel with or bundled with the power
cables, magnetic and static induction noises may be propagated to the
signal cables causing misoperation of the devices and the following
measures must be taken:
(1) Install easily affected devices as far away as possible from the
inverter.
4), 5), 6)
(2) Run easily affected signal cables as far away as possible from the
inverter.
(3) Do not run the signal cables and power cables (inverter I/O cables) in
(4) Use shielded cables for signal cables and power cables and run them
in individual metal conduits to further reduce effects.
When the power supplies of the peripheral devices are connected to the
power supply of the inverter within the same line, inverter-generated noise
may flow back through the power supply cables causing misoperation of
the devices and the following measures must be taken:
7)
(1) Install the radio noise filter (FR-BIF) to the power cables (input cables)
of the inverter.
(2) Install the line noise filter (FR-BLF, FR-BSF01) to the power cables
(I/O cables) of the inverter.
When a closed loop circuit is formed by connecting the peripheral device
wiring to the inverter, leakage current may flow through the ground cable
8) of the inverter causing misoperation of the device. In such a case,
disconnection of the ground cable of the device may cause the device to
operate properly.
38
z Data line filter

Noise entry can be prevented by providing a data line filter for the detector or other
cable.
z Data examples
By decreasing the carrier frequency, the By using shielded cables as signal cables,
noise terminal voltage* can be reduced. induction noise can be reduced greatly (1/10 to
Use Pr. 72 to set the carrier frequency to1/100). Induction noise can also be reduced by
a low value (1kHz). moving the signal cables away from the inverter
Though motor noise increases at a low output cables.
carrier frequency, selection of Soft-PWM (Separation of 30cm (11.81 inches) reduces noise
to 1/2 to 1/3.)
will make it unoffending.
By fitting the FR-BSF01 or BLF on the inverter
output side, induction noise to the signal cables
can be reduced.
Differences between noise terminal Noise induced to signal cables by inverter output
voltages at different carrier frequencies cables
Conditions
Average terminal voltage
Conditions
0dB=1µV
Induction voltage (dB)
100 Inverter: FR-E520-3.7K-NA

Noise terminal voltage (dB)
120dB=1V Parallel cable Motor: FR-JR 4P 3.7kW (5HP)

120 80 Output frequency: 30Hz
Carrier frequency 10kHz Twisted pair cable Noise form: Normal mode
100 60
80 5cm
40 Inverter d(cm) Motor
60 Coaxial cable
20 FR-BLF
40 FR-BSF01
Carrier frequency 1kHz Terminal
20 (4T)
0
0 10 20 30 40 50 Measuring instrument 2
0.1 1 10 Line-to-line distance d (cm)
Noise frequency (MHz)
* Noise terminal voltage: Represents the magnitude of noise propagated from the
inverter to the power supply.
z Example of measures against noise

FR-BLF FR-BLF
Install filter to Install filter to
FR-BSF01 Control box Reduce carrier frequency. FR-BSF01
inverter input side. inverter output side.
Motor
Inverter FR- FR-
Inverter BSF01 IM
power supply BSF01
Install filter FR-BIF to

inverter input side.
FR- Use 4-core cable for motor power
BIF cable and use one wire as earth cable.
Separate inverter and power line 30cm
(11.81inches) or more (at least 10cm Use twisted pair shielded cable.
(3.94inches)) from sensor circuit. Sensor
Control power Power supply
supply for sensor
Do not ground control
Do not ground shield but connect it to signal
box directly.
common cable.
Do not ground control cable.
39
2.3.4 Leakage currents and countermeasures

Due to the static capacitance existing in the inverter I/O wiring and motor, leakage
currents flow through them. Since their values depend on the static capacitance, carrier
frequency, etc., take the following measures.
(1) To-ground leakage currents

Leakage currents may flow not only into the inverter's own line but also into the other
lines through the ground cable, etc. These leakage currents may operate earth leakage
circuit breakers and earth leakage relays unnecessarily.
z Countermeasures
y If the carrier frequency setting is high, decrease the carrier frequency (Pr. 72) of
the inverter.
Note that motor noise increases. Selection of Soft-PWM (Pr. 240) will make it
unoffending.
y By using earth leakage circuit breakers designed for harmonics and surges (e.g.
Mitsubishi's Progressive Super Series) in the inverter's own line and other line,
operation can be performed with low noise (with the carrier frequency kept high).
z To-ground leakage current

y Note that a long wiring length will increase leakage currents. Decrease the carrier
frequency of the inverter to reduce leakage currents.
y Higher motor capacity leads to larger leakage currents. The leakage currents of
the 400V class are higher than those of the 200V class
(2) Line-to-line leakage currents

Harmonics of leakage currents flowing in static capacities between the inverter output
cables may operate the external thermal relay unnecessarily.
When the wiring length is long (50m (164.04 feet) or more) for the 400V class models,
the external thermal relay is likely to operate unnecessarily because the ratio of the
leakage current to the rated motor current increases.
NFB Thermal relay Motor
Power IM
Inverter
supply
Line static capacitances
Line-to-line leakage current path
40
z Countermeasures
y Use the electronic overcurrent protection of the inverter.
y Decrease the carrier frequency. Note that motor noise increases. Selection of
Soft-PWM will make it unoffending.
To ensure that the motor is protected against line-to-line leakage currents, it is
recommended to use a temperature sensor to directly detect motor temperature.
2.3.5 Inverter-driven 400V class motor

In the PWM type inverter, a surge voltage attributable to wiring constants is generated
at the motor terminals. Especially for a 400V class motor, the surge voltage may
deteriorate the insulation. When the 400V class motor is driven by the inverter,
consider the following measures:
z Measures
It is recommended to take either of the following measures:
(1) Rectifying the motor insulation

For the 400V class motor, use an insulation-rectified motor. Specifically,
1) Specify the "400V class inverter-driven, insulation-rectified motor".
2) For the dedicated motor such as the constant-torque motor and low-vibration motor,
use the "inverter-driven, dedicated motor".
2
(2) Suppressing the surge voltage on the inverter side
On the secondary side of the inverter, connect the optional surge voltage suppression
filter (FR-ASF-H).
41
2.3.6 Peripheral devices
(1) Selection of peripheral devices

Check the capacity of the motor to be used with the inverter you purchased.
Appropriate peripheral devices must be selected according to the capacity.
Refer to the following list and prepare appropriate peripheral devices:
Power No-Fuse Breaker (NFB) or Earth Magnetic Contactor
Motor
Supply Leakage Circuit Breaker (NV) (MC)
Inverter Type Output
Capacity With power factor
(kW (HP)) Standard A B C
(kVA) improving reactor
Type NF30,
FR-E520-0.1K-NA 0.1 (1/8) 0.4 Type NF30, NV30 5A S-N11 S-N18 S-N20
NV30 5A
Type NF30,
NV30 5A
Type NF30,
NV30 5A
Three-phase 200V
Type NF30,
FR-E520-0.75K-NA 0.75 (1) 2.5 Type NF30, NV30 10A S-N18 S-N21 S-N21
NV30 10A
Type NF30,
FR-E520-1.5K-NA 1.5 (2) 4.5 Type NF30, NV30 15A S-N21 S-N25 S-K50
NV30 15A
Type NF30,
FR-E520-2.2K-NA 2.2 (3) 5.5 Type NF30, NV30 15A S-N11,S-N12
NV30 20A
Type NF30,
FR-E520-3.7K-NA 3.7 (5) 9 Type NF30, NV30 30A S-N20
NV30 30A
Type NF50,
FR-E520-5.5K-NA 5.5 (7.5) 12 Type NF50, NV50 40A S-N25
NV50 50A
Type NF100,
NV100 60A
Type NF30,
FR-E540-0.4K-NA 0.4 (1/2) 1.5 Type NF30, NV30 5A S-N10
NV30 5A
Type NF30,
FR-E540-0.75K-NA 0.75 (1) 2.5 Type NF30, NV30 5A S-N10
NV30 5A
Three-phase 400V
Type NF30,
NV30 10A
Type NF30,
NV30 15A
Type NF30,
NV30 20A
Type NF30,
FR-E540-5.5K-NA 5.5 (7.5) 12 Type NF30, NV30 20A S-N20
NV30 30A
Type NF30,
NV30 30A
Type BH-K,
FR-E510W-0.1K-NA 0.1 (1/8) 0.5 Type BH-K, NV30 10A S-N18 S-N21 S-N21
Single-phase 100V
NV30 10A
Type BH-K,
FR-E510W-0.2K-NA 0.2 (1/4) 0.9 Type BH-K, NV30 15A S-N21 S-N25 S-N25
NV30 15A
Type BH-K,
FR-E510W-0.4K-NA 0.4 (1/2) 1.5 Type BH-K, NV30 20A S-N21 S-N25 S-K50
NV30 20A
Type BH-K,
FR-E510W-0.75K-NA 0.75 (1) 2.5 Type BH-K, NV30 30A S-N21 S-N25 S-K50
NV30 30A
42
Note: 1. Select the type of the no-fuse breaker

(NFB) in response to the power
Power supply capacity(kVA)

Power factor
supply capacity. improving
2. The power supply cable size of the AC reactor
motor indicated assumes that its range
500 B A
length is 20m (65.62 feet).
C
3. The inverter input side magnetic
50
contactor to be chosen differs
0 10 20 Wiring length(m)
between the applicable ranges A, B
and C shown on the right, depending Note: Power supply used has the above
recommended size.
on the power supply capacity and
wiring length. For the FR-E520-0.4K to 1.5K-NA, FR-E510W-0.4K to 0.75K-
NA, choose the S-N10 when the power factor improving reactor (FR-BEL or
FR-BAL) is used.
4. When the inverter capacity is greater than the motor capacity, choose the
breaker and magnetic contactor in accordance with the inverter type and
choose the cables and power factor improving reactor in accordance with
the motor output.
z Installation and selection of no-fuse breaker
Install a no-fuse breaker (NFB) in the power supply side for protection of the inverter's
primary wiring. Refer to the previous table and choose the NFB according to the
inverter's power supply side power factor (which changes with the power supply
voltage, output frequency and load). Especially for a completely electromagnetic type
NFB, the one with a larger capacity must be selected since its operational
characteristics change with harmonic currents. (Check the data of the corresponding
breaker for confirmation.) Also, the earth leakage circuit breaker used should be
durable against harmonic/surge (such as the Progressive Super Series).
z Power factor improving reactor 2
Inverter Model Power Factor Improving AC Reactor Power Factor Improving DC Reactor
FR-E520-0.1K FR-BAL-0.4K (Note 1) FR-BEL-0.4K (Note 1)
FR-E520-0.2K FR-BAL-0.4K (Note 1) FR-BEL-0.4K (Note 1)
Three-phase 200V
FR-E520-0.4K FR-BAL-0.4K FR-BEL-0.4K

FR-E540-0.4K FR-BAL-H0.4K FR-BEL-H0.4K
Three-phase 400V

 (Note 2)
phase 100V
FR-E510W-0.1K FR-BAL-0.75K (Note 1)

Single-
FR-E510W-0.2K FR-BAL-1.5K (Note 1)  (Note 2)

Note: 1. The power factor may be a little lower than 0.9.
2. The single-phase 100V input models do not accept the power factor improving DC reactor.
43
When the inverter is connected near a large- NFB FR-BAL Inverter

capacity power supply transformer (500kVA R X R (L1) U
or more, wiring length 10m (32.81 feet) Power S Y
maximum) or there is power capacitor switch- supply S (L2) V
T Z T (L3) W
over, excessive peak currents may flow into P(+)P1
the power input circuit and damage the
converter circuit. In such a case, the power
supply improving reactor (FR-BEL or FR- FR-BEL
BAL) must be installed.
When the FR-E510W-0.4K-NA is connected Power
1500 factor
to a single-phase 100V class output power Power improving
transformer (in excess of 50kVA capacity), supply 1000 reactor
capacity range
install the power factor improving reactor (kVA) 500
(FR-BAL-2.2K) to improve reliability.
0 10 Wiring length(m)
(2) Selecting the rated sensitivity current for the earth leakage circuit
breaker
When using the earth leakage circuit breaker with the inverter circuit, select its rated
sensitivity current as follows, independently of the PWM carrier frequency:
Example of leakage current per 1kW in Leakage current example of 3-phase
cable path during commercial power induction motor during commercial
supply operation when the CV cable is power supply operation (200V 60Hz)
routed in metal conduit
(200V 60Hz)
Leakage current(mA)
Leakage current(mA)
120 2.0
100 1.0
80 0.7
60 0.5
40 0.3
0.2
20
0 0.1
2 3.5 8 14 22 38 80 150 1.5 3.7 7.5 15 22 37 55
5.5 30 60 100 2.2 5.5 11 18.5 30 45
Cable size(mm2) Motor capacity(kW)
y Progressive Super series (Type SP, CF, SF, CP)

Rated sensitivity current: I∆n ≥ 10 × (lg1+Ign+lg2+lgm)
y Conventional NV series (Type CA, CS, SS produced prior to ′91)
Rated sensitivity current: I∆n ≥ 10 × {lg1+lgn+3×(lg2+lgm)}
lg1, lg2 : Leakage currents of cable path during commercial power supply operation
lgn* : Leakage current of noise filter on inverter input side
lgm : Leakage current of motor during commercial power supply operation
44
<Example>
5.5mm2 × 5m 5.5mm2 × 70m

(16.40 feet) (229.66 feet)
NV Noise filter
Inverter IM 3φ
200V 2.2kW (3HP)
Ig1 Ign Ig2 Igm
Note: 1. The earth leakage circuit breaker should be installed to the primary (power
supply) side of the inverter.
2. Ground fault in the secondary side of the inverter can be detected at the
running frequency of 120Hz or lower.
3. In the connection neutral point grounded system, the sensitivity current
becomes worse for ground fault in the inverter secondary side. Hence, the
protective grounding of the load equipment should be class D grounding (10Ω
or less).
4. When the breaker is grounded on the secondary side of the inverter, it may be
unnecessarily operated by harmonics if the effective value is less than the
rating. In this case, note that the eddy current and hysteresis loss increase
and temperature rises.
* For the leakage current value of the noise filter installed on the inverter input
side, contact the corresponding filter manufacturer.
2
Progressive Super series Conventional NV
(Type SP, CF, SF, CP) (Type CA, CS, SS)
5m (16.40 feet )
Leakage current (Ig1) 33 × = 0.17
1000m (3280.80 feet)
Leakage current (Ign) 0 (without noise filter)
70m (229.66 feet )
Leakage current (Ig2) 33 × = 2.31
1000m (3280.80 feet)
Motor leakage
0.18
current (Igm)
Total leakage current 2.66 7.64
Rated sensitivity current
30 100
( ≥ Ig × 10)
45
2.3.7 Instructions for compliance with the UL and CSA standards

(Since we obtained the approval of the UL and CSA Standards
from the UL, the products conforming to the Standards carry the
US, Canada UL mark.)
(1) Installation
The above types of inverter have been approved as products for use in enclosure and
approval tests were conducted under the following conditions. For enclosure design,
refer to these conditions so that the ambient temperature of the inverter is 50°C
(122°F) or less.
Cabinet (enclosure)
Inverter
Size (Unit: mm Vent Hole Area Cooling Fan
Type (inches))
• 55% of both the side of Installed at the enclosure top
W H D the Cabinet to suck air from inside the
FR-E520 - • Width of each slit: enclosure to the outside.
255×192×218
3.7K-NA 3.2mm (0.12 inches) (Fan air flow: 2 × 0.59m3/min
(10.04×7.56×8.58) • To be provided on each or more)
of the upper side areas.
(2) Wiring of the power supply and motor
Use the UL-listed cables (rated at 75°C (167°F)) and round crimping terminals to wire
the input (R (L1), S (L2), T (L3)) and output (U, V, W) terminals of the inverter. Crimp the
terminals with the crimping tool recommended by the terminal manufacturer.
(3) Fuse
The fuse used on the input side should be any of the UL Class K5 fuses having the
ratings as listed below:
Applicable Inverter Type Rating (A) Applicable Inverter Type Rating (A)
FR-E520-0.1K-NA 4 FR-E540-0.4K-NA 5
FR-E520-0.2K-NA 6 FR-E540-0.75K-NA 8
FR-E520-0.4K-NA 7.5 to 10 FR-E540-1.5K-NA 10
FR-E520-0.75K-NA 15 to 20 FR-E540-2.2K-NA 20
FR-E520-1.5K-NA 25 to 30 FR-E540-3.7K-NA 35
FR-E520-2.2K-NA 30 to 40 FR-E540-5.5K-NA 45
FR-E520-3.7K-NA 45 to 60 FR-E540-7.5K-NA 60
FR-E520-5.5K-NA 75 to 90 FR-E510W-0.1K-NA 7.5 to 10
FR-E520-7.5K-NA 90 to 125 FR-E510W-0.2K-NA 15 to 20
FR-E510W-0.4K-NA 25 to 30
FR-E510W-0.75K-NA 30 to 40
(4) Short-circuit ratings
Suitable For Use in a Circuit Capable of Delivering Not More Than * A rms
Symmetrical Amperes, 500 Volts Maximum.
Inverter Type *
1.5kW to 7.5kW (2HP to 10HP) 5,000
46
2.3.8 Instructions for compliance with the European standards

(Only the 200V and 400V classes comply. The products conforming to the Low Voltage
Directive carry the CE mark.)
(1) EMC Directive
1) Our view of transistorized inverters for the EMC Directive
A transistorized inverter does not function independently. It is a component
designed for installation in a control box and for use with the other equipment to
control the equipment/device. Therefore, we understand that the EMC Directive
does not apply directly to transistorized inverters. For this reason, we do not place
the CE mark on the transistorized inverters themselves. (The CE mark is placed
on inverters in accordance with the Low Voltage Directive.) The European power
drive manufacturers' organization (CEMEP) also holds this point of view.
2) Compliance
We understand that the transistorized inverters themselves are not covered
directly by the EMC Directive. However, the EMC Directive applies to
machines/equipment into which transistorized inverters have been incorporated,
and these machines and equipment must carry the CE marks. Hence, we
prepared the technical information "EMC Installation Guidelines" (information
number BCN-A21041-202) so that machines and equipment incorporating
transistorized inverters may conform to the EMC Directive more easily.
3) Outline of installation method 2

Install an inverter using the following methods:
* Use the inverter with an European Standard-compliant noise filter.
* For wiring between the inverter and motor, use shielded cables or run them
in a metal piping and ground the cables on the inverter and motor sides with
the shortest possible distance.
* Insert a line noise filter and ferrite core into the power and control lines as
required.
Full information including the European Standard-compliant noise filter
specifications are written in the technical information "EMC Installation
Guidelines" (BCN-A21041-202). Please contact your sales representative.
(2) Low Voltage Directive

1) Our view of transistorized inverters for the Low Voltage Directive
Transistorized inverters are covered by the Low Voltage Directive.
2) Compliance
We have self-confirmed our inverters as products compliant to the Low Voltage
Directive and place the CE mark on the inverters.
47
3) Outline of instructions
* In the 400V class inverters, the rated input voltage range is three-phase,
380V to 415V, 50Hz/60Hz.
* Connect the equipment to the earth securely. Do not use an earth leakage circuit
breaker as an electric shock protector without connecting the equipment to the earth.
* Wire the earth terminal independently. (Do not connect two or more cables to
one terminal.)
* The wire size on pages 20 and 22 are shown for following conditions
y Ambient Temp : 40°C (104°F) maximum
y Wire installation : On wall without ducts or conduits
If conditions are different from above, select appropriate wire according to EN
60204 ANNEX C TABLE 5.
* Use the no-fuse breaker and magnetic contactor which conform to the EN or
IEC Standard.
Design notice : Where residual-current-operated protective device (RCD) is
used for protection in case of direct or indirect contact, only
RCD of Type B is allowed on the supply side of this
Electronic Equipment (EE). Otherwise another protective
measure shall be applied such as separation of the EE from
the environment by double or reinforced insulation or
isolation of EE and supply system by a transformer. (Extract
from EN51078)
* Use the inverter under the conditions of overvoltage category II and
contamination level 2 or higher specified in IEC664.
(a) To meet the overvoltage category II, insert an EN or IEC standard-
compliant earthed star connection isolation transformer in the input of the
inverter.
(b) To meet the contamination level 2, install the inverter in a control box
protected against ingress of water, oil, carbon, dust, etc. (IP54 or higher).
* On the input and output of the inverter, use cables of the type and size set
forth in EN60204 Appendix C.
* The operating capacity of the relay outputs (terminal symbols A, B, C) should
be 30VDC, 0.3A.
* The control circuit terminals shown with { and z on page 14 provide safe
separation to the main circuit terminal (primary circuit).
Environment
During
During operation In storage
Transportation
Ambient -10°C to +50°C -20°C to +65°C -20°C to +65°C
Temperature (14°F to 122°F) (-4°F to 149°F) (-4°F to 149°F)
Ambient Humidity 90%RH or less 90%RH or less 90%RH or less
1,000m 1,000m 10,000m
Ambient Altitude
(3280.80feet) (3280.80feet) (32808.00feet)
Details are given in the technical information "Low Voltage Directive
Conformance Guide" (BCN-A21041-203). Please contact your sales
representative.
48
CCHAPTER
H A P T E R 33
O P E R A T IO N
OPERATION/CONTROL
This chapter provides the basic "operation/control" for use

of this product.
Always read this chapter before using the equipment.
3.1 Pre-Operation Information ........................................ 49

3.2 About the Control Panel............................................ 52 Chapter 1
3.3 Operation.................................................................. 59
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
3 OPERATION/CONTROL
3.1.1 Types of operation modes
The inverter can be operated in any of "PU operation mode", "external operation
mode", "combined operation mode" and "communication operation mode". Prepare
required instruments and parts according to the operation mode. For the way of
changing the operation mode, refer to page 55.
(1) External operation mode
(factory setting Pr. 79 "operation mode selection" = 0)
Pr. 79 "operation mode selection" is factory-set to 0 and the external operation mode is
selected at power-on.
The inverter is operated using an external start signal and an
external frequency setting signal.
Preparation
y Start signal..........................Switch, relay, etc.
y Frequency setting signal.....0 to 5V, 0 to 10V or 4 to
20mADC signals from the
external potentiometer or from
outside the inverter
Note: 1. Operation cannot be started by the start signal alone. Both the start signal
and frequency setting signal are required to run the inverter.
(2) PU operation mode (Pr. 79 "operation mode selection" = 1)

How to perform operation using the optional control
panel or parameter unit
Preparation
y Operation unit ................ Control panel (FR-PA02-02) or parameter unit (FR-PU04)

y Connection cable ........... To be prepared for use of the control panel (FR-PA02-02)
away from the inverter or for use of the parameter unit (FR-
PU04).
FR-CB2 (option)
y FR-E5P (option)............. To be prepared for use of the control panel away from the
inverter. It is available as a set of control panel cover and
connection cable junction adaptor.
49
(3) Combined operation mode 1 (Pr. 79 "operation mode selection" = 3)
The start signal is an external signal.
The frequency setting signal is set using the optional control
panel or parameter unit.
Preparation
y Start signal............... Switch, relay, etc.
y Operation unit .......... Control panel (FR-PA02-02) or
parameter unit (FR-PU04)
y Connection cable..... Refer to (1) PU operation mode.
y FR-E5P (option)....... Refer to (1) PU operation mode.
(4) Combined operation mode 2 (Pr. 79 "operation mode selection" = 4)

The start signal is entered from the operation command key
of the optional control panel.
The frequency setting signal is set using the external
frequency setting signal.
Preparation
y Frequency.................. 0 to 5V, 0 to 10V, 4 to 20mA DC
setting signal signals from an external
potentiometer or from outside the
inverter
y Operation unit ............ Control panel (FR-PA02-02) or
parameter unit (FR-PU04)
y Connection cable....... Refer to (1) PU operation mode.
y FR-E5P (option)......... Refer to (1) PU operation mode.
(5) Communication operation mode

(Pr. 79 "operation mode selection" = 0 or 1)
Communication operation can be performed by connecting a personal computer and 3
the PU connector with the RS-485 communication cable.
Preparation
y Connection cable ..........................Connector: RJ45 connector
Cable: Cable conforming to EIA568
(e.g. 10BASE-T cable)
y Personal computer
y RS-485, RS-232C converter.........T o be prepared w hen the com m unication port of the
personal com puter has R S -232C specifications.
50
3.1.2 Power on
Before switching power on, check the following.
z Installation check
Make sure that the inverter is installed correctly in a correct place. (Refer to page 12.)
z Wiring check
Make sure that the main and control circuits are wired correctly.
Make sure that the options and peripheral devices are selected and connected
correctly. (Refer to page 14.)
z Switch power on.

Power-on is complete if the POWER lamp is lit to give a correct indication and the
ALARM lamp is off.
51
3.2 About the Control Panel
3.2 About the Control Panel
With the optional control panel (FR-PA02-02), you can run the inverter, set the
frequency, monitor the operation command display, set parameters, and display an
error.
3.2.1 Names and functions of the control panel (FR-PA02-02)
Cover opened
Unit indication
Hz RUN Display Hz RUN Operation status
A MON A MON
PU EXT
LED 4 digits PU EXT indication
Setting key Reverse key
Mode key MODE SET REV
STOP STOP
RUN FWD
RESET
RESET
RUN key STOP/RESET key Forward key STOP/RESET key Up/down keys
z Key indication
Key Description
RUN key Used to give a start rotation command.
MODE key You can select the operation mode or setting mode.
SET key You can determine the frequency and parameter setting.
z Used to increase or decrease the running frequency
/ key consecutively. Hold down this key to change the frequency.

z Press this key in the setting mode to change the parameter
setting consecutively.
FWD key Used to give a forward rotation command.
REV key Used to give a reverse rotation command.
z Used to stop operation. 3
STOP
RESET key z Used to reset the inverter when its output is stopped by the
activated protective function.
z Unit indications, operating status indications

Indication Description
Hz Lit to indicate the frequency.
A Lit to indicate the current.
Lit while the inverter is operating. Lit to indicate forward rotation, and flickers to
RUN
indicate reverse rotation.
MON Lit in the monitor display mode.
PU Lit in the PU operation mode.
EXT Lit in the external operation mode.
52
3.2.2 Control panel mode is changed by pressing the MODE key
zMonitoring mode zFrequency setting zParameter setting mode

mode (Note)
Hz Hz
MON MODE MODE MODE
PU EXT PU PU
MODE SET REV MODE SET REV MODE SET REV
STOP STOP STOP

FWD FWD FWD
RESET RESET RESET
zHelp mode zOperating mode

MODE MODE
PU EXT PU
MODE SET REV MODE SET REV
STOP STOP
FWD FWD
RESET RESET
(Note) The frequency setting mode is displayed only in the PU operation mode.
3.2.3 Monitoring
y Operation command indications given while a monitor display is being provided
EXT is lit to indicate external operation.
PU is lit to indicate PU operation.
Both EXT and PU are lit to indicate combined operation.
y The monitor display can also be changed during operation.
zFrequency monitor
zCurrent monitor zVoltage monitor zAlarm monitor
Hz
Alarm absent
MON
PU EXT SET SET SET
A MON MON
MODE SET REV PU EXT PU EXT
STOP
SET SET
FWD
RESET
*1 *1
Alarm present
SET
SET SET
*1
MODE *2
To 3.2.4 Frequency setting mode (Note3)
Note: 1. Hold down the SET key marked *1 for more than 1.5 seconds to change the
current monitor to the power-on monitor.
2. Hold down the SET key marked *2 for more than 1.5 seconds to display four
errors including the most recent one.
3. To the parameter setting mode when in the external operation mode.
53
3.2.4 Frequency setting
In the PU operation mode, set the frequency value used for operation performed
under the operation command given by the RUN key ( FWD or REV key).
This mode is displayed only in PU operation.
To frequency monitoring
zFrequency setting mode zSet frequency changing zSet frequency MODE
write
Hz SET
Hz
Hz
PU PU
PU
MODE SET REV Change the set Flicker

FWD
STOP frequency with
RESET Hz
PU
MODE
To 3.2.5 Parameter setting mode
3.2.5 Parameter setting method
With the exception of some parameters, parameter setting can be made only when the
PU operation mode is selected by the Pr. 79 setting.
y A parameter value may either be set by updating its parameter number or setting
the value digit-by-digit using the / key.
y To write the setting, change it and press the SET key for about 1.5 seconds.
Note: If parameter write cannot be performed, refer to page 174. 3
54
(1) Example: To change the Pr. 79 "operation mode selection" setting
from "2" (external operation mode) to "1" (PU operation
mode)
(For details of Pr. 79, refer to page 109.)
Press the MODE key, to choose the
parameter setting mode.
zParameter setting mode
Most significant Least significant

PU digit flickers Middle digit flickers digit flickers
SET SET
MODE SET REV
STOP
FWD
RESET
×7 times ×9 times
MODE
or or
×3 times ×1 times
To 3.2.6 Operation mode
SET
0 to 9 0 to 9
zCurrent setting zSetting change
SET
Press for
1.5 sec.
SET
zSetting write
When appears
1) If the RUN indication is lit or flickering, RUN
STOP
stop operation by pressing the RESET
key or turning off the forward rotation

(STF) or reverse rotation (STR) signal
Flicker connected to the control terminal.
2) You cannot set any value that is outside the
parameter setting range. Write a value within
the setting range.
"1" (PU operation mode) has been set in Pr. 79.
If the value and do not flicker but
appears, you did not press the SET key
for 1.5 seconds when writing the value.
Press the key once, press the SET key, and
restart the setting from the beginning.
55
3.2.6 Operation mode
The operation mode change method which is shown below is only allowed when Pr. 79
"operation mode selection" is "0".
zPU operation
zPU jog operation zExternal operation
PU
PU EXT
MODE SET REV
STOP
FWD
RESET
MODE MODE MODE
To 3.2.7 Help mode
Note: If the operation mode cannot be changed, refer to page 174.
3.2.7 Help mode
zAlarm history
zAlarm history clear zParameter clear
PU EXT
MODE SET REV
FWD
STOP
zSoftware version
zAll clear
RESET
read
3
MODE
To 3.2.3 Monitoring mode
56
(1) Alarm history
Four past alarms can be displayed with the / key.
("." is appended to the most recent alarm.)
When no alarm exists, E._ _0 is displayed.
zMost recent alarm
SET
SET
When alarm occurs

Hz
Frequency Current A
PU EXT PU EXT
Energization time Voltage

PU EXT PU EXT
(2) Alarm history clear

Clears all alarm history.
Flicker
SET SET
1.5sec
SET Cancel
57
(3) Parameter clear
Initializes the parameter values to the factory settings. The calibration values are not
initialized.
(Parameter values are not cleared by setting "1" in Pr. 77 "parameter write disable
selection")
Flicker
SET SET
1.5sec
SET Cancel
Note: 1. In the FR-E520-0.1K to 7.5K-NA and FR-E510W-0.1K to 0.75K-NA, Pr. 122

"communication check time interval" setting is "0". (Factory setting: 9999)
2. The Pr. 75 "reset selection/PU disconnection detection/PU stop selection"
value is not initialized.
(4) All clear

Initializes the parameter values and calibration values to the factory settings.
Flicker
SET SET
1.5sec
SET Cancel
Note: 1. In the FR-E520-0.1K to 7.5K-NA and FR-E510W-0.1K to 0.75K-NA, Pr. 122

"communication check time interval" setting is "0". (Factory setting: 9999)
3
2. The Pr. 75 "reset selection/PU disconnection detection/PU stop selection"
value is not initialized.
58
3.3 Operation
3.2 Operation
3.3.1 Pre-operation checks

Before starting operation, check the following:
z Safety
Perform test operation after making sure that safety is ensured if the machine
should become out of control.
z Machine
Make sure that the machine is free of damage.
z Parameters
Set the parameter values to match the operating machine (system) environment.
z Test operation
Perform test operation and make sure that the machine operates safely under light
load at a low frequency. After that, start operation.
Since the Pr. 240 "Soft-PWM setting" value is factory-set to select Soft-PWM
control, the tone is different from that in the conventional non-low acoustic noise
mode, this is not a fault.
59
3.3.2 External operation mode (Operation using the external
frequency setting potentiometer and external start signal)
(1) Operation at 60Hz

Operation command: Externally connected start signal.
Frequency setting: Externally connected frequency setting potentiometer
Step Description Image
Power on → Operation mode check
With the factory setting, the external operation mode is ON
1 selected and the [EXT] indication is lit when power is

switched on. If the [EXT] indication is not lit, refer to page
EXT
55 and set "2" in Pr. 79.
Start
Set the start switch (STF or STR) to ON.
The [RUN] indication is lit to indicate forward rotation, or Forward rotation
flickers to indicate reverse rotation. Reverse
rotation
2 Note: The motor does not start if both the forward Hz RUN
MON
and reverse rotation switches are turned on. If EXT
both switches are turned on during operation,
the motor decelerates to a stop.
Acceleration → Constant speed External potentiometer

Slowly turn the potentiometer connected across terminals
3 2-5 (frequency setting potentiometer) fully clockwise.
The frequency shown on the display increases gradually to
60.00Hz.
Deceleration
External potentiometer
S low ly turn the potentiom eter connected across term inals 2-5 3
(frequency setting potentiom eter) fully counterclockw ise.
4
The frequency shown on the display decreases gradually
to 0.00Hz.
The motor stops running.
Stop Forward rotation
Turn off the start switch (STF or STR). Reverse
rotation
5 Stop
OFF
<Reference> If other frequency is required at fully clockwise position, change Pr. 38

"Frequency at 5V (10V)" setting.
60
3.3.3 PU operation mode (Operation using the control panel)
(1) Using the control panel (FR-PA02-02) for operation at 60Hz with
digital frequency setting
Operation command: RUN key or FWD / REV key of the control panel (FR-PA02-02)
Frequency setting: / key
Related parameters: Pr. 79 "operation mode selection".
By repeating step 2 below during motor run, speed can be varied.
Power on → Operation mode check
Switch power on, refer to page 55, and set "1" in Pr. 79 ON
1 "operation mode selection".

Hz RUN
The [PU] indication is lit. A MON
PU EXT
Running frequency setting

Set the running frequency to 60Hz.
(or)
1) Refer to page 53 and select the frequency setting mode
2
with the MODE key. Hz RUN
A MON
PU EXT
2) Refer to page 54, make setting with the / key,

MODE SET REV
STOP
FWD
RESET
and write the setting with the SET key.

Start
RUN
Press the RUN key (or FWD / REV key). The monitoring
mode is automatically selected and the output frequency is FWD REV
3
displayed.
Hz RUN
A MON
PU EXT
MODE SET REV
The [RUN] indication is lit to indicate forward rotation, or FWD

STOP
RESET
flickers to indicate reverse rotation.

Stop
STOP
Press the RESET key.
Hz
4 The motor is decelerated to a stop. MON

PU
The [RUN] indication goes off.
(2) PU jog operation

Hold down the RUN (or FWD or REV ) key to perform operation, and release it to stop.
1) Set Pr. 15 "jog frequency" and Pr. 16 "jog acceleration/deceleration time".
2) Select the PU jog operation mode. (Refer to page 56.)
3) Hold down the RUN or FWD , REV key to perform operation.
(If the motor remains stopped, check Pr. 13 "starting frequency". The motor will not
start if its setting is lower than the starting frequency.
61
3.3.4 Combined operation mode 1 (Operation using both external
start signal and control panel)
When the start signal is provided externally (switch etc.) and the running frequency is
set from the control panel (Pr. 79 = 3).
The external frequency setting signal and PU's forward rotation, reverse rotation and
STOP
RESET keys are not accepted. (Note)
Operation command: externally connected start signal

Frequency setting: / key of the control panel (FR-PA02-02)
Power on
Switch power on.
ON
1
Operation mode selection

Refer to page 55 and set "3" in Pr. 79 "operation mode
selection".
2 Flicker
Start
Turn on the start switch (STF or STR). Forward rotation
Note: The motor does not start if both the forward and Reverse
rotation
reverse rotation switches are turned on. If both
3 Hz RUN
switches are turned on during operation, the motor ON MON
decelerates to a stop. PU EXT
The [RUN] indication is lit to indicate forward

rotation, or flickers to indicate reverse rotation.
Running frequency setting
Set the running frequency to 60.00Hz with the /
key. 3
4
<Step setting>
Stop
Turn off the start switch (STF or STR).
The motor stops. Hz
5 The [RUN] indication goes off.

MON
PU EXT
STOP
Note: The RESET key is made valid if any of "14" to "17" is set in Pr. 75 "PU stop
selection".
62
3.3.5 Combined operation mode 2
When the running frequency is set from a potentiometer connected across terminals 2-
5 (frequency setting potentiometer) and the start signal is provided by the RUN key or
FWD / REV key of the control panel (FR-PA02-02).
Operation command: RUN key (or FWD / REV key) of the control panel (FR-PA02-02)
Frequency setting: Externally connected frequency setting potentiometer
Power on
Switch power on.
ON
1

Refer to page 55 and set "4" in Pr. 79 "operation mode
2 selection". Flicker
The [PU] and [EXT] indications are lit.
Start
RUN
Press the RUN key (or FWD / REV key) of the control panel.
3 The [RUN] indication is lit to indicate forward rotation, or FWD REV
Hz RUN
flickers to indicate reverse rotation. MON
PU EXT
Acceleration → Constant speed External potentiometer

Slowly turn the potentiometer connected across terminals
4 2-5 (frequency setting potentiometer) fully clockwise.
The frequency shown on the display increases gradually to
60.00Hz.
Deceleration
Slowly turn the potentiometer connected across terminals External potentiometer
2-5 (frequency setting potentiometer) fully
5 counterclockwise.
The frequency shown on the display decreases gradually
to 0.00Hz.
The motor stops running.
Stop
STOP
Press the RESET key.
6 The operation command indication RUN goes off.
<Reference> If other frequency is required at fully clockwise position, change Pr. 38

"Frequency at 5V (10V)" setting.
63
C CHAPTER
H A P T E R 44
P PARAMETERS
A R A M E T E R S
This chapter explains the "parameters" of this product.
With the factory settings, the inverter is designed to perform
simple variable-speed operation. Set necessary parameter
values according to the load and operating specifications.
Chapter 1
4.1 Parameter List .......................................................... 64
4.2 Parameter Function Details ...................................... 73
Chapter 2
Note: By making parameter settings, you can change the

functions of contact input terminals RL, RM, RH, MRS, Chapter 3
open collector output terminals RUN, FU, and contact
output terminals A, B, C. Therefore, signal names
corresponding to the functions are used in the description
of this chapter (except in the wiring examples). Note that
they are not terminal names. Chapter 4
Chapter 5
Chapter 6
4.1 Parameter List
PARAMETERS
4 PARAMETERS
4.1 Parameter List
4.1.1 Parameter list

Param- Minimum Custo-
Func- Setting Factory Refer
eter Name Setting mer
tion Range Setting To:
Number Increments Setting
6%/4%
0 Torque boost (Note 1) 0 to 30% 0.1% 73
Parameter List
(Note 11)
1 Maximum frequency 0 to 120Hz 0.01H z (N ote 3) 120Hz 74
2 Minimum frequency 0 to 120Hz 0.01H z (N ote 3) 0Hz 74
3 Base frequency (Note 1) 0 to 400Hz 0.01H z (N ote 3) 60Hz 75
Multi-speed setting
4 0 to 400Hz 0.01H z (N ote 3) 60Hz 76
(high speed)
Basic functions
Multi-speed setting
5 0 to 400Hz 0.01H z (N ote 3) 30Hz 76
(middle speed)
Multi-speed setting
6 0 to 400Hz 0.01H z (N ote 3) 10Hz 76
(low speed)
0 to 3600 s/ 5 s/10s
7 Acceleration time 0.1 s/0.01 s 77
0 to 360 s (Note 4)
0 to 3600 s/ 5 s/10s
8 Deceleration time 0.1 s/0.01 s 77
0 to 360 s (Note 4)
Rated
Electronic thermal O/L output
9 0 to 500A 0.01A 79
relay current
(Note 5)
DC injection brake 0.01Hz
10 0 to 120Hz 3Hz 80
operation frequency (Note 3)
DC injection brake
11 0 to 10 s 0.1 s 0.5 s 80
operation time
12 DC injection brake voltage 0 to 30% 0.1% 6% 80
13 Starting frequency 0 to 60Hz 0.01Hz 0.5Hz 81
Load pattern selection
14 0 to 3 1 0 82
(Note 1)
0.01Hz
15 Jog frequency 0 to 400Hz 5Hz 83
(Note 3)
Jog acceleration/ 0 to 3600 s/
16 0.1 s/0.01 s 0.5 s 83
Standard operation functions
deceleration time 0 to 360 s

High-speed maximum 120 to
18 0.1H z 120Hz 74
frequency 400Hz
Base frequency voltage 0 to 1000V,
19 0.1V 9999 75
(Note 1) 8888,9999
Acceleration/deceleration 0.01Hz
20 1 to 400Hz 60Hz 77
reference frequency (Note 3)
Acceleration/deceleration
21 0, 1 1 0 77
time increments
Stall prevention operation
22 0 to 200% 0.1% 150% 84
level
0 to 200%,
23 level at double speed 0.1% 9999 84
9999
(Note 6)
Multi-speed setting 0 to 400Hz, 0.01Hz
24 9999 76
(speed 4) 9999 (Note 3)
25 9999 76
(speed 5) 9999 (Note 3)
26 9999 76
(speed 6) 9999 (Note 3)
27 9999 76
(speed 7) 9999 (Note 3)
64
PARAMETERS

29 0, 1, 2 1 0 86
pattern
Regenerative function
30 0, 1 1 0 87
selection
Parameter List
0 to 400Hz, 0.01Hz
31 Frequency jump 1A 9999 88
9999 (Note 3)
0 to 400Hz, 0.01Hz
32 Frequency jump 1B 9999 88
9999 (Note 3)
0 to 400Hz, 0.01Hz
9999 (Note 3)
0 to 400Hz, 0.01Hz
9999 (Note 3)
0 to 400Hz, 0.01Hz
9999 (Note 3)
0 to 400Hz, 0.01Hz
9999 (Note 3)
0,
37 Speed display 0.01 to 0.001 r/min 0 89
9998
Frequency at 5V (10V) 0.01Hz 60H z
38 1 to 400Hz 90
input (Note 3) (N ote 2)
0.01Hz 60H z
39 Frequency at 20mA input 1 to 400Hz 90
(Note 3) (N ote 2)
41 Up-to-frequency sensitivity 0 to 100% 0.1% 10% 91
functions
terminal
Output frequency 0.01Hz

Output
42 0 to 400Hz 6Hz 91
detection (Note 3)
Output frequency detection 0 to 400Hz, 0.01Hz
43 9999 91
for reverse rotation 9999 (Note 3)
Second
0 to 3600 s/ 5s/10s
44 acceleration/deceleration 0.1 s/0.01 s 77
0 to 360 s (Note 4)
time
Second functions
0 to 3600 s/
45 Second deceleration time 0 to 360 s, 0.1 s/0.01 s 9999 77
9999
Second torque boost 0 to 30%,
46 0.1% 9999 73
(Note 1) 9999
Second V/F 0 to 400Hz, 0.01Hz
47 9999 75
(base frequency) (Note 1) 9999 (Note 3)
Second electronic 0 to 500A,
48 0.01A 9999 79
overcurrent protection 9999
Control panel/PU main
52 0, 23, 100 1 0 93
display data selection 4
Display functions
FM terminal function
54 0, 1, 2 1 0 93
selection (Note 9)
Frequency monitoring 0.01Hz
55 0 to 400Hz 60Hz 95
reference (Note 3)
Rated
Current monitoring
56 0 to 500A 0.01A output 95
reference
current
Automatic
0 to 5 s,
functions
57 Restart coasting time 0.1 s 9999 96

restart
9999
58 Restart cushion time 0 to 60 s 0.1 s 1.0 s 96
65
PARAMETERS

Additional
function
Remote setting function

59 0, 1, 2 1 0 97
selection
Parameter List
Shortest acceleration/ 0, 1, 2,
60 1 0 98
deceleration mode 11, 12
0 to 500A,
61 Reference current 0.01A 9999 98
9999
Reference current for 0 to 200%,
62 1% 9999 98
acceleration 9999
Reference current for 0 to 200%,
63 1% 9999 98
deceleration 9999
65 Retry selection 0, 1, 2, 3 1 0 100
0.01Hz
66 level reduction starting 0 to 400Hz 60Hz 84
(Note 3)
frequency (Note 6)
Number of retries at alarm 0 to 10,
Operation selection functions
67 1 0 100
occurrence 101 to 110
68 Retry waiting time 0.1 to 360 s 0.1 s 1s 100
Retry count display
69 0 1 0 100
erasure
Special regenerative
70 0 to 30% 0.1% 0% 87
brake duty
0, 1, 3, 5, 6,
13, 15, 16, 23,
71 Applied motor (Note 6) 100, 101, 103, 1 0 102
105, 106, 113,
115, 116, 123
72 PWM frequency selection 0 to 15 1 1 103
73 0-5V/0-10V selection 0, 1 1 0 104
74 Filter time constant 0 to 8 1 1 105
Reset selection/
0 to 3,14 to
75 disconnected PU detection/ 1 14 105
17
PU stop selection
Parameter write disable
77 0, 1, 2 1 0 107
selection
Reverse rotation
78 0, 1, 2 1 0 108
prevention selection
79 0 to 4,6 to 8 1 0 109
(Note 6)
0.1 to
7.5kW,
80 Motor capacity 0.01kW 9999 112
9999
Magneticflux vector control
(Note 8)
General-purpose
0 to 500A,
82 Motor exciting current 0.01A 9999 114
9999
200V/
83 Rated motor voltage 0 to 1000V 0.1V 114
400V
0.01Hz
84 Rated motor frequency 50 to 120Hz 60Hz 114
(Note 3)
0 to 50Ω,
90 Motor constant (R1) (Note 6) 0.001Ω 9999 114
9999
Auto-tuning setting/status
96 0, 1 1 0 114
(Note 6)
66
PARAMETERS

117 Station number 0 to 31 1 0 120
118 Communication speed 48, 96, 192 1 192 120
0, 1 (data
Communication functions
length 8)
Parameter List
119 Stop bit length/data length 1 1 120
10, 11 (data
length 7)
Parity check
120 0, 1, 2 1 2 120
presence/absence
Number of communication 0 to 10,
121 1 1 120
retries 9999
Communication check 0 to 999.8 s,
122 0.1 s 9999 120
time interval 9999
0 to 150,
123 Waiting time setting 1 9999 120
9999
CR, LF presence/absence
124 0, 1, 2 1 1 120
selection
128 PID action selection 0, 20, 21 1 0 131
0.1 to
129 PID proportional band 1000%, 0.1% 100% 131
9999
0.1 to 3600 s,
130 PID integral time 0.1 s 1s 131
9999
PID control
0 to 100%,
131 Upper limit 0.1% 9999 131
9999
0 to 100%,
132 Lower limit 0.1% 9999 131
9999
PID action set point for PU
133 0 to 100% 0.01% 0% 131
operation
0.01 to
134 PID differential time 10.00 s, 0.01 s 9999 131
9999
Additional
function
145 Parameter for option (FR-PU04).
146 Parameters set by manufacturer. Do not set.

Output current detection
150 0 to 200% 0.1% 150% 139
Current detection
level
Output current detection
151 0 to 10 s 0.1 s 0 139
period
Zero current detection
152 0 to 200.0% 0.1% 5.0% 140
level
Zero current detection 4
153 0.05 to 1 s 0.01 s 0.5 s 140
period
monitor function function
156 0 to 31,100 1 0 141

selection
Sub
AM terminal function
158 0, 1, 2 1 0 93
selection (Note 10)
Initial Additional
160 User group read selection 0, 1, 10, 11 1 0 143

168
Parameters set by manufacturer. Do not set.
169
Actual operation hour

171 0  0 145
meter clear
67
PARAMETERS

173 User group 1 registration 0 to 999 1 0 143
U ser functions
0 to
174 User group 1 deletion 1 0 143
999,9999
175 User group 2 registration 0 to 999 1 0 143
Parameter List
0 to
999,9999
RL terminal function
180 0 to 8, 16, 18 1 0 145
selection
RM terminal function
181 0 to 8, 16, 18 1 1 145
assignment functions
selection
RH terminal function
182 0 to 8, 16, 18 1 2 145
selection
Terminal
MRS terminal function

183 0 to 8, 16, 18 1 6 145
selection
RUN terminal function
190 0 to 99 1 0 147
selection
FU terminal function
191 0 to 99 1 4 147
selection
A, B, C terminal function
192 0 to 99 1 99 147
selection
232 9999 76
(speed 8) 9999 (Note 3)
233 9999 76
(speed 9) 9999 (Note 3)
Multi-speed operation

234 9999 76
(speed 10) 9999 (Note 3)
235 9999 76
(speed 11) 9999 (Note 3)
236 9999 76
(speed 12) 9999 (Note 3)
237 9999 76
(speed 13) 9999 (Note 3)
238 9999 76
(speed 14) 9999 (Note 3)
239 9999 76
(speed 15) 9999 (Note 3)
240 Soft-PWM setting 0, 1 1 1 103
Cooling fan operation
244 0, 1 1 0 148
selection
0 to 50%,
Sub functions
245 Rated motor slip 0.01% 9999 149

9999
Slip compensation
246 0.01 to 10 s 0.01 s 0.5 s 149
response time
Constant-output region
247 slip compensation 0, 9999 1 9999 149
selection
Ground fault detection at
249 0, 1 1 0 150
start (Note 9)
0 to 100 s,
selection
function
Stop
1000 to
250 Stop selection 1 9999 151
1100 s,
8888, 9999
68
PARAMETERS

FM terminal calibration
900    153
(Note 9)
AM terminal calibration
901    155
Calibration functions
(Note 10)
Parameter List
Frequency setting voltage 0 to 0 to
902 0.01Hz 0V 0Hz 157
bias 10V 60Hz
Frequency setting voltage 0 to 1 to
903 0.01Hz 5V 60Hz 157
gain 10V 400Hz
Frequency setting current 0 to 0 to 4
904 0.01Hz 0Hz 157
bias 20mA 60Hz mA
Frequency setting current 0 to 1 to 20
905 0.01Hz 60Hz 157
gain 20mA 400Hz mA
990
Parameter for option (FR-PU02-02).
991
Note: 1. Indicates the parameter of which setting is ignored when the general-
purpose magnetic flux vector control mode is selected.
2. Since calibration is made before shipment from the factory, the settings differ
slightly between inverters. The inverter is preset to provide a frequency
slightly higher than 60Hz.
3. When the control panel is used and the setting is 100Hz or more, the setting
increments are 0.1Hz.
4. The setting depends on the inverter capacity: (0.1K to 3.7K)/(5.5K to 7.5K).
5. Set to 85% of the rated inverter current for the 0.1K to 0.75K.
6. If "2" is set in Pr. 77 (parameter write inhibit selection), the setting cannot be
changed during operation.
7. The half-tone screened parameters allow their settings to be changed during
operation if "0" (factory setting) has been set in Pr. 77 (parameter write
inhibit selection). (However, the Pr. 72 value may be changed during PU
operation only.)
8. The setting range changes with the inverter: 0.2kW to 7.5kW, 9999 for the
400V class.
9. Pr. 249 is not available for the 400V class.
10. Setting may be made on the 400V class inverter only. 4
11. The setting depends on the inverter capacity: 4% for the FR-E540-5.5K and
7.5K-NA.
69
PARAMETERS
4.1.2 List of parameters classified by purpose of use

Set the parameters according to the operating conditions. The following list indicates
purpose of use and corresponding parameters.
Parameter Numbers
Parameter List
Purpose of Use
Parameter numbers which must be set
Operation mode selection Pr. 79
Acceleration/deceleration time/pattern
Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 29
adjustment
Selection of output characteristics
Pr. 3, Pr. 14, Pr. 19
optimum for load characteristics
Output frequency restriction (limit) Pr. 1, Pr. 2, Pr. 18
Operation over 60Hz Pr. 1, Pr. 18, Pr. 38, Pr. 39, Pr. 903, Pr. 905
Adjustment of frequency setting
Pr. 38,Pr. 39, Pr. 73, Pr. 902 to Pr. 905
Related to operation
signals and outputs

Motor output torque adjustment Pr. 0, Pr. 80
Brake operation adjustment Pr. 10, Pr. 11, Pr. 12
Pr. 1, Pr. 2, Pr. 4, Pr. 5, Pr. 6, Pr. 15, Pr. 24,
Multi-speed operation Pr. 25, Pr. 26, Pr. 27, Pr. 232, Pr. 233, Pr. 234,
Pr. 235, Pr. 236, Pr. 237, Pr. 238, Pr. 239
Jog operation Pr. 15, Pr. 16
Frequency jump operation Pr. 31, Pr. 32, Pr. 33, Pr. 34, Pr. 35, Pr.36
Automatic restart operation after
Pr. 57, Pr. 58
instantaneous power failure
Optimum acceleration/deceleration
Pr. 60
within continuous rated range
Slip compensation setting Pr. 245 to Pr. 247
Output stop method selection Pr. 250
General-purpose magnetic flux vector
Pr. 80
control operation
Related to application operation
Electromagnetic brake operation timing Pr. 42, Pr. 190 to Pr. 192
Offline auto tuning setting Pr. 82 to Pr. 84, Pr. 90, Pr. 96
Pr. 0, Pr.3, Pr. 7, Pr. 8, Pr. 9, Pr. 44, Pr. 45,
Sub-motor operation
Pr. 46, Pr. 47, Pr. 48
Regenerative function selection Pr. 30, Pr. 70
Operation in communication with
Pr. 117 to Pr. 124
personal computer
Pr. 73, Pr. 79, Pr. 128 to Pr. 134, Pr. 180 to Pr.
Operation under PID control
183, Pr. 190 to Pr. 192
Noise reduction Pr. 72, Pr. 240
70
PARAMETERS
Parameter Numbers
Purpose of Use
Parameter numbers which must be set
Related to monitoring
Frequency meter calibration Pr. 54, Pr. 55, Pr. 56, Pr. 158, Pr. 900, Pr. 901
Monitor display on control panel (FR-
Pr. 54, Pr. 55, Pr. 56, Pr. 158, Pr. 900, Pr. 901
PA02-02) or parameter unit (FR-PU04)
Parameter List
Display of speed, etc. Pr. 37, Pr. 52
Clearing of inverter's actual operation
Pr. 171
time
operation prevention
Function write prevention Pr. 77

Related to false
Reverse rotation prevention Pr. 78

Parameter grouping Pr. 160, Pr. 173 to Pr. 176
Current detection Pr. 150 to Pr. 153, Pr.190 to Pr. 192
Motor stall prevention Pr. 22, Pr. 23, Pr. 66, Pr. 156
Input terminal function assignment Pr. 180 to , Pr.183
Output terminal function assignment Pr. 190 to Pr. 192
Increased cooling fan life Pr. 244
Others
Motor protection from overheat Pr. 9, Pr. 71

Automatic restart operation at alarm
Pr. 65, Pr. 67, Pr. 68, Pr. 69
stop
Ground fault overcurrent setting Pr. 249
Inverter reset selection Pr. 75
71
PARAMETERS
4.1.3 Parameters recommended to be set by the user

We recommend the following parameters to be set by the user.
Set them according to the operation specifications, load, etc.
Parameter List
Parameter
Name Application
Number
1 Maximum frequency Used to set the maximum and minimum output
2 Minimum frequency frequencies.
7 Acceleration time Used to set the acceleration and deceleration
8 Deceleration time times.
Used to set the current of the electronic
Electronic overcurrent
9 overcurrent protection to protect the motor from
protection
overheat.
Used to select the optimum output characteristics
14 Load pattern selection which match the application and load
characteristics.
Used to set the thermal characteristics of the
71 Applied motor electronic overcurrent protection according to the
motor used.
Used to select the specifications of the frequency
73 0-5V/0-10V selection setting signal entered across terminal 2-5 to
perform operation with the voltage input signal.
Used to calibrate the meter connected across
900 FM terminal calibration
terminals FM-SD.
Used to calibrate the meter connected across
901 AM terminal calibration
terminals AM-5.
Frequency setting voltage
902
bias
Frequency setting voltage
903 Used to set the magnitude (slope) of the output
gain
frequency relative to the frequency setting signal
Frequency setting current
904 (0 to 5V, 0 to 10V or 4 to 20mA DC) as desired.
bias
Frequency setting current
905
gain
72
4.2 Parameter Function Details
PARAMETERS
4.2 Parameter Function Details
4.2.1 Torque boost (Pr. 0, Pr. 46)

Pr. 0 "torque boost" Related parameters
Pr. 3 "base frequency"
Pr. 46 "second torque boost" Pr. 19 "base frequency voltage"
Pr. 71 "applied motor"
Pr. 80 "motor capacity"
Pr. 180 to Pr. 183 (input terminal
function selection)
Increase the setting when the inverter-to-motor distance is long or motor torque in the
low-speed range is insufficient, for example;
z Motor torque in the low-frequency range can be adjusted to the load to increase the
starting motor torque.
z You can select either of the two starting torque boosts by RT terminal switching.
Parameter Factory
Setting Range Remarks
Number Setting
(Note) FR-E520-0.1K to 7.5K-NA: 6%
6%/4% FR-E540-0.4K to 3.7K-NA: 6%
0 0 to 30%
(Note) FR-E510W-0.1K to 0.75K-NA: 6%
FR-E540-5.5K, 7.5K-NA: 4%
46 9999 0 to 30%, 9999 9999: Function invalid
Output voltage
100%
Pr.0
Pr.46
Setting range Base frequency
0 Output frequency (Hz)
<Setting>
y Assuming that the base frequency voltage is 100%, set the 0Hz voltage in %. 4
y Pr. 46 "Second torque boost" is valid when the RT signal is on. (Note 3)
Note: 1. This parameter setting is ignored when the general-purpose magnetic flux
vector control mode has been selected.
2. A large setting may result in an overheated motor or overcurrent trip. The
guideline for the largest value for this parameter is about 10%.
3. The RT signal serves as the second function selection signal and makes the
other second functions valid. Refer to page 145 for Pr. 180 to Pr. 183 (input
terminal function selection).
73
PARAMETERS
4.2.2 Output frequency range (Pr. 1, Pr. 2, Pr. 18)

Related parameters
Pr. 1 "maximum frequency"
Pr. 13 "starting frequency"
Pr. 2 "minimum frequency" Pr. 38 "frequency at 5V (10V)
input"
Pr. 18 "high-speed maximum frequency" Pr. 39 "frequency at 20m A input"
Pr. 79 "operation m ode selection"
Used to clamp the upper and lower limits of the
output frequency. Used for high-speed operation at
or over 120Hz.
z Can be used to set the upper and lower limits of motor speed.
Parameter Factory Setting
Output frequency
Number Setting Range
1 120Hz 0 to 120Hz
Pr.1
2 0Hz 0 to 120Hz
Pr.18
120 to
18 120Hz Pr.2 Frequency setting
400Hz
0 5,10V
(4mA) (20mA)
<Setting>
y Use Pr. 1 to set the upper limit of the output frequency. If the frequency of the
frequency command entered is higher than the setting, the output frequency is
clamped at the maximum frequency.
To perform operation over 120Hz, set the upper limit of the output frequency in Pr. 18.
(When the Pr. 18 value is set, Pr. 1 automatically changes to the frequency in Pr. 18.
Also, when the Pr. 1 value is set, Pr. 18 automatically changes to the frequency in
Pr. 1.)
y Use Pr. 2 to set the lower limit of the output frequency.
Note: When the potentiometer (frequency setting potentiometer) connected across

terminals 2-5 is used for operation beyond 60Hz, change the value of Pr. 38
(or Pr. 39 for use of the potentiometer connected across terminals 4-5).
Operation over 60Hz cannot be performed by merely changing the settings of
Pr. 1 and Pr. 18.
CAUTION
When the Pr. 2 setting is higher than the Pr. 13 "starting frequency" value,
note that the motor will run at the set frequency by merely switching the
start signal on, without entering the command frequency.
74
PARAMETERS
4.2.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19, Pr. 47)
Related parameters
Pr. 3 "base frequency"
Pr. 19 "base frequency voltage" Pr. 80 "motor capacity"
Pr. 83 "rated motor voltage"
Pr. 47 "second V/F (base frequency)" Pr. 180 to Pr. 183 (input terminal
function selection)
Used to adjust the inverter outputs (voltage, frequency) to the motor rating.
z When running a standard motor, generally set the rated motor frequency. When
running the motor using the commercial power supply-inverter switch-over, set the
base frequency to the same value as the power supply frequency.

Remarks
3 60Hz 0 to 400Hz
0 to 1000V, 8888: 95% of power supply voltage
19 9999
8888, 9999 9999: Same as power supply voltage
0 to 400Hz, 9999: Function invalid
47 9999
9999
Output voltage
Pr.19
Output
frequency
Pr.3
Pr.47
<Setting>
y Use Pr. 3 and Pr. 47 to set the base frequency (rated motor frequency). Two base
frequencies can be set and the required frequency can be selected from them.
y Pr. 47 "Second V/F (base frequency) " is valid when the RT signal is on. (Note 3)
y Use Pr. 19 to set the base voltage (e.g. rated motor voltage).
4
Note: 1. Set 60Hz in Pr. 3 "base frequency" when using a Mitsubishi constant-torque
motor.
2. When the general-purpose magnetic flux vector control mode has been
selected, Pr. 3, Pr. 19 and Pr. 47 are made invalid and Pr. 83 and Pr. 84 are
made valid.
75
PARAMETERS
4.2.4 Multi-speed operation

(Pr. 4, Pr. 5, Pr. 6, Pr. 24 to Pr. 27, Pr. 232 to Pr. 239)
Pr. 4 "3-speed setting (high speed)" Related parameters
Pr. 5 "3-speed setting (middle speed)" Pr. 1 "maximum frequency"

Pr. 2 "minimum frequency"
Pr. 6 "3-speed setting (low speed)" Pr. 29 "acceleration/deceleration
Pr. 24 to Pr. 27 "multi-speed setting pattern"
(speeds 4 to 7)" Pr. 79 "operation mode
selection"
Pr. 232 to Pr. 239 "multi-speed setting Pr. 180 to Pr. 183 (input terminal
(speeds 8 to 15)"
function selection)
Used to switch between the predetermined running
speeds.
z Any speed can be selected by merely switching
on/off the corresponding contact signals (RH, RM, RL, REX signals).
z By using these functions with Pr. 1 "maximum
frequency" and Pr. 2 "minimum frequency", up to 17 speeds can be set.
z Valid in the external operation mode or combined mode (Pr. 79 = 4).
When Pr. 79 = 4, the contact signals (RH, RM, RL, REX signals) are made valid.
Parameter Number Factory Setting Setting Range Remarks
4 60Hz 0 to 400Hz
5 30Hz 0 to 400Hz
6 10Hz 0 to 400Hz
24 to 27 9999 0 to 400Hz, 9999 9999: Not selected
232 to 239 9999 0 to 400Hz, 9999 9999: Not selected
Speed 1
(high speed)
Output frequency(Hz)
Speed 10
Speed 5
Speed 2 Speed 11
(middle speed) Speed 6 Speed 9 Speed 12
Speed 3 Speed 13
Speed 4 Speed 8
(low speed) Speed 14
Speed 7 Speed 15
Time Time
ON ON ON ON ON ON ON ON
RH RH
RM RM
ON ON ON ON ON ON ON
RL RL
REX
<Setting>
y Set the running frequencies in the corresponding parameters.
y Each speed (frequency) can be set as desired between 0 and 400H z during inverter operation.
After the required multi-speed setting parameter has been read, the setting can be
changed by pressing the / key. In this case, when you release the /
key, press the SET key ( WRITE key when using the parameter unit (FR-PU04)) to store
the set frequency.
y Use any of Pr. 180 to Pr. 183 to assign the terminal used to input the REX signal.
76
PARAMETERS
Note: 1. The multi-speed settings override the main speeds (across terminals 2-5, 4-5).
2. The multi-speeds can also be set in the PU or external operation mode.
3. For 3-speed setting, if two or three speeds are simultaneously selected,
priority is given to the frequency setting of the lower signal.
4. Pr. 24 to Pr. 27 and Pr. 232 to Pr. 239 settings have no priority between
them.
5. The parameter values can be changed during operation.
6. When terminal assignment is changed using Pr. 180 to Pr. 183, the other
functions may be affected. Check the functions of the corresponding
terminals before making setting.
4.2.5 Acceleration/deceleration time

(Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45)
Related parameters
Pr. 7 "acceleration time" Pr. 3 "base frequency"
Pr. 29 "acceleration/deceleration
Pr. 8 "deceleration time" pattern"
Pr. 20 "acceleration/deceleration reference frequency"
Pr. 21 "acceleration/deceleration time increments"
Pr. 44 "second acceleration/deceleration time"
Pr. 45 "second deceleration time"

Used to set motor acceleration/deceleration time.
Set a larger value for a slower speed increase/decrease or a smaller value for a faster
speed increase/decrease.
Parameter
Factory Setting Setting Range Remarks
Number
0.1K to 3.7K 5s
7 0 to 3600s/0 to 360s
5.5K, 7.5K 10s
0.1K to 3.7K 5s
8 0 to 3600s/0 to 360s
5.5K, 7.5K 10s
20 60Hz 1 to 400Hz 4
0: 0 to 3600s
21 0 0, 1
1: 0 to 360s
0.1K to 3.7K 5s
44 0 to 3600s/0 to 360s
5.5K, 7.5K 10s
0 to 3600s/ 9999: acceleration time =
45 9999
0 to 360s, 9999 deceleration time
77
PARAMETERS
Output frequency
Pr.20
Running frequency
Time
Pr.7 Pr.8
Pr.44 Pr.45
Acceleration Deceleration
<Setting>
y Use Pr. 21 to set the acceleration/deceleration time and minimum setting
increments:
Set value "0" (factory setting) ....0 to 3600 seconds (m inim um setting increm ents: 0.1 second)
Set value "1"..............................0 to 360 seconds (m inim um setting increm ents: 0.01 second)
y Use Pr. 7 and Pr. 44 to set the acceleration time required to reach the frequency set
in Pr. 20 from 0Hz.
y Use Pr. 8 and Pr. 45 to set the deceleration time required to reach 0Hz from the
frequency set in Pr. 20.
y Pr. 44 and Pr. 45 are valid when the RT signal is on.
y Set "9999" in Pr. 45 to make the deceleration time equal to the acceleration time
(Pr. 44).
Note: 1. In S-shaped acceleration/deceleration pattern A (refer to page 86), the set
time is the period required to reach the base frequency set in Pr. 3.
• Acceleration/deceleration time calculation expression when the set
frequency is the base frequency or higher
4 T 5
t = 9 × (Pr. 3)2 × f 2 + 9 T
T: Acceleration/deceleration time setting (sec.)
f : Set frequency (Hz)
• Guideline for acceleration/deceleration time at the base frequency of 60Hz
(0Hz to set frequency)
Frequency setting (Hz)
Acceleration/ 60 120 200 400
deceleration tim e (sec.)
5 5 12 27 102
15 15 35 82 305
2. If the Pr. 20 setting is changed, the settings of calibration functions Pr. 903
and Pr. 905 (frequency setting signal gains) remain unchanged.
To adjust the gains, adjust calibration functions Pr. 903 and Pr. 905.
3. When the setting of Pr. 7, Pr. 8, Pr. 44 or Pr. 45 is "0", the acceleration/
deceleration time is 0.04 seconds. At this time, set 120Hz or less in Pr. 20.
4. When the RT signal is on, the other second functions such as second torque
boost are also selected.
5. If the shortest acceleration/deceleration time is set, the actual motor
acceleration/deceleration time cannot be made shorter than the shortest
acceleration/deceleration time determined by the mechanical system's
GD2 and motor torque.
78
PARAMETERS
4.2.6 Electronic overcurrent protection (Pr. 9, Pr. 48)

Related parameter
Pr. 9 "electronic overcurrent protection" Pr. 71 "applied motor"
Pr. 180 to Pr. 183
Pr. 48 "second electronic overcurrent (input terminal function
protection" selection)
Set the current of the electronic overcurrent protection to protect the motor from
overheat. This feature provides the optimum protective characteristics, including
reduced motor cooling capability, at low speed.
Parameter
Factory Setting Setting Range Remarks
Number
Rated output
9 0 to 500A
current*
48 9999 0 to 500A, 9999 9999: Function invalid
*0.1K to 0.75K are set to 85% of the rated inverter current.
<Setting>
y Set the rated current [A] of the motor.
y Setting "0" makes the electronic overcurrent protection (motor protective function)
invalid. (The inverter's protective function is valid.)
y When using Mitsubishi constant-torque motor, first set "1" in Pr. 71 to choose the
100% continuous torque characteristic in the low-speed range. Then, set the rated
motor current in Pr. 9.
y Pr. 48 "Second electronic overcurrent protection" is made valid when the RT signal
is on. (Note 4)
Note: 1. When two or more motors are connected to the inverter, they cannot be
protected by the electronic overcurrent protection. Install an external thermal
relay to each motor.
2. When the difference between the inverter and motor capacities is large and
the setting is small, the protective characteristics of the electronic
overcurrent protection will be deteriorated. In this case, use an external
thermal relay. 4
3. A special motor cannot be protected by the electronic overcurrent protection.
Use an external thermal relay.
79
PARAMETERS
4.2.7 DC dynamic brake (Pr. 10 to Pr. 12)
Pr. 10 "DC injection brake operation frequency"

Pr. 11 "DC injection brake operation time"
Pr. 12 "DC injection brake voltage"
By setting the DC injection brake voltage (torque),
operation time and operation starting frequency, the stopping accuracy of positioning
operation, etc. or the timing of operating the DC injection brake to stop the motor can
be adjusted according to the load.
Output frequency
10 3Hz 0 to 120Hz
11 0.5 s 0 to 10 s
12 6% 0 to 30% Pr.10
Operation
frequency
Time
DC injection Pr.12
brake voltage Operation
voltage Time
Pr.11 Operation time
<Setting>
y Use Pr. 10 to set the frequency at which the DC injection brake operation is started.
y Use Pr. 11 to set the period during when the brake is operated.
y Use Pr. 12 to set the percentage of the power supply voltage.
CAUTION
Install a mechanical brake. No holding torque is provided.
80
PARAMETERS
4.2.8 Starting frequency (Pr. 13)

Related parameters
Pr. 13 "starting frequency" Pr. 2 "minimum frequency"
You can set the starting frequency between 0 and 60Hz.

y Set the starting frequency at which the start signal is switched on.
Parameter Factory Setting Output frequency
Number Setting Range (Hz)
Setting range
13 0.5Hz 0.01 to 60Hz 60
Pr.13
0 Time
Frequency setting signal (V)
Foward rotation ON
Note: The inverter will not start if the frequency setting signal is less than the value
set in Pr. 13 "starting frequency".
For example, when 5Hz is set in Pr. 13, the motor will not start running until
the frequency setting signal reaches 5Hz.
CAUTION
When the Pr. 13 setting is lower than the Pr. 2 value, note that the motor
will run at the set frequency by merely switching the start signal on,
without entering the command frequency.
81
PARAMETERS
4.2.9 Load pattern selection (Pr. 14)

Related parameter
Pr. 14 "load pattern selection" Pr. 0 "torque boost"
Pr. 46 "second torque boost"
Pr. 180 to Pr. 183
(input terminal function selection)
You can select the optimum output characteristic (V/F characteristic) for the application
and load characteristics.
14 0 0 to 3
Pr.14=0 Pr.14=1
For constant-torque loads For variable-torque loads
(e.g. conveyor, cart) (Fan, pump)
100% 100%
Output Output
voltage voltage
Base frequency Base frequency

Output frequency (Hz) Output frequency (Hz)
Pr.14=2 Pr.14=3
For lift For lift
Boost for forward rotation...Pr. 0 (Pr. 46) setting Boost for forward rotation...0%
Boost for reverse rotation...0% Boost for reverse rotation...Pr. 0 (Pr. 46) setting
100% 100%
Forward Reverse
Output rotation Output rotation
voltage voltage
Pr. 0 Reverse Pr. 0 Forward

rotation rotation
Pr. 46 Pr. 46
Base frequency Base frequency
Note: 1. This parameter setting is ignored when the general-purpose magnetic flux
vector control mode has been selected.
2. Pr. 46 "second torque boost" is made valid when the RT signal turns on.
The RT signal acts as the second function selection signal and makes the
other second functions valid.
Refer to page 145 for Pr. 180 to Pr. 183 (input terminal function selection).
82
PARAMETERS
4.2.10 Jog operation (Pr. 15, Pr. 16)

Related parameters
Pr. 15 "jog frequency" Pr. 20 "acceleration/deceleration
reference frequency"
Pr. 16 "jog acceleration/deceleration time" Pr. 21 "acceleration/deceleration
tim e increm ents"
Jog operation can be started and stopped by selecting the jog mode from the control
panel and pressing and releasing the RUN key ( FWD , REV key).
y Set the frequency and acceleration/deceleration time for jog operation.
Remarks
15 5Hz 0 to 400Hz
When
0 to 3600 s
Pr. 21 = 0
16 0.5 s
When
0 to 360 s
Pr. 21 = 1
Output frequency (Hz)

Pr.20
Jog frequency
Pr.15 Forward Reverse
setting range Time
rotation rotation
Pr.16
ON
FWD key
ON
REV key
Note: 1. In S-shaped acceleration/deceleration pattern A, the acceleration/

deceleration time is the period of time required to reach Pr. 3 "base
frequency", not Pr. 20. 4
2. The acceleration time and deceleration time cannot be set separately for jog
operation.
3. The value set in Pr. 15 "jog frequency" should be equal to or greater than the
Pr. 13 "starting frequency" setting.
Pr. 18 Î Refer to Pr. 1, Pr. 2.
Pr. 19 Î Refer to Pr. 3.
Pr. 20, Pr. 21 Î Refer to Pr. 7, Pr. 8.

83
PARAMETERS
4.2.11 Stall prevention (Pr. 22, Pr. 23, Pr. 66)

Related parameters
Pr. 22 "stall prevention operation level" Pr. 9 "electronic overcurrent
protection"
Pr. 23 "stall prevention operation level at Pr. 48 "second electronic
overcurrent protection"
double speed" Pr. 73 "0-5V/0-10V selection"
Pr. 66 "stall prevention operation level reduction starting frequency"
y Set the output current level at which the output frequency will be adjusted to prevent
the inverter from stopping due to overcurrent etc.
y For high-speed operation at or over the motor base frequency, acceleration may not
be made because the motor current does not increase.
To improve the operation characteristics of the motor in such a case, the stall
prevention level in the high-frequency range can be reduced. This is effective for
operation of a centrifugal separator up to the high-speed range. Normally, set 60Hz
in Pr. 66 and 100% in Pr. 23.
y For operation in the high-frequency range, the current in the locked motor state is
smaller than the rated output current of the inverter and the inverter does not result
in an alarm (protective function is not activated) if the motor is at a stop. To improve
this and activate the alarm, the stall prevention level can be reduced.
Remarks
22 150% 0 to 200%
0 to 200%, 9999: Constant
23 9999
9999 according to Pr. 22
66 60Hz 0 to 400Hz
Pr.22 Setting example

Pr.23 =9999 (Pr.22=150%, Pr.23=100%, Pr.66=60Hz)
operation level (%)
operation level (%)
150
Stall prevention
Reduction ratio
Current limit
compensation 90
factor (%)
60
45
Pr.23 30
22.5
Pr.66 400Hz 0 60 100 200 300 400
84
PARAMETERS
<Setting>
y In Pr. 22, set the stall prevention operation level. Normally set it to 150% (factory
setting). Set "0" in Pr. 22 to disable the stall prevention operation.
y To reduce the stall prevention operation level in the high-frequency range, set the
reduction starting frequency in Pr. 66 and the reduction ratio compensation factor in
Pr. 23.
Calculation expression for stall prevention operation level
Pr. 22 − A Pr. 23 − 100
Stall prevention operation level (%) = A + B × [ ]×[ ]
Pr. 22 − B 100
Pr. 66 (Hz) × Pr. 22 (%) Pr. 66 (Hz) × Pr. 22 (%)
where, A = ,B=
output frequency (Hz) 400Hz
y By setting "9999" (factory setting) in Pr. 23, the stall prevention operation level is
constant at the Pr. 22 setting up to 400Hz.
CAUTION
Do not set a small value as the stall prevention operation current.
Otherwise, torque generated will reduce.
Test operation must be performed.
Stall prevention operation during acceleration may increase the
acceleration time.
Stall prevention operation during constant speed may change the speed
suddenly.
Stall prevention operation during deceleration may increase the
deceleration time, increasing the deceleration distance.
Pr. 24 to Pr. 27 Î Refer to Pr. 4 to Pr. 6.
85
PARAMETERS
4.2.12 Acceleration/deceleration pattern (Pr. 29)

Related parameters
Pr. 29 "acceleration/deceleration pattern" Pr. 3 "base frequency"
Pr. 7 "acceleration time"
Pr. 8 "deceleration time"
Pr. 20 "acceleration/deceleration
reference frequency"
Set the acceleration/deceleration pattern. Pr. 44 "second
acceleration/deceleration time"
Parameter Factory Setting Pr. 45 "second deceleration
Number Setting Range time"
29 0 0, 1, 2
Set value 0 Set value 1 Set value 2

[Linear acceleration/deceleration] [S-shaped [S-shaped
acceleration/deceleration A] acceleration/deceleration B]
frequency(Hz)
frequency(Hz)
frequency(Hz)
f1
Output
Output
Output
fb
f2
Time Time Time
<Setting>
Pr. 29 Setting Function Description
Linear Linear acceleration/deceleration is made up/down to the
0 acceleration/ preset frequency (factory setting).
deceleration
For machine tool spindles
This setting is used when it is necessary to make
S-shaped acceleration/deceleration in a short time up to the base
acceleration/ frequency or higher speed range.
1 deceleration In this acceleration/deceleration pattern, fb (base frequency)
A is always the inflection point of an S shape, and you can set
(Note) the acceleration/deceleration time according to the reduction
in motor torque in the base frequency or higher constant-
output operation range.
For prevention of cargo collapse on conveyor, etc.
S-shaped
This setting provides S-shaped acceleration/deceleration
acceleration/
2 from f2 (current frequency) to f1 (target frequency), easing
deceleration
an acceleration/deceleration shock. This pattern has an
B
effect on the prevention of cargo collapse, etc.
Note: For the acceleration/deceleration time, set the time required to reach the
"base frequency" in Pr. 3, not the "acceleration/deceleration reference
frequency" in Pr. 20. For details, refer to Pr. 7 and Pr. 8.
86
PARAMETERS
4.2.13 Regenerative brake duty (Pr. 30, Pr. 70)
Pr. 30 "regenerative function selection"
Pr. 70 "special regenerative brake duty"
y When making frequent starts/stops, use the optional "brake resistor" to increase the
regenerative brake duty. (more than 0.4K)
30 0 0,1
70 0% 0 to 30%
<Setting>
(1) W hen using the brake resistor (M RS), brake unit, high pow er factor converter
y Set "0" in Pr. 30.
y The Pr. 70 setting is made invalid.
(2) W hen using the brake resistors (2 M YSs in parallel) (3.7K is only allow ed)
y Set "6%" in Pr. 70.
(3) When using the high-duty brake resistor (FR-ABR)
y Set "10%" in Pr. 70.
Note: 1. Pr. 70 "regenerative brake duty" indicates the %ED of the built-in brake
transistor operation. The setting should not be higher than the permissible
value of the brake resistor used. Otherwise, the resistor can overheat.
2. When Pr. 30 = "0", Pr. 70 is not displayed but the brake duty is fixed at 3%. 4
(Fixed at 2% for 5.5K, 7.5K)
3. The brake resistor cannot be connected to 0.1K and 0.2K inverters.
WARNING
The value set in Pr. 70 should not exceed the value set to the brake
resistor used.
Otherwise, the resistor can overheat.
87
PARAMETERS
4.2.14 Frequency jump (Pr. 31 to Pr. 36)
Pr. 31 "frequency jump 1A"

Pr. 32 "frequency jump 1B"
y When it is desired to avoid resonance attributable to the natural frequency of a
mechanical system, these parameters allow resonant frequencies to be jumped. Up
to three areas may be set, with the jump frequencies set to either the top or bottom
point of each area.
y The value set to 1A, 2A or 3A is a jump point and operation is performed at this
frequency.
Parameter Factory
Number Setting
31 9999 0 to 400Hz, 9999 9999: Function invalid
Frequency jump
Running frequency
Pr.36
Pr.35
Pr.34
Pr.33
Pr.32
Pr.31
<Setting>
y To fix the frequency at 30Hz between Pr. 33 and Pr.34:35Hz
Pr.33:30Hz
Pr. 34 (30Hz and 35Hz), set 35Hz in Pr. 34 and
30Hz in Pr. 33.
Pr.33:35Hz
y To jump to 35Hz between 30 and 35Hz, set 35Hz in Pr.34:30Hz
Pr. 33 and 30Hz in Pr. 34.
Note: During acceleration/deceleration, the running frequency within the set area is
valid.
88
PARAMETERS
4.2.15 Speed display (Pr. 37)

Related parameter
Pr. 37 "speed display"
Pr. 52 "control panel/PU main
display data selection"
The unit of the output frequency display of the control panel (FR-PA02-02) and PU
(FR-PU04) can be changed from the frequency to the motor speed or machine speed.
Remarks
0, 0.01 to 0: Output
37 0
9998 frequency
<Setting>
y To display the machine speed, set in Pr. 37 the machine speed for 60Hz operation.
Note: 1. The motor speed is converted into the output frequency and does not match
the actual speed.
2. To change the control panel monitor (PU main display), refer to Pr. 52 and
Pr. 53.
3. As the control panel display is 4 digits, "----" is displayed when the monitored
value exceeds "9999".
4. Only the PU monitor display uses the unit set in this parameter. Set the other
speed-related parameters (e.g. Pr. 1) in the frequency unit.
5. Due to the restrictions of the resolution of the set frequency, the displayed
value may be different from the setting for the second decimal place.
CAUTION
Make sure that the running speed setting is correct.
Otherwise, the motor might run at extremely high speed, damaging the 4
machine.
89
PARAMETERS
4.2.16 Frequency at 5V (10V) input (Pr. 38)

Related parameters
Pr. 38 "frequency at 5V (10V)" Pr. 73 "0 to 5V, 0 to 10V
selection"
Pr. 902 "frequency setting voltage bias"
Pr. 903 "frequency setting voltage gain"
y You can set the frequency Output frequency(Hz)

fm1 Pr.38
provided when the
Output frequency
frequency setting signal range
from the potentiometer
fm2
connected across terminals
2-5 (frequency setting
potentiometer) is 5VDC (or
10VDC). Frequency setting signal 5V (10V)
Parameter
Factory Setting Setting Range
Number
38 60Hz 1 to 400Hz
4.2.17 Frequency at 20mA input (Pr. 39)

Related parameters
Pr. 39 "frequency at 20mA" Pr. 73 "0 to 5V, 0 to 10V selection"
Pr. 79 "operation mode selection"
Pr. 904 "frequency setting current bias"
Pr. 905 "frequency setting current gain"
y You can set the frequency

fm1 Pr.39
provided when the Output frequency
frequency setting signal range
input across terminals 4-5 is fm2
20mA.
Frequency setting signal 20mA
Parameter
Factory Setting Setting Range
Number
39 60Hz 1 to 400Hz
90
PARAMETERS
4.2.18 Up-to-frequency sensitivity (Pr. 41)

Related parameters
Pr. 41 "up-to-frequency sensitivity" Pr. 190 "RUN term inal function selection"
Pr. 191 "FU term inal function selection"
Pr. 192 "A, B, C output terminal
function selection"
The ON range of the up-to-frequency signal (SU) output when the output frequency
reaches the running frequency can be adjusted between 0 and ±100% of the running
frequency.
This parameter can be used to ensure that the running frequency has been reached or
used as the operation start signal etc. for related equipment.
Output frequency
Running frequency
Number Setting Range Adjustable range Pr.41
41 10% 0 to 100%
Time
Output signal
SU OFF ON OFF
y Use any of Pr. 190 to Pr. 192 to allocate the terminal used for SU signal output.
Refer to page 147 for Pr. 190 to Pr. 192 (output terminal function selection).
Note: When terminal assignment is changed using Pr. 190 to Pr. 192, the other
functions may be affected. Check the functions of the corresponding
terminals before making settings.
4.2.19 Output frequency detection (Pr. 42, Pr. 43)

Related parameters
Pr. 42 "output frequency detection" Pr. 190 "RUN term inal function selection"
Pr. 191 "FU term inal function selection"
Pr. 43 "output frequency detection for Pr. 192 "A, B, C output terminal
reverse rotation" function selection" 4
The output frequency detection signal (FU) is output when the output frequency
reaches or exceeds the setting. This function can be used for electromagnetic brake
operation, open signal etc.
91
PARAMETERS
y You can also set the detection of the frequency used exclusively for reverse rotation.
This function is effective for switching the timing of electromagnetic brake operation
between forward rotation (rise) and reverse rotation (fall) during vertical lift operation etc.
Remarks
42 6Hz 0 to 400Hz
0 to 400Hz,
43 9999 9999: Same as Pr. 42 setting
9999
<Setting>
Refer to the figure below and set the corresponding parameters:
y When Pr. 43 ≠ 9999, the Pr. 42 setting applies to forward rotation and the Pr. 43
setting applies to reverse rotation.
y Assign the terminal used for FU signal output with any of Pr. 190 to Pr. 192 (output
Refer to page 147 for Pr. 190 to Pr. 192 (output terminal function selection).
Output frequency
Pr.42
Forward
rotation Reverse Time
rotation
Pr.43
Output signal ON ON
FU OFF OFF OFF
Note: Changing the terminal assignment using Pr. 190 to Pr. 192 may affect the
other functions. Make setting after confirming the function of each terminal.
Pr. 44, Pr. 45 Î Refer to Pr. 7.
Pr. 48 Î Refer to Pr. 9
92
PARAMETERS
4.2.20 Monitor display (Pr. 52, Pr. 54, Pr. 158)

Related parameters
Pr. 52 "control panel/PU main display
Pr. 37 "speed display"
data selection" Pr. 55 "frequency monitoring
reference"
Pr. 54 "FM terminal function selection" Pr. 56 "current monitoring
reference"
Pr. 158 "AM terminal function selection" Pr. 171 "actual operation hour
meter clear"
Pr. 900 "FM term inal calibration"
Pr. 901 "A M term inal calibration"
You can select the signal displayed on the control panel (FR-PA02-02)/parameter unit
(FR-PU04) main display screen and the signal output to the FM terminal (100V class,
200V class) and AM terminal (400V class).
<100V class, 200V class>
y Output terminal: Terminal FM (pulse train output)
y Output signal selection: Pr. 54 "FM terminal function selection"
<400V class>
y Output terminal: Terminal AM (analog output)
y Output signal selection: Pr. 158 "AM terminal function selection"
52 0 0, 23, 100
54 0 0, 1, 2
158 0 0, 1, 2
<Setting>
Set Pr. 52, Pr. 54 and Pr. 158 in accordance with the following table:
Parameter Setting
Pr. 52 Pr. 54 Pr. 158
Full-Scale Value of
Signal Type Unit Control
panel
PU main FM AM FM, AM Level Meter 4
monitor terminal terminal
LED
Output
Hz 0/100 0/100 0 0 Pr. 55
frequency
Output current A 0/100 0/100 1 1 Pr. 56
Output voltage  0/100 0/100 2 2 400V or 800V
Alarm display  0/100 0/100 × × 
Actual
operation time
10hr 23 23 × × 
93
PARAMETERS
When 100 is set in Pr. 52, the monitored values during stop and during operation differ
as indicated below:
Pr. 52
0 100
During
During stop During operation
operation/during stop
Output
Output frequency Set frequency Output frequency
frequency
Output current Output current
Output voltage Output voltage
Alarm display Alarm display
Note: 1. During an error, the output frequency at error occurrence is displayed.

2. During MRS, the values are the same as during a stop.
During offline auto tuning, the tuning status monitor has priority.
Note: 1. The monitoring of items marked × cannot be selected.

2. By setting "0" in Pr. 52, the monitoring of "output frequency to alarm display"
can be selected in sequence by the SHIFT key.
3. Running speed on the PU main monitor is selected by "other monitor
selection" of the parameter unit (FR-PU04).
4. The actual operation time displayed by setting "23" in Pr. 52 is calculated
using the inverter operation time. (Inverter stop time is not included.) Set "0"
in Pr. 171 to clear it.
5. The actual operation time is calculated from 0 to 99990 hours, then cleared,
and recalculated from 0. If the operation time is less than 10 hours there is
no display.
6. The actual operation time is not calculated if the inverter has not operated
for more than 1 hour continuously.
7. When the control panel is used, the display unit is Hz or A only.
94
PARAMETERS
4.2.21 Monitoring reference (Pr. 55, Pr. 56)

Related parameters
Pr. 55 "frequency monitoring reference"
Pr. 54 "FM terminal function
selection"
Pr. 56 "current monitoring reference"
Pr. 158 "AM terminal function
selection"
Set the frequency or current which is referenced Pr. 900 "FM terminal calibration"
when the output frequency or output current is Pr. 901 "AM terminal calibration"
selected for terminals FM and AM.
55 60Hz 0 to 400Hz
Rated output
56 0 to 500A
current
1440Hz (terminal FM) 1440Hz (terminal FM)

10VDC (terminal AM) 10VDC (terminal AM)
Output or display
Output or display
Output frequency Pr.55 Output current Pr.56
<Setting>
Refer to the above diagrams and set the frequency monitoring reference value in
Pr. 55 and the current monitoring reference value in Pr. 56.
(For 200V and 100V class inverters)
Pr. 55 is set when Pr. 54 = 0 and Pr. 56 is set when Pr. 54 = 1.
Set the Pr. 55 and Pr. 56 values so that the output pulse train output of terminal FM is
1440Hz.
Note: The maximum pulse train output of terminal FM is 2400Hz. If Pr. 55 is not
adjusted, the output of terminal FM will be filled to capacity. Therefore, adjust
Pr. 55. 4
(For 400V class inverter)

Refer to the above diagrams and set the frequency monitoring reference value in
Pr. 55 and the current monitoring reference value in Pr. 56.
Pr. 55 is set when Pr. 158 = 0 and Pr. 56 is set when Pr. 158 = 1.
In Pr. 55 and Pr. 56, set the frequency and current at which the output voltage of
terminal AM will be 10V.
Note: The maximum output voltage of terminal AM is 10VDC.
95
PARAMETERS
4.2.22 Automatic restart after instantaneous power failure

(Pr. 57, Pr. 58)
Pr. 57 "coasting tim e for autom atic restart after instantaneous pow er failure"
Pr. 58 "cushion tim e for autom atic restart after instantaneous pow er failure"
y You can restart the inverter without stopping the motor (with the motor coasting)
when power is restored after an instantaneous power failure.
Parameter Number Factory Setting Setting Range Remarks
57 9999 0 to 5 s, 9999 9999: No restart
58 1.0 s 0 to 60 s
<Setting>
Refer to the following table and set the parameters:
Parameter
Setting Description
Number
0.1K to 1.5K 0.5 s coasting time
0 Generally use this setting.
2.2K to 7.5K 1.0 s coasting time
Waiting time for inverter-triggered restart after power is restored
57 from an instantaneous power failure. (Set this time between 0.1
0.1 to 5 s 2
second and 5 seconds according to the inertia moment (GD )
and torque of the load.)
9999 No restart
Normally the inverter may be run with the factory settings. These
58 0 to 60 s
values are adjustable to the load (inertia moment, torque).
Note: 1. Automatic restart after instantaneous power failure uses a reduced-voltage

starting system in which the output voltage is raised gradually with the preset
frequency unchanged, independently of the coasting speed of the motor.
As in the FR-A024/A044, a motor coasting speed detection system (speed
search system) is not used but the output frequency before an instantaneous
power failure is output. Therefore, if the instantaneous power failure time is
longer than 0.2 seconds, the frequency before the instantaneous power
failure cannot be stored and the inverter will start at 0Hz.
2. The SU and FU signals are not output during restart but are output after the
restart cushion time has elapsed.
CAUTION
When automatic restart after instantaneous power failure has been
selected, the motor and machine will start suddenly (after the reset time
has elapsed) after occurrence of an instantaneous power failure.
Stay away from the motor and machine.
When you have selected automatic restart after instantaneous power
failure, apply the supplied CAUTION seals in easily visible places.
STOP
When the start signal is turned off or the RESET key is pressed during the
cushion time for automatic restart after instantaneous power failure,
deceleration starts after the automatic restart cushion time set in Pr. 58
"cushion time for automatic restart after instantaneous power failure"
has elapsed.
96
PARAMETERS
4.2.23 Remote setting function selection (Pr. 59)

Related parameters
Pr. 59 "remote setting function selection"
Pr. 1 "maximum frequency"
If the operator panel is located away from the Pr. 8 "deceleration time"
control box, you can use contact signals to Pr. 18 "high-speed maximum
perform continuous variable-speed operation, frequency"
Pr. 44 "second acceleration/
without using analog signals. deceleration time"
y By merely setting this parameter, you can use Pr. 45 "second deceleration tim e"
the acceleration, deceleration and setting clear
functions of the motorized speed setter (FR-FK).
y When the remote function is used, the output frequency of the inverter can be
compensated for as follows:
External operation mode Frequency set by RH/RM operation plus built-in
frequency setting potentiometer or external analog
frequency command
PU operation mode Frequency set by RH/RM operation plus PU's digitally-set
frequency
frequency
Parameter Factory Setting Output
59 0 0, 1, 2
<Setting> Acceleration (RH)

Refer to the following table and set the Deceleration (RM)
Clear (RL)
parameter: Forward rotation (STF) ON ON
Pr. 59 Operation
Setting Rem ote setting function Frequency setting storage function
0 No 
1 Yes Yes
2 Yes No
y Use Pr. 59 to select whether the remote setting function is used or not and whether
the frequency setting storage function in the remote setting mode is used or not.
When "remote setting function - yes" is selected, the functions of signals RH, RM
and RL are changed to acceleration (RH), deceleration (RM) and clear (RL). Use
Pr. 180 to Pr. 183 (input terminal function selection) to set signals RH, RM and RL.
Note: 1. The frequency can be varied by RH (acceleration) and RM (deceleration)
between 0 and the maximum frequency (Pr. 1 or Pr. 18 setting).
2. When the acceleration or deceleration signal switches on, the set frequency 4
varies according to the slope set in Pr. 44 or Pr. 45. The output frequency
acceleration/deceleration times are as set in Pr. 7 and Pr. 8, respectively.
Therefore, the longer preset times are used to vary the actual output
frequency.
3. If the start signal (STF or STR) is off, turning on the acceleration (RH) or
deceleration (RM) signal varies the set frequency.
4. T he frequency setting storage function stores in m em ory the rem otely-set
frequency (frequency set by R H /R M operation) w hen the acceleration and
deceleration signals rem ain off for m ore than 1 m inute or as soon as the start
signal (S T F or S T R ) sw itches off. W hen pow er is sw itched off once, then on,
operation is resum ed w ith that value.
97
PARAMETERS
CAUTION
W hen selecting this function, re-set the m axim um frequency according to the
m achine.
4.2.24 Shortest acceleration/deceleration mode (Pr. 60 to Pr. 63)
Pr. 60 "shortest acceleration/deceleration mode" Related parameters

Pr. 61 "reference current" Pr. 7 "acceleration time"
Pr. 62 "reference current for acceleration"
Pr. 63 "reference current for deceleration"
The inverter automatically sets appropriate parameters for operation.

y If you do not set the acceleration and deceleration times and V/F pattern, you can
run the inverter as if appropriate values had been set in the corresponding
parameters. This operation mode is useful to start operation immediately without
making fine parameter settings.
Parameter Factory
Number Setting
60 0 0, 1, 2, 11, 12
9999: Referenced from rated
61 9999 0 to 500A, 9999
inverter current.
62 9999 0 to 200%, 9999
63 9999 0 to 200%, 9999
<Setting>
Automatically
Pr. 60 Operation
Description Set
Setting Mode
Parameters
Ordinary
0 operation  
mode
Set to accelerate/decelerate the motor in the
shortest time.
The inverter makes acceleration/deceleration in
the shortest time using its full capabilities. During
deceleration, an insufficient brake capability may
Shortest
cause the regenerative overvoltage alarm
1, 2, 11, acceleration/
(E.OV3). Pr. 7, Pr. 8
12 deceleration
"1" : Stall prevention operation level 150%
mode
"2" : Stall prevention operation level 180%
"11": Stall prevention operation level 150%
when brake resistor or brake unit is used
"12": Stall prevention operation level 180%
when brake resistor or brake unit is used
98
PARAMETERS
<Setting>
• Set the parameters when it is desired to improve the performance in the shortest
acceleration/deceleration mode.
(1) Pr. 61 "reference current setting"
Setting Reference Current
9999 (factory setting) Referenced from rated inverter current
0 to 500A Referenced from setting (rated motor current)
(2) Pr. 62 "reference current for acceleration"

The reference current setting can be changed.
9999 (factory setting) 150% (180%) is the limit value.
0 to 200% The setting of 0 to 200% is the limit value.
(3) Pr. 63 "reference current for deceleration"

The reference current setting can be changed.
9999 (factory setting) 150% (180%) is the limit value.
0 to 200% The setting of 0 to 200% is the limit value.
Note: Pr. 61 to Pr. 63 are only valid when any of "1, 2, 11, 12" are selected for
Pr. 60.
99
PARAMETERS
4.2.25 Retry function (Pr. 65, Pr. 67 to Pr. 69)
Pr. 65 "retry selection"

Pr. 67 "number of retries at alarm occurrence"
Pr. 68 "retry waiting time"
Pr. 69 "retry count display erasure"
When any protective function (major fault) is activated and the inverter stops its output,
the inverter itself resets automatically and performs retries. You can select whether
retry is made or not, alarms reset for retry, number of retries made, and waiting time.
Parameter Factory
Setting Range
Number Setting
65 0 0 to 3
67 0 0 to 10, 101 to 110
68 1s 0.1 to 360 s
69 0 0
<Setting>
Use Pr. 65 to select the protective functions (major faults) which execute retry.
Errors Reset
Setting
for Retry
Display 0 1 2 3
E.OC1 z z z
E.OC2 z z z
E.OC3 z z z
E.OV1 z z z
E.OV2 z z z
E.OV3 z z z
E.THM z
E.THT z
E.FIN
E. BE z
E. GF z
E.LF
E.OHT z
E.OLT z
E.OPT z
E. PE z
E.PUE
E.RET
E.CPU
Note: z indicates the retry items selected.
100
PARAMETERS
Use Pr. 67 to set the number of retries at alarm occurrence.
Pr. 67 Setting Number of Retries Alarm Signal Output

0 Retry is not made. 
1 to 10 1 to 10 times Not output.
101 to 110 1 to 10 times Output.
y Use Pr. 68 to set the waiting time from when an inverter alarm occurs until a restart
in the range 0.1 to 360 seconds.
y Reading the Pr. 69 value provides the cumulative number of successful restart
times made by retry. The setting of "0" erases the cumulative number of times.
Note: 1. The cumulative number in Pr. 69 is incremented by "1" when retry operation
is regarded as successful, i.e. when normal operation is continued without
the protective function (major fault) activated during a period five times
longer than the time set in Pr. 68.
2. If the protective function (major fault) is activated consecutively within a
period five times longer than the above waiting time, the control panel may
show data different from the most recent data or the parameter unit
(FR-PU04) may show data different from the first retry data. The data stored
as the error reset for retry is only that of the protective function (major fault)
which was activated the first time.
3. When an inverter alarm is reset by the retry function at the retry time, the
stored data of the electronic over current protection, etc. are not cleared.
(Different from the power-on reset.)
CAUTION
When you have selected the retry function, stay away from the motor and
machine unless required. They will start suddenly (after the reset time
has elapsed) after occurrence of an alarm.
When you have selected the retry function, apply the supplied CAUTION
4
seals in easily visible places.
101
PARAMETERS
4.2.26 Applied motor (Pr. 71)

Related parameters
Pr. 0 "torque boost"
Pr. 12 "DC dynamic brake voltage"
Pr. 19 "base frequency voltage"
Pr. 96 "auto tuning setting/status"
Set the motor used.
y When using the Mitsubishi constant-torque motor, set "1" in Pr. 71 for either V/F
control or general-purpose magnetic flux vector control.
The electronic overcurrent protection is set to the thermal characteristic of the
constant-torque motor.
Parameter Factory
Setting Range
Number Setting
0, 1, 3, 5, 6, 13, 15, 16, 23, 100, 101,
71 0
103, 105, 106, 113, 115, 116, 123
<Setting>
y Refer to the following list and set this parameter according to the motor used.
Applied motor
Pr. 71 Thermal Characteristics of Electronic
Constant-
Setting Overcurrent Protection Standard
Torque
0, 100 Thermal characteristics matching a standard motor {
Thermal characteristics matching the Mitsubishi
1, 101
constant-torque motor
{
3, 103 Standard motor {
13, 113 Constant-torque motor {
Mitsubishi general- Select "offline auto tuning
purpose motor SF- setting".
23, 123
JR4P (1.5kW (2HP) or
{
less)
5, 105 Standard motor Star Motor {
15, 115 Constant-torque motor connection constants can {
6, 106 Standard motor Delta be entered {
16, 116 Constant-torque motor connection directly. {
By setting any of "100 to 123", the electronic overcurrent protection thermal

characteristic (applied motor) can be changed as indicated below according to the
ON/OFF status of the RT signal:
RT Signal Electronic Overcurrent Protection Thermal Characteristic (Applied Motor)
OFF As indicated in the above table
ON Constant-torque motor
CAUTION
Set this parameter correctly according to the motor used.
Incorrect setting may cause the motor to overheat and burn.
102
PARAMETERS
4.2.27 PWM carrier frequency (Pr. 72, Pr. 240)
Pr. 72 "PWM frequency selection"
Pr. 240 "Soft-PWM setting"

You can change the motor tone.
y By parameter setting, you can select Soft-PWM control which changes the motor
tone.
y Soft-PWM control changes motor noise from a metallic tone into an unoffending
complex tone.
Remarks
0 : 0.7kHz,
72 1 0 to 15
15 : 14.5kHz
240 1 0, 1 1: Soft-PWM valid
<Setting>
y Refer to the following list and set the parameters:
Parameter
Setting Description
Number
PWM carrier frequency can be changed.
72 0 to 15 The setting displayed is in [kHz].
Note that 0 indicates 0.7kHz and 15 indicates 14.5kHz.
0 Soft-PWM invalid
240
1 When any of "0 to 5" is set in Pr. 72, Soft-PWM is made valid.
Note: 1. Note that when the inverter is run at the ambient temperature above
40°C (104°F) with a 2kHz or higher value set in Pr. 72, the rated output
current of the inverter must be reduced. (Refer to page 188 (depending upon
the inverter).)
2. An increased PWM frequency will decrease motor noise but noise and
leakage current will increase. Take proper action (refer to pages 36 to 40).
4
103
PARAMETERS
4.2.28 Voltage input (Pr. 73)

Related parameters
Pr. 73 "0-5V/0-10V selection"
Pr. 22 "stall prevention operation level"
Pr. 38 "frequency at 5V (10V) input"
y You can change the input (terminal 2) specifications in response to the frequency
setting voltage signal. When entering 0 to 10VDC, always make this setting.
73 0 0, 1
Setting Terminal 2 Input Voltage

0 For 0 to 5VDC input (factory setting)
1 For 0 to 10VDC input
Note: 1. To change the maximum output frequency at the input of the maximum
frequency command voltage, use Pr. 38. Also, the acceleration/deceleration
time, which is a slope up/down to the acceleration/deceleration reference
frequency, is not affected by the change in Pr. 73 setting.
2. When connecting a frequency setting potentiometer across terminals 10-2-5
for operation, always set "0" in this parameter.
104
PARAMETERS
4.2.29 Input filter time constant (Pr. 74)
Pr. 74 "filter time constant"

You can set the input section's internal filter constant for an external voltage or current
frequency setting signal.
y Effective for eliminating noise in the frequency setting circuit.

y Increase the filter time constant if steady operation cannot be performed due to
noise. A larger setting results in slower response. (The time constant can be set
between approximately 1ms to 1s with the setting of 0 to 8. A larger setting results in
a larger filter time constant.)
74 1 0 to 8
4.2.30 Reset selection/PU disconnection detection/PU stop

selection (Pr. 75)
Pr. 75 "reset selection/PU disconnection detection/PU stop selection"

You can select the reset input acceptance, control panel (FR-PA02-02) or PU (FR-
PU04) connector disconnection detection function and PU stop function.
y Reset selection :You can select the reset function input timing.
y PU disconnection detection :W hen it is detected that the control panel
(FR-PA02-02)/PU(FR-PU04) is disconnected from the
inverter for more than 1 second, the inverter outputs an
alarm code (E.PUE) and comes to an alarm stop.
y PU stop selection : When an alarm occurs in any operation mode, you can
STOP
stop the inverter from the PU by pressing the RESET key.
Parameter Factory
Setting Range
Number Setting
75 14 0 to 3, 14 to 17 4
105
PARAMETERS
<Setting>
Pr. 75 PU Disconnection PU Stop

Reset Selection
Setting Detection Selection
0 Reset input normally enabled.
If the PU is disconnected, Pressing the
Reset input enabled only when the
1 operation will be continued. STOP
RESET key
protective function is activated.
decelerates the
2 Reset input normally enabled. When the PU is
inverter to a stop
disconnected, an error is only in the PU
3 displayed on the PU and the operation mode.
inverter output is shut off.
14 Reset input normally enabled. Pressing the
If the PU is disconnected, STOP
Reset input enabled only when the RESET key
15 operation will be continued. decelerates the
16 Reset input normally enabled. inverter to a stop
When the PU is
in any of the PU,
disconnected, an error is external and
17 displayed on the PU and the communication
inverter output is shut off. operation modes.
STOP
How to make a restart after a stop by the RESET key on the PU
(1)Control panel (FR-PA02-02)

1) After completion of deceleration to a stop, switch off the STF or STR signal.
2) Press the MODE key two times* to display .
Note: When Pr. 79 = 3, press the MODE key three times to display . Then,
press the key and proceed to step 3).
(For the monitor screen)..........Refer to page 53 for the monitor display provided
by pressing the MODE key.
3) Press the SET key.
4) Switch on the STF or STR signal.
(2)Parameter unit (FR-PU04)

1) After completion of deceleration to a stop, switch off the STF or STR signal.
2) Press the EXT key.
3) Switch on the STF or STR signal.
Speed
Time
SET key
Control panel
STOP
STF ON RESET key
(STR) OFF
Stop and restart example for external operation
106
PARAMETERS
Note: 1. By entering the reset signal (RES) during operation, the inverter shuts off
output while it is reset, the data of the electronic overcurrent protection and
regenerative brake duty are reset, and the motor coasts.
2. The PU disconnection detection function judges that the PU is disconnected
when it is removed from the inverter for more than 1 second. If the PU had
been disconnected before power-on, it is not judged as an alarm.
3. To resume operation, reset the inverter after confirming that the PU is
connected securely.
4. The Pr. 75 value can be set any time. Also, if parameter (all) clear is
executed, this setting will not return to the initial value.
5. When the inverter is stopped by the PU stop function, PS is displayed but an
alarm is not output.
When the PU connector is used for RS-485 communication operation, the
reset selection and PU stop selection functions are valid but the PU
disconnection detection function is invalid.
CAUTION
Do not reset the inverter with the start signal on.
Otherwise, the motor will start instantly after resetting, leading to
potentially hazardous conditions.
4.2.31 Parameter write inhibit selection (Pr. 77)

Related parameters
Pr. 77 "parameter write disable selection" Pr. 79 "operation m ode selection"
You can select between write-enable and disable for parameters. This function is used
to prevent parameter values from being rewritten by incorrect operation.
Parameter Factory
Setting Range
Number Setting
77 0 0, 1, 2
<Setting>
4
Pr. 77
Function
Setting
Parameter values may only be written during a stop in the
0
PU operation mode. (Note 1)
Write disabled.
1 Values of Pr. 75, Pr. 77 and Pr. 79 "operation mode
selection" may be written.
2 Write enabled even during operation.
107
PARAMETERS
Note: 1. The parameters half-tone screened in the parameter list can be set at any
time.
2. If Pr. 77 = "2", the values of Pr. 23, Pr. 66, Pr. 71, Pr. 79, Pr. 90, Pr. 96,
Pr. 180 to Pr. 183 and Pr. 190 to Pr. 192 cannot be written during operation.
Stop operation when changing their parameter settings.
3. By setting "1" in Pr. 77, the following clear operations can be inhibited:
y Parameter clear
y Parameter all clear
4.2.32 Reverse rotation prevention selection (Pr. 78)

Related parameters
Pr. 78 "reverse rotation prevention selection"
This function can prevent any reverse rotation fault resulting from the incorrect input of
the start signal.
y Used for a machine which runs only in one direction, e.g. fan, pump.
(The setting of this function is valid for the combined, PU, external and
communication operations.)
78 0 0, 1, 2
<Setting>
Pr. 78 Setting Function
Both forward and reverse
0
rotations allowed
1 Reverse rotation disallowed
2 Forward rotation disallowed
108
PARAMETERS
4.2.33 Operation mode selection (Pr. 79)

Related parameters
Pr. 4 to Pr. 6, Pr. 24 to Pr. 27,
Pr. 232 to Pr. 239
Used to select the operation mode of the inverter. "m ulti-speed operation"
The inverter can be run from the control panel or Pr. 180 to Pr. 183
parameter unit (PU operation), with external (input terminal function
signals (external operation), or by combination of selection)
PU operation and external operation (external/PU
combined operation).
When power is switched on (factory setting), the External operation mode is selected.
79 0 0 to 4, 6 to 8
<Setting>
In the following table, operation using the control panel or parameter unit is
abbreviated to PU operation.
Pr. 79
Function
Setting
When power is switched on, the external operation mode is selected.
0 PU or external operation can be selected by pressing the keys of the control panel or
parameter unit. (Refer to page 56) For these modes, refer to the setting 1 and 2 below.
Operation mode Running frequency Start signal
Digital setting by key operation of RUN ( FWD , REV ) key of
1 PU operation
the control panel or parameter control panel or FWD or REV
mode
unit key of parameter unit
External signal input (across
External External signal input
2 terminals 2 (4)-5, multi-speed
operation mode (terminal STF, STR)
selection)
Digital setting made by the key
External/PU
operation of the control panel or External signal input
3 combined
parameter unit, or external signal (terminal STF, STR)
operation m ode 1
input (multi-speed setting only)
External/PU External signal input (across RUN ( FWD , REV ) key of 4
4 combined terminals 2 (4)-5, multi-speed control panel or FWD or REV
operation m ode 2 selection) key of parameter unit
Switch-over mode
6
Switch-over between PU and external operation modes can be done while running.
External operation mode (PU operation interlock)
MRS signal ON ..........Able to be switched to PU operation mode (output
7
stop during external operation)
MRS signal OFF.........Switching to PU operation mode inhibited
Switching to other than external operation mode (disallowed during operation)
8 X16 signal ON ............Switched to external operation mode
X16 signal OFF ..........Switched to PU operation mode
109
PARAMETERS
Note: Either "3" or "4" may be set to select the PU/external combined operation.
These settings differ in starting method.
(1) Switch-over mode

During operation, you can change the current operation mode to another operation
mode.
Operation Mode
Switching Control/Operating Status
Switching
External operation to PU 1) Operate the control panel keys to select the PU operation
operation mode.
z Rotation direction is the same as that of external operation.
z Set frequency is the same as the external frequency setting
signal value. (Note that the setting will disappear when
power is switched off or the inverter is reset.)
PU operation to external 1) Operate the control panel keys to select the external operation
operation mode.
z Rotation direction is determined by the external operation
input signal.
z Set frequency is determined by the external frequency
setting signal.
(2) PU operation interlock

PU operation interlock forces the operation mode to be changed to the external
operation mode when the MRS signal switches off. This function prevents the inverter
from being inoperative by the external command if the mode is accidentally left
unswitched from the PU operation mode.
1) Preparation
y Set "7" in Pr. 79 (PU operation interlock).
y Set the terminal used for MRS signal input with any of Pr. 180 to Pr. 183 (input
functions may be affected.
Check the functions of the corresponding terminals before making settings.
110
PARAMETERS
2) Function
MRS Signal Function/Operation
Output stopped during external operation.
Operation mode can be switched to PU operation mode.
ON
Parameter values can be rewritten in PU operation mode.
PU operation allowed.
Forcibly switched to external operation mode.
OFF External operation allowed.
Switching to PU operation mode inhibited.
<Function/operation changed by switching on-off the MRS signal>

Operating Condition Opera-
tion Switching to
Parameter
Operation MRS Signal Mode Operating Status PU Operation
Status Write
mode (Note Mode
4)
ON → OFF Allowed →
During stop During stop Disallowed
(Note 3) disallowed
If external operation
frequency setting
PU External
During ON → OFF and start signal are Allowed →
Disallowed
operation (Note 3) entered, operation is disallowed
performed in that
status.
Disallowed →
OFF → ON Allowed
disallowed
During stop During stop
Disallowed →
ON → OFF Disallowed
disallowed
External External
During operation → Disallowed →
OFF → ON Disallowed
During output stop disallowed
operation Output stop → Disallowed →
ON → OFF Disallowed
operation disallowed
Note: 1. If the MRS signal is on, the operation mode cannot be switched to the PU
operation mode when the start signal (STF, STR) is on.
2. The operation mode switches to the external operation mode independently
of whether the start signal (STF, STR) is on or off.
Therefore, the motor is run in the external operation mode when the MRS
signal is switched off with either of STF and STR on.
3. When the protective function (major fault) is activated, the inverter can be
STOP
4
reset by pressing the RESET key of the control panel.
4. Switching the MRS signal on and rewriting the Pr. 79 value to other than "7"
in the PU operation mode causes the MRS signal to provide the ordinary
MRS function (output stop). Also as soon as "7" is set in Pr. 79, the
operation mode is switched to PU operation mode.
111
PARAMETERS
(3) Operation mode switching by external signal

1) Preparation
Set "8" (switching to other than external operation mode) in Pr. 79.
Use any of Pr. 180 to Pr. 183 (input terminal function selection) to set the terminal
used for X16 signal input.
functions may be affected.
Check the functions of the corresponding terminals before making settings.
2) Function
T his switching is enabled during an inverter stop only and cannot be achieved during operation.
X16 Signal Operation Mode
ON External operation mode (cannot be changed to the PU operation mode)
OFF PU operation mode (cannot be changed to the external operation mode)
4.2.34 General-purpose magnetic flux vector control selection (Pr. 80)

Related parameters
Pr. 83 "rated motor voltage"
Pr. 84 "rated motor frequency"
You can set the general-purpose magnetic flux vector control.

z General-purpose magnetic flux vector control
Provides large starting torque and sufficient low-speed torque.
If the motor constants vary slightly, stable, large low-speed torque is provided
without specific motor constant setting or tuning.
Parameter Factory
Number Setting
0.1kW to 7.5kW,
80 9999 9999: V/F control
9999 (Note)
Note: The setting range changes with the inverter: 0.2kW to 7.5kW, 9999 for the
400V class.
If any of the following conditions are not satisfied, faults such as torque shortage and
speed fluctuation may occur. In this case, select V/F control.
112
PARAMETERS
<Operating conditions>
y The motor capacity is equal to or one rank lower than the inverter capacity.
y The number of motor poles is any of 2, 4, and 6. (4 poles only for the constant-
torque motor)
y Single-motor operation (one motor for one inverter) is performed.
y The wiring length between the inverter and motor is within 30m (98.42 feet). (If the
length is over 30m (98.42 feet), perform offline auto tuning with the cables wired.)
<Setting>
(1) General-purpose magnetic flux vector control

y By setting the capacity of the motor used in Pr. 80, you can choose general-purpose
magnetic flux vector control.
Parameter
Setting Description
Number
9999 V/F control
General-
0.1 to 7.5/
80 purpose
0.2 to 7.5 Set the motor capacity applied.
magnetic flux
(Note)
vector control
Note: The setting range changes with the inverter: 0.2kW to 7.5kW, 9999 for the
400V class.
y When using Mitsubishi's constant-torque motor (SF-JRCA), set "1" in Pr. 71. (When
using the SF-JRC, perform the offline auto tuning .)
113
PARAMETERS
4.2.35 Offline auto tuning function (Pr. 82 to Pr. 84, Pr. 90, Pr. 96)
Related parameters
Pr. 82 "motor exciting current"
Pr. 83 "rated motor voltage" Pr. 9 "electronic overcurrent
protection"
Pr. 84 "rated motor frequency" Pr. 71 "applied motor"
Pr. 90 "motor constant (R1)" Pr. 80 "motor capacity"
When you use the general-purpose magnetic flux vector control, you can perform the
offline auto tuning operation to calculate the motor constants automatically.
z Offline auto tuning is made valid only when Pr. 80 is set to other than "9999" to
select the general-purpose magnetic flux vector control.
z The general-purpose magnetic flux vector control can be used without using the
offline auto tuning function but if the motor used is not Mitsubishi's standard motor or
Mitsubishi's constant-torque motor (e.g. motor of another company make) or the
wiring distance is long, the motor can be run with the optimum operating
characteristics by using the offline auto tuning function.
z Offline auto tuning
Automatically measures the motor constants used for general-purpose magnetic flux
vector control.
y Offline auto tuning can be performed with the load connected. (As the load is smaller,
tuning accuracy is higher. Tuning accuracy does not change if inertia is large.)
y The offline auto tuning status can be monitored with the control panel
(FR-PA02-02) or PU (FR-PU04).
y Only a static auto tune can be performed.
y Offline auto tuning is available only when the motor is at a stop.
z Tuning data (motor constants) can be copied to another inverter with the PU
(FR-PU04).
y You can read, write and copy the motor constants tuned by the offline auto tuning.
Parameter Factory
Number Setting
0 to 500A,
82 9999 9999: Mitsubishi standard motor
9999
83 200V/400V 0 to 1000V Rated inverter voltage
84 60Hz 50 to 120Hz
90 9999 0 to 50Ω, 9999 9999: Mitsubishi standard motor
96 0 0, 1 0: No tuning
114
PARAMETERS
<Operating conditions>
y The motor is connected.
y The motor capacity is equal to or one rank lower than the inverter capacity.
y Special motors such as high-slip motors and high-speed motors cannot be tuned.
y The motor may move slightly. Therefore, fix the motor securely with a mechanical
brake, or before tuning, make sure that there will be no problem in safety if the
motor runs.
*This instruction must be followed especially for vertical lift applications.
If the motor runs slightly, tuning performance is unaffected.
y Offline auto tuning will not be performed properly if it is started when a reactor or
surge voltage suppression filter (FR-ASF-H) is connected between the inverter and
motor. Remove it before starting tuning.
<Setting>
(1) Parameter setting

y Set the motor capacity (kW) in Pr. 80 and select the general-purpose magnetic flux
vector control.
y Refer to the parameter details list and set the following parameters:
1) Set "1" in Pr. 96.
2) Set the rated motor current (A) in Pr. 9.
3) Set the rated motor voltage (V) in Pr. 83.
4) Set the rated motor frequency (Hz) in Pr. 84.
5) Select the motor using Pr. 71.
y Standard motor ..................................................................Pr. 71 = "3" or "103"
y Constant-torque motor .......................................................Pr. 71 = "13" or "113"
y M itsubishi standard m otor
SF-JR 4 poles (1.5kW (2HP) or less)......................................Pr. 71 = "23" or "123"
Note: Pr. 83 and Pr. 84 are only displayed when the general-purpose magnetic flux
vector control is selected.
In these parameters, set the values given on the motor plate. Set 200V/60Hz
4
or 400V/60Hz if the standard or other motor has more than one rated value.
After tuning is over, set the Pr. 9 "electronic overcurrent protection" value to
the rated current at the operating voltage/frequency.
115
PARAMETERS
Parameter details
Parameter
Setting Description
Number
9 0 to 500A Set the rated motor current (A).
0, 100 Thermal characteristics suitable for standard motor
Thermal characteristics suitable for Mitsubishi's constant-
1, 101
torque motor
3, 103 Standard motor
13, 113 Constant-torque motor Select "offline auto
71 (Note) Mitsubishi's SF-JR4P standard motor tuning setting"
23, 123
(1.5kW (2HP) or less)
Star connection Direct input of
15, 115 Constant-torque motor
motor constants
Delta connection enabled
16, 116 Constant-torque motor
83 0 to 1000V Set the rated motor voltage (V).
84 50 to 120Hz Set the rated motor frequency (Hz).
Tuning data
90 0 to 50Ω, 9999
(Values measured by offline auto tuning are set automatically.)
0 Offline auto tuning is not performed.
96
1 Offline auto tuning is performed.
Note: The electronic overcurrent protection characteristics are also selected

simultaneously. By setting any of "100 to 123", the electronic overcurrent
protection changes to the thermal characteristic of the constant-torque motor
when the RT signal switches on.
(2) Tuning execution

y For PU operation or combined operation 2, press the FWD or REV key.
y For external operation or combined operation 1, switch on the run command.
Note: 1. To force tuning to end

y Switch on the MRS or RES signal or press the RESET STOP
key to end.
y Switch off the tuning start command to make a forced end.
2. During offline auto tuning, only the following I/O signals are valid:
y Input signals
<Valid signals>
MRS, RES, STF, STR
y Output signals
RUN, FM, AM, A, B, C
3. Special caution should be exercised when a sequence has been designed
to open the mechanical brake with the RUN signal.
116
PARAMETERS
(3) Monitoring the offline tuning status

When the parameter unit (FR-PU04) is used, the Pr. 96 value is displayed during
tuning on the main monitor as shown below. When the control panel is used, the same
value as on the PU is only displayed:
y Control panel display (FR-PA02-02)

(For inverter trip)
2. Tuning in 4. Error-
1. Setting 3. Completion
progress activated end
Displayed
1 2 3 9
value
y Parameter unit (FR-PU04) main monitor

(For inverter trip)
2. Tuning in 4. Error-
1. Setting 3. Completion
progress activated end
1 TUNE 2 TUNE 3 TUNE
Display COMPLETION ERROR 9
STOP PU STF FWD PU STF STOP PU STF STOP PU
y Reference: Offline auto tuning time (factory setting) is about 10 seconds.
(4) Ending the offline auto tuning

1) Confirm the Pr. 96 value.
y Normal end: "3" is displayed.
y Abnormal end: "9", "91", "92" or "93" is displayed.
y Forced end: "8" is displayed.
2) When tuning ended normally

STOP
For PU operation or combined operation 2, press the RESET key. For external
operation or combined operation 1, switch off the start signal (STF or STR) once.
This operation resets the offline auto tuning and the PU's monitor display returns to
the ordinary indication. (Without this operation, next operation cannot be done.) 4
3) When tuning was ended due to an error

Offline auto tuning did not end normally. (The motor constants have not been set.)
Reset the inverter and start tuning all over again.
117
PARAMETERS
4) Error display definitions

Error Display Error Cause Remedy
9 Inverter trip Make setting again.
Increase
Current limit (stall prevention) function was
91 acceleration/deceleration time.
activated.
Set "1" in Pr. 156.
Converter output voltage reached 75% of Check for fluctuation of power
92
rated value. supply voltage.
Check the motor wiring and
93 Calculation error
make setting again.
No connection with motor will result in a calculation (93) error.
5) When tuning was forced to end

STOP
An forced end occurs when you forced the tuning to end by pressing the RESET key or
switching off the start signal (STF or STR) during tuning.
In this case, the offline auto tuning has not ended normally.
(The motor constants are not set.)
Reset the inverter and restart the tuning.
Note: 1. The R1 motor constant measured during in the offline auto tuning is stored
as a parameter and its data is held until the offline auto tuning is performed
again.
2. An instantaneous power failure occurring during tuning will result in a tuning
error.
After power is restored, the inverter goes into the ordinary operation mode.
Therefore, when STF (STR) is on, the motor runs in forward (reverse)
rotation.
3. Any alarm occurring during tuning is handled as in the ordinary mode. Note
that if an error retry has been set, retry is ignored.
4. The set frequency monitor displayed during the offline auto tuning is 0Hz.
CAUTION
When the offline auto tuning is used in vertical lift application, e.g. a lifter,
it may drop due to insufficient torque.
118
PARAMETERS
<Setting the motor constant as desired>

z To set the motor constant without using the offline auto tuning data
<Operating procedure>
1. Set "801" in Pr. 77. Only when the Pr. 80 setting is other than "9999", the
parameter value of the motor constant (Pr. 90) can be displayed. Though the
parameter values of other than the motor constant (Pr. 90) can also be displayed,
they are parameters for manufacturer setting and should be handled carefully
without misuse.
2. Set any of the following values in Pr. 71:
Star Connection Motor Delta Connection Motor

Standard motor 5 or 105 6 or 106
Setting
Constant-torque motor 15 or 115 16 or 116
By setting any of "105 to 116", the electronic overcurrent protection changes to the
thermal characteristics of the constant-torque motor when the RT signal switches on.
3. In the parameter setting mode, read the following parameters and set desired
values:
Parameter Setting Factory
Name Setting Range
Motor exciting 0 to 500A,
82 0.01A 9999
current 9999
Motor constant
90 0 to 10Ω, 9999 0.001Ω 9999
(R1)
4. Refer to the following table and set Pr. 84:

Parameter Setting Factory
Name Setting Range
Rated motor
84 50 to 120Hz 0.01Hz 60Hz
frequency
5. Return the Pr. 77 setting to the original value.

4
Note: 1. The Pr. 90 value may only be read when general-purpose magnetic flux
vector control has been selected.
2. Set "9999" in Pr. 90 to use the standard motor constant (including that for
the constant-torque motor).
3. If "star connection" is mistaken for "delta connection" or vice versa during
setting of Pr. 71, general-purpose magnetic flux vector control cannot be
exercised normally.
119
PARAMETERS
4.2.36 Computer link operation (Pr. 117 to Pr. 124)
Pr. 117 "station number"

Pr. 118 "communication speed"
Pr. 119 "stop bit length/data length"
Pr. 120 "parity check presence/absence"
Pr. 121 "number of communication retries"
Pr. 122 "communication check time interval"
Pr. 123 "waiting time setting"
Pr. 124 "CR, LF presence/absence selection"
Used to perform required settings for RS-485 communication between the inverter and
personal computer.
z The motor can be run from the PU connector of the inverter using RS-485
communication.
Communication specifications
Conforming standard RS-485
Number of inverters connected 1:N (maximum 32 inverters)
Communication speed Selectable between 19200, 9600 and 4800bps
Control protocol Asynchronous
Communication method Half-duplex
Communication
Character system ASCII (7 bits/8 bits) selectable

specifications
Stop bit length Selectable between 1 bit and 2 bits.

Terminator CR/LF (presence/absence selectable)
Check Parity check Selectable between presence (even/odd) and absence
system Sum check Present
Waiting time setting Selectable between presence and absence
z For the data codes of the parameters, refer to Appendix 1 "Data Code List"
(page 199).
Parameter Factory
Setting Range
Number Setting
117 0 0 to 31
118 192 48, 96, 192
Data length 8 0, 1
119 1
Data length 7 10, 11
120 2 0, 1, 2
121 1 0 to 10, 9999
122 9999 (Note) 0 to 999.8 s, 9999
123 9999 0 to 150, 9999
124 1 0, 1, 2
Note: In the FR-E520-0.1K to 7.5K-NA and FR-E510W-0.1K to 0.75K-NA, executing
parameter clear or all clear resets the setting to "0".
120
PARAMETERS
<Setting>
Parameter
Name Setting Description
Number
Station number specified for communication from the
Station PU connector.
117 0 to 31
number Set the inverter station numbers when two or more
inverters are connected to one personal computer.
48 4800 baud
Communica-
118 96 9600 baud
tion speed
192 19200 baud
8 data 0 Stop bit length 1 bit
Stop bit bits 1 Stop bit length 2 bits
119 length/data
length 10 Stop bit length 1 bit
7 bits
11 Stop bit length 2 bits
Parity check 0 Absent
120 presence/ 1 Odd parity present
absence 2 Even parity present
Set the permissible number of retries at occurrence
of a data receive error.
0 to 10
If the number of consecutive errors exceeds the
permissible value, the inverter will come to an alarm stop.
Number of If a communication error occurs, the inverter will not
121 com m unication come to an alarm stop. At this time, the inverter can
retries be coasted to a stop by MRS or RESET input.
9999
During an error, the light fault signal (LF) is given to
(65535)
the open collector output. Allocate the used terminal
with any of Pr. 190 to Pr. 192 (multi-function
outputs).
0 No communication
Set the communication check time [seconds]
Communica- interval.
122 tion check 0.1 to 999.8 If a no-communication state persists for longer than
time interval the permissible time, the inverter will come to an
alarm stop.
9999 Communication check suspension
Set the waiting time between data transmission to
Waiting time 0 to 150
123 the inverter and response.
setting
9999 Set with communication data.
CR, LF 0 Without CR/LF
instruction
124 1 With CR, without LF
presence/
absence 2 With CR/LF
4
<Computer programming>
(1) Communication protocol
Data communication between the computer and inverter is performed using the
following procedure:
Data read
Computer
↓ (Data flow) *2
Inverter 1) 4) 5)
Time
Inverter 2) 3)
*1
↓ (Data flow)
Computer Data write
121
PARAMETERS
*1. If a data error is detected and a retry must be made, execute retry operation with
the user program. The inverter comes to an alarm stop if the number of consecutive
retries exceeds the parameter setting.
*2. On receipt of a data error occurrence, the inverter returns "reply data 3" to the
computer again. The inverter comes to an alarm stop if the number of consecutive
data errors reaches or exceeds the parameter setting.
(2) Communication operation presence/absence and data format types
Communication operation presence/absence and data format types are as follows:
Run Running Parameter Inverter Monitor- Parame-
No. Operation
Com m and Frequency Write Reset ing ter Read
Communication request is
sent to the inverter in A A
1) accordance with the user A' A B B
(A")Note (A")Note
program in the computer.
2) Inverter data processing time Present Present Present Absent Present Present
Reply data No error
from the E, E'
Request C C C Absent E
inverter accepted (E")Note
3) (Data 1) is With error
checked for
error. request D D D Absent F F
rejected
Computer processing delay
4) time Absent Absent Absent Absent Absent Absent
Answer from No error
computer in No Absent Absent Absent Absent G G
response to reply processing
5) data 3. (Data 3 is
checked for With error 3 Absent Absent Absent Absent H H
error)
Note: Data format is A" or E" when you set any of "0.01 to 9998" in Pr. 37 "output
frequency setting" and "1" in data code "HFF".
(3) Data format
Data used is hexadecimal.
Data is automatically transferred in ASCII between the computer and inverter.
1) Data format types
(1) Communication request data from computer to inverter
[Data write]
Waiting
Inverter
station Instruction
time
Format A *3 Sum *4
Data check
ENQ number code
1 2 3 4 5 6 7 8 9 10 11 12 13←Number of characters
Waiting
time *5
*3 Inverter
Instruction Sum *4
Format A' ENQ
station Data check
number code
1 2 3 4 5 6 7 8 9 10 11←Number of characters
Waiting
*3 Inverter Instruction Sum

time
Format A" *4
ENQ station code
Data check
number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15←Number of characters
[Data read]
Waiting
time *5
*3 Inverter
Format B station Instruction Sum *4
ENQ
number code check
1 2 3 4 5 6 7 8 9 ←Number of characters
122
PARAMETERS
Note: 1. The inverter station numbers may be set between H00 and H1F (stations 0
and 31) in hexadecimal.
2. *3 indicates the control code.
3. *4 indicates the CR or LF code.
When data is transmitted from the computer to the inverter, codes CR
(carriage return) and LF (line feed) are automatically set at the end of a data
group on some computers. In this case, setting must also be made on the
inverter according to the computer.
Also, the presence and absence of the CR and LF codes can be selected
using Pr. 124.
4. At *5, when Pr. 123 "waiting time setting" ≠ 9999, create the communication
request data without "waiting time" in the data format.
(The number of characters is decremented by 1.)
2) Send data from computer to inverter during data write

[No data error detected] [Data error detected]
*3
Inverter *3 Inverter Error
Format C station *4 Format D station *4
ACK number NAK number code
1 2 3 4←Number of characters 1 2 3 4 5 ←Number of characters
3) Reply data from inverter to computer during data read

*3 Inverter Read *3 Sum
Format E station *4
STX number data ETX check
1 2 3 4 5 6 7 8 9 10 11 Format F
*3 Inverter Read Inverter

Sum station Error *4
*3 *3
Format E' station *4
STX number data ETX check NAK number code
1 2 3 4 5 6 7 8 9 1 2 3 4 5
Inverter
*3
station Read *3 Sum *4
Format E" STX number data ETX check
1 2 3 4 5 6 7 8 9 10 11 12 13
4) Reply data from computer to inverter during data read
*3
Inverter *3 Inverter
Format G station *4 Format H station *4
ACK number NAK number
1 2 3 4←Number of characters 1 2 3 4←Number of characters

4
(4) Data definitions
1) Control codes
Signal ASCII Code Description
STX H02 Start of Text (Start of data)
ETX H03 End of Text (End of data)
ENQ H05 Enquiry (Communication request)
ACK H06 Acknowledge (No data error detected)
LF H0A Line Feed
CR H0D Carriage Return
NAK H15 Negative Acknowledge (Data error detected)
123
PARAMETERS
2) Inverter station number

Specify the station number of the inverter which communicates with the computer.
3) Instruction code
Specify the processing request, e.g. operation, monitoring, given by the computer to
the inverter. Hence, the inverter can be run and monitored in various ways by
specifying the instruction code as appropriate. (Refer to page 199.)
4) Data
Indicates the data such as frequency and parameters transferred to and from the
inverter. The definitions and ranges of set data are determined in accordance with
the instruction codes. (Refer to page 199.)
5) Waiting time
Specify the waiting time between the receipt of data at the inverter from the
computer and the transmission of reply data. Set the waiting time in accordance with
the response time of the computer between 0 and 150ms in 10ms increments
(e.g. 1 = 10ms, 2 = 20ms).
Computer
Inverter data processing time
↓
= waiting time + data check time
Inverter
(setting×10ms) (12ms)
Inverter
↓
Computer
Note: If the Pr. 123 "waiting time setting" value is not 9999, create the communication
request data with no "waiting time" in the data format. (The number of
characters is decremented by 1.)
6) Sum check code

The sum check code is 2-digit ASCII (hexadecimal) representing the lower 1 byte
(8 bits) of the sum (binary) derived from the checked ASCII data.
(Example 1)
Waiting
E Station Sum
Instruction
Computer → inverter check
time
N number code Data

code
Q 0 1 E 1 1 0 7 A D F 4 ←Binary code
ASCII code → H05 H30 H31 H45 H31 H31 H30 H37 H41 H44 H46 H34
H H H H H H H H H
30 + 31 + 45 + 31 + 31 + 30 + 37 + 41 + 44
H
=1F4
Sum
(Example 2) S E Sum
inverter → Computer T
Station Read time T check
number code
X X
0 1 1 7 7 0 3 0 ←Binary code
ASCII code → H02 H30 H31 H31 H37 H37 H30 H03 H33 H30
H H H H H H
30 + 31 + 31 + 37 + 37 + 30
H
=130
Sum
124
PARAMETERS
7) Error code
If any error is found in the data received by the inverter, its definition is sent back to
the computer together with the NAK code. (Refer to page 129.)
Note: 1. When the data from the computer has an error, the inverter will not accept
that data.
2. Any data communication, e.g. run command, monitoring, is started when the
computer gives a communication request. Without the computer's command,
the inverter does not return any data. For monitoring, therefore, design the
program to cause the computer to provide a data read request as required.
3. When accessing the parameter settings, data for link parameter expansion
setting differs between the parameters as indicated below:
Instruction
Data
Code
Read H7F H00: Pr. 0 to Pr. 96 values are accessible.
H01: Pr. 100 to Pr. 158 and Pr. 900 to Pr. 905
Link values are accessible.
parameter H02: Pr. 160 to Pr. 196 and Pr. 232 to Pr. 250
expansion Write HFF values are accessible.
setting H03: Pr. 338 to Pr. 340 values are accessible.
H09: Pr. 990, Pr. 991 values are accessible.
CAUTION
When the inverter's permissible communication time interval is not set,
interlocks are provided to disable operation to prevent hazardous
conditions. Always set the communication check time interval before
starting operation.
Data communication is not started automatically but is made only once
when the computer provides a communication request. If communication
is disabled during operation due to signal cable breakage etc, the inverter
cannot be stopped. When the communication check time interval has
elapsed, the inverter will come to an alarm stop (E.PUE).
4
The inverter can be coasted to a stop by switching on its RES signal or
by switching power off.
If communication is broken due to signal cable breakage, computer fault
etc, the inverter does not detect such a fault. This should be fully noted.
125
PARAMETERS
<Setting items and set data>

After completion of parameter settings, set the instruction codes and data then start
communication from the computer to allow various types of operation control and
monitoring.
Number
Instruction
No. Item Description of Data
Code Digits
H0001: External operation
Read H7B
Operation H0002: Communication operation
1 4 digits
mode H0001: External operation
Write HFB
H0002: Communication operation
H0000 to HFFFF:Output frequency
(hexadecimal) in 0.01Hz
Output frequency increments
H6F [Speed (hexadecimal) in 4 digits
[speed]
1r/min increments if Pr. 37 =
1 to 9998]
H0000 to HFFFF: Output current
Output current H70 (hexadecimal) in 0.01A 4 digits
increments
H0000 to HFFFF: Output voltage
Output voltage H71 (hexadecimal) in 0.1V 4 digits
increments
H0000 to HFFFF: Two most recent alarm
definitions
A larm definition display
Monitoring
exam ple (instruction code H 74)

b15 b8b7 b0
2
001 1000010100000
Previous alarm Most recent alarm

(H30) (HA0)
H74 to Alarm data

Alarm definition Data Description Data Description 4 digits
H77
H00 No alarm H60 OLT
H10 OC1 H70 BE
H11 OC2 H80 GF
H12 OC3 H81 LF
H20 OV1 H90 OHT
H21 OV2 HA0 OPT
H22 OV3 HB0 PE
H30 THT HB1 PUE
H31 THM HB2 RET
H40 FIN
b7 b0 b0 :
0 0 0 0 0 0 1 0 b1 : Forward rotation (STF)
b2 : Reverse rotation (STR)
[For example 1] b3 :
3 Run command HFA [Example 1] H02 ... Forward rotation b4 : 2 digits
[Example 2] H00 ... Stop b5 :
b6 :
b7 :
126
PARAMETERS
Number
Instruction
Code
Digits
b7 b0 b0: Inverter running (RUN)
0 0 0 0 0 0 1 0 b1: Forward rotation
b2: Reverse rotation
(For example 1)
Inverter status b3: Up to frequency (SU)
4 H7A [Example 1] H02 ... During forward b4: Overload (OL) 2 digits
monitor rotation b5:
[Example 2] H80 ... Stop due to b6: Frequency detection (FU)
alarm b7: Alarm occurrence
H0000 to H9C40: 0.01Hz increments

(hexadecimal)
Running frequency
(0 to 400.00Hz)
5 write HEE 4 digits
To change the running frequency
(E2PROM)
consecutively, write data to the inverter RAM.
(Instruction code: HED)
H9696: Resets the inverter.
As the inverter is reset on start of communica-
6 Inverter reset HFD 4 digits
tion by the computer, the inverter cannot send
reply data back to the computer.
All parameters return to the factory settings.
Any of four different all clear operations is
performed according to the data.
Pr. Commu- HEC
Calibra- Other
nication HF3
tion Pr.
Data Pr. HFF
H9696 { × { {
7 All parameter clear HFC H9966 { { { 4 digits {
H5A5A × × { {
H55AA × { { {
When all parameter clear is executed for
H9696 or H9966, communication-related
parameter settings also return to the factory
settings. When resuming operation, set the
parameters again.
H80 to Refer to the "Data Code List" (page 199) and
8 Parameter write
HFD write and/or read the values as required.
4 digits
H00 to Note that some parameters may not be
9 Parameter read
H7B accessible. 4
127
PARAMETERS
Number
Instruction
Code
Digits
H00 to H6C and H80 to HEC parameter values
are changed.
Read H7F
H00: Pr. 0 to Pr. 96 values are accessible.
Link
parameter
10 values are accessible. 2 digits
expansion
setting
Write HFF values are accessible.
H03: Pr. 338 to Pr. 340 values are accessible.
H09: Pr. 990, Pr. 991 value is accessible.
When setting the bias/gain (data codes H5E to
Second Read H6C H6A, HDE to HED)
parameter parameters
11 2 digits
changing H00: Offset/gain
(Code HFF=1) Write HEC H01: Analog
H02: Analog value of terminal
128
PARAMETERS
<Error Code List>

The corresponding error code in the following list is displayed if an error is detected in
any communication request data from the computer:
Error
Item Definition Inverter Operation
Code
The number of errors consecutively
Computer NAK detected in communication request data
H0
error from the computer is greater than allowed
number of retries.
The parity check result does not match the
H1 Parity error
specified parity.
The sum check code in the computer does Brought to an alarm
H2 Sum check error not match that of the data received by the stop (E.PUE) if error
inverter. occurs continuously
Data received by the inverter is in wrong more than
protocol, data receive is not completed the allowable
H3 Protocol error
within given time, or CR and LF are not as number of retries.
set in the parameter.
The stop bit length is not as specified by
H4 Framing error
initialization.
New data has been sent by the computer
H5 Overrun error before the inverter completes receiving the
preceding data.
H6   
Does not accept
The character received is invalid (other received data but is
H7 Character error
than 0 to 9, A to F, control code). not brought to alarm
stop.
H8   
H9   
Parameter write was attempted in other
HA Mode error than the computer link operation mode or
Does not accept
during inverter operation.
received data but is
Instruction code
HB The specified command does not exist. not brought to alarm
error
stop.
Invalid data has been specified for
HC Data range error
parameter write, frequency setting, etc. 4
HD   
HE   
HF   
129
PARAMETERS
(5) Communication specifications for RS-485 communication
Operation Mode
Operation Communication
Item
Location Operation from PU External Operation
Connector
Run command (start) Enable Disable
Enable
Running frequency setting Enable
(Combined operation mode)
Computer user
Monitoring Enable Enable
program via
Parameter write Enable (*3) Disable (*3)
PU connector
Parameter read Enable Enable
Inverter reset Enable Enable
Stop command (*2) Enable Enable
Inverter reset Enable Enable
Control circuit
Run command Disable Enable
terminal
Running frequency setting Disable Enable
*1 At occurrence of RS-485 communication fault, the inverter cannot be reset from the
computer.
*2 As set in Pr. 75.
*3 As set in Pr. 77.
(6) Operation at alarm occurrence
Operation Mode
Communication
Fault Location Description External
Operation
Operation
(PU connector)
Inverter operation Stop Stop
Inverter fault
Communication PU connector Continued Continued
Communication Inverter operation Stop/continued (*4) Continued
error
(Communication
Communication PU connector Stop Stop
from PU
connector)
*4: Can be selected using the corresponding parameter (factory-set to stop).
(7) Communication error
Fault Location Error Message Remarks

Communication error
Not displayed Error code is E.PUE
(Communication from PU connector)
130
PARAMETERS
4.2.37 PID control (Pr. 128 to Pr. 134)

Related parameters
Pr. 128 "PID action selection"
Pr. 73 "0-5V/0-10V selection"
Pr. 129 "PID proportional band"
Pr. 180 to Pr. 183 (input
terminal function selection)
Pr. 130 "PID integral time"
Pr. 191 to Pr. 192 (output
terminal function selection)
Pr. 131 "upper limit" Pr. 902 to Pr. 905 (frequency
setting voltage (current)
Pr. 132 "lower limit" biases and gains)
Pr. 133 "PID action set point for PU operation"
Pr. 134 "PID differential time"

The inverter can be used to exercise process control, e.g. flow rate, air volume or
pressure.
y The voltage input signal (0 to ±5V or 0 to ±10V) or Pr. 133 setting is used as a set
point and the 4 to 20mA DC current input signal used as a feedback value to
constitute a feedback system for PID control.
Parameter Factory
Number Setting
128 0 0, 20, 21
129 100% 0.1 to 1000%, 9999 9999: No proportional control
130 1s 0.1 to 3600s, 9999 9999: No integral control
133 0% 0 to 100%
134 9999 0.01 to 10.00s, 9999 9999: No differential control
<Setting>
(1) Basic PID control configuration 4
Manipulated variable
Deviation Motor
(x) (fi) Inverter y
Set point PID operation Kp 1 + 1 + Td×S drive IM
+ Ti×S circuit
(U)
- (y)
Process value
Kp : Proportional constant
Ti : Integral time
S : Operator
Td : Differential time
131
PARAMETERS
(2) PID action overview

1) PI action
A combination of proportional control action (P) and integral control action (I) for
providing a manipulated variable in response to deviation and changes with time.
[Operation example for stepped changes of process value]

Note: PI action is the sum of P and I Deviation Set point
actions. Process value
P action
Time
I action
Time
PI action
Time
2) PD action
A combination of proportional control action (P) and differential control action (D)
for providing a manipulated variable in response to deviation speed to improve the
transient characteristic.
[Operation example for proportional changes of process value]
Note: PD action is the sum of P and D Process value
actions. Deviation
Set
P action point
Time
D action
Time
PD action
Time
3) PID action
The PI action and PD action are combined to utilize the advantages of both
actions for control.
Note: The PID action is the sum of P, I and D actions.
132
PARAMETERS
4) Reverse action
Increases the manipulated variable (output frequency) if deviation X (set point -
process value) is positive, and decreases the manipulated variable if deviation is
negative.
Deviation Process value
[Heating]
+ X>0 Cold → fi up
Set point
X<0 Hot → fi down
− Set point
Process value
5) Forward action
Increases the manipulated variable (output frequency) if deviation X (set point -
process value) is negative, and decreases the manipulated variable if deviation is
positive.
Set point
[Cooling]
+ X>0 Too cold → fi down Process value
Set point
X<0 Hot → fi up
−
Process value
Deviation
Relationships between deviation and manipulated variable (output frequency)

Deviation
Positive Negative
Reverse
Ò Ô
action
Forward
Ô Ò
action
133
PARAMETERS
(3) Wiring example

y Pr. 190 = 14
y Pr. 191 = 15
y Pr. 192 = 16
Inverter
NFB Motor Pump
R (L1) U
Power supply S (L2) V IM P
T (L3) W
Forward rotation STF

Reverse rotation STR
SD
For 2-wire For 3-wire
(Note 2) type type
Detector
SU Upper limit
10 RUN Lower limit
Setting potentiometer − + + − +
2 SE Limit signal common
(24V)
(Set point setting)
(COM)
(OUT)
5 A Forward rotation output
Reverse rotation output
Deviation signal C
Forward (reverse)
4 rotation output
signal common
(Process value) 4 to 20mADC
0 24V
DC power
(Note 1)
supply
AC1φ
200/220V 50/60Hz
Note: 1. The power supply must be selected in accordance with the power
specifications of the detector used.
2. The output signal terminals used depends on the Pr. 190 to Pr. 192 settings.
134
PARAMETERS
(4) I/O signals
Signal Terminal Used Function Description

2 2 Set point input Enter the set point for PID control.
Input
Enter the 4 to 20mADC process value signal

4 4 Process value input
from the detector.
Output to indicate that the process value
FUP Upper limit output
signal exceeded the upper limit value.
Output to indicate that the process value
FDN Depending on Lower limit output
Output
signal exceeded the lower limit value.

Pr. 190 to
"Hi" is output to indicate that the output
Pr. 192 Forward (reverse)
indication of the parameter unit is forward
RL rotation direction
rotation (FWD) or "Low" to indicate that it is
output
reverse rotation (REV) or stop (STOP).
z Enter the set point across inverter terminals 2-5 or in Pr. 133 and enter the process
value signal across inverter terminals 4-5.
Item Entry Description

Set 0V as 0% and When "0" is set in Pr. 73 (5V
5V as 100%. selected for terminal 2).
Set point Across terminals 2-5
Set 0V as 0% and When "1" is set in Pr. 73 (10V
10V as 100%. selected for terminal 2).
Set point Pr. 133 Set the set point (%) in Pr. 133.
Process value Across terminals 4-5 4mA DC is equivalent to 0% and 20mA DC to 100%.
135
PARAMETERS
(5) Parameter setting

Parameter
Setting Name Description
Number
0 PID No PID action
128 20 action For heating, pressure control, etc. PID reverse action
21 selection
For cooling, etc. PID forward action
If the proportional band is narrow (parameter setting
is small), the manipulated variable varies greatly
PID with a slight change of the process value. Hence, as
0.1 to
propor- the proportional band narrows, the response
129 1000% sensitivity (gain) improves but the stability
tional
band deteriorates, e.g. hunting occurs.
Gain Kp = 1/proportional band
9999 No proportional control
Time required for the integral (I) action to provide
the same manipulated variable as that for the
0.1 to PID
proportional (P) action. As the integral time
130 3600 s integral decreases, the set point is reached earlier but
time hunting occurs more easily.
9999 No integral control.
Set the upper limit. If the feedback value exceeds
0 to 100% Upper the setting, the FUP signal is output. (Process value
131 of 4mA is equivalent to 0% and 20mA to 100%.)
limit
9999 No function
Set the lower limit. (If the process value goes out of
the setting range, an alarm can be output. In this
0 to 100% Lower
132 case, the process value of 4mA is equivalent to 0%
limit and 20mA to 100%.)
9999 No function
PID Only valid for the PU command in the PU operation
action set or PU/external combined operation mode.
For external operation, the voltage across 2-5 is the
133 0 to 100% point for
set point.
PU (Pr. 902 value is equivalent to 0% and Pr. 903 value
operation to 100%.)
Time required for the differential (D) action to provide
0.01 to the same process value as that for the proportional
PID (P) action. As the differential time increases, greater
10.00 s
134 differential response is made to a deviation change.
time
9999 No differential control.
(6) Adjustment procedure

Parameter setting Adjust the PID control parameters, Pr. 128 to Pr. 134.
Terminal setting Set the I/O terminals and PID control terminals.
Run
136
PARAMETERS
(7) Calibration example

(A detector of 4mA at 0°C (32°F) and 20mA at 50°C (122°F) is used to adjust the room
temperature to 25°C (77°F) under PID control. The set point is given to across inverter
terminals 2-5 (0-5V).)
START
Determine the set point. xxxxxx Set the room temperature to 25°C (77°F)
Determine the set point of the item Set "20" or "21" in Pr. 128 to enable PID control.
to be adjusted.
Convert the set point into %. xxxxxx Detector specifications

When the detector used has the specifications that 0°C (32°F)
Calculate the ratio of the set point is equivalent to 4mA and 50°C (122°F) to 20mA, the set point of
to the detector output. 25°C (77°F) is 50% because 4mA is equivalent to 0% and
20mA to 100%.
Make calibration. xxxxxx When the set point setting input (0 to 5V) and detector output (4
to 20mA) must be calibrated, make the following calibration*
Set the set point. xxxxxx Set point = 50%
Enter a voltage to across Since the specifications of terminal 2 are such that 0% is
terminals 2-5 according to the set equivalent to 0V and 100% to 5V, enter 2.5V into terminal 2.
point (%).
Operation xxxxxx For PU operation, set the set point (0 to 100%) in Pr. 133.
Set the proportional band and During operation, set the proportional band and integral time to
integral time to slightly higher slightly higher values and set the differential time to a slightly
values and the differential time to lower value. In accordance with the system operation, reduce
the proportional band and integral time and increase the
a slightly lower value, and switch differential time.
on the start signal.
Is the process Yes

value steady?
No
Adjust parameters. Optimize parameters.
Set the proportional band and integral While the process value is steady, the
time to slightly higher values and set proportional band and integral time may
the differential time to a slightly lower be reduced and the differential time
value to stabilize the process value. increased throughout the operation.
4
END
* When calibration is required, use Pr. 902 to Pr. 905 to calibrate the
detector output and set point setting input in the PU mode during an
inverter stop.
137
PARAMETERS
<Set point input calibration>

1. Apply the input voltage of 0% set point setting (e.g. 0V) to across terminals 2-5.
2. Make calibration using Pr. 902. At this time, enter the frequency which should be
output by the inverter at the deviation of 0% (e.g. 0Hz).
3. Apply the voltage of 100% set point setting (e.g. 5V) to across terminals 2-5.
4. Make calibration using Pr. 903. At this time, enter the frequency which should be
output by the inverter at the deviation of 100% (e.g. 60Hz).
<Detector output calibration>

1. Apply the output current of 0% detector setting (e.g. 4mA) across terminals 4-5.
2. Make calibration using Pr. 904.
3. Apply the output current of 100% detector setting (e.g. 20mA) across terminals 4-5.
4. Make calibration using Pr. 905.
Note: The frequencies set in Pr. 904 and Pr. 905 should be the same as set in
Pr. 902 and Pr. 903.
The results of the above calibration are as shown below:
[Set point setting] [Detection value] [Manipulated variable]

Manipulated
(%) (%) variable(Hz)
100 100 60
0 0 0
0 5 (V) 0 4 20 (mA) 0 100 Deviation
(%)
Note: 1. If the multi-speed (RH, RM, RL) signal or jog operation (jog) signal is
entered, PID control is stopped and multi-speed or jog operation is started.
2. When the terminal functions are changed using Pr. 190 to Pr. 192, the other
functions may be affected. Confirm the functions of the corresponding
3. When you have chosen the PID control, the minimum frequency is as set in
Pr. 902 and the maximum frequency is as set in Pr. 903.
(The settings of Pr. 1 "maximum frequency" and Pr. 2 "minimum frequency"
are also valid.)
138
PARAMETERS
4.2.38 Output current detection function (Pr. 150, Pr.151)

Related parameters
Pr. 150 "output current detection level"
Pr. 190 to Pr. 192
Pr. 151 "output current detection time" (output terminal function
selection)
y If the output current remains higher than the Pr. 150 setting during inverter operation
for longer than the time set in Pr. 151, the output current detection signal (Y12) is
output from the inverter's open collector output terminal.
(Use any of Pr. 190 to Pr. 192 to assign the terminal used for Y12 signal output.)
Number Setting Range 100ms
Output current
150 150% 0 to 200.0% detection signal (Y12) OFF ON OFF
Output current
151 0 0 to 10 s
Pr.150
Pr.151
Time
<Setting>
Refer to the following list and set the parameters:
Parameter
Description
Number
Set the output current detection level.
150
100% is the rated inverter current.
Set the output current detection time. Set a period of time from when the
151 output current rises to or above the Pr. 150 setting to when the output
current detection signal (Y12) is output.
Note: 1. The output current detection signal is held on for about 100ms (at least) if it
switches on once when the output current rises to or above the preset
detection level.
2. This function is also valid during execution of offline auto tuning.
4
139
PARAMETERS
4.2.39 Zero current detection (Pr. 152, Pr.153)

Related parameters
Pr. 152 "zero current detection level"
Pr. 190 to Pr. 192 (output
Pr. 153 "zero current detection time" terminal function selection)
When the inverter's output current falls to "0", torque will not be generated. This may
cause a gravity drop when the inverter is used in vertical lift application.
To prevent this, the output current "zero" signal can be output from the inverter to close
the mechanical brake when the output current has fallen to "zero".
y If the output current remains lower than the Pr. 152 setting during inverter operation
for longer than the time set in Pr. 153, the zero current detection (Y13) signal is
output from the inverter's open collector output terminal.
(Use any of Pr. 190 to Pr. 192 to assign the terminal used for Y13 signal output.)
152 5.0% 0 to 200.0%
153 0.5 s 0.05 to 1 s
Start signal OFF ON
Pr. 152 "zero current

detection level" Pr.152 (Note) Output current 0 [A]
100ms
Zero current OFF OFF
ON ON
detection signal
output (Y13)
Pr. 153 "detection time" Pr. 153 "detection time"
<Setting>
Refer to the following list and set the parameters:
Parameter
Description
Number
Set the zero current detection level.
152 Set this parameter to define the percentage of the rated current at which the
zero current will be detected.
Set the zero current detection time.
153 Set a period of time from when the output current falls to or below the
Pr. 152 setting to when the zero current detection signal (Y13) is output.
Note: 1. If the current falls below the preset detection level but the timing condition is
not satisfied, the zero current detection signal is held on for about 100ms.
2. This function is also valid during execution of offline auto tuning.
140
PARAMETERS
CAUTION
The zero current detection level setting should not be too high, and the
zero current detection time setting should not be too long. Otherwise, the
detection signal may not be output when torque is not generated at a low
output current.
To prevent the machine and equipment from resulting in hazardous
conditions by use of the zero current detection signal, install a safety
backup such as an emergency brake.
4.2.40 Stall prevention function and current limit function (Pr. 156)
Related parameters
Pr. 156 " stall prevention operation
Pr. 22 "stall prevention operation level"
selection" Pr. 23 "stall prevention operation level
at double speed"
Pr. 47 "second stall prevention
operation current"
Pr. 48 "second stall prevention
operation frequency"
You can make a setting to disable stall prevention caused by overcurrent, make a
setting to disable the fast-response current limit (which limits the current to prevent the
inverter from resulting in an overcurrent trip if an excessive current occurs due to
sudden load variation or ON-OFF, etc. in the output side of the running inverter), and
set the OL signal output delay.
156 0 0 to 31, 100
141
PARAMETERS
<Setting>
Refer to the following tables and set the parameter as required.
Stall Prevention OL Stall Prevention OL
Operation Voltage Signal Operation Voltage Signal
{ Output { Output
{ {
: Activated : Activated
Fast-Response : z
Not activated :
Operation
Fast-Response : Not z
activated :
Operation
Pr. 156 Current Limit Pr. 156 Current Limit
{ continued
z { continued
z
Deceleration
Deceleration
Acceleration
Acceleration
Constant
Constant
Setting : Activated Setting : Activated
z :
z :
speed
speed
: Not activated Operation : Not activated Operation
not not
continued continued
(Note 1) (Note 1)
0 { { { { { 16 { { { { z
1 z { { { { 17 z { { { z
2 { z { { { 18 { z { { z
3 z z { { { 19 z z { { z
4 { { z { { 20 { { z { z
5 z { z { { 21 z { z { z
6 { z z { { 22 { z z { z
7 z z z { { 23 z z z { z
8 { { { z { 24 { { { z z
9 z { { z { 25 z { { z z
10 { z { z { 26 { z { z z
11 z z { z { 27 z z { z z
12 { { z z { 28 { { z z z
13 z { z z { 29 z { z z z
14 { z z z { 30 { z z z z
15 z z z z { 31 z z z z z
{ { { { {
Regenerative Driving
100
z z z z {
Note 1: When "Operation not continued for OL signal output" is selected, the
"E.OLT" alarm code (stopped by stall prevention) is displayed and operation
stopped.
(Alarm stop display "E.OLT")
2: If the load is heavy, the lift is predetermined, or the acceleration/deceleration
time is short, the stall prevention may be activated and the motor not
stopped in the preset acceleration/deceleration time. Therefore, set optimum
values to the Pr. 156 and stall prevention operation level.
CAUTION
Always perform test operation.
Stall prevention operation performed during acceleration may increase
the acceleration time.
Stall prevention operation performed during constant speed may cause
sudden speed changes.
Stall prevention operation performed during deceleration may increase
the deceleration time, increasing the deceleration distance.

142
PARAMETERS
4.2.41 User group selection (Pr. 160, Pr. 173 to Pr. 176)
Pr. 160 "user group read selection"

Pr. 173 "user group 1 registration"
Pr. 174 "user group 1 deletion"
Pr. 175 "user group 2 registration"
Pr. 176 "user group 2 deletion"
Among all parameters, a total of 32 parameters can be registered to two different user
groups. The registered parameters may only be accessed.
The other parameters cannot be read.
Parameter Factory
Number Setting
160 0 0, 1, 10, 11
173 0 0 to 999
174 0 0 to 999, 9999 9999: Batch deletion
175 0 0 to 999
176 0 0 to 999, 9999 9999: Batch deletion
<Setting example show the use of the control panel (FR-PA02-02)>

(1) Registration of parameter to user group (when registering Pr. 3 to
user group 1)
Flickering
Pr. 173 reading
1) 2) 3) 4) 5)
SET SET
1.5 sec.

The number of Press the / Pr. 3 is registered Press the /

parameters set and key to select the to user group 1. key to shift to the next
registered by the parameter number to parameter to be
user appears. be registered. registered.
Press the SET key to
register the parameter.
(2) Deletion of parameter from the user group (when Pr. 5 is deleted
from user group 1)
Flickering 4
Pr. 174 reading
1) 2) 3) 4) 5)
SET SET
1.5 sec.

The number of Press the / Pr. 5 is deleted Press the /

parameters set and key to select the from user group 1. key to shift to the next
registered by the parameter number to parameter to be
user appears. be deleted. deleted.
Press the SET key to
delete the parameter.
143
PARAMETERS
(3) Set the required value in Pr. 160 to make the user group or groups
valid or invalid.
Pr. 160 Setting Description
0 Previous parameters read
1 User group 1's parameters read
10 User group 2's parameters read
11 User group 1 and 2 parameters read
Note: 1. The Pr. 77, Pr. 160 and Pr. 991 values may always be read independently of
the user group setting.
2. The Pr. 173 or Pr. 174 value read indicates the number of parameters
registered to group 1, and the Pr. 175 or Pr. 176 value read indicates the
number of parameters registered to group 2.
3. If "0" is set in the second digit of two-digit Pr. 160, it is not displayed.
However, "0" is displayed when it is set in the first digit only.
4. When "9999" is set in Pr. 174 or Pr. 176, the parameters registered to the
corresponding user group are batch-deleted.
144
PARAMETERS
4.2.42 Actual operation hour meter clear (Pr. 171)

Pr. 171 "actual operation hour meter Related parameter
clear" Pr. 52 "Control panel/PU main
display data selection"
You can clear the actual operation hour of the monitoring function.
171 0 0
<Setting>
Write "0" in the parameter to clear the actual operation hour.
Pr. 173 to Pr. 176 Î Refer to Pr. 160.
4.2.43 Input terminal function selection (Pr. 180 to Pr. 183)
Pr. 180 "RL terminal function selection"
Pr. 181 "RM terminal function selection"
Pr. 182 "RH terminal function selection"
Pr. 183 "MRS terminal function selection"

Use these parameters to select/change the input terminal functions.
Parameter Terminal Factory Factory-Set Terminal Setting
Number Symbol Setting Function Range
Low-speed operation
180 RL 0 0 to 8, 16, 18
command (RL)
Middle-speed operation
181 RM 1
command (RM)
0 to 8, 16, 18 4
High-speed operation
182 RH 2 0 to 8, 16, 18
command (RH)
183 MRS 6 Output shut-off (MRS) 0 to 8, 16, 18
145
PARAMETERS
<Setting>
Refer to the following list and set the parameters.
Signal Related
Setting Function
Name Parameters
Pr. 4 to Pr. 6
Pr. 59 = 0 Low-speed operation command Pr. 24 to Pr. 27
0 RL Pr. 232 to Pr. 239
Pr. 59 = 1, 2 * Remote setting (setting clear) Pr. 59
Pr. 4 to Pr. 6,
Middle-speed operation
Pr. 59 = 0 Pr. 24 to Pr. 27,
1 RM command
Pr. 232 to Pr. 239
Pr. 59 = 1, 2 * Remote setting (deceleration) Pr. 59
Pr. 4 to Pr. 6,
Pr. 59 = 0 High-speed operation command Pr. 24 to Pr. 27,
2 RH Pr. 232 to Pr. 239
Pr. 59 = 1, 2 * Remote setting (acceleration) Pr. 59
3 RT Second function selection Pr. 44 to Pr. 48
4 AU Current input selection
5 STOP Start self-holding terminal
6 MRS Output shut-off terminal
External thermal relay input **
The external thermal relay provided for overheat
7 OH Refer to page 163.
protection or the embedded temperature relay
within the motor is activated to stop the inverter.
Pr. 4 to Pr. 6,
15-speed selection (combination with three speeds
8 REX Pr. 24 to Pr. 27,
of RL, RM, RH)
Pr. 232 to Pr. 239
16 X16 PU operation-external operation switch-over Pr. 79
General-purpose magnetic flux vector-V/F switch-
18 X18 over (OFF: general-purpose magnetic flux vector Pr. 80
control, ON: V/F control) (Note 3)
**: When Pr. 59 = "1" or "2", the functions of the RL, RM and RH signals change as
listed above.
**: Activated when the relay contact "opens".
Note: 1. One function can be assigned to two or more terminals. In this case, the
terminal inputs are OR' ed.
2. The speed command priorities are higher in order of multi-speed setting
(RH, RM, RL, REX) and AU.
3. When V/F control is selected using the V/F-general-purpose magnetic flux
switch-over function, the secondry functions are also selected.
During operation, you cannot switch between V/F and general-purpose
magnetic flux. Should you switch between V/F and general-purpose
magnetic flux, only the second functions are selected.
4. Use common terminals to assign multi-speeds (7 speeds) and remote
setting. They cannot be set individually.
(Common terminals are used since these functions are designed for multiple
speed setting and need not be set at the same time.)
5. Functions are invalid if values other than the above are set to Pr. 180 to
Pr. 183 (input terminal function selection).
146
PARAMETERS
4.2.44 Output terminal function selection (Pr. 190 to Pr. 192)
Pr. 190 "RUN terminal function selection"

Pr. 191 "FU terminal function selection"
Pr. 192 "ABC terminal function selection"
You can change the functions of the open collector and contact output terminals.
Parameter Terminal Factory Factory-Set Terminal Setting
Number Symbol Setting Function Range
190 RUN 0 Inverter running 0 to 99
191 FU 4 Output frequency detection 0 to 99
192 ABC 99 Alarm output 0 to 99
<Setting>
Refer to the following table and set the parameters:
Signal Related
Setting Function Operation
Name Parameters
Output during operation when
the inverter output frequency
0 RUN Inverter running 
rises to or above the starting
frequency.
Refer to Pr. 41 "up-to-frequency
1 SU Up to frequency Pr. 41
sensitivity". (Note 1)
Output while stall prevention Pr. 22, Pr. 23,
3 OL Overload alarm
function is activated. Pr. 66
Output frequency Refer to Pr. 42, Pr. 43 (output
4 FU Pr. 42, Pr. 43
detection frequency detection).
Output when the inverter is
Inverter operation
11 RY ready to be started by switching 
ready
the start signal on.
Output current Refer to Pr. 150 and Pr. 151 Pr. 150,
12 Y12
detection (output current detection). Pr. 151
Zero current Refer to Pr. 152 and Pr. 153 Pr. 152,
13 Y13
detection (zero current detection). Pr. 153
14 FDN PID lower limit
15 FUP PID upper limit Refer to Pr. 128 to Pr. 134 (PID Pr. 128 to
PID forward- control). Pr. 134
16 RL reverse rotation
output 4
Output when a minor fault
98 LF Minor fault output Pr. 244
occurs.
Output when the inverter's
99 ABC Alarm output protective function is activated to 
stop the output (major fault).
Note: 1. The same function may be set to more than one terminal.
2. Pr. 190 to Pr. 192 do not function if the values set are other than the above.
147
PARAMETERS
Pr. 232 to Pr. 239 Î Refer to Pr. 4.
4.2.45 Cooling fan operation selection (Pr. 244)
Pr. 244 "cooling fan operation selection"

You can control the operation of the cooling fan built in the inverter (whether there is a
cooling fan or not depends on the models. Refer to the outline dimensional drawing
(Refer to page 193).)
244 0 0, 1
<Setting>
Setting Description
Operated at power on (independent of whether the inverter is running or at
0
a stop).
Cooling fan on-off control valid
(The cooling fan is always on while the inverter is running. During a stop,
1
the inverter status is monitored and the fan switches on-off according to
temperature.)
<Reference>
In either of the following cases, fan operation is regarded as faulty, [FN] is shown on
the control panel, and the minor fault (LF) signal is output. Use any of Pr. 190 to
Pr. 192 (output terminal function selection) to allocate the terminal used to output the
LF signal.
1) Pr. 244 = "0"
When the fan comes to a stop with power on.
2) Pr. 244 = "1"
When the inverter is running and the fan stops during fan ON command or the fan
starts during fan OFF command.
Note: When the terminal assignment is changed using Pr. 190 to Pr. 192, the other
148
PARAMETERS
4.2.46 Slip compensation (Pr. 245 to Pr. 247)
Pr. 245 "rated slip"
Pr. 246 "slip compensation time constant"
Pr. 247 "constant-output region slip compensation selection"

The inverter output current may be used to assume motor slip to keep the motor speed
constant.
Parameter Factory
Number Setting
245 9999 0 to 50%, 9999 9999: No slip compensation
246 0.5 0.01 to 10 s
247 9999 0, 9999 9999: Slip compensation made
<Setting>
Synchronous speed at base frequency - rated speed
Rated slip = ×100[%]
Synchronous speed at base frequency
Parameter
Setting Function
Number
0 to 50% Used to set the rated motor slip.
245
9999 Slip compensation is not made.
246 0.01 to 10 s Used to set the slip compensation response time. (Note)
Slip compensation is not made in the constant output
0
247 range (frequency range above the frequency set in Pr. 3).
9999 Slip compensation is made in the constant output range.
Note: When this value is made smaller, response will be faster.

However, as load inertia is greater, a regenerative overvoltage (OVT) error is
more liable to occur.
149
PARAMETERS
4.2.47 Ground fault detection at start (Pr. 249)

(400V class does not have this function)
Pr. 249 "ground fault detection at start"

You can select whether ground fault detection at start is made or not. Ground fault
detection is made only immediately after the start signal is input to the inverter.
If a ground fault occurs during operation, the protective function is not activated.
Parameter Factory
Setting Range
Number Setting
249 0 0, 1
<Setting>
Setting Description
0 Ground fault detection not made
1 Ground fault detection made
Note: 1. Since detection is made at a start, an about 20ms output delay occurs at
every start.
2. When a ground fault is detected with "1" set in Pr. 249, alarm output "E.GF"
is detected and the output is shut off.
3. If the motor capacity is less than 0.1kW, protection may not be provided
against a ground fault.
150
PARAMETERS
4.2.48 Stop selection (Pr. 250)

Related parameters
Pr. 250 "stop selection"
Pr. 44 "second acceleration/
deceleration time"
Pr. 45 "second deceleration
time"
Used to select the stopping method (deceleration to a stop or coasting) when the start
signal (STF/STR) switches off.
Parameter Factory
Setting Range
Number Setting
0 to 100 s, 1000 to
250 9999
1100 s, 8888, 9999
(1)Pr. 250 = "9999"

When the start signal switches off, the motor is decelerated to a stop.
Start signal
ON OFF
Output
frequency Decelerated when start signal switches off.
Deceleration time (time set in Pr. 8, etc.)
DC brake
Time
(2)Pr. 250 = 0 to 100 seconds (output is shut off after preset time)
The output is shut off when the time set in Pr. 250 has elapsed after the start signal
was switched off. The motor coasts to a stop.
Start signal
4
OFF
Output is shut off when time set in Pr. 250
has elapsed after start signal was switched
Output off.
frequency
Motor coasts to a stop.
Time
RUN signal
OFF
151
PARAMETERS
When the Pr. 250 value is 8888, the functions of terminals STF and STR change as
shown below:
STF = start signal, STR = rotation direction signal
STF STR Inverter Operating Status
OFF OFF
Stop
OFF ON
ON OFF Forward rotation
ON ON Reverse rotation
When the Pr. 250 value is any of 1000 to 1100 seconds, the functions of terminals STF
and STR are the same as when the Pr. 250 value is 8888.
Also, for the stopping method used when the start signal switches off, the output is shut
off (the motor coasts to a stop) after the period set in Pr. 250 (i.e. 1000 seconds) have
elapsed.
Note: 1. The RUN signal switches off when the output stops.
2. When the start signal is switched on again during motor coasting, the motor
starts at 0Hz.
3. When the Pr. 250 value is 0, the output is shut off within the shortest time.
152
PARAMETERS
4.2.49 Meter (frequency meter) calibration (Pr. 900)

(200V class, 100V class)
Related parameters
Pr. 900 "FM terminal calibration" Pr. 54 "FM terminal function
selection"
Pr. 55 "frequency monitoring
reference"
Pr. 56 "current monitoring
reference"
z By using the control panel or parameter unit, you can calibrate a meter connected to
terminal FM to full scale deflection.
z Terminal FM provides the pulse output. By setting Pr. 900, you can calibrate the
meter connected to the inverter from the parameter unit without providing a
calibration resistor.
z You can display a digital value on a digital counter using the pulse train signal from
terminal FM. A 1440 pulses/sec. output is provided at the full scale value as
explained in the section of Pr. 54. When the running frequency has been selected
for monitoring, the ratio of this FM terminal output frequency can be set in Pr. 55.
Meter
1mA full scale 1440 pulses/sec.
Analog meter (Digital meter)
T1 1mA (−) (+)
FM FM
DC8V
T2 SD SD
Pulse width T1 : Adjusted with Pr. 900 Note : The parameter is factory-set to 1mA
Pulse period T2 : Set in Pr. 55 (frequency monitoring) full-scale or 1440 pulses/sec. FM
Set in Pr. 56 (current monitoring) output frequency at 60Hz.
(1)Calibration of terminal FM
1) Connect a meter (frequency meter) across inverter terminals FM-SD. 4
(Note the polarity. FM is the positive terminal.)
2) When a calibration resistor has already been connected, adjust the resistance to
"0" or remove the resistor.
3) Set any of "0 to 2" in Pr. 54.
When the running frequency or inverter output current has been selected as the
output signal, preset in Pr. 55 or Pr. 56 the running frequency or current at which
the output signal is 1440Hz.
At this 1440 pulses/sec., the meter normally deflects to full scale.
153
PARAMETERS
<Operation procedure>
y When using the control panel (FR-PA02-02)

1) Select the PU operation mode.
2) Set the running frequency.
4) Read Pr. 900 "FM terminal calibration".
5) Press the FWD key to run the inverter. (Motor need not be connected.)
6) Hold down the / key to adjust the meter pointer to a required position.
(Depending on the setting, it may take some time unit the pointer moves.)
7) Press the SET key for about 1.5 sec.
STOP
8) Press the RESET key to stop the inverter.
Note: 1. Pr. 900 is factory-set to 1mA full-scale or 1440 pulses/sec. FM output

frequency at 60Hz. The maximum pulse train output of terminal FM is 2400
pulses/sec.
2. When a frequency meter is connected across terminals FM-SD to monitor
the running frequency, the FM terminal output is filled to capacity at the
factory setting if the maximum output frequency reaches or exceeds 100Hz.
In this case, the Pr. 55 setting must be changed to the maximum frequency.
154
PARAMETERS
4.2.50 Meter (frequency meter) calibration (Pr. 901) (400V class)

Related parameters
Pr. 901 "AM terminal calibration"
Pr. 55 "frequency monitoring
reference"
Pr. 56 "current monitoring
reference"
Pr. 158 "AM terminal function
selection"
z By using the control panel or parameter unit, you can calibrate a meter connected to
terminal AM to full scale deflection.
z Terminal AM is factory-set to provide a 10VDC output in the full-scale state of each
monitored data. Pr. 901 allows the output voltage ratio (gain) to be adjusted
according to the meter reading. Note that the maximum output voltage is 10VDC.
Meter
10V full scale
Analog meter
AM
(1)Calibration of terminal AM
1) Connect a 0-10VDC meter (frequency meter) across inverter terminals AM-5.
(Note the polarity. AM is the positive terminal.)
2) Set any of "0, 1, 2" in Pr. 158.
output signal, preset in Pr. 55 or Pr. 56 the running frequency or current at which
the output signal is 10V.
155
PARAMETERS
<Operation procedure>
y When using the control panel (FR-PA02-02)
1) Select the PU operation mode.
2) Set the running frequency.
4) Read Pr. 901 "AM terminal calibration".
5) Press the FWD key to run the inverter. (Motor need not be connected.)
6) Hold down the / key to adjust the meter pointer to a required position.
(Depending on the setting, it may take some time until the pointer moves.)
7) Press the SET key for about 1.5 sec.
STOP
8) Press the RESET key to stop the inverter.
156
PARAMETERS
4.2.51 Biases and gains of the frequency setting voltage (current)

(Pr. 902 to Pr. 905)
Pr. 902 "frequency setting voltage bias" Related parameters

Pr. 38 "frequency at 5V (10V)
Pr. 903 "frequency setting voltage gain" input"
Pr. 39 "frequency at 20mA
Pr. 904 "frequency setting current bias" input"
Pr. 73 "0-5/0-10V selection"
Pr. 905 "frequency setting current gain" Pr. 79 "operation m ode selection"
The "bias" and "gain" functions are used to adjust the relationship between the input
signal entered from outside the inverter (to set the output frequency), i.e. 0 to 5VDC,
0 to 10VDC or 4 to 20mADC, and the output frequency.
z Use Pr. 902 to set the bias of the voltage signal and use Pr. 903 to set its gain.
z Use Pr. 904 to set the bias of the current signal and use Pr. 905 to set its gain.
Parameter Factory
Output frequency (Hz)
Setting Range
Number Setting
902 0V 0Hz 0 to 10V 0 to 60Hz Factory setting
903 5V 60Hz 0 to 10V 1 to 400Hz (60Hz)
904 4mA 0Hz 0 to 20mA 0 to 60Hz
905 20mA 60Hz 0 to 20mA 1 to 400Hz Gain Pr.903
Bias Pr.905
Pr.902
Pr.904
0 5V Pr.73
0 10V
4 20mA
Frequency setting signal
<Setting>
(1)The frequency setting voltage (current) biases and gains may be adjusted by any of
the three following ways:
1) Any point can be adjusted with a voltage applied across terminals 2-5 (with a
current flowing across terminals 4-5).
2) Any point can be adjusted with no voltage applied across terminals 2-5 (with no 4
current flowing across terminals 4-5).
3) Only the bias and gain frequencies are adjusted and the voltage (current) is not
adjusted.
157
PARAMETERS
Pr. 903 "frequency setting voltage gain"

(Pr.902, Pr. 904, Pr. 905 can also be adjusted similarly.)
<Adjustment procedure> When using an external frequency setting signal to set the
frequency.
(1)Power-on (monitoring mode)
Hz RUN
A MON
PU EXT
MODE SET REV
STOP
FWD
RESET
(2)Choose the PU operation mode.

1) Using the MODE key, make sure that the PU operation mode has been selected.
zFrequency setting zParameter setting
zMonitoring mode MODE
mode
MODE
mode
MODE
Hz Hz
MON
PU EXT PU PU
zOperation mode
(PU operation mode)
MODE
zHelp mode MODE
PU
PU EXT MODE SET REV
STOP
FWD
RESET
Confirm that the PU operation mode

( ) has been chosen.
In the JOG operation mode ( )
or external operation mode ( ),
press the / key to display .
If cannot be displayed by pressing
the / key in the external operation mode
( ).
(if Pr. 79 "operation mode selection" ≠ "0"),
refer to 2) and set "1" (PU operation mode)
in Pr. 79 "operation mode selection".
158
PARAMETERS
2) Set "1" (PU operation mode) in Pr. 79 "operation mode selection".

Example:To change the external operation mode (Pr. 79=2) to the PU
operation mode (Pr. 79=1)
Using the MODE key,

choose the "parameter
setting mode" as in 1).

Most significant Least significant
PU digit flickers Middle digit flickers digit flickers
SET SET
MODE SET REV
STOP
FWD
RESET
×7 times ×9 times
SET
0 to 9 0 to 9
zCurrent setting zSetting change

SET
Press for
1.5 sec.
SET
zSetting write
If appears, make sure that the forward
rotation (STF) or reverse rotation (STR) signal
Flicker connected to the control terminal is not on.
If it is on, turn it off.
"1" (PU operation mode) has been set in Pr. 79.

If appears, you did not press the SET 4
key for 1.5 seconds when writing the setting.
Press the key once, press the SET key, and
restart the setting from the beginning.
159
PARAMETERS
(3)Read Pr. 903 and show the current setting of the gain frequency.
(Pr. 902, Pr. 904 and Pr. 905 can also be adjusted similarly.)
Using the MODE key, choose the "parameter setting mode" as in (2)-1).
PU
MODE SET REV
STOP
FWD
RESET
SET
Most significant Middle digit Least significant

digit flickers. flickers. digit flickers.
SET
×9
times ×3
SET
times
SET
0 to 9 0 to 9
Current setting of gain frequency

Hz RUN
A MON
PU EXT
(4)Set a new gain frequency in Pr. 903 and show the analog voltage monitor value
across terminals 2-5 (when the frequency is set to 80Hz)
Current setting of zChanging the gain
gain frequency frequency
Hz RUN Hz RUN
A MON A MON
PU EXT PU EXT
Press to change
the set frequency.
Press for 1.5 sec.
SET
zMonitoring the analog voltage (%)

across terminals 2-5
Hz RUN
A MON
PU EXT
In any of the methods in (5) to (7) on the following pages,

continue the setting until the analog voltage monitor value
flickers. If you end the setting here, the gain frequency
change will not be reflected.
160
PARAMETERS
1) When not adjusting the gain voltage → go to (5)

2) When adjusting any point by applying a voltage → go to (6)
3) When adjusting any point without applying a voltage → go to (7)
(5)How to adjust the gain frequency only without the voltage being adjusted
zMonitoring the analog zPress the or key once to display
voltage across terminals 2-5 the current analog voltage adjustment.
Hz RUN
A MON Example: When analog voltage
PU EXT
adjustment value is 100%
Press for 1.5 sec.
SET
Flicker
(6)How to adjust any point by applying a voltage across terminals 2-5 (e.g. from the
external potentiometer) (current: across terminals 4-5) (When applying 5V)
zMonitoring the analog zApply a 5V voltage.
voltage across terminals 2-5 (Turn the external potentiometer
Hz RUN connected across terminals 2-5 to MAX.)
A MON
PU EXT
Press for 1.5 sec.

SET
When the potentiometer

Flicker is at the MAX position,
the value is nearly 100.
(7)How to adjust any point without applying a voltage across terminals 2-5 (without a
current flowing across terminals 4-5) (when changing from 4V (80%) to 5V
(100%))
zSet the gain voltage (%) with
zMonitoring the analog zPress the or key the / key.
voltage across terminals once to display the current [0(%) for 0V (0mA), 100(%) for 4
2-5 analog voltage calibration value. 5V (10V, 20mA)]
Hz RUN
A MON
PU EXT
/
Press for 1.5 sec.
SET
Flicker
161
PARAMETERS
(8)Press the SET key to shift to the next parameter.

(9)Re-set Pr. 79 "operation mode" according to the operation mode to be used.
Note: 1. If the Pr. 903 or Pr. 905 (gain adjustment) value is changed, the Pr. 20 value
does not change.
2. When the Pr. 903 or Pr. 905 value is set, the value of Pr. 38 "frequency at
5V (10V) input" or Pr. 39 "frequency at 20mA input" changes automatically.
CAUTION
Be careful when setting the bias frequency at 0V to any value other than
"0". Even without the speed command, the motor will start running at the
set frequency by merely switching on the start signal.
162
C CHAPTER
H A P T E R 55
PROTECTIVE
PROTECTIVE
FUNCTIONS
FUNCTIONS
This chapter explains the "protective functions" of this

product.
5.1 Errors (Alarms) ....................................................... 163

5.2 Troubleshooting ...................................................... 172 Chapter 1
5.3 Precautions for Maintenance and Inspection .......... 175
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
5.1 Errors (Alarms)
PROTECTIVE FUNCTIONS
5 PROTECTIVE
5.1 FUNCTIONS
Errors (Alarms)
If any fault has occurred in the inverter, the corresponding protective function is
activated to bring the inverter to an alarm stop and automatically give the
corresponding error (alarm) indication on the optional control panel or the panel
display.
If your fault does not correspond to any of the following errors or if you have any other
problem, please contact your sales representative.
• Retention of alarm output signal .........When the magnetic contactor (MC) provided on the
power supply side of the inverter is opened at the
activation of the protective function, the inverter's
control power will be lost and the alarm output will not
be held.
• Alarm indication ..................................When the protective function is activated, the
operation panel display automatically switches to the
above indication.
• Resetting method ...............................When the protective function is activated, the inverter
output is kept stopped. Unless reset, therefore, the
inverter cannot restart. Switch power off once, then on
again; or apply RES signal for more than 0.1 seconds.
Kept on, "Err." appears (flickers) to indicate that the
inverter is being reset.
• When the protective function is activated, take the corresponding corrective action, then
reset the inverter, and resume operation.
5.1.1 Error (alarm) definitions
(1) Major faults

Operation Panel Indication E. OC1 FR-PU04 OC During Acc
Name Overcurrent shut-off during acceleration
When the inverter output current reaches or exceeds
Description approximately 200% of the rated current during acceleration,
the protective circuit is activated to stop the inverter output.
Check for sudden acceleration.
Check point
Check for output short-circuit/ground fault.
Corrective action Increase the acceleration time.
Operation Panel Indication E. OC2 FR-PU04 Stedy Spd OC

Name Overcurrent shut-off during constant speed
approximately 200% of the rated current during constant
Description
speed, the protective circuit is activated to stop the inverter
output.
Check for sudden load change.
Check point
Check for output short-circuit/ground fault.
Corrective action Keep load stable.
163
Operation Panel Indication E. OC3 FR-PU04 OC During Dec

Name Overcurrent shut-off during deceleration
approximately 200% of the rated current during deceleration
Description
(other than acceleration or constant speed), the protective
circuit is activated to stop the inverter output.
Check for sudden speed reduction.
Check point Check for output short-circuit/ground fault.
Check for too fast operation of motor's mechanical brake.
Increase the deceleration time.
Corrective action
Adjust brake operation.
Operation Panel Indication E. OV1 FR-PU04 OV During Acc

Name Regenerative overvoltage shut-off during acceleration
If regenerative energy causes the inverter's internal main
circuit DC voltage to reach or exceed the specified value, the
Description protective circuit is activated to stop the inverter output. It
may also be activated by a surge voltage generated in the
power supply system.
Check point Check for too slow acceleration.
Corrective action Decrease the acceleration time.
Operation Panel Indication E. OV2 FR-PU04 Stedy Spd OV

Name Regenerative overvoltage shut-off during constant speed
Description protective circuit is activated to stop the inverter output.
It may also be activated by a surge voltage generated in the
Check point Check for sudden load change.
• Keep load stable.
Corrective action • Use the brake unit or power return converter (FR-RC) as
required.
164
Operation Panel Indication E. OV3 FR-PU04 OV During Dec

Name Regenerative overvoltage shut-off during deceleration or stop
Description protective circuit is activated to stop the inverter output.
It may also be activated by a surge voltage generated in the
Check point Check for sudden speed reduction.
• Increase the deceleration time. (Set the deceleration time
which meets load GD2)
Corrective action • Decrease the braking duty.
• Use the brake unit or power return converter (FR-RC) as
required.
Operation Panel Indication E. THM FR-PU04 Motor Overload

Motor overload shut-off (electronic overcurrent protection)
Name
(Note 1)
The electronic overcurrent protection in the inverter detects
motor overheat due to overload or reduced cooling capability
Description during constant-speed operation to stop the inverter output.
When a multi-pole motor or two or more motors are run,
provide a thermal relay in the output side of the inverter.
Check point Check the motor for use under overload.
• Reduce the load weight.
Corrective action • For the constant-torque motor, change the Pr. 71 setting to
the constant-torque motor setting.
Operation Panel Indication E. THT FR-PU04 Inv. Overload

Inverter overload shut-off (electronic overcurrent protection)
Name
(Note 1)
If a current of more than 150% of the rated output current
flows and overcurrent shut-off does not occur (200% or less),
Description inverse-time characteristics cause the electronic overcurrent
protection to be activated to stop the inverter output in order
to protect the output transistors.
Corrective action Reduce the load weight.
Note: 1 Resetting the inverter initializes the internal heat integrating data of the
electronic overcurrent protection.
165
Operation Panel Indication E. FIN FR-PU04 H/Sink O/Temp

Name Fin overheat
If the cooling fin overheats, the overheat sensor is actuated
Description
to stop the inverter output.
• Check for too high ambient temperature.
Check point
• Check for cooling fin clogging.
Corrective action Set the ambient temperature to within the specifications.
Operation Panel Indication E. BE FR-PU04 Br. Cct. Fault (Note)

Name Brake transistor alarm detection (Note 2)
If a brake transistor fault occurs due to excessively large
regenerative energy from the motor, for example, that fault is
Description
detected to stop the inverter output. In this case, the inverter
power must be switched off immediately.
Check point Check for improper braking duty.
Change the inverter.
Corrective action
Please contact your sales representative.
Note: 2 This function is activated only when the optional brake resistor is connected.
Operation Panel Indication E. GF FR-PU04 Ground Fault

Name Output side ground fault overcurrent protection
This function stops the inverter output if a ground fault
overcurrent flows due to a ground fault which occurred in the
inverter's output (load) side. Use Pr. 249 "ground fault
Description
detection at start" to set whether the protective function is to
be activated or not. (In the 400V class, the protective function
is always active.)
Check point Check for a ground fault in the motor and connection cable.
Corrective action Remedy the ground fault portion.
Operation Panel Indication E. OHT FR-PU04 OH Fault

Name External thermal relay operation (Note 3)
If the external thermal relay designed for motor overheat
protection or the internally mounted temperature relay in the
Description motor switches on (contacts open), the inverter output is
stopped. If the relay contacts are reset automatically, the
inverter will not restart unless it is reset.
• Check for motor overheating.
Check point • Check that the value of 7 (OH signal) is set correctly in any
of Pr. 180 to Pr. 183 (input terminal function selection).
5
Corrective action Reduce the load and operating duty.
Note: 3 The output terminals used must be allocated using Pr. 190 to Pr. 192. This
function is activated only when OH has been set to any of Pr. 180 to Pr. 183
(input terminal function selection).
166
Operation Panel Indication E. OLT FR-PU04 Stll Prev STP

Name Stall prevention
The running frequency has fallen to 0 by stall prevention
Description
activated. (OL while stall prevention is being activated.)
Corrective action Reduce the load weight.
Operation Panel Indication E. OPT FR-PU04 Option Fault

Name Option alarm
Stops the inverter output if the dedicated option used in the
inverter results in setting error or connection (connector)
fault.
Description
When the high power factor converter connection is selected,
this alarm appears if an AC power supply is connected to
R (L1), S (L2), T (L3).
Check point Check that the plug-in option connector is plugged securely.
Connect the plug-in option securely.
Corrective action
Please contact your sales representative.
Operation Panel Indication E. PE FR-PU04 Corrupt Memory

Name Parameter storage device alarm
A fault occurred in parameters stored (example: E2PROM
Description
fault).
Check point Check for too many number of parameter write times.
Corrective action Change the inverter.
Operation Panel Indication E. PUE FR-PU04 PU Leave Out

Name Parameter unit disconnection
This function stops the inverter output if communication
between the inverter and PU is suspended, e.g. the PU is
disconnected, when "2", "3", "16" or "17" was set in Pr. 75.
Description This function stops the inverter output if the number of
successive communication errors is greater than the number
of permissible retries when the Pr. 121 value is "9999" for
RS-485 communication from the PU connector.
• Check for loose fitting of the operation panel or FR-PU04.
Check point
• Check the Pr. 75 setting.
Corrective action Fit the operation panel and FR-PU04 securely.
167
Operation Panel Indication E. RET FR-PU04 Retry No Over

Name Retry count exceeded
If operation cannot be resumed properly within the number of
Description
retries set, this function stops the inverter output.
Check point Find the cause of alarm occurrence.
Eliminate the cause of the error preceding this error
Corrective action
indication.
Operation Panel Indication E. CPU FR-PU04 CPU Fault

Name CPU error
If the arithmetic operation of the built-in CPU does not end
Description within a predetermined period, the inverter self-determines it
as an alarm and stops the output.
Check point 
Corrective action Please contact your sales representative.
Operation Panel Indication E. LF FR-PU04 E. LF

Name Output phase failure protection
This function stops the inverter output if one of the three
Description phases (U, V, W) on the inverter's output side (load side)
results in open phase.
Check point Check the wiring (Check the motor for a fault.)
Corrective action Wire the cables properly.
(2) Minor fault
Operation Panel Indication FN FR-PU04 Fan Failure

Name Fan fault
For the inverter which contains a cooling fan, FN appears on
the operation panel when the cooling fan stops due to a fault
Description
or operates differently from the setting of Pr. 244 "cooling fan
operation selection".
Check point Check the cooling fan for a fault.
Corrective action Change the fan.
168
(3) Warnings
Operation Panel Indication OL FR-PU04 OL (Stll Prev STP)
Name Stall prevention (overcurrent)
During If a current of more than 150% (Note 4) of
acceleration the rated inverter current flows in the
motor, this function stops the increase in
frequency until the overload current
reduces to prevent the inverter from
resulting in overcurrent shut-off. When the
overload current has reduced below 150%,
this function increases the frequency
again.
constant-speed the rated inverter current flows in the
operation motor, this function lowers the frequency
until the overload current reduces to
Description
prevent overcurrent shut-off. When the
this function increases the frequency up to
the set value.
deceleration the rated inverter current flows in the
motor, this function stops the decrease in
frequency until the overload current
reduces to prevent the inverter from
resulting in overcurrent shut-off. When the
this function decreases the frequency
again.
The acceleration/deceleration time may change.
Increase the stall prevention operation level with Pr. 22 "stall
Corrective action
prevention operation level", or disable stall prevention with
Pr. 156 "stall prevention operation selection".
Note: 4 The stall prevention operation current can be set as desired. It is factory-set to
150%.
Operation Panel Indication oL FR-PU04 oL

Name Stall prevention (overvoltage)
During If the regenerative energy of the motor
deceleration increases too much to exceed the brake
capability, this function stops the decrease
Description
in frequency to prevent overvoltage shut-
off. As soon as the regenerative energy
has reduced, deceleration resumes.
Check point Check for sudden speed reduction.
The deceleration time may change. Increase the deceleration
Corrective action
time using Pr. 8 "deceleration time"
169
Operation Panel Indication PS FR-PU04 PS

Name PU stop
STOP
A stop made by pressing the RESET key of the PU has been
Description
set in Pr. 75 "PU stop selection".
STOP
Check for a stop made by pressing the RESET key of the
Check point
operation panel during external operation.
Corrective action Refer to page 105.
Operation Panel Indication Err.

This alarm appears if:
• The RES signal is on;
• You attempted to set any parameter value in the external
operation mode;
• You attempted to change the operation mode during
operation;
Description • You attempted to set any parameter value outside its
setting range.
• You attempted to set any parameter value during operation
(while signal STF or STR is ON).
• You attempted to set any parameter value while parameter
write is being inhibited in Pr. 77 "parameter write inhibit
selection".
Corrective action Perform operation correctly.
170
5.1.2 To know the operating status at the occurrence of alarm

When any alarm has occurred, the display automatically switches to the indication of
the corresponding protective function (error). By pressing the MODE key at this point
without resetting the inverter, the display shows the output frequency. In this way, it is
possible to know the running frequency at the occurrence of the alarm. It is also
possible to know the current in the same manner. However, these values are not
stored in memory and are erased when the inverter is reset.
5.1.3 Correspondence between digital and actual characters

There are the following correspondences between the actual alphanumeric characters
and the digital characters displayed on the control panel (FR-PA02-02):
Actual Display Actual Display Actual Display
0 A M
1 B N
2 C O
3 D °
4 E P
5 F S
6 G T
7 H U
8 I V
9 J r
L -
5.1.4 Resetting the inverter
The inverter can be reset by performing any of the following operations. Note that the
electronic overcurrent protection's internal heat calculation value and the number of
retries are cleared (erased) by resetting the inverter.
STOP
Operation 1: ....... Using the control panel (FR-PA02-02), press the RESET key to reset the
inverter. (This may only be performed when the inverter protective
function (major fault) is activated.)
Operation 2: ....... Switch power off once, then switch it on again.
Operation 3: ....... Switch on the reset signal (RES).
171
5.2 Troubleshooting
5.2 Troubleshooting
POINT: Check the corresponding areas. If the cause is still unknown, it is

recommended to initialize the parameters (return to factory settings), re-set
the required parameter values, and check again.
5.2.1 Motor remains stopped

1) Check the main circuit
y Check that a proper power supply voltage is applied (control panel display is
provided).
y Check that the motor is connected properly.
2) Check the input signals
y Check that the start signal is input.
y Check that both the forward and reverse rotation start signals are not input.
y Check that the frequency setting signal is not zero.
y Check that the AU signal is on when the frequency setting signal is 4 to 20mA.
y Check that the output stop signal (MRS) or reset signal (RES) is not on.
3) Check the parameter settings
y Check that the reverse rotation prevention (Pr. 78) is not selected.
y Check that the operation mode (Pr. 79) setting is correct.
y Check that the bias and gain (Pr. 902 to Pr. 905) settings are correct.
y Check that the starting frequency (Pr. 13) setting is not greater than the
running frequency.
y Check that various operational functions (such as three-speed operation),
especially the maximum frequency (Pr. 1), are not zero.
y Check that the manufacturer setting parameter Pr. 146 = 1.
4) Check the load
y Check that the load is not too heavy.
y Check that the shaft is not locked.
5) Others
y Check that the ALARM lamp is off.
y Check that the control panel display does not show an error (e.g. E.OC1).
y Check that the Pr. 15 "jog frequency" setting is not lower than the Pr. 13
"starting frequency" value.
5.2.2 Motor rotates in opposite direction

y Check that the phase sequence of output terminals U, V and W is correct. 5
y Check that the start signals (forward rotation, reverse rotation) are connected
properly.
172
5.2.3 Speed greatly differs from the setting

y Check that the frequency setting signal is correct. (Measure the input signal
level.)
y Check that the following parameter settings are correct (Pr. 1, Pr. 2, Pr. 38,
Pr. 39, Pr. 245, Pr. 902 to Pr. 905, Pr. 19).
y Check that the input signal lines are not affected by external noise. (Use shielded
cables)
5.2.4 Acceleration/deceleration is not smooth

y Check that the acceleration and deceleration time settings are not too short.
y Check that the torque boost setting is not too large to activate the stall prevention
function.
5.2.5 Motor current is large

y Check that the torque boost setting is not too large.
5.2.6 Speed does not increase

y Check that the maximum frequency setting is correct.
y Check that the load is not too heavy. (In agitators, etc., load may become heavier
in winter.)
y Check that the torque boost setting is not too large to activate the stall prevention
function.
y Check that the brake resistor is not connected to terminals P (+) - P1 accidentally.
5.2.7 Speed varies during operation

When slip compensation is selected, the output frequency varies with load fluctuation
between 0 and 2Hz. This is a normal operation and is not a fault.
1) Inspection of load
y Check that the load is not varying.
2) Inspection of input signal
y Check that the frequency setting signal is not varying.
y Check that the frequency setting signal is not affected by noise.
3) Others
y Check that the setting of the applied motor capacity (Pr. 80) is correct for the
inverter capacities in general-purpose magnetic flux vector control.
y Check that the wiring length is within 30m (98.42 feet) in general-purpose
magnetic flux vector control.
y Check that the wiring length is correct in V/F control.
173
5.2.8 Operation mode is not changed properly

If the operation mode does not change correctly, check the following:
1. External input signal ...Check that the STF or STR signal is off.
When it is on, the operation mode cannot be changed.
2. Parameter setting .......Check the Pr. 79 setting.
When the setting of Pr. 79 "operation mode selection" is
"0", switching input power on places the inverter in the
external operation mode. By pressing the MODE key three
times, the external operation mode changes into the PU
operation mode. For any other setting (1 to 8), the
operation mode is limited according to the setting.
(For details of Pr. 79, refer to page 109.)
5.2.9 Control panel display is not operating

y Make sure that the control panel is connected securely with the inverter.
5.2.10 POWER lamp is not lit

y Make sure that the wiring and installation are correct.
5.2.11 Parameter write cannot be performed

y Make sure that operation is not being performed (signal STF or STR is not ON).
y Make sure that you pressed the SET key ( WRITE key) for longer than 1.5 seconds.
y Make sure that you are not attempting to set the parameter outside the setting
range.
y Make sure that you are not attempting to set the parameter in the external
operation mode.
y Check Pr. 77 "parameter write inhibit selection".
174
5.3 Precautions for Maintenance and Inspection
5.3 Precautions for Maintenance and Inspection
The transistorized inverter is a static unit mainly consisting of semiconductor devices.

Daily inspection must be performed to prevent any fault from occurring due to adverse
influence by the operating environment, such as temperature, humidity, dust, dirt and
vibration, changes in the parts with time, service life, and other factors.
5.3.1 Precautions for maintenance and inspection

For some short time after the power is switched off, a high voltage remains in the
smoothing capacitor. Therefore, when more than 10 minutes have elapsed after
power-off, make sure that the voltage across the main circuit terminals P (+) - N (−) of
the inverter is 30VDC or less using a meter, etc. Then, access the inverter for
inspection.
5.3.2 Check items
(1) Daily inspection

y 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
y During operation, check the inverter input voltages using a meter.
(2) Cleaning
Always run the inverter in a clean state.
When cleaning the inverter, gently wipe dirty areas with a soft cloth immersed in
neutral detergent or ethanol.
Note: Do not use solvent, such as acetone, benzene, toluene and alcohol, as they
will cause the inverter surface paint to peel off.
Do not use detergent or alcohol to clean the display and other sections of the
control panel as these sections do not like them.
5.3.3 Periodic inspection

Check the areas inaccessible during operation and requiring periodic inspection.
1) Cooling system: ....... Clean the air filter, etc.
2) Screws and bolts: .... These parts may become loose due to vibration, temperature
changes, etc. Check that they are tightened securely and
retighten as necessary.
3) Conductors and insulating materials: Check for corrosion and damage.
4) Insulation resistance: Measure.
5) Cooling fan, smoothing capacitor: Check and change if necessary.
175
5.3.4 Insulation resistance test using megger

1) Before performing the insulation resistance test using a megger on the external
circuit, disconnect the cables from all terminals of the inverter so that the test voltage
is not applied to the inverter.
2) For the continuity test of the control circuit, use a meter (high resistance range) and
do not use the megger or buzzer.
3) For the inverter, conduct the insulation resistance test on the main circuit only as
shown below and do not perform the test on the control circuit. (Use a 500VDC
megger.)
Motor
R (L1) Inverter U
Power supply S (L2) V IM
T (L3) W
500VDC
megger
Earth terminal
5.3.5 Pressure test

Do not conduct a pressure test. The inverter's main circuit uses semiconductors, which
may deteriorate if a pressure test is made.
176
5.3.6 Daily and Periodic Inspection

Interval
Inspection
Periodic*
Area of
Inspection
Daily
2 years
Description Method Criterion Instrum ent
1 year
Item
Ambient
temperature:
-10°C to +50°C
Check ambient (14°F to 122°F), Therm om eter,
Surrounding
environment
temperature, humidity, { Refer to page 12. non-freezing. hygrom eter,
dust, dirt, etc. Ambient recorder
humidity: 90%
General
or less, non-
condensing.
Overall unit
Check for unusual
vibration and noise.
{ Visual and auditory
checks.
No fault.
Within
Measure voltage
Power Check that main permissible AC Meter,
supply circuit voltage is { across inverter
terminals R-S-T (L1-
(DC) voltage digital
voltage normal. fluctuation (Refer multimeter
L2-L3).
to page 188).
(1) Check with megger { { (1) Disconnect all (1) 5MΩ or
(across main cables from more.
circuit terminals inverter and
and ground measure across
terminal). terminals R (L1), 500VDC
General (2) Check for loose { S (L2), T (L3), U, (2), (3) No class
screws and bolts. V, W and ground fault. megger
(3) Check for overheat { terminal with
on each part. megger.
(4) Clean. (2) Retighten.
(3) Visual check.
(1) Check conductors { (1), (2) Visual (1), (2) No
Conductors, for distortion. check. fault.
cables (2) C heck cable sheaths {
for breakage.
Main circuit
Terminal Check for damage. { Visual check No fault

block
D isconnect cables
from inverter and
Inverter m easure across
module
Converter
Check resistance
across terminals.
{ term inals R , S, T-P, N R efer to page
(L 1 , L 2 , L 3 - +, −), and 179.
Analog
meter
module across U , V, W -P (+),
N (−) w ith a m eter w ith
a 100 Ω range.
(1) Check for liquid { (1), (2) Visual (1), (2) No
leakage. check. fault.
(2) Check for safety {
Smoothing valve projection Capacity
capacitor and bulge. (3) Measure with (3) 85% or more meter
(3) Measure { capacity meter. of rated
electrostatic capacity.
capacity.
177
Main circuit Area of Inspection PROTECTIVE FUNCTIONS
Interval
Inspection Periodic*
Description Method Criterion Instrum ent
Daily
Item
2 years
1 year
(1) Check for chatter { (1) Auditory check. (1) No fault.
during operation.
Relay (2) Check for rough { (2) Visual check. (2) No fault.
surface on
contacts.
(1) Check balance of { (1) Measure voltage (1) Phase-to-
output voltages across inverter phase
across phases with output terminals voltage
Protective circuit
inverter operated U-V-W. balance

Control circuit
Digital
independently. within 4V
multimeter,
Operation (2) Perform sequence (8V) for
check protective { (2) Simulate 200V (400V).
rectifier
type
operation test to connection of (2) Fault must
voltmeter
make sure there is inverter occur
no fault in protective circuit because of
protective or output terminals. sequence.
display circuits.
(1) Check for unusual { (1) Turn by hand No unusual
Cooling
system
vibration and with power off. vibration and

Cooling fan noise. unusual noise.
(2) Check for loose { (2) Visual check.
connection.
(1) Check for LED { (1) Lamps indicate (1) Check that
lamp blown. indicator lamps lamps are lit.
Display
on panel.
{
Display
(2) Clean. (2) Clean with rag.

Check that reading is { Check reading of Must satisfy Voltmeter,
normal. meters on panel. specified and ammeter,
Meter
management etc.
values.
(1) Check for unusual { (1) Auditory, (1), (2) No fault.
vibration and sensory, visual
noise. checks.
General (2) Check for unusual { (2) Check for
odor. unusual odor due
Motor
to overheats,
damage, etc.
Check with megger { Disconnect cables 5MΩ or more. 500V
Insulation (across terminals and from U, V, W, megger
resistance ground terminal). including motor
cables.
Note: The values within the parentheses are for the 400V class.
* For periodic inspection, contact you nearest Mitsubishi sales representative.
5
178
z Checking the inverter and converter modules
<Preparation>
(1)Disconnect the external power supply cables (R, S, T (L1, L2, L3)) and motor cables
(U, V, W).
(2)Prepare a meter. (Use 100Ω range.)
<Checking method>
Change the polarity of the meter alternately at the inverter terminals R (L1), S (L2),
T (L3), 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 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
Value Value
R (L1) P (+) Discontinuity R (L1) N (−) Continuity
D1 D4
P (+) R (L1) Continuity N (−) R (L1) Discontinuity
Converter
module
S (L2) P (+) Discontinuity S (L2) N (−) Continuity

D2 D5
P (+) S (L2) Continuity N (−) S (L2) Discontinuity
T (L3) P (+) Discontinuity T (L3) N (−) Continuity
D3 D6
P (+) T (L3) Continuity N (−) T (L3) Discontinuity
U P (+) Discontinuity U N (−) Continuity
Inverter module
TR1 TR4
P (+) U Continuity N (−) U Discontinuity
V P (+) Discontinuity V N (−) Continuity
TR2 TR6
P (+) V Continuity N (−) V Discontinuity
W P (+) Discontinuity W N (−) Continuity
TR5 TR2
P (+) W Continuity N (−) W Discontinuity
Converter module P (+) Inverter module
TR1 TR3 TR5
D1 D2 D3
R (L1) C U
S (L2) V
T (L3) W
D4 D5 D6
TR4 TR6 TR2
N (-)
Note: The FR-E510W-0.1K to 0.75K-NA do not have T (L3), D3 and D6.
179
5.3.7 Replacement of parts

The inverter consists of many electronic parts such as semiconductor devices.
The following parts may deteriorate with age because of their structural or physical
characteristics, leading to reduced performance or failure of the inverter. For preventive
maintenance, the parts must be changed periodically.
Standard Replacement
Part Name Description
Interval
Cooling fan 2 to 3 years Change (as required)
Smoothing capacitor in main circuit 5 years Change (as required)
Change the board
Smoothing capacitor on control board 5 years
(as required).
(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.
When unusual noise and/or vibration is noticed during inspection, the cooling fan must
be changed immediately. When you need to change the cooling fan, contact the
nearest Mitsubishi FA center.
Inverter Model No. Fan Type
FR-E520-0.75K-NA MMF-04C24DS BKO-CA1382H01
FR-E520-1.5K, 2.2K, 3.7K-NA MMF-06D24DS BKO-C2461H07
FR-E520-5.5K, 7.5K-NA MMF-06D24ES BKO-CA1027H08
FR-E540-1.5K, 2.2K, 3.7K-NA MMF-06D24ES-FC4 BKO-CA1027H09
FR-E540-5.5K, 7.5K-NA MMF-06D24ES FC5 BKO-CA1027H10
z Removal
1) Remove the wiring cover. (Refer to page 7.)
2) Unplug the fan connector.
The cooling fan is plugged into the cooling fan
connector beside the inverter terminal block.
Unplug the connector and separate the inverter
from the cooling fan.
3) Remove the cooling fan cover.
Push the cover in the direction of arrow and pull it
down.
4) Remove the cooling fan and cooling fan cover.
The cooling fan is secured by the fixing catches.
5
Disengage the fixing catches to remove the
cooling fan and cooling fan cover.
180

1) Remove the front cover
(Refer to page 5.).
2) Unplug the fan connector.
The cooling fan is connected to
the cooling fan connector beside
the main circuit terminal block of
the inverter. Unplug the
connector.
Fan connector
3) Remove the inverter and cooling

fan.
Push in the direction of arrow A
and pull out in the direction of
arrow B.
A B
A
4) Remove the cooling fan and

cooing fan cover.
The cooling fan is secured by the
fixing catches. Cooling fan
You can remove the cooling fan
and cooling fan cover by
disengaging the fixing catches.
Cooling fan cover
181
z Reinstallation
1) After confirming the orientation of the fan,
reinstall the fan to the cover so that the
arrow on the left of "AIR FLOW" faces in AIR FLOW
the opposite direction of the fan cover.

Note: If the air flow is set in the wrong
direction, the inverter life can be
shorter.
2) Reinstall the fan cover to the inverter. (For 5.5K, 7.5K-NA)
Run the cable through the wiring groove to
prevent it from being caught between the
chassis and cover.
3) Reconnect the cable to the connector.
4) Reinstall the wiring cover.
*Wire the cables using care so that they

are not caught by the cooling fan.
182

1) After confirming the orientation of
the fan, reinstall the fan to the
↑AIR FLOW
cover so that the arrow on the left
of "AIR FLOW" faces in the
opposite direction of the fan cover.
Note: If the air flow is set in the
wrong direction, the
inverter life can be shorter.
2) Reinstall the fan cover to the

inverter. Wiring groove
Run the cable through the wiring
groove to prevent it from being
caught between the chassis and
cover.
3) Reconnect the cable to the

connector.
Fan connector
4) Reinstall the inverter front cover.
183
(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. When the inverter is
operated in an ordinary, air-conditioned environment, change the capacitors about
every 5 years. When 5 years have 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 remarkable warp and extreme crack)
3) Appearance, external cracks, discoloration, leakage.
When the measured capacitance of the capacitor has reduced below 85% of the
rating, change the capacitor.
When you need to change the capacitors, contact the nearest Mitsubishi FA center.
184
5.3.8 Measurement of main circuit voltages, currents and powers

z Measurement of voltages and currents
Since the voltages and currents on the inverter power supply and output sides include
harmonics, accurate measurement depends on the instruments used and circuits
measured.
When instruments for commercial frequency are used for measurement, measure the
following circuits using the instruments given on the next page.
Three-phase 200V
power input
Three-phase 400V
power input
Input Output
voltage voltage
Input
Output
current
current
Single-phase 100V
power input
Inverter
Ar W11 R (L1) U Au W12
Vr Vu
3-phase As W12 S (L2) V Av To motor
power Vv
Vs
At W13 T (L3) W Aw W22
Vt Vw
P (+) N (-)
2 5
V
+ −
Instrument types (Note 2)
Typical Measuring Points and Instruments
Note: 1. Use FFT (Fast Fourier Transforms) to measure the output voltage
accurately.
It cannot be measured accurately with a meter or general instrument.
2. For FR-E510W-0.1K to 0.75K-NA do not use At, Vt, Vs and W13.
185
Measuring Points and Instruments

Measuring Remarks
Item Measuring Point
Instrument (Reference Measured Value)
Power supply Is the commercial power supply
Across R-S (L1-L2), S-T (L2- Moving-iron type AC
voltage within permissible variation of AC
L3) and T-R (L3-L1) voltmeter
(V1) voltage (refer to page 188).
Power supply
R, S and T line currents Moving-iron type AC
side current
(L1, L2 and L3 line currents) ammeter
(I1)
Power supply At R (L1), S (L2) and T (L3), Electrodynamic type
P1 = W11 + W12 + W13
side power and across R-S (L1-L2), S-T single-phase
(3-wattmeter method)
(P1) (L2-L3) and T-R (L3-L1) wattmeter
Calculate after measuring power supply voltage, power supply side current and power
Power supply supply side power.
side power factor P1
(Pf1) Pf1 = × 100%
3 V1 × I1
Output side (Note 1)
Difference between phases is within
voltage Across U-V, V-W and W-U (Cannot be measured
±1% of maximum output voltage.
(V2) by moving-iron type)
Current should be equal to or less
Output side
Moving-iron type AC than rated inverter current.
current U, V and W line currents
ammeter (Note 2) Difference between phases is 10%
(I2)
or lower.
Output side Electrodynamic type P2 = W21 + W22
At U, V and W, and across
power single-phase 2-wattmeter method (or 3-wattmeter
U-V and V-W
(P2) wattmeter method)
Output side Calculate in similar manner to power supply side power factor.
power factor P2
Pf2 = × 100%
(Pf2) 3 V2 × I2
Inverter LED display is lit. 1.35 × V1
Moving-coil type
Converter output Across P-N (+ - −) Maximum 380V (760V) during
(such as tester)
regenerative operation
"5" is com m on.

Frequency Across 2 (positive)-5 0 to 5V/0 to 10VDC
setting signal Across 4 (positive)-5 4 to 20mADC
Frequency
setting power Across 10 (positive)-5 5VDC
supply
Approximately 5VDC at
maximum frequency (without
frequency meter)
T1
Moving-coil type
SD is common.
(Meter, etc. may be

used) 8VDC
Across FM (positive)-SD (Internal resistance:
50kΩ or larger) T2
Frequency meter Pulse width T1:
signal Adjusted with Pr. 900
Pulse cycle T2:
Set with Pr. 55
(Valid for frequency monitor-
ing only)
com m on.
Approximately 10DVC at
"5" is
Across AM (+)-5 maximum frequency (without

frequency meter)
Start signal Across STF, STR, RH, RM, Moving-coil type
common.
Select signal RL, MRS, RES-SD (Meter, etc. may be

SD is
20 to 30VDC when open.

Reset Across RES (positive)-SD used)
ON voltage: 1V or less
Output stop Across MRS (positive)-SD
(Internal resistance:
50kΩ or larger)
5
Continuity check
Across A-C Moving-coil type <Normal> <Fault>
Alarm signal
Across B-C (such as a meter) A cross A -C : D iscontinuity C ontinuity
A cross B -C : C ontinuity D iscontinuity
186
Note: 1. Use FFT to measure the output voltage accurately. It can not be measured
accurately with a meter or general instrumentation.
2. When the carrier frequency exceeds 5kHz, do not use the instrument because
overcurrent losses occurring in the metallic parts inside the instrument will
increase and may lead to burnout.
In this case, use an approximate effective value type instrument.
* The value within the parentheses is for the 400V class.
187
C CHAPTER
H A P T E R 66
S SPECIFICATIONS
P E C IF IC A T IO N S
This chapter provides the "specifications" of this product.
Always read the instructions before using the equipment
6.1 Standard Specifications .......................................... 188
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
6.1 Standard Specifications
SPECIFICATIONS
6 SPECIFICATIONS
6.1 Standard Specifications
6.1.1 Model specifications
(1) 3-phase 200V power supply

Type FR-E520- -NA 0.1K 0.2K 0.4K 0.75K 1.5K 2.2K 3.7K 5.5K 7.5K
Applicable motor capacity kW 0.1 0.2 0.4 0.75 1.5 2.2 3.7 5.5 7.5
(Note 1) HP 1/8 1/4 1/2 1 2 3 5 7.5 10
Rated capacity (kVA) (Note 2) 0.3 0.6 1.2 2.0 3.2 4.4 7.0 9.2 12.6
0.8 1.5 3 5 8 11 17.5 24 33
Rated current (A) (Note 6)
Output
(0.8) (1.4) (2.5) (4.1) (7) (10) (16.5) (23) (31)

150% 60 seconds 200% 0.5 seconds
Overload capacity (Note 3)
(inverse-time characteristics)
Voltage (Note 4) Three phase, 200V to 240V 50Hz/60Hz
Rated input AC (DC) voltage, Three phase, 200V to 240V 50Hz/60Hz
frequency (280VDC, Note 7)
Power supply
Permissible AC (DC) voltage 170 to 264V 50Hz/60Hz

fluctuation (252 to 310VDC, Note 7)
Permissible frequency
±5%
fluctuation
Power supply system capacity
0.4 0.8 1.5 2.5 4.5 5.5 9 12 17
(kVA) (Note 5)
Protective structure (JEM1030) Enclosed type (IP20)
Cooling system Self-cooling Forced air cooling
0.6 0.6 0.8 1.0 1.7 1.7 2.2 4.4 4.9
Approximate weight (kg (lbs))
(1.32) (1.32) (1.76) (2.2) (3.75) (3.75) (4.85) (9.7) (10.8)
Note: 1. The applicable motor capacity indicated is the maximum capacity applicable
when a Mitsubishi 4-pole standard motor is used.
2. The rated output capacity indicated assumes that the output voltage is 230V.
3. The overload capacity indicated in % is the ratio of the overload current to the
inverter's rated current. For repeated duty, allow time for the inverter and
motor to return to or below the temperatures under 100% load.
4. The maximum output voltage cannot exceed the power supply voltage. The
maximum output voltage may be set as desired below the power supply
voltage.
5. The power supply capacity changes with the values of the power supply side
inverter impedances (including those of the input reactor and cables).
6. The rated output current in the parentheses applies when low acoustic noise
operation is to be performed at the ambient temperature higher than 40°C
(104°F) with the Pr. 72 (PWM frequency selection) value set to 2kHz or
higher.
7. When using a DC power supply
(1) The guideline for the power supply voltage fluctuation range is 280VDC
±10%, and usually use the power supply at or below 300VDC.
(2) When DC power is switched on, a larger inrush current flows than in AC
power. The number of power-on times should be minimized.
(3) 300VDC must be reserved to make the torque characteristic equal to when
AC power supply is used.
188
SPECIFICATIONS
(2) 3-phase 400V power supply

Type FR-E540- -NA 0.4K 0.75K 1.5K 2.2K 3.7K 5.5K 7.5K
Applicable motor capacity kW 0.4 0.75 1.5 2.2 3.7 5.5 7.5
(Note 1) HP 1/2 1 2 3 5 7.5 10
Rated capacity (kVA) (Note 2) 1.2 2.0 3.0 4.6 7.2 9.1 13.0
1.6 2.6 4.0 6.0 9.5
Rated current (A) (Note 6) 12 17
Output
(1.4) (2.2) (3.8) (5.4) (8.7)

150% 60 seconds 200% 0.5 seconds
(inverse-time characteristics)
Voltage (Note 4) Three phase, 380V to 480V 50Hz/60Hz
Rated input AC voltage,
frequency Three phase, 380V to 480V 50Hz/60Hz
Power supply
Permissible AC voltage
325 to 528 V 50Hz/60Hz
fluctuation
Within ±5%
fluctuation
Power supply system capacity
1.5 2.5 4.5 5.5 9 12 17
(kVA) (Note 5)
Cooling system Self-cooling Forced air cooling
1.9 1.9 2.0 2.1 2.1 3.8 3.8
Approximate weight (kg (lbs))
(4.19) (4.19) (4.41) (4.63) (4.63) (8.38) (8.38)
inverter's rated current. For repeated duty, allow time for the inverter and
motor to return to or below the temperatures under 100% load.
4. The maximum output voltage cannot exceed the power supply voltage. The
maximum output voltage may be set as desired below the power supply
voltage.
inverter impedances (including those of the input reactor and cables).
operation is to be performed at the ambient temperature higher than 40°C
(104°F) with the Pr. 72 (PWM frequency selection) value set to 2kHz or
higher.
6
189
SPECIFICATIONS
(3) Single-phase 100V power supply

Type FR-E510W- K-NA 0.1K 0.2K 0.4K 0.75K
Applicable motor capacity kW 0.1 0.2 0.4 0.75
(Note 1) HP 1/8 1/4 1/2 1
Rated capacity (kVA) (Note 2) 0.3 0.6 1.2 2
Rated output current (A) 0.8 1.5 3.0 5.0
Output
(Note 7) (0.8) (1.4) (2.5) (4.1)

150% 60 seconds 200% 0.5 seconds (inverse-time
characteristics)
Rated output voltage (Note 4) Three phase, 200V to 230V 50Hz/60Hz
Rated input AC voltage,
Single phase, 100V to 115V 50Hz/60Hz
frequency
Power supply
Permissible AC voltage
Single phase, 90V to 132V 50Hz/60Hz
fluctuation
Within ±5%
fluctuation
Power supply capacity (kVA)
0.5 0.9 1.5 2.5
(Note 5)
Cooling system Self-cooling
Approximate weight (kg(Ibs)) 0.6 (1.32) 0.6 (1.32) 1.0 (2.2) 1.7 (3.75)
Normally, the rated current (at 50Hz) of the motor applied should not exceed
the rated current.
inverter's rated output current. For repeated duty, allow time for the inverter
and motor to return to or below the temperatures under 100% load.
4. The output voltage provided cannot be more than twice the power supply
voltage.
inverter impedances (including those of the input reactor and cables). Use the
power supply capacity larger than the indicated.
6. Load applied to the motor will reduce the output voltage about 10 to 15%.
When using a general-purpose motor, it must be used under reduced load.
operation is to be performed at the ambient temperature higher than 40°C with
the Pr. 72 (PWM frequency selection) value set to 2kHz or higher.
190
SPECIFICATIONS
6.1.2 Common specifications

Soft-PWM control/high carrier frequency PWM control can be selected.
Control system V/F control or general-purpose magnetic flux vector control can be
selected.
Output frequency range 0.2 to 400Hz (starting frequency variable between 0 and 60Hz)
Across terminals 2-5: 1/500 of maximum set frequency (5VDC input),
Frequency Analog input
1/1000 (10VDC, 4-20mADC input)
setting
0.01Hz (less than 100Hz), 0.1Hz (100Hz or more) when digital setting
resolution Digital input
is made using the control panel
Analog input Within ±0.5% of maximum output frequency (25°C ±10°C (77°F±18°F))
Frequency
Within 0.01% of set output frequency when setting is made from
accuracy Digital input
control panel.
Voltage/frequency Base frequency set as required between 0 and 400Hz. Constant torque
characteristic or variable torque pattern can be selected.
150% or more (at 1Hz), 200% or more (at 3Hz) when general-purpose
Starting torque
magnetic flux vector control or slip compensation is selected
Torque boost Manual torque boost, 0 to 30% may be set.
0.01, 0.1 to 3600 s (acceleration and deceleration can be set
Acceleration/deceleration time
individually), linear or S-pattern acceleration/deceleration mode can be
setting
selected.
Regene-rative 0.1K, 0.2K ... 150% or more, 0.4K, 0.75K ... 100% or more,
Braking (Note 3) 1.5K ... 50% or more, 2.2K, 3.7K, 5.5K, 7.5K ... 20% or more
torque Operation frequency (0 to 120Hz), operation time (0 to 10 s), operation
DC dynamic brake
voltage (0 to 30%) variable
Control specifications
Current stall prevention Operation current level can be set (0 to 200% variable), presence or
operation level absence can be selected.
Voltage stall prevention
Operation level is fixed, presence or absence can be selected.
operation level
Fast-response current limit
Operation level is fixed, presence or absence can be selected.
level
Analog
0 to 5VDC, 0 to 10VDC, 4 to 20mADC.
Frequency input
setting signal Digital
Entered from control panel optional (FR-PA02 -02).
input
Forward and reverse rotation, start signal automatic self-holding input
Start signal
(3-wire input) can be selected.
Used to reset alarm output provided when protective function is
Alarm reset
activated.
Up to 15 speeds can be selected. (Each speed can be set
Multi-speed selection between 0 and 400Hz, running speed can be changed
Input signals
during operation from the control panel.)

Used to select second functions (acceleration time,
Second function selection deceleration time, torque boost, base frequency,
electronic overcurrent protection).
Instantaneous shut-off of inverter output (frequency, Use
Output stop
voltage). Pr. 180 to
Used to select input of frequency setting signal 4 to Pr. 183 for
Current input selection
20mADC (terminal 4). selection.
External thermal relay Thermal relay contact input for use when the inverter is
input stopped by the external thermal relay.
PU operation-external Used to switch between PU operation and external
operation switching operation from outside the inverter.
V/F-general-purpose Used to switch between V/F control and general-purpose
magnetic flux switching magnetic flux vector control from outside the inverter.
6
191
SPECIFICATIONS
Maximum/minimum frequency setting, frequency jump operation,

external thermal relay input selection, automatic restart operation after
Control specifications
Operation functions instantaneous power failure, forward/reverse rotation prevention, slip

compensation, operation mode selection, offline auto tuning function,
PID control, computer link operation (RS-485)
2 open collector output signals can be selected from inverter running,
Output signals
up to frequency, frequency detection, overload alarm, zero current

Operating status detection, output current detection, PID upper limit, PID lower limit, PID
forward/reverse rotation, operation ready, minor fault and alarm, and 1
contact output (230VAC 0.3A, 30VDC 0.3A) can be selected.
1 signal can be selected from output frequency, motor current and
For meter
output voltage. Pulse train output (1440 pulses/second/full scale).
Operating
Output voltage, output current, set frequency, running.
Control panel status
Display
display Alarm Alarm definition is displayed when protective function is activated. 4

definition alarm definitions are stored.
LED display Power application (POWER), Alarm (ALARM)
Overcurrent shut-off (during acceleration, deceleration, constant
speed), regenerative overvoltage shut-off, undervoltage (Note 1),
instantaneous power failure (Note 1), overload shut-off (electronic
overcurrent protection), brake transistor alarm, output short circuit, stall
Protective/alarm functions
prevention, brake resistor overheat protection, fin overheat, fan failure
(Note 4), parameter error, PU disconnection, ground fault over current
protection (400V class), starting-time ground fault overcurrent
protection (other than 400V class) .
Ambient temperature Constant torque : -10°C to +50°C (14°F to 122°F) (non-freezing)
Environment
Storage temperature
-20°C to +65°C (-4°F to 149°F)
(Note 2)
Ambience Indoors (no corrosive and flammable gases, oil mist, dust and dirt.)
Maximum 1000m (3280.80 feet) above sea level for standard
operation.
Altitude, vibration
After that derate by 3% for every extra 500m (1640.40 feet) up to
2500m (8202.00 feet) (91%).
Note: 1. When undervoltage or instantaneous power failure has occurred, alarm

display or alarm output is not provided but the inverter itself is protected.
Overcurrent, regenerative overvoltage or other protection may be activated
at power restoration according to the operating status (load size, etc.)
2. Temperature applicable for a short period in transit, etc.
3. The braking torque indicated is a short-duration average torque (which
varies with motor loss) when the motor alone is decelerated from 60Hz in
the shortest time and is not a continuous regenerative torque. When the
motor is decelerated from the frequency higher than the base frequency,
the average deceleration torque will reduce. Since the inverter does not
contain a brake resistor, use the optional brake resistor when regenerative
energy is large. (The optional brake resistor cannot be used with 0.1K and
0.2K.) A brake unit (BU) may also be used.
4. Not provided for the FR-E540-0.4K, 0.75K-NA, FR-E520-0.1K to 0.4K-NA
and FR-E510W-0.1K to 0.75K-NA which are not equipped with a cooling
fan.
192
SPECIFICATIONS
6.1.3 Outline drawings
(1) 200V class, 100V class

z FR-E520-0.1K-NA, 0.2K-NA, 0.4K-NA, 0.75K-NA
z FR-E510W-0.1K-NA, 0.2K-NA, 0.4K-NA
5 (0.20)
φ5 hole
118 (4.65)
128 (5.04)
(0.20)
5
5 (0.20) 4 (0.16)
6 (0.24) 56 (2.20) 6 (0.24) 11 55 (2.17) D1
(0.43)
68 (2.68) D
Capacity D D1 D2
FR-E520-0.1K-NA 76 (2.99) 10 (0.39) 55 (2.17)
FR-E520-0.2K-NA 76 (2.99) 10 (0.39) 55 (2.17)
FR-E520-0.4K-NA 108 (4.25) 42 (1.65) 55 (2.17)
Wiring holes
FR-E520-0.75K-NA 128 (5.04) 62 (2.44) 55 (2.17)
FR-E510W-0.1K-NA 76 (2.99) 10 (0.39) 55 (2.17)
FR-E510W-0.2K-NA 106 (4.17) 10 (0.39) 85 (3.35)
FR-E510W-0.4K-NA 138 (5.43) 42 (1.65) 85 (3.35)
Note: FR-E520-0.75K-NA is provided with cooling fan.
(Unit: mm (inches))
6
193
SPECIFICATIONS
z FR-E520-1.5K-NA, 2.2K-NA
z FR-E510W-0.75K-NA
5 (0.20)
2-φ5 hole
118 (4.65)
128 (5.04)
(0.20)
8 (0.31)
5
5 (0.20)
29 (1.14) 68 (2.68) 11 (0.43) 11 D2 D1
6 (0.24) 96 (3.78) 6 (0.24) (0.43) D
108 (4.25)
Wiring holes
Inverter Model D D1 D2
FR-E520-1.5K-NA,
131 (5.16) 65 (2.56) 55 (2.17)
2.2K-NA
Cooling
fan×1 FR-E510W-0.75K-NA 155 (6.10) 59 (2.32) 85 (3.35)
Note: FR-E510W-0.75K-NA is not equipped with a
cooling fan.
(Unit: mm (inches))
194
SPECIFICATIONS
z FR-E520-3.7K-NA
5 (0.20)
2-φ5 hole
118 (4.65)
128 (5.04)
(0.20)
5 (0.20)
5
82.5 5 (0.20)
(3.25) 68 (2.68) 19.5 (0.77)
11 (0.43) 55 (2.17) 72 (2.83)
55.5 (2.19) 114.5 (4.51) 138 (5.43)
6 (0.24) 158 (6.22) 6 (0.24)
170 (6.69)
Wiring holes
Cooling fan×2
(Unit: mm (inches))
6
195
SPECIFICATIONS
z FR-E520-5.5K-NA, 7.5K-NA
8 (0.31)
2-φ6 hole
260 (10.24)
244 (9.61)
16
8 (0.31)
6 (0.24) 96 (3.78) 68 (2.68) (0.63) 11 (0.43) 57.5 10 (0.39)

8 (0.31) 164 (6.46) 8 (0.31) 112.5 (4.43) (2.26)
180 (7.09) 170 (6.69)
Wiring holes
Cooling fan
(Unit: mm (inches))
196
SPECIFICATIONS
(2) 400V class

z FR-E540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-NA
6 (0.24)
2-φ5 hole
138 (5.43)
150 (5.91)
11 (0.43)
6 (0.24)
5 (0.20) 61 (2.40) D1
D
6 (0.24) 128 (5.04) 6 (0.24)

140 (5.51)
Inverter Type D D1
FR-E540-0.4K, 116 (4.57) 44 (1.73)
0.75K-NA
FR-E540-1.5K 136 (5.35) 64 (2.52)
to 3.7K-NA
Note: There is no cooling fan in the
Cooling fan × 1
FR-E540-0.4K and 0.75K-NA
(Unit: mm (inches))
197
SPECIFICATIONS
z FR-E540-5.5K, 7.5K-NA
6 (0.24)
2-φ5 hole
138 (5.43)
150 (5.91) 11 64 (2.52) 73 (2.87)
6 (0.24)
5
(0.20) (0.43) 148 (5.83)
6 208 (8.19) 6 (0.24)

(0.24) 220 (8.66)
Cooling fan × 2
(Unit: mm (inches))
198
APPENDIX
A P P E N D IX
This chapter provides "supplementary information" for use

of this product.
Appendix 1 Data Code List ......................................... 199

APPENDIX
APPENDIX 1 Data Code List
APPENDIX
Appendix 1 Data Code List
Data Code Link Parameter Extension

Func- Parameter
Name Setting
tion Number Read Write (Data Code 7F/FF)
0 Torque boost 00 80 0
1 Maximum frequency 01 81 0
2 Minimum frequency 02 82 0
Basic functions
3 Base frequency 03 83 0
4 Multi-speed setting (high speed) 04 84 0
5 Multi-speed setting (middle speed) 05 85 0
6 Multi-speed setting (low speed) 06 86 0
7 Acceleration time 07 87 0
8 Deceleration time 08 88 0
9 Electronic thermal O/L relay 09 89 0
DC injection brake operation
10 0A 8A 0
frequency
11 DC injection brake operation time 0B 8B 0
12 DC injection brake voltage 0C 8C 0
13 Starting frequency 0D 8D 0
14 Load pattern selection 0E 8E 0
15 Jog frequency 0F 8F 0
16 Jog acceleration/deceleration time 10 90 0
18 High-speed maximum frequency 12 92 0
19 Base frequency voltage 13 93 0
20 14 94 0
reference frequency
Acceleration/deceleration time
21 15 95 0
increments
22 Stall prevention operation level 16 96 0
Stall prevention operation level at
23 17 97 0
double speed
24 Multi-speed setting (speed 4) 18 98 0
25 Multi-speed setting (speed 5) 19 99 0
26 Multi-speed setting (speed 6) 1A 9A 0
27 Multi-speed setting (speed 7) 1B 9B 0
29 Acceleration/deceleration pattern 1D 9D 0
30 Regenerative function selection 1E 9E 0
31 Frequency jump 1A 1F 9F 0
32 Frequency jump 1B 20 A0 0
33 Frequency jump 2A 21 A1 0
35 Frequency jump 3A 23 A3 0
37 Speed display 25 A5 0
38 Frequency at 5V (10V) input 26 A6 0
39 Frequency at 20mA input 27 A7 0
199
Func- Parameter
Name Setting
41 Up-to-frequency sensitivity 29 A9 0
functions
terminal
Output
42 Output frequency detection 2A AA 0

Output frequency detection for
43 2B AB 0
reverse rotation
Second acceleration/deceleration
Second functions
44 2C AC 0
time
45 Second deceleration time 2D AD 0
46 Second torque boost 2E AE 0
47 Second V/F (base frequency) 2F AF 0
Second electronic overcurrent
48 30 B0 0
protection
Control panel/PU main display
52 34 B4 0
functions
data selection
Display
54 FM terminal function selection 36 B6 0

55 Frequency monitoring reference 37 B7 0
56 Current monitoring reference 38 B8 0
Automatic
functions
57 Restart coasting time 39 B9 0

restart
58 Restart cushion time 3A BA 0

Additional
function
59 Remote setting function selection 3B BB 0
Shortest acceleration/deceleration
60 3C BC 0
mode
61 Reference current 3D BD 0
62 Reference current for acceleration 3E BE 0
63 Reference current for deceleration 3F BF 0
65 Retry selection 41 C1 0
Stall prevention operation level
Operation selection functions
66 42 C2 0
reduction starting frequency
Number of retries at alarm
67 43 C3 0
occurrence
68 Retry waiting time 44 C4 0
69 Retry count display erasure 45 C5 0
70 Special regenerative brake duty 46 C6 0
71 Applied motor 47 C7 0
72 PWM frequency selection 48 C8 0
73 0-5V/0-10V selection 49 C9 0
74 Filter time constant 4A CA 0
Reset selection/disconnected PU
75 4B CB 0
detection/PU stop selection
77 Parameter write disable selection 4D CD 0
Reverse rotation prevention
78 4E CE 0
selection
79 Operation mode selection 4F CF 0
200
Func- Parameter
Name Setting
80 Motor capacity 50 D0 0
General-purpose
vector control
magnetic flux
82 Motor exciting current 52 D2 0

83 Rated motor voltage 53 D3 0
84 Rated motor frequency 54 D4 0
90 Motor constant (R1) 5A DA 0
96 Auto-tuning setting/status 60 E0 0
117 Station number 11 91 1
118 Communication speed 12 92 1
Communication
119 Stop bit length/data length 13 93 1

120 Parity check presence/absence 14 94 1
functions
121 Number of communication retries 15 95 1

Communication check time
122 16 96 1
interval
123 Waiting time setting 17 97 1
CR, LF presence/absence
124 18 98 1
selection
128 PID action selection 1C 9C 1
129 PID proportional band 1D 9D 1
PID control
130 PID integral time 1E 9E 1

131 Upper limit 1F 9F 1
132 Lower limit 20 A0 1
PID action set point for PU
133 21 A1 1
operation
134 PID differential time 22 A2 1
Parameter unit language switch
Additional
145 2D AD 2
function
over
146 Parameter set by manufacture. Do not set.
150 Output current detection level 32 B2 1

detection
Current
151 Output current detection period 33 B3 1

152 Zero current detection level 34 B4 1
153 Zero current detection period 35 B5 1
156 38 B8 1
function
selection
Sub
158 AM terminal function selection 3A BA 1

Additional
function
160 User group read selection 00 80 2

monitor
Initial
171 Actual operation hour meter clear 0B 8B 2
173 User group 1 registration 0D 8D 2

functions
174 User group 1 deletion 0E 8E 2

User
175 User group 2 registration 0F 8F 2

201
Func- Parameter
Name Setting
180 RL terminal function selection 14 94 2
181 RM terminal function selection 15 95 2

assignment functions
182 RH terminal function selection 16 96 2

Terminal
183 MRS terminal function selection 17 97 2
190 RUN terminal function selection 1E 9E 2
191 FU terminal function selection 1F 9F 2
192 A, B, C terminal function selection 20 A0 2
232 Multi-speed setting (speed 8) 28 A8 2
233 Multi-speed setting (speed 9) 29 A9 2

Multi-speed operation
234 Multi-speed setting (speed 10) 2A AA 2
235 Multi-speed setting (speed 11) 2B AB 2
236 Multi-speed setting (speed 12) 2C AC 2
237 Multi-speed setting (speed 13) 2D AD 2
238 Multi-speed setting (speed 14) 2E AE 2
239 Multi-speed setting (speed 15) 2F AF 2
240 Soft-PWM setting 30 B0 2
244 Cooling fan operation selection 34 B4 2

Sub functions
245 Rated motor slip 35 B5 2
246 Slip compensation response time 36 B6 2

Constant-output region slip
247 37 B7 2
compensation selection
249 Ground fault detection at start 39 B9 2
selection
function
Stop
250 Stop selection 3A BA 2
338 Operation command right 26 A6 3

Computer
function
link
339 Speed command right 27 A7 3
340 Link start mode selection 28 A8 3
900 FM terminal calibration 5C DC 1
901 AM terminal calibration 5D DD 1

Calibration functions
902 Frequency setting voltage bias 5E DE 1
903 Frequency setting voltage gain 5F DF 1
904 Frequency setting current bias 60 E0 1
905 Frequency setting current gain 61 E1 1
990 Buzzer beep control 5A DA 9
991 LCD contrast 5B DB 9
202
REVISIONS
*The manual number is given on the bottom left of the back cover.
Print Date *Manual Number Revision

Jul., 1998 IB(NA)-66866-A First edition
Mar., 1999 IB(NA)-66866-B Additions
• Three-phase 400V power input specifications
May., 1999 IB(NA)-66866-C Additions
• Single-phase 100V power input specifications
PARAMETER UNIT
FR-PU04
FR-PU04
– INSTRUCTION MANUAL –
HEAD OFFICE:MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100

INSTRUCTION MANUAL
TYPE FR-PU04 EIBUN TORISETSU
CODE 1A2H30
IB (NA) 66807-A (9710) ROD Printed in Japan Specifications subject to change without notice.
Thank you for choosing the Mitsubishi transistorized inverter option unit.
This instruction manual gives handling information and precautions for use of this
equipment. Incorrect handling might cause an unexpected fault. Before using the
equipment, please read this manual carefully to use the equipment to its optimum.
Please forward this manual to the end user.
This section is specifically about safety matters.

Do not attempt to install, operate, maintain or inspect this product until you have read
through this instruction manual and appended documents carefully and can use the
equipment correctly. Do not use this product until you have a full knowledge of the
equipment, safety information and instructions.
In this instruction manual, the safety instruction levels are classified into "WARNING"
and "CAUTION".

WARNING conditions, resulting in death or severe injury.

CAUTION conditions, resulting in medium or slight injury, or may
cause physical damage only.
Note that the CAUTION level may lead to a serious consequence according to
conditions. Please follow the instructions of both levels because they are important to
personnel safety.
A-1
SAFETY INSTRUCTIONS
1. Electric Shock Prevention
WARNING
● Do not run the inverter with the front cover removed. Otherwise, you may access
exposed high voltage terminals or charging devices and get an electric shock.
● Any person who is involved in the wiring or inspection of this equipment should be
fully competent to do the work.
● Always install the inverter before wiring. Otherwise, you may get an electric shock
or be injured.
● Operate the keys with dry hands to prevent an electric shock.
● Do not subject the cables to scratches, excessive stress, heavy loads or pinching.
Otherwise, you may get an electric shock.
2. Additional Instructions
To prevent injury, damage or product failure, please note the following points.
(1) Transportation and mounting

CAUTION
● Do not install and operate the parameter unit (FR-PU04) if it is damaged or has
parts missing.
● Do not stand or rest heavy objects on this equipment.
● Check the inverter mounting orientation is correct.
● The parameter unit (FR-PU04) is a precision device. Do not drop it or subject it
to impact.
● Use the product under the following environmental conditions:
Environment Conditions
Ambient
-10℃ to +50℃ (non-freezing)
temperature
Storage
-20℃ to +65℃*
temperature
Indoors (free from corrosive gas, flammable gas, oil mist,
Ambience
dust and dirt)
Max. 1000m above sea level, 5.9m/S2 {0.6G} or less
Altitude, vibration
(conforming to JIS C0911)
*Temperatures applicable for a short time, e.g. in transit.
A-2
(2) Test operation and adjustment
CAUTION
● Before starting operation, confirm and adjust the parameters. A failure to do so
may cause some machines to make unexpected motions.
(3) Usage
WARNING
● The [STOP] key is only valid when function setting has been made. Provide an
emergency stop switch separately.
● Make sure that the start signal is off before resetting the alarm. A failure to do so
may restart the motor suddenly.
● Do not modify the equipment.
CAUTION
● When parameter clear or all parameter clear is performed, each parameter
returns to the factory setting. Re-set the required parameters before starting
operation.
(4) Corrective actions for alarm
CAUTION
● Provide safety backup devices, such as an emergency brake, to protect
machines and equipment from hazard if the parameter unit (FR-PU04) becomes
faulty.
(5) Disposal
CAUTION
● Treat as industrial waste.
(6) General instruction

All illustrations given in this manual may have been drawn with covers or safety
guards removed to provide in-depth description. Before starting operation of the
product, always return the covers and guards into original positions as specified and
operate the equipment in accordance with the manual.
A-3
- CONTENTS -
1 PRE-OPERATION INFORMATION 1
1.1 Structure ････････････････････････････････････････････････････････････････ 1

1.2 Installation and Removal ･･････････････････････････････････････････････････ 3
1.3 Pre-Operation Instructions･････････････････････････････････････････････････ 4
1.4 Related Parameters ･･････････････････････････････････････････････････････ 6
2 FUNCTIONS 7
2.1 Monitoring Function ･･････････････････････････････････････････････････････ 7

2.2 Setting and Changing the Parameter Values ････････････････････････････････ 11
2.3 Copy and Verify Functions････････････････････････････････････････････････ 27
2.4 Help Function ･･･････････････････････････････････････････････････････････ 29
3 OPERATION 55
3.1 Operation Modes････････････････････････････････････････････････････････ 55

3.2 PU Operation ･･･････････････････････････････････････････････････････････ 57
3.3 Combined Operation (Operation using external input signals and PU) ･･････････ 59
4 SPECIFICATIONS 62
4.1 Specifications･･･････････････････････････････････････････････････････････ 62
CHAPTER 1
PRE-OPERATION
INFORMATION
This chapter provides the basic "pre-operation information
(overview)" for use of this product.
Always read the instructions before using the equipment
1.1 Structure ･･････････････････････････････････････ 1

1.2 Installation and Removal ･････････････････････････ 3
1.3 Pre-Operation Instructions ･･･････････････････････ 4
1.4 Related Parameters ･････････････････････････････ 6
CHAPTER 1 PRE-OPERATION INFORMATION

CHAPTER 2 FUNCTIONS
CHAPTER 3 OPERATION
CHAPTER 4 SPECIFICATIONS
1
1.1 Structure
PRE-OPERATION INFORMATION
1PRE-OPERATION INFORMATION
1.1Structure
The parameter unit (FR-PU04) is an option unit designed to exclusively operate the
FR-A500 series inverters. Before using this equipment, confirm the rating plate on the
rear side and make sure that the parameter unit is intact.
Connector
[SET] key [EXT] key

[MON] key [PU] key
[ESC] key
[HELP] key
Model
[SHIFT] key [FWD] key
Number keys [REV] key
[WRITE] key [UP] and [DOWN] key

[READ] key [STOP/RESET] key
Key Description
[SET] key Used to select the parameter setting mode.
[MON] key Used to select the monitoring mode.
[ESC] key Operation cancel key.
[HELP] key Used to select the help mode.
[SHIFT] key Used to shift to the next item in the setting or monitoring mode.
Number keys Used to enter a frequency, parameter number or set value.
[EXT] key Used to select the external operation mode.
[PU] key Used to select the PU operation mode.
Used to keep on increasing or decreasing the running frequency. Hold
down to vary the frequency.
Press either of these keys on the setting mode screen to change the
parameter setting sequentially.
[UP] and [DOWN] On the monitoring, parameter or help menu screen, these keys are used
keys to move the cursor.
Hold down the [SHIFT] key and press either of these keys to advance or
return the display screen one page.
In the parameter copy or verify mode, the [DOWN] key is used as a verify
key.
[FWD] key Forward rotation command key.
[REV] key Reverse rotation command key.
[STOP/RESET] ・ Stop command key.
key ・ Used as a reset key when an alarm occurs.
・ Used to write a set value in the setting mode.
[WRITE] key ・ Used as a clear key in the all parameter clear or alarm history clear
mode.
1
Key Description
Used also as a decimal point key.
Used as a parameter number read key in the setting mode.
Used as an item select key on the menu screen such as parameter list or
[READ] key
monitoring list.
Used as an alarm definition display key in the alarm history display mode.
Used as a command voltage read key in the calibration mode.
16 character × 4 line liquid crystal display screen shows monitoring data,
Display such as frequency, motor current and I/O terminal states, as well as
troubleshooting guidance and other information.
Used for connection of the parameter unit with the inverter. You may
Connector either connect the unit directly or use the connection cable (FR-CB2□□)
for connection.
FR-PU04
Model
MITSUBISHI ELECTRIC CORPORATION
MADE IN JAPAN
Note: 1. Do not use a sharp-pointed tool to push the keys.

2. The display is a liquid crystal display. Do not press your fingers against the
display.
2
1.2 Installation and Removal
1.2 Installation and Removal
To ensure safety, install and remove the parameter unit after switching the power off.
(1) Installation
1) Remove the operation panel (FR-DU04) and accessory cover.
2) Fit the fixing holes of the parameter unit on the catches of the inverter and push the
parameter unit against the inverter, using the unit bottom as a support.
Fixing holes
Catches
3) When using the parameter unit

connection cable (FR-CB2□□) for
connection, insert the cable plugs
along the cable guides in the
connectors of the inverter and
parameter unit (FR-PU04) until
their stoppers are activated.
Note: The parameter unit must be installed when the front cover is fitted on the
inverter.
(2) Removal
Hold down the top button of the FR-
PU04 and pull the parameter unit
toward you, using the catches as a
support.
Catches
3
1.3 Pre-Operation Instructions
1.3Pre-Operation Instructions
1.3.1 Instructions for operating the parameter unit

When operating the parameter unit, note the following points to make proper settings
and enter correct values.
(1) Instructions for operation performed from the parameter unit
・ Operation from the parameter unit is only valid when the [PU] key is pressed with "0"
set in Pr. 79 "operation mode selection" or when PU operation or combined operation
is selected in Pr. 79.
・ In the monitoring mode, the running frequency cannot be set by direct setting (by
entering the frequency directly from the numeric keypad). Perform step setting (vary
the frequency sequentially by pressing the [UP]/[DOWN] key) and press the [WRITE]
key, or after pressing the [PU] key to exit from the monitoring mode, set the running
frequency.
Exiting from
Monitoring mode monitoring mode Frequency setting screen
PU DIRECTLY
Set 30.00Hz
30.00Hz
STF FWD PU 0～400
・ Jog operation cannot be performed when:

1) The motor is running; or
2) The jog frequency (Pr. 15) is less than the starting frequency (Pr. 13).
(2) Instructions for monitoring
・ When the motor is to be run in the PU operation mode, setting the running frequency
and then pressing the start key ([FWD] or [REV] key) automatically switches the PU
operation mode to the monitoring mode.
(3) Instructions for the operation modes
・ If the [PU] (or [EXT]) key is pressed, the mode cannot be switched when:
1) The motor is running;
2) The external operation start signal (STF or STR signal) is on; or
3) The setting of the operation mode selection parameter (Pr. 79) is other than "0".
・ If "0" is set in the operation mode selection parameter (Pr. 79), switching the inverter
power off, then on again or resetting the inverter switches it to the external operation
mode.
4
(4) Instructions for the number of digits and decimal point of an input value
・ A value of up to five digits may be entered. If the value entered is in more than five
digits, the most significant digit is ignored.
12345.6 ■2345.6
(Entered) ↑Ignored
(5) Instructions for writing set values

・ Set values may be written when the inverter is at a stop in the PU operation mode or
combined operation mode. They cannot be written in the external operation mode.
(Set values may be read in any mode.) Note that some parameters accept values
written in the external operation mode or when the inverter is running. Refer to the
instruction manual of the inverter used.
・ In addition, set values cannot be written when:
1) Parameter write inhibit (Pr. 77) has been selected;
2) Any parameter number that does not exist in the parameter list is selected;
3) The value entered is outside the setting range; or
・ If a parameter value cannot be written and (Example: Pr. 7 "acceleration time")
an error (×) is displayed, press the [ESC] 7 Acc. T1
key and set the value again. Setting Error
20000S
< ESC>
(6) Instructions for setting the running frequency

・ When using the [UP]/[DOWN] key to set the frequency (step setting), the frequency
may only be set within the range of the maximum and minimum frequencies.
(7) Other instructions
・ Refer to page 50 if the following message is
PU to Inverter
displayed when you switched the input power comms. Error
on (or reset the inverter): Inv. Reset ON
(8) Display at power-on

1) When the inverter's power is switched on, the
initial screen is shown on the display of the MITSUBISHI
parameter unit connected. (For about 3
seconds)
2) The parameter unit is put in the monitoring mode when it starts communication with
the inverter.
5
1.4 Related Parameters
1.4Related Parameters
Related parameters
Change the following parameter settings as required.
For the changing procedures, refer to page 11.
1.4.1 Parameter unit display language selection

By setting the Pr. 145 "parameter unit display language selection" value, you can
select the language displayed on the parameter unit.
Pr. 145 Setting Display Language
0 Japanese (factory setting of Japanese domestic version)
1 English (factory setting of NA version)
2 German
3 French
4 Spanish
5 Italian
6 Swedish
7 Finnish
1.4.2 Buzzer beep control

By setting the Pr. 990 "buzzer beep control" value, you can control the "beep" which
sounds when you press any of the parameter unit keys.
Pr.990 Setting Description
0 No sound
1 Sound generated (factory setting)
1.4.3 LCD contrast

By setting the Pr. 991 "LCD contrast" value, you can adjust the contrast of the parameter
unit LCD. Adjust the value with the [UP]/[DOWN] key to any brightness, and press the
[WRITE] key to enter that value.
Pr. 991 Setting Description
0 Bright
53 (factory setting)
63 Dark
Note: If the [WRITE] key is not pressed, the LCD contrast setting is not stored.
6
CHAPTER 2
FUNCTIONS
This chapter describes the basic "functions" for use of this
product.
2.1 Monitoring Function ･･･････････････････････････････ 7

2.2 Setting and Changing the Parameter Values･････････11
2.3 Copy and Verify Functions ････････････････････････27
2.4 Help Function ･･･････････････････････････････････29

CHAPTER 2 FUNCTIONS
CHAPTER 3 OPERATION
2
2.1 Monitoring Function
FUNCTIONS
2FUNCTIONS
2.1Monitoring Function
2.1.1 Display overview
Main monitor (3-digit integer part, 2 decimal places)

Any of 5 different monitor data types can be selected in sequence by
the [SHIFT] key. Also, by setting the Pr. 52 value, any of 21 different
data types (for the FR-A500) can be selected and displayed.
PU level meter
By setting the Pr. 53 value, any of 15 different data types (for the FR-A500)
can be selected and displayed. (The meter is graduated in 5% increments.)
No indication: Normal
OL: Stall (current)
oL: Stall (voltage)
120.00 OL
Hz
RB: Regenerative brake pre-alarm
TH: Electronic overcurrent protection pre-alarm
STF FWD PU PS: PU stop
Unit indication
Rotation direction monitoring

STF: Forward rotation
STR: Reverse rotation
---: No command or both
Operation mode indication
---: STF and STR on
EXT: External operation mode
PU: PU operation mode
Operating status indication EXTj: External jog mode
STOP: During stop PUj: PU jog mode
FWD: During forward rotation NET: Link operation mode
REV: During reverse rotation PU+E: Combined operation mode
JOGf: During jog forward rotation PRG: Programmed operation mode
JOGr: During jog reverse rotation
7
FUNCTIONS
2.1.2 SHIFT operation sequence on the PU main monitor

When "0" (factory setting) is set in Pr. 52 "PU main display data selection", merely
pressing the [SHIFT] key calls 5 different monitor screens in sequence. Among the five
monitor screens, the fifth monitor screen (selective monitor) can be selected from
among the frequency setting, running speed and other monitor screens using Pr. 52.
Switch power on or press [MON] key.

1
First priority screen

(Output frequency monitor)
0.00 Hz
--- STOP EXT
[SHIFT] [SHIFT]
2 6
0.00Hz
0.00A
(Output current monitor) 0.00 A (3-step monitor) 0.0V
--- STOP EXT
--- STOP EXT Up to 3 monitor
data types are
[SHIFT] displayed in line [SHIFT]
from top of the left
3 5
column.
OTHERS
(Output voltage monitor) 0.0 V (Selective monitor) <HELP> [HELP]
--- STOP EXT
Monitor
[SHIFT] [SHIFT] [SHIFT] selection
4
ALARM HISTORY 1 UVT 5
2 UVT 6
(Alarm history monitor)
<READ> READ 3 7
4 8
Note: 1. By pressing the [WRITE] key on any screen other than the alarm history,
selective or three-step monitor screen shown above, that monitor screen is
given the first priority. After power-on or when the [MON] key is pressed in
the setting or other mode to enter the monitoring mode, the first priority
screen is displayed first.
2. When "17" (load meter) or "18" (motor exciting current) is selected in Pr. 52,
the "output current monitor" shown above is switched to the "load meter" or
"motor exciting current". When "19" (position pulse), "20" (cumulative
operation time) or "23" (actual operation time) is selected in Pr. 52, the
"output voltage monitor" is switched to the "position pulse", "cumulative
operation time" or "actual operation time".
8
FUNCTIONS
2.1.3 Selecting a new monitor item in the selective monitoring mode

● Operation procedure (Example: Select the output current peak monitor
screen. (For FR-A500))
1) Press the [MON] key.
The parameter unit is placed in the monitoring mode.
0.00Hz
--- STOP PU
2) Press the [HELP] key.

1 Frequency
The monitoring list appears. 2 Current
3 Voltage
4 Alarm His
3) Hold down the [SHIFT] key and press the [DOWN] key ････Hold down [SHIFT]
twice, then release the [SHIFT] key, and press the and press the [DOWN]
[DOWN] key twice. or [UP] key to shift the
screen one page.
(Move the cursor to Peak Ι.)
4) Press the [READ] key.
The screen shown on the right appears.
(Note 1) A 0.00
STOP EXT
5) Press the [WRITE] key. ････Subsequently press

The screen in step 4) is set as the first priority screen. the [SHIFT] key to call
(Note 2) another monitor
screen.
Note: 1. The selective monitor screen is not yet the first priority screen in the above
step 4) when the [READ] key was pressed. Hence, the selected item is
erased from memory as soon as the power is switched off or another
operation mode (such as external operation) is selected.
In this case, the item must be selected again in the above procedure.
When you press the [WRITE] key to select the first priority screen, the
selected item is stored in memory.
2. In step 5) where the [WRITE] key was pressed in the above setting example,
the "output current peak" selected here is first displayed with priority when the
other operation mode is switched to the monitoring mode. To give first priority
to another monitor screen, press the [WRITE] key with that monitor screen
being displayed. That monitor screen is then set as the first priority screen.
(Note that the input terminal state monitor, output terminal state monitor and
simultaneous monitor cannot be set as the first priority screen.)
9
FUNCTIONS
● When "load meter", "motor exciting current", "position pulse"

"cumulative operation time" or "actual operation time" monitor screen
is selected
When the "load meter" or "motor exciting current" is selected by Pr. 52, the output
current monitor screen is switched to either of these monitor screens selected. When the
"position pulse", "cumulative operation time" or "actual operation time" is selected by Pr.
52, the output voltage monitor screen is switched to any of these screens selected.
Therefore, when any of these five items is selected, the output current or output voltage
monitor screen cannot be used.
When "position pulse"

When "load meter" or "cumulative operation time"
"motor exciting current" or "actual operation time"
monitor is selected, this monitor is selected, this
screen is switched screen is switched to the
to the selected screen. selected screen.
First priority screen
[SHIFT] [SHIFT]
[MON]
0.00 Hz 0.00 A 0.0 V
--- STOP EXT --- STOP EXT
--- STOP EXT
(Output current monitor) (Output voltage monitor)
(Output frequency monitor)
● When "current monitor" or "power monitor" is selected

Note that any current or power not more than 5% of the rated inverter current cannot be
detected and displayed.
Example: When a small motor is used with a large-capacity inverter (a 0.4kW motor is
used with a 55kW inverter), power monitor is inoperative.
10
2.2 Setting and Changing the Parameter Values
FUNCTIONS
2.2Setting and Changing the Parameter Values
The inverter has a number of parameters. Using the PU, you can choose parameters
required for operation and set and/or change their values as appropriate according to the
load and running conditions. For full information on the parameters, refer to the
"Parameter Function Details" in the corresponding inverter manual. Set "1" in Pr. 77
"parameter write inhibit selection" to inhibit write.
2.2.1 Direct setting

● Operation procedure (Reading and writing the Pr. 8 "deceleration time"
value)
1) Press the [PU] key.
DIRECTLY
The frequency setting screen appears. Set 0.00Hz
0～400
2) Press the [SET] key.

SETTING MODE
The parameter unit enters the parameter setting mode. Set Pr.NO.
FOR PR.List
<HELP>
3) Enter the required parameter number (8).

SETTING MODE
The screen on the right appears. Pr.NO.
8
<READ>

8 Dec.T1
The current setting appears on the display. 15.0S
0～3600
5) Enter the required value. (Example: To set to 180

8 Dec.T1
seconds) 15.0S
A new setting appears on the display. 180S
0～3600
(Note 1, 2)
6) Press the [WRITE] key.
8 Dec.T1
The setting is stored into memory. 180.0S
Note: If an error is displayed when you press the [WRITE]
Completed
key, refer to page 49.
7) Press the [SHIFT] key to move to the next parameter (Pr. 9) and call the current
setting. Then, press the [SHIFT] key to advance to the next parameter.
11
FUNCTIONS
Note: 1. If a setting error has occurred during a value entry, press the [ESC] key to
return to the status prior to that entry.
2. You can also use the [UP]/[DOWN] key to change the setting.
3. Set and/or change the parameter values in the PU operation mode. When
the PU operation indication is not shown, refer to page 54 and switch to the
PU operation mode.
Note that the values of some parameters may be set and/or changed in the
external operation and combined operation modes.
For such parameters, refer to the parameter list of the corresponding
inverter.
In addition to the above procedure, the help function may be used to call the parameter
list for setting. For more information, refer to page 29.
2.2.2 Function-by-function parameter setting

You can set and/or change only the parameters classified function-by-function.
1) Press [SET] key.

SETTING MODE
The parameter unit is put in the setting mode. Set Pr.NO
Pr.List→HELP
Pr.COPY→
2) Press [READ] key.

<List select>
Select "2 " with the [UP]/[DOWN] key and press the 1 User List
[READ] key to read. 2 Appl.Grp
3) Selecting the function

1 Shaft Trp
Select the function with the [UP]/[DOWN] key and press 2 F Command
the [READ] key to read. 3 Acc.Dec.
4 Shut Off
4) Select the parameter to be set with the [UP]/[DOWN] key

Pr.NO. Pr.NAME
and press the [READ] key to read the parameter setting Pr.NO. Pr.NAME
screen. Pr.NO. Pr.NAME
Pr.NO. Pr.NAME
5) Type the set value with the number keys and press the
Pr.NO Pr.NAME
[WRITE] key to enter.
12
FUNCTIONS
2.2.3 User parameter registration and deletion

Among all parameters, a total of 32 parameters can be registered to two different user
groups.
The registered parameters may only be accessed in the same procedure as in Pr. 160
"user group read selection".
(1) Confirmation
Confirm the user-registered parameters.
1) Press [SET] key.

SETTING MODE
The parameter unit is put in the parameter setting mode. Set Pr.NO
Pr.List→HELP
Pr.COPY→

<List select>
The parameter classification monitor screen appears. 1 User List
Select "1 " with the [UP]/[DOWN] key and press the 2 Appl.Grp
[READ] key to advance to the next monitor screen.
3) Select the user group with the [UP]/[DOWN] key and
1 User List1
press the [READ] key to read the parameters. 2 User List2
4) You can confirm the parameters registered to the user

Pr.NO. Pr.NAME
group. Pr.NO. Pr.NAME
Pr.NO. Pr.NAME
Pr.NO. Pr.NAME
13
FUNCTIONS
(2) Registration
1) Press [SET] key.

SETTING MODE
The parameter unit is put in the parameter setting mode. Set Pr.NO
Pr.List→HELP
Pr.COPY→
2) Enter the parameter number to be registered to the user

SETTING MODE
group with the number keys, and press the [READ] key to Pr.NO.
read the parameter setting.
<READ>
3) When changing the parameter setting, enter a new value

Pr.NO Pr.NAME
with the number keys and press the [WRITE] key to write.
4) Press [WRITE] key.

<Add Pr.List>
Select the user registration destination with the 1 User List1
[UP]/[DOWN] key and press the [READ] key to read. 2 User List2
3 Def Pr.
5) Select Yes: or No: with the [UP]/[DOWN] key and press

Add Pr.
the [WRITE] key to enter. User List1
Yes:Add
No :Cancel
14
FUNCTIONS
(3) Deletion
1) Press [SET] key.

SETTING MODE
The parameter unit is put in the setting mode. Set Pr.NO
Pr.List→HELP
Pr.COPY→

<List select>
Select "1 " with the [UP]/[DOWN] key and press the 1 User List
[READ] key to read. 2 Appl.Grp
3) Select the user group with the [UP]/[DOWN] key and

1 User List1
press the [READ] key to read the parameters. 2 User List2
4) Select the parameter to be deleted with the [UP]/[DOWN]

Pr.NO. Pr.NAME
key and press the [WRITE] key to enter. Pr.NO. Pr.NAME
Pr.NO. Pr.NAME
Pr.NO. Pr.NAME
5) Select Yes: or No: with the [UP]/[DOWN] key and press

Delet Pr.
the [WRITE] key to enter. User List
Yes:Delete
No :Cancel
15
FUNCTIONS
2.2.4 Calibration of the Meter (Frequency Meter)

● Using the parameter unit, you can calibrate a meter connected to
terminal FM to full-scale.
● Terminal FM is designed to output pulses. By setting Pr. 900, you can
calibrate the meter connected to the inverter from the parameter unit
without providing a calibration resistor.
● You can display a digital value on a digital counter using the pulse train
output of terminal FM. 1440 pulses/second are output at the full scale
value as explained in the Pr. 54 section. When the running frequency
has been selected for monitoring, you can set the ratio of this FM
terminal output frequency in Pr. 55.
Meter
1mA full-scale
Analog meter (Digital meter) 1440
T1 1mA (-) (+) pulses/sec.
FM(AM) FM(AM)
(-) (+)
DC8V
SD(5) SD(5)
T2
Pulse width T1: Adjusted with Pr. 900 Note: The parameter is factory-set to
Pulse period T2: Set in Pr. 55 Note: full-scale of 1mA or FM output
Pulse period T2: (valid for frequency monitoring only) Note: frequency of 1440 pulses/sec. at 60Hz.
● Terminal AM is factory-set to provide a 10VDC output in the full-scale

state of each monitored item. Using Pr. 901, you can adjust the output
voltage ratio (gain) to the meter reading. Note that the maximum output
voltage is 10VDC.
(1) Calibration of the FM terminal

1) Connect a meter (frequency meter) across inverter terminals FM-SD. (Note the
polarity. FM is the positive terminal.)
2) When a calibration resistor has already been connected, adjust the resistance to
"zero" or remove the resistor.
3) Set any of "1 to 3, 5 to 14, 17, 18 or 21" in Pr. 54.
output signal, preset in Pr. 55 or Pr. 56 the running frequency or current at which the
output signal will be 1440 pulses/second.
At 1440 pulses/second, the meter normally deflects to full-scale.
16
FUNCTIONS
● Calibration procedure (Example: To calibrate the meter at the running

frequency of 60Hz)
1) Press the [SET] key in the PU operation mode.
SETTING MODE
The parameter unit is placed in the parameter setting Set Pr.NO.
mode. FOR PR.List
<HELP>
2) Type 900 with the number keys and press the [READ]
900 FM Tune
key. RUN Inverter
The current PU set frequency appears. Set 0.00Hz
PU
3) Type 60 with the number keys.

900 FM Tune
The screen changes as shown on the right. RUN Inverter
Set 60.00Hz
PU
4) Press the [FWD] key to start forward rotation at 60Hz.

900 FM Tune
You need not connect the motor. MntrF 60.00Hz
<WRITE>PU
5) Using the [UP] or [DOWN] key, adjust the meter pointer to

a predetermined position.
The meter pointer moves. (It takes a long time before the
pointer moves.)
900 FM Tune
Calibration is complete. Completed
<MONITOR>
Press any of the [MON], [SET], [EXT] and [PU] keys to switch to the corresponding
mode.
Note: This calibration (Pr. 900) is only valid when you have chosen terminal FM to
output a signal by setting any of "1 to 3, 5 to 14, 17, 18 and 21" in Pr. 54.
When a frequency meter is connected across terminals FM-SD to monitor the
running frequency, the factory setting will fill the FM terminal output to
capacity if the maximum output frequency reaches or exceeds 100Hz.
Therefore, the Pr. 55 "frequency monitoring reference" setting must be
changed to the maximum frequency.
17
FUNCTIONS
(2) Calibration of the AM terminal

1) Connect a 0-10VDC meter (frequency meter) across inverter terminals AM-5. (Note
the polarity. AM is the positive terminal.)
2) Set any of "1 to 3, 5 to 14, 17, 18 and 21" in Pr. 158.
output signal, preset in Pr. 55 or Pr. 56 the running frequency or current at which the
output signal will be 10V.
3) When outputting the output current or other item which cannot easily achieve a 100%
value through operation, set "21" in Pr. 158 and perform the following operation. After
that, set "2" (output current, for example) in Pr. 158.
● Calibration procedure 1 (Example: To calibrate the meter at the running
frequency of 60Hz)
1) Press the [SET] key in the PU operation mode.
SETTING MODE
The parameter unit enters the parameter setting mode. Set Pr.NO.
FOR PR.List
<HELP>
2) Type 901 with the number keys and press the [READ]
901 AM Tune
key. RUN Inverter
The current PU-set frequency appears. Set 0.00Hz
PU

901 AM Tune
The screen changes as shown on the right. RUN Inverter
Set 60.00Hz
PU
4) Press the [FWD] key to start forward rotation at 60Hz.

901 AM Tune
You need not connect the motor. MntrF 60.00Hz
<WRITE>PU
5) Using the [UP] or [DOWN] key, adjust the meter pointer to

a predetermined position.
The meter pointer moves.
901 AM Tune
Calibration is complete. Completed
<MONITOR>
Press any of the [MON], [SET], [EXT] and [PU] keys to switch to the corresponding
mode.
Note: This calibration (Pr. 901) is only valid when any of "1 to 3, 5 to 14, 17, 18 and
21" has been set in Pr. 158.
18
FUNCTIONS
● Calibration procedure 2 (Example: Output current)

To output the output current or another item which cannot easily achieve a 100% value if
operation is performed, adjust the reference voltage output (when the Pr. 54 "FM
terminal function selection" setting is "21"), then select any of the choices displayed.
1) Press the [SET] key in the PU operation

SETTING MODE
mode. Set Pr.NO.
The parameter unit is placed in the FOR PR.List
<HELP>
parameter setting mode.
2) Type 54 with the number keys and press
54 Set FM
the [READ] key. 1
The current Pr. 54 setting appears.
1～21

54 Set FM
the [WRITE] key. 1
The setting of reference voltage output is 21
Setting of reference voltage output
Completed
complete.
SETTING MODE
The parameter unit is put in the Set Pr.NO.
parameter setting mode. FOR PR.List
<HELP>
5) Type 901 with the number keys and

901 AM Tune
press the [READ] key. RUN Inverter
The current Pr. 901 setting appears. Set 0.00Hz
PU

901 AM Tune
the [WRITE] key. RUN Inverter
The setting of maximum running Set 60.00Hz
PU
frequency is complete.
7) Press the [FWD] key.
Forward rotation is performed at 60Hz.
You need not connect the motor to make
adjustment.
8) Using the [UP] or [DOWN] key, adjust the
901 AM Tune
voltage across terminals AM-5 to 10V Completed ･･･ When the output
and press the [WRITE] key. <MONITOR> is 100%, the
Setting is complete. output voltage
will be 10V. This
voltage is not
stored if you do
not press the
[WRITE] key.
19
FUNCTIONS

SETTING MODE
<HELP>
Setting of output current
10) Type 54 with the number keys and

54 Set FM
press the [READ] key. 21
The current Pr. 54 setting appears.
1～21

54 Set FM ･･･ The current set in
the [WRITE] key. 2
Pr. 56 "current
The setting of output current is monitoring
Completed
complete. reference" is a
100% value and
the output at this
point is 10V.
2.2.5 Adjustment of the frequency setting signals "bias" and "gain"

You can set the output frequency as desired in relation to the frequency setting signal
(0 to 5V, 0 to 10V or 4 to 20mA DC).
The "bias" and "gain" functions are used to adjust the relationship between the input
signal entered from outside the inverter to set the output frequency, e.g. 0 to 5VDC, 0 to
10VDC or 4 to 20mADC, and the output frequency.
● Use Pr. 902 to set the bias frequency at 0V.
● Use Pr. 903 to set the output frequency relative to the frequency command voltage
set in Pr. 73.
● Use Pr. 904 to set the bias frequency at 4mA.
● Use Pr. 905 to set the output frequency relative to the frequency command current
(4 to 20mA) of 20mA.
Parameter Number Factory Setting Setting Range
902 0V 0Hz 0～10V 0～60Hz
903 5V 60Hz 0～10V 1～400Hz
904 4mA 0Hz 0～20mA 0～60Hz
905 20mA 60Hz 0～20mA 1～400Hz
Factory setting
(60Hz)
Output
frequency
(Hz) Gain Pr.903
Pr.902 Bias Pr.905
Pr.904
0 Frequency setting 5V Pr.73
0 signal 10V
4 20mA
20
FUNCTIONS
● Adjustment procedure 1 (adjusted without a voltage applied across

terminals 2-5)
(1) Setting of the frequency setting voltage bias

DIRECTLY
0～400

SETTING MODE
<HELP>

SETTING MODE
The screen changes as shown on the Pr.NO.
right. 902
<READ>

SETTING MODE
The current Pr. 902 setting appears. Pr.NO.
902
<READ>

902 EXTVbias ････ Voltage need not be
The screen changes as shown on the 10.00Hz
applied across
right. Set <WRITE>
EXT <READ> terminals 2-5.

902 EXTVbias ････ The bias setting is
The set value is stored into memory and 10.00 Hz 10Hz.
bias setting is complete.
Completed f
10Hz
0 V
If the voltage is
being applied across
terminals 2-5 at this
time, the bias setting
is as shown above.
21
FUNCTIONS
(2) Setting of the frequency setting voltage gain
7) Press the [SHIFT] key.

903 EXTVgain
The current Pr. 903 setting appears. 60.00Hz
Set <WRITE>
EXT <READ>
8) Type 50 with the number keys. ････ Voltage need not be

903 EXTVgain
applied across
right. Set <WRITE> terminals 2-5.
EXT <READ> At this time, set the
gain on the
9) Press the [WRITE] key. assumption that the
903 EXTVgain
The set value is stored into memory and 50.00 Hz 5V (10V) in the
gain setting is complete. inverter is the set
Completed voltage.
The adjustment of the frequency setting voltage bias f
50Hz
and gain is complete.
10Hz
0 V
50V
Note: 1. The current input (Pr. 904, Pr. 905) can also be adjusted using a similar
procedure.
2. The Pr. 903 (frequency setting gain) value remains unchanged if the Pr. 20
"acceleration/deceleration reference frequency" setting is changed.
22
FUNCTIONS
● Adjustment procedure 2 (any point is adjusted with a voltage applied

across terminals 2-5)
DIRECTLY
The frequency setting screen Set 0.00Hz
appears.
0～400
2) Press the [SET] key. SETTING MODE

<HELP>
3) Type 902 with the number keys. SETTING MODE

The screen changes as shown Pr.NO.
on the right. 902
<READ>
4) Press the [READ] key twice. 902 EXTVbias

The current Pr. 902 setting 5.00Hz The previous setting is
appears. - 0.5% displayed.
EXT 20.0% The current set voltage
across terminals 2-5 is
5) Type 10 with the number keys. 902 EXTVbias displayed in %.
The screen changes as shown 10.00Hz When the set voltage is
on the right. - 0.5% changed, the % value also
EXT - 20.0% changes.
This example assumes that
a 1V voltage is applied.
The value selected in Pr. 73
6) Press the [WRITE] key. 902 EXTVbias
(5V in this example) is 100%.
The cursor ( ) moves to the set 10.00Hz ････ Adjust the set voltage.
voltage. - 0.5% If the voltage set is 1V, the
EXT 20.0% bias setting is as shown
below:
f
7) Apply a 0V voltage.
902 EXTVbias 10Hz
10.00Hz 0 V
- 0.5% 1V
EXT - 0.2%
････ In this example, 0V is applied
as 10Hz is set for 0V.
8) Press the [WRITE] key. 902 EXTVbias (Indicated on the right of
The set value is stored into 10.00Hz changes.)
memory and bias setting is - 0.2% 0.0% may not be displayed in
Completed some cases.
complete.
Setting is completed as
shown below:
f
10Hz
0 V
(Continued on the next page)
23
FUNCTIONS
(From the preceding page)

9) Press the [SHIFT] key, then the

903 EXTVgain
[READ] key. 60.00Hz The previous setting is
The current Pr. 903 setting 97.1% displayed.
appears.
10) Type 50 with the number keys. displayed in %.
903 EXTVgain
The screen changes as shown 50.00Hz When the set voltage is
on the right. 97.1% changed, the % value also
EXT 99.0%
changes.
The value selected in Pr. 73
11) Press the [WRITE] key. (5V in this example) is
903 EXTVgain 100%.
The cursor ( ) moves to the 50.00Hz
set voltage. 97.1%
EXT 99.0% Set the voltage across
terminals 2-5 to achieve
100%.
12) Apply a 5V voltage.
903 EXTVgain
50.00Hz ････ In this example, 5V is
97.1% applied as 50Hz is set for 5V
EXT 99.0% input.
903 EXTVgain
The set value is stored into 50.00Hz
memory and gain setting is 99.6% The value displayed may not
Completed be just 100.0% in some
complete.
cases.
Setting is completed as
shown below:
f
50Hz
10Hz
V
The adjustment of the frequency setting voltage bias 0 5V
and gain is completed. (0%) (100%)
procedure.
24
FUNCTIONS
● Adjustment procedure 3 (any point is adjusted without a voltage applied

across terminals 2-5)

DIRECTLY
0～400
SETTING MODE
<HELP>

SETTING MODE
The screen changes as shown on the Pr.NO.
right. 902
<READ>
4) Press the [READ] key twice.

902 EXTVbias
The current Pr. 902 setting appears. 10.00Hz The previous setting is
- 0.5% displayed.
EXT 20.0%
The current set voltage
5) Type 10 with the number keys. across terminals 2-5 is
902 EXTVbias displayed in %.
- 0.5% When the set voltage is
right.
EXT - 20.0% changed, the % value
also changes.
The value selected in
Pr. 73 (5V in this
example) is 100%.
902 EXTVbias ･･･ Voltage need not be
The cursor ( ) moves to the set 10.00Hz
- 0.5% applied across
voltage.
EXT 20.0% terminals 2-5.
7) Type 0 with the number key.

902 EXTVbias
10.00Hz ･･･ In this example, 0V is
- 0% applied as 10Hz is set
EXT - 0.5% for 0V.
902 EXTVbias
The set value is stored into memory 10.00Hz
and bias setting is complete. 0.0% Setting is completed as
Completed shown below:
f
10Hz
0 V
(Continued on the next page)
25
FUNCTIONS
(From the preceding page)

9) Press the [SHIFT] key, then the

903 EXTVgain
[READ] key. 60.00Hz The previous setting is
The current Pr. 903 setting appears. 97.1% displayed.
903 EXTVgain displayed in %.
The screen changes as shown on 50.00Hz When the set voltage is
the right. 97.1% changed, the % value
EXT 99.0%
also changes.
The value selected in
Pr. 73 (5V in this
example) is 100%.
903 EXTVgain ･･･ Voltage need not be
The cursor ( ) moves to the set 50.00Hz applied across
voltage. 97.1%
EXT 99.0% terminals 2-5.

903 EXTVgain ･･･ In this example, 100%
50.00Hz
- 100% is input as 50Hz is set
EXT 99.0% for 5V (100%).

903 EXTVgain
The set value is stored into memory 50.00Hz
and gain setting is complete. 100% Setting is completed as
Completed shown below:
f
50Hz
10Hz
V
The adjustment of the frequency setting 0 5V
voltage bias and gain is completed. (0%) (100%)
procedure.
26
2.3 Copy and Verify Functions
FUNCTIONS
2.3Copy and Verify Functions
You can read and store parameter settings into the FR-PU04. You can also copy the
stored parameter settings to another inverter of the same series and same capacity.
<Precautions for setting>
● Select the PU operation mode.
● Use these functions after stopping the inverter.
● Parameter values cannot be copied when you have set "1" in Pr. 77 "parameter write
inhibit selection" of the copy destination inverter to inhibit parameter write.
(1) Reading the parameter settings
1) Connect the FR-PU04 to the inverter.

SETTING MODE
2) Select the setting mode. Set Pr.NO
Pr.List→HELP
Pr.COPY→
3) Press the [UP] key.

ALL Pr.S
The parameter unit enters the ROM batch mode. READ <READ>
WRITE <WRITE>
VER

ALL Pr.S
The inverter's parameter settings are stored.
Reading
Completed
(2) Writing the parameter settings

SETTING MODE
Pr.List→HELP
Pr.COPY→

ALL Pr.S
The parameter unit goes into the ROM batch mode. READ <READ>
WRITE <WRITE>
VER

ALL Pr.S
The parameter settings stored in the FR-PU04 are copied to Writing
the copy destination inverter. Completed
Please Reset
5) Reset the inverter.
27
FUNCTIONS
(3) Verify

SETTING MODE
Pr.List→HELP
Pr.COPY→

ALL Pr.S
The parameter unit enters the ROM batch mode. READ <READ>
WRITE <WRITE>
VER
4) Press the [DOWN] key.

ALL Pr.S
The parameter settings stored in the FR-PU04 are verified
with those of the inverter. (If an error is detected during verify, Verifying
Completed
the corresponding Pr. is shown.)
Note: 1. Note that all data stored in the parameter unit is updated when read is
performed from the inverter.
2. Write cannot be performed while the inverter is running. Read and verify can
be performed during running.
3. Read and write cannot be stopped partway through the operation.
4. If power is switched off, parameter data stored in the parameter unit remains
unerased. Therefore, a backup power supply is not needed.
5. Exercise care not to switch power off while parameters are being written.
28
2.4 Help Function
FUNCTIONS
2.4Help Function
2.4.1 Help function menu

Press the [HELP] key twice in any operation mode to call the help function menu, on
which you can perform various functions. (For details, refer to page 31.)
● Menu screen page 1
1 MONITOR (1) MONITOR

2 PU Oper
3 Pr.List
The monitoring list appears and you can change from one
4 Pr.Clear monitor screen to another and set the first priority screen.
(2) PU Operation
You can select the PU operation mode via direct input
(direct setting with the number keys) or select the jog
operation mode from the PU and display how to operate
the keys.
(3) Parameter List
The parameter menu appears and you can select and
Press the [SHIFT] and perform any of the following five operations:
[DOWN] keys together to 1 Setting
move to the next page. 2 Pr. List
3 Set Pr. List
4 Def. Pr. List
5 Def. Pr. List 2
(4) Parameter Clear
The parameter clear menu appears and you can select
and perform any of the following four operations:
1 Clear Pr.
2 Clear All
3 Clear User
● Menu screen page 2 4 Clear None
5 Alarm Hist (5) Alarm History

6 AlarmClear Shows the history of eight past alarms.
7 Inv.Reset
8 T/Shoting (6) Alarm Clear
Clears all the alarm history.
(7) Inverter Reset
Resets the inverter.
Press the [SHIFT] and (8) Troubleshooting
[DOWN] keys together to
The inverter displays the cause of mismatch between
move to the next page.
inverter operation and control/setting or the cause of an
inverter fault.
29
FUNCTIONS
● Menu screen page 3
9 S/W (9) S/W

10 Selectop Displays the inverter software management numbers.
11 Option
(10) Selectop
Displays the signals assigned to the I/O terminals of the
control circuit and their ON-OFF states.
(11) Option
Displays what options are fitted to the option connectors 1
Press any of the [MON],
to 3.
[SET], [EXT] and [PU]
keys to switch to the
corresponding mode.
30
FUNCTIONS
2.4.2 Help function display data
[HELP] key
Press twice.
[READ]
11 MONITOR 11 Frequency Frequency [Hz]
12 PU Oper 12 Current Current [A]
13 Pr.List 13 Voltage Voltage [V]
14 Pr.Clear 14 Alarm His Error definition *When more than 8 errors have occurred, the earlier ones
15 Alarm Hist 15 F Command are cleared.
16 Alarm Clear 16 RPM Frequency setting (shows the frequency already set.) [Hz]
17 Inv.Reset 17 Shaft Trg Running speed (shows the motor speed and moving speed.) [r.]
18 T/Shooting 18 DC Link Motor torque (force produced by the motor under advanced magnetic flux
19 S/W 19 Br Duty % vector control) [%]
10 Selectop 10 Therm OL Converter output voltage (DC current in converter output) [V]
11 Option 11 Peak I Regenerative brake duty [%]
12 DC Peak V Electronic overcurrent protection load factor [%]
13 I/P Power Output current peak [A]
14 O/P Power Converter output voltage peak (maximum value of converter output
15 I/P Signal voltage) [V]
16 O/P Signal Input power (input side power amount currently used) [kW]
Output power (output side power amount currently used) [kW]
Input signal (ON-OFF states of STF, STR, etc.) ＊■ON □OFF
Input signal (ON-OFF states of RUN, FU, etc.) ＊■ON □OFF
[HELP] key
Press twice.
1 ━━━━━ [READ] 1 PU:Diectly PU operation mode selected by setting running

2 PU Oper 2 JOG:Jogging frequency from ten-key pad
3 Pr.List Jog operation mode
4 ━━━━━
5 ━━━━━ [READ] [HELP]
1 Setting MODE SETTING MODE 0 Trq.Bst1
6 ━━━━━ [READ] 2 Pr.List Set Pr.NO 1 Max.F1
7 ━━━━━ 3 Set Pr.List Pr.List HELP 2 ━━━━━━
8 ━━━━━ 4 Def.Pr.List Pr.COPY [READ]
9 ━━━━━ 5 Def.Pr.List2 991 ━━━━━━
10 ━━━━━ SET Pr.List
11 ━━━━━ [READ] Pr.0 ━━
Pr.1 60 Current status
[READ]
Pr.991 ━━ 0 Trq.Bst1
[READ] …%
[READ]
DEF.Pr.LIST 0～30
Pr.0 6.0
[READ] Pr.1 120.0
Pr.2 0.00
Pr.991
User's initial value list

<DEF.Pr.LIST2>
[READ] Pr.0 4.0
Pr.7 20.00
…
31
FUNCTIONS
[HELP] key
Press twice.
[READ]
1 ━━━━━ [READ] 1 Clear Pr. Clear Pr. [WRITE] Clear Pr.
2 ━━━━━ 2 Clear All Exec <Write> ━━━━━━━━
3 Clear User Cancel<ESC> Executing
3 ━━━━━ 4 Clear None ━━━━━━━━
4 Pr.Clear
5 Alarm Hist [READ]
Clear Pr.
6 Alarm Clear Exec <Write>
7 Inv.Reset Cancel<ESC>
8 T/Shooting [READ]
You can perform user parameter clear.
9 S/W [READ]
10 Selectop [READ] Returns to the previous screen.
11 Option Error definition
*When more than 8 errors have occurred, the earlier
ones are cleared.
[READ]
ALARM CLEAR
Exec <WRITE>
Cancel<ESC>
[READ]
INV.RESET
Exec <WRITE>
Cancel<ESC>
32
FUNCTIONS
[HELP] key
Press twice. [Estimated cause]
[READ]
1 ━━━━━ 1 M.Not Run Inv.Output M.NOT RUNNING
[READ] 2 M.Spd Error ━━━ Hz [SHIFT] MRS is ON
2 ━━━━━ 3 M.A/Dec Err ━━ A ━━━ V
3 ━━━━━ 4 M.Curr.High <SHIFT>
4 Pr.Clear
5 Alarm Hist [READ] Inv.Output M.SPEED ERROR
━━━ Hz [SHIFT] SetF>MaxF1/F2
6 Alarm Clear ━━ A ━━━ V 60.00 Hz
7 Inv.Reset <SHIFT> Pr1/18
8 T/Shooting
9 S/W Set ━━━━ S Stll Pv.ON?
[READ] O Hz [DOWN] Set Too Low?
10 Selectop
Set ━━━━ S Load Too Big?
11 Option ━ Hz O Pr.22 Error?
Inv.Output Low Impedance
[READ] ━━━ Hz [SHIFT] Motor?
━━ A ━━━ V Reduce TrqBst
<SHIFT> Pr.0,46,112
<S/W>
[READ]
Settings of function numbers (input terminal functions

selected in Pr. 180 to Pr. 186) are displayed.
Terminal name ■ON □OFF
RL: RL □
[READ] RM: RM □
RH: RH □
RT: REX □
<Option>
[READ] OP1: ----
OP2: ----
OP3: ----
33
FUNCTIONS
2.4.3 Help function operation procedures
(1) MONITOR
The monitoring list appears and you can change from one monitor screen to another and
set the first priority screen.
● Operation procedure 1 (To call the monitoring list from the help function
menu)
1) Press the [HELP] key twice in the monitoring mode.
1 MONITOR
The help function menu is called. 2 PU Oper
3 Pr.List
4 Pr.Clear
2) Make sure that the cursor ( ) is located at "1 MONITOR".
If not, move the cursor with the [UP]/[DOWN] key.

1 Frequency
The monitoring list is called. 2 Current
3 Voltage
4 Alarm His
4) Press the [UP] or [DOWN] key to move the cursor to the

1 Frequency
required item. 2 Current
3 Voltage
4 Alarm His
5) If the required item is not found, press the [SHIFT] key

and [DOWN] key together to shift to the next page.

The monitor screen indicated by the cursor appears.
Press the [WRITE] key to give the first priority to this 0.00 A
--- STOP PU
monitor screen.
34
FUNCTIONS
● Operation procedure 2 (To call the monitoring list directly in the

monitoring mode)
1) Press the [MON] key. (Note)
The parameter unit is put in the monitoring mode.
0.00 Hz
--- STOP PU

1 Frequency
The monitoring list is called. 2 Current
3 Voltage
4 Alarm His

1 Frequency
required item. 2 Current
3 Voltage
4 Alarm His


The monitor screen indicated by the cursor appears.
Press the [WRITE] key to give the first priority to this 0.00 A
--- STOP PU
monitor screen.
Note: You need not press this key when the parameter unit is already in the
monitoring mode.
35
FUNCTIONS
(2) PU Operation
You can select the PU operation mode via direct input (direct setting from the ten-key
pad) or select the jog operation mode from the PU and show how to operate the keys.
■ Selection of the PU operation mode (direct input)

● Operation procedure 1 (To call the key operation guide from the help
function menu)
1 MONITOR
3 Pr.List
4 Pr.Clear
2) Using the [DOWN] key, move the cursor to "2 PU

1 MONITOR
Operation". 2 PU Oper
3 Pr.List
4 Pr.Clear

1 PU:Directly
The menu on the right appears. 2 JOG:Jogging
4) Make sure that the cursor is located at "1 PU: Directly".


DIRECTLY
The PU operation mode is selected and the frequency Set 0.00Hz
setting screen appears.
0～400

KEY OPERATION
The key operation guide appears. Fset:0～9
Then:WRITE
Then:FWD,REV
36
FUNCTIONS
● Operation procedure 2 (To call the key operation guide directly)

DIRECTLY
0～400

KEY OPERATION
Then:WRITE
Then:FWD,REV
37
FUNCTIONS
■ Selection of the PU jog operation mode

● Operation procedure 1 (To call the key operation guide from the help
function menu)
1 MONITOR
3 Pr.List
4 Pr.Clear
2) Using the [DOWN] key, move the cursor to "2 PU

1 MONITOR
Operation". 2 PU Oper
3 Pr.List
4 Pr.Clear

1 PU:Directly
The menu on the right appears. 2 JOG:Jogging
4) Using the [DOWN] key, move the cursor to "2 JOG:

Jogging".

PU/JOG
The PU jog operation mode is selected and the frequency Set 5.00Hz
0～400

KEY OPERATION
The key operation guide is displayed. Fset:0～9
Then:WRITE
Then:FWD,REV
38
FUNCTIONS
● Operation procedure 2 (To call the key operation guide directly)

DIRECTLY
0～400
2) Press the [SHIFT] key.

PU/JOG
The PU jog operation mode is selected and the frequency Set 5.00Hz
0～400

KEY OPERATION
Then:WRITE
Then:FWD,REV
39
FUNCTIONS
(3) Parameter List

The parameter menu appears and you can select and perform any of the following five
operations:
1 Setting: ･････････････Switches to the parameter setting mode.
2 Pr. List: ･････････････Lists the parameters in numerical order so that you
can read and write individual parameter values.
3 Set Pr. List:･･････････Lists only the parameters whose factory settings have
been changed, together with their Pr. numbers. (For
parameters whose factory settings remain unchanged,
their Pr. numbers are only displayed.)
4 Def. Pr. List: ･････････Lists the initial values (default factory settings) of
parameters.
5 Def. Pr. List 2: ･･･････Lists user's initial values (settings of parameters
selected in Pr. 199) of parameters.
● Display of the parameter menu

1 MONITOR
3 Pr.List
4 Pr.Clear
2) Using the [DOWN] key, move the cursor to "3 Pr. List".
1 MONITOR
2 PU Oper
3 Pr.List
4 Pr.Clear

1 SettingMODE
The parameter menu appears. 2 Pr.List
3 Set Pr.List
4 Def.Pr.List
40
FUNCTIONS
■ Selection and execution of "1 Setting"

● Operation procedure
1) Refer to page 40 and call the parameter menu.
1 SettingMODE
2 Pr.List
3 Set Pr.List
4 Def.Pr.List
2) Make sure that the cursor is located at "1 Setting

MODE".

SETTING MODE
The parameter unit switches to the setting mode. Set Pr.NO.
FOR Pr.List
<HELP>
41
FUNCTIONS
■ Selection and execution of "2 Pr. List"

1 SettingMODE
2 Pr.List
3 Set Pr.List
4 Def.Pr.List
2) Using the [DOWN] key, move the cursor to "2 Pr. List".
1 SettingMODE
2 Pr.List
3 Set Pr.List
4 Def.Pr.List

1 Trq.Bst1
The parameter list is displayed. 2 Max.F1
3 Min.F1
4 VFbaseF1

required item.


0 Trq.Bst1
The parameter indicated by the cursor is read and the 6.0%
parameter unit enters the parameter setting mode.
0～30
Press the [SHIFT] key to move to the next parameter.
42
FUNCTIONS
■ Display of "3 Set Pr. List", "4 Def. Pr. List" or "5 Def. Pr. List 2"
● Operation procedure (To call the Set Pr. List)
1 SettingMODE
2 Pr.List
3 Set Pr.List
4 Def.Pr.List
2) Using the [DOWN] key, move the cursor to "3 Set Pr. List".
1 SettingMODE
2 Pr.List
3 Set Pr.List
4 Def.Pr.List

Set Pr.LIST
The SET Pr. LIST appears. (Note) Pr 0 8.0
Pr 1 ━
Pr 2 ━
To call the Def. Pr. List or Def. Pr. List 2, move the cursor to "4 Def. Pr. List" or
"5 Def. Pr. List 2" in above step 2.
Note: Press the [SHIFT] key and [DOWN] key together to move to the next page.
43
FUNCTIONS
(4) Parameter Clear (To be performed in the PU operation mode)

The parameter clear menu appears and you can select and perform any of the following
four operations:
1 Clear Pr.: ･････････････ Returns (initializes) the parameters to the factory
settings with the exception of the some parameters
(Pr. 75 and calibration values in Pr. 900 to 905).
2 Clear All: ･･････････････ Initializes all parameters with the exception of Pr.
75.
3 Clear User: ････････････ Returns the parameters registered for user's initial
values in Pr. 199 to the user's initial values and the
other parameters to the factory settings.
4 Clear None: ･･･････････ Does not initialize.
● Display of the parameter clear menu

1) Press the [HELP] key twice in the operation mode.
1 SettingMODE
The help function menu is called. 2 Pr.List
3 Set Pr.List
4 Def.Pr.List
2) Using the [DOWN] key, move the cursor to "4 Pr. Clear".
1 SettingMODE
2 Pr.List
3 Set Pr.List
4 Def.Pr.List

1 Clear Pr.
The parameter clear menu appears. 2 Clear All
3 Clear User
4 Clear None
44
FUNCTIONS
■ Selection and execution of "1 Clear Pr.", "2 Clear All" or "3 Clear User"
1 Clear Pr.
2 Clear All
3 Clear User
4 Clear None
2) Make sure that the cursor is located at "1 Clear Pr.".


Clear Pr.
The screen changes as shown on the right. Exec <WRITE>
Cancel<ESC>

Clear Pr.
The screen changes as shown on the right and the
parameters are initialized. Executing
(Note)
To execute Clear All or Clear User, move the cursor to "2 Clear All" or "3 Clear User"
in above step 2.
Note: When you press the [ESC] key, the clear operation is not performed.
■ "4 Clear None"

When "4 Clear None" is selected, the parameters are not initialized.
45
FUNCTIONS
(5) Alarm History

Shows the history of eight past alarms.
1 MONITOR
3 Pr.List
4 Pr.Clear
2) Press the [SHIFT] key and [DOWN] key together.

5 Alarm Hist
The screen moves to the next page. 6 AlarmClear
7 Inv.Reset
8 T/Shooting
3) Make sure that the cursor is located at "5 Alarm Hist".

5 Alarm Hist
If not, move the cursor with the [UP]/[DOWN] key. 6 AlarmClear
7 Inv.Reset
8 T/Shooting

1 OV3 5 UVT
The alarm history appears. 2 UVT 6
3 UVT 7
4 UVT 8
46
FUNCTIONS
(6) Alarm Clear

Clears all the alarm history.
1 MONITOR
3 Pr.List
4 Pr.Clear

5 Alarm Hist
7 Inv.Reset
8 T/Shooting
3) Using the [DOWN] key, move the cursor to "6 Alarm

5 Alarm Hist
Clear". 6 AlarmClear
7 Inv.Reset
8 T/Shooting

Alarm Clear
Cancel<ESC>

ALARM CLEAR
The screen changes as shown on the right and the alarm
history is cleared. Completed
(Note)
Note: When you press the [ESC] key, the alarm history clear operation is not
performed.
47
FUNCTIONS
(7) Inverter Reset

Resets the inverter.
A similar reset operation may also be performed by switching power "off" or by switching
the RES signal on. If the inverter's protective function is activated to bring the inverter to
an alarm stop (output shutoff), the alarm stop state may be canceled by pressing the
[STOP/RESET] key, without performing the following operation:
1 MONITOR
3 Pr.List
4 Pr.Clear

5 Alarm Hist
7 Inv.Reset
8 T/Shooting
3) Using the [DOWN] key, move the cursor to "7 Inv. Reset".
5 Alarm Hist
6 AlarmClear
7 Inv.Reset
8 T/Shooting

Inv.RESET
Cancel<ESC>

The inverter is reset and the parameter unit switches to
the monitoring mode. 0.00 Hz
--- STOP EXT
(Note)
Note: When you press the [ESC] key, the inverter is not reset and the parameter unit
switches to the monitoring mode.
48
FUNCTIONS
(8) Troubleshooting
If the inverter appears to operate improperly, perform the following operation to display
the most likely cause of the fault.
This operation may also be performed during inverter operation (PU operation, external
operation) or during alarm trip (protection activated).
1 MONITOR
3 Pr.List
4 Pr.Clear

5 Alarm Hist
7 Inv.Reset
8 T/Shooting
3) Using the [DOWN] key, move the cursor to "8

5 Alarm Hist
T/Shooting". 6 AlarmClear
7 Inv.Reset
8 T/Shooting

1 M.Not Run
The alarm phenomenon menu appears. 2 M.Spd Error
3 M.A/Dec Err
4 M.Curr.High

1 M.Not Run
required item. 2 M.Spd Error
3 M.A/Dec Err
4 M.Curr.High

M.SPEED ERROR
The cause of the fault is displayed. (See page 50.) SetF>MaxF1/F2
60.00 Pr1/18
Hz
49
FUNCTIONS
Troubleshooting guidance
1 M.NOT RUNNING (Motor does not run)

M.NOT RUNNING The inverter has alarm- M.NOT RUNNING The inverter cannot start
ALARM tripped (protection Max.F1<StartF because the inverter
Indicated activated), resulting in Pr.1 Pr.13 starting frequency (Pr. 13)
<SHIFT> output shut-off. is higher than the
Press the [SHIFT] key to maximum frequency (Pr. 1).
display the cause of the trip.
M.NOT RUNNING The inverter's main circuit M.NOT RUNNING The inverter cannot start
NO I/P Power power is lost or there is an EnableFR Set because you attempted to
or Phase Loss open phase in the power See Pr.78 run the motor in the
supply. Check the power direction in which forward
supply. or reverse rotation is
inhibited as set in Pr. 78.
M.NOT RUNNING Both start signals STF and M.NOT RUNNING The inverter cannot start
STF,STR STR are ON or OFF. Current Limit since the current limit
both are OFF Activated function is activated. Press
or ON <SHIFT> the [SHIFT] key to display
the estimated cause that
the current limit function
was activated.
M.NOT RUNNING The output shut-off input M.NOT RUNNING The inverter does not start
MRS is ON signal MRS is ON. because it is in a stop
TS Control period in the programmed
Standby Mode operation mode.
M.NOT RUNNING The inverter starting M.NOT RUNNING The inverter does not start
SetF<StartF frequency (Pr. 13) setting Under because the inverter need
Pr.13 is higher than the PID Control not start the motor as a
frequency currently set. result of the arithmetic
operation of PID control.
M.NOT RUNNING The current input select M.NOT RUNNING The inverter will not restart
AU is OFF signal AU remains OFF since the automatic restart
(not ON). CS is OFF after instantaneous power
See Pr.57 failure select signal CS is
OFF.
Neither of the FWD and REV It is estimated that an
M.NOT RUNNING instantaneous power
NO Command keys are ON in the PU operation
From PU mode. failure has occurred or the
inverter in the commercial
power supply switch-over
operation mode.
50
FUNCTIONS
2 M.SPEED ERROR 3 M.A/Dec Err

(Speed does not match the running (Actual acceleration/deceleration time
frequency(setting) is(longer than the Pr. 7/Pr. 8 setting)
M.SPEED ERROR Since the running Set 5.0S Acceleration time
SetF>MaxF1/F2 frequency setting is higher 0 60.00Hz setting (Pr. 7) is
60.00 Hz than the maximum Set 5.0S displayed.
Pr1/18 frequency (Pr. 1) setting, 60.00Hz 0
the running frequency Frequency reached
remains at the maximum in the above set time
frequency. (acceleration/
deceleration
M.SPEED ERROR Since the running reference frequency,
SetF>MinF1 frequency setting is lower Pr. 20) is displayed.
60.00 Hz than the minimum Stll Pv.ON?
Pr2 frequency (Pr. 2) setting, Set Too Low?
Deceleration time
the running frequency Load Too Big?
Pr.22 Error? setting (Pr. 8) is
has been increased to the displayed.
minimum frequency.
Frequency from
M.SPEED ERROR Since the running which deceleration is
Fjump Working frequency setting is within made in the above
See Pr.31 36 the frequency jump setting set time
SetF= 60.00Hz range (Pr. 31 to 36), the (acceleration/
running frequency has deceleration
jumped. reference frequency,
The current limit function Pr. 20) is displayed.
M.SPEED ERROR
Current Limit was activated and forced
Activated the running frequency to Estimated cause that
<SHIFT> reduce. Press the [SHIFT] actual acceleration/
key to display the cause deceleration time is
that the current limit longer than the setting is
function was activated. displayed.
M.SPEED ERROR As a result of arithmetic

Under operation of PID control,
PI Control the running frequency
differs from the set value.
51
FUNCTIONS
4 M.Curr.High
(Inverter output current is larger Note: When the fault could not be
than normal) identified after the above
operation
Inv.Output First, the running
60.00Hz frequency,output current If you could not find the cause
10A 182.4V and output voltage of the of the fault, the current running
<SHIFT> inverter are displayed. frequency, output current and
Press the [SHIFT] key to
display the estimated output voltage are displayed on
[SHIFT]
cause of large output the screen.
current.
Inv.Output
Low Impedance The motor used may be a 60.00Hz
Motor? special motor other than 0.01A 182.8V
Reduce TrqBst the general-purpose <SHIFT>
Pr.0,46,112 3-phase induction motor.
If so, reduce the torque
boost setting. Press the [SHIFT] key to
[UP] [DOWN]
Related parameters: display the relevant estimated
Pr. 0, 46, 112 cause.
Low Trq The motor used may be a
Motor? constant-torque motor
Reduce TrqBst (motor for inverter).
Pr.0,46,112 If so, reduce the torque
boost setting.
[UP] [DOWN] Related parameters:
Pr. 0, 46, 112
Trq.Bst Since the torque boost
Setting Err? setting may be
See Pr.0,46, inappropriate, check the
112 following relevant
parameters: Related
[UP] [DOWN] parameters: Pr. 0, 46, 112
V/F Setting Since the V/F pattern

Error? setting may be
See Pr.3,14, inappropriate, check the
19,47 following relevant
parameters: Related
[UP] [DOWN] parameters: Pr. 3, 14, 19,
47
The load may be too
Load Too Big? heavy.
OutPut An open phase may have
Phase Loss? occurred between the
inverter and motor.
52
FUNCTIONS
(9) Selectop
Displays the signals assigned to the I/O terminals of the control circuit and their ON-OFF
states.

1 MONITOR
3 Pr.List
4 Pr.Clear
2) Press the [SHIFT] key and [DOWN] key together twice.

9 S/W
The screen moves two pages. 10 Selectop
11 Option
3) Using the [DOWN] key, move the cursor to "10 ".

9 S/W
10 Selectop
11 Option

RL: 0(Note 2) ■
The signals assigned to the control circuit terminals and RM: 1 □
their ON-OFF states are displayed. RH: 2 □
RT: 3 □
(Note)
Note: 1. When the [SHIFT] key and [DOWN] key are pressed together, the screen
moves to the next page.
2. The screen shows "--" when you set "9999" in Pr. 180 to Pr. 186.
53
FUNCTIONS
(10) Option
Displays what options are fitted to the option connectors 1 to 3.

1 MONITOR
3 Pr.List
4 Pr.Clear
2) Press the [SHIFT] key and [DOWN] key together twice.

9 S/W
The screen moves two pages. 10 Selectop
11 Option
3) Using the [DOWN] key, move the cursor to "11 ".

9 S/W
10 Selectop
11 Option

<Option>
What options are fitted are displayed. OP1:----
OP2:----
OP3:----
54
CHAPTER 3
OPERATION
This chapter explains the basic "operation" for use of this
product.
3.1 Operation Modes ･･････････････････････････････55

3.2 PU Operation ･････････････････････････････････57
3.3 Combined Operation
(Operation using external input signals and PU)････59

CHAPTER 2 FUNCTIONS
CHAPTER 3 OPERATION
3
3.1 Operation Modes
OPERATION
3OPERATION
3.1Operation Modes
3.1.1 How to select the operation mode

When Pr. 79 = "0", the inverter may be operated by switching between "external
operation" and "PU operation". At power-on, the inverter is placed in the "external
operation" mode. Use the PU to switch to the other operation mode.
(1) Switching from the ･････････Make sure that the external input signal is off
external operation mode (STF or STR is OFF).
to the PU operation mode Then, press the [PU] key to switch to the PU
operation mode, in which the frequency setting
DIRECTLY
PU Set 0.00Hz screen is displayed.
0～400
Frequency setting screen
(2) Switching from the PU ･････････Make sure that the external input signal is off
operation mode to the (STF or STR is OFF) and that the operation
external operation mode command indication is "---".
Then, press the [EXT] key to switch to the
EXT external operation mode, in which "EXT" is
Hz 0.00
displayed in the operation mode indication
--- STOP EXT position.
Operation command Operation mode

indication indication
(3) Switching to the ･････････Change the Pr. 79 "operation mode selection"

combined operation setting as indicated below.
mode "PU+E" is displayed in the operation mode
indication position.
Description
0.00 Hz Setting Running frequency
--- STOP PU+E Start signal
setting
Operation mode indication Parameter unit Terminal
●Direct setting and signal
3
[UP]/[DOWN] key setting ●STF
●STR
Terminal signal Parameter unit
●0 to 5VDC across 2-5 ●[FWD] key
●0 to 10VDC across 2-5 ●[REV] key
4 ●4 to 20mADC across 4-5
●Multi-speed selection
(Pr. 4 to 6, 24 to 27)
●Jog frequency (Pr. 15)
55
OPERATION
Note: If the operation mode cannot be switched properly, check the following:
1. External input signal ････････････Make sure that the signal is off. If it is on,
(STF or STR signal) the operation mode cannot be switched
properly.
2. Parameter setting･･･････････････Confirm the Pr. 79 "operation mode
selection" setting.
Setting Description
Operation can be performed with the mode
switched between PU operation and external
0
operation.
(Factory setting)
PU operation may only be performed.
1
(Cannot be switched to the other mode.)
External operation may only be performed.
2
(Cannot be switched to the other mode.)
3, 4 Combined operation mode
3. Limitation of the operation mode ･･When the Pr. 79 "operation mode

selection" setting is "0" (factory setting),
the inverter is put in the external operation
mode at input power-on. Press the [PU]
key to switch to the PU operation mode.
For the other settings, the operation mode
is limited accordingly.
56
3.2 PU Operation
OPERATION
3.2PU Operation
3.2.1 Ordinary operation

You can change speed by repeating the following steps 2 and 3 during motor operation:
Step Operation Procedure Image
1 Switch power on, press the [PU] key, and make sure that
1. Power on →
the frequency setting screen appears on the display. Operation mode check
(If it is not shown, switch to the PU operation mode.) ON
DIRECTLY
SET 0.00Hz
0～400
2 Set the running frequency to 60Hz. 2. Running frequency setting

After setting the running frequency in either of the following <Direct setting>
ways, press the [WRITE] key to enter the running 7 8 9
frequency: 4 5 6
1 2 3
● Direct setting 0 (or)
After pressing the [PU] key, enter the frequency directly
with the number keys.
Note that this setting is not available in the monitoring
mode. In this case, press the [PU] key to leave the
monitoring mode and re-set the frequency.
● Step setting
Press the [UP]/[DOWN] key to keep on varying the
frequency.
Hold down the [UP] (or [DOWN]) key to vary the
frequency. At the beginning, the frequency varies slowly
and this feature may be used for fine adjustment.
Step setting may also be made during inverter
operation. However, if the [UP] (or [DOWN]) key is
pressed in the monitoring mode, the frequency does not
stop varying as soon as the key is released but rises (or
falls) further. (Since the [UP] (or [DOWN]) key varies the
set frequency, switch operation does not match the
actual frequency.)
3 Press the [FWD] or [REV] key. 3. Start
The motor starts running. The parameter unit
automatically enters the monitoring mode and shows the FWD (or) REV
output frequency.
60.00Hz
STF FWD PU
4 Press the [STOP] key. 4. Stop

The motor is decelerated to a stop. STOP
RESET
Stop
57
OPERATION
3.2.2 PU jog operation

Hold down the [FWD] or [REV] key to perform operation, and release it to stop.
1 Switch power on, press the [PU] key, and make sure that
1. Power on →
the frequency setting screen appears on the display. Operation mode check
If it is not shown, switch to the PU operation mode. ON
DIRECTLY
SET 0.00Hz
0～400
2 The frequency and acceleration/deceleration time for jog 2. Running frequency setting
operation can be set in the following parameters.
<Factory setting>
・ Pr. 15 "jog frequency" ････････････ 5Hz SET 15
READ
8 WRITE
・ Pr. 16 "jog acceleration/deceleration" 0.5 sec.
3 Press the [PU] key, then the [SHIFT] key. 3. Jog operation mode selection
The jog operation mode is selected and the PU JOG
PU SHIFT
frequency setting screen appears on the display.
To change the frequency, enter the value and press the
PU/JOG
[WRITE] key. Set 8.00Hz
0～400
4 Press the [FWD] or [REV] key. 4. Operation

The display changes to the monitor screen. Hold down the
key to perform operation and release it to stop. FWD (or) REV
If the motor does not run, check Pr. 13 "starting frequency".

If its setting is less than the starting frequency, the motor
will not run.
5 Press the [PU] key. 5. Exit from jog operation mode

The inverter exits from the jog operation mode and returns
PU
to the ordinary PU operation mode.
To return to the jog operation mode, press the [SHIFT] key.
DIRECTLY
Set 0.00Hz
0～400
58
3.3 Combined Operation (Operation using external input signals and PU)
OPERATION
3.3Combined Operation (Operation using external input signals and PU)
3.3.1 Entering the start signal from outside and setting the running
frequency from the PU (Pr. 79=3)
The external frequency setting signals and the PU's [FWD] and [REV] keys are not
accepted. (Whether the PU's [STOP] key is accepted or not depends on the Pr. 75
setting.)
1 Switch the power on. 1. Power on
ON
2 Set "3" in Pr. 79 "operation mode selection". 2. Operation mode selection

The combined operation mode is selected and the
SET 79
operation mode indication on the display changes to READ
"PU+E". 3 WRITE
0.00PU+E
--- STOP
Hz
3 Set the start switch (STF or STR) to ON. 3. Start

Note: If the forward and reverse rotation switches are both Forward rotation
Reverse rotation
set to ON, the inverter will not start. Also, if these switches
are both set to ON during operation, the motor is
decelerated to a stop. ON 60.00Hz
STF FWD PU+E
4 Set the running frequency to 60Hz from the parameter unit. 4. Running frequency setting
The operation command indication changes to "STF" or <Direct setting>
"STR" and the operation status indication changes to the 7 8 9
output (FWD or REV) indication. 4 5 6
● Direct setting 1 2 3
After pressing the [PU] key, enter the frequency directly with 0
the number keys. <Step setting>
Note that this setting is not available in the monitoring mode.
In this case, press the [WRITE] key to leave the monitoring
mode and then re-set the frequency.
● Press the [PU] key to call the frequency setting screen, and
perform step setting.
Press the [UP]/[DOWN] key to keep on varying the frequency.
Hold down the [UP] (or [DOWN]) key to vary the frequency. As
the frequency varies slowly at the beginning, this feature may
be used for fine adjustment.
5 Set the start switch (STF or STR) to OFF. 5. Stop
The motor stops running. Forward rotation
Reverse rotation
Stop
OFF
59
OPERATION
3.3.2 Entering the running frequency from outside and making

start and stop from the PU (Pr. 79 = 4)

ON
2 Set "4" in Pr. 79 "operation mode selection". 2. Operation mode selection

The combined operation mode is selected and the
operation mode indication on the display changes to SET 79
READ
"PU+E". 4 WRITE
0.00Hz
--- STOP PU+E
3 Enter the external running frequency signal (select the 3. Running frequency
multi-speed signal or turn the frequency setting High speed
ON Mid speed
potentiometer). Low speed
or
4 Press the [FWD] or [REV] key of the PU.

4. Start
The motor starts running.
The state of the output frequency is shown on the display. FWD (or) REV
Note 1: The starting terminals (STF, STR) of the inverter

are invalid.
The inverter may also be started by pressing the 60.00 Hz
STF FWD PU+E
[FWD] or [REV] key of the PU and then increasing
the level of the frequency setting signal.
5 Press the [STOP] key of the PU.
5. Stop
The motor is decelerated to a stop.
STOP
RESET
Stop
60
OPERATION
3.3.3 Entering the start signal and multi-speed signal from outside
and setting multiple speeds from the PU

ON
2 Select the multi-speed signal required for operation (switch 2. Multi-speed signal selection
the RH, RM, RL or REX signal on).
High speed
Mid speed
ON Low speed
3 Set the start switch (STF or STR signal) to ON. 3. Start

The operation command indication changes to "STF" or Forward rotation
Reverse rotation
"STR", the operation status indication changes to the
output (FWD or REV) indication, and the motor starts
running. ON 60.00 Hz
Note: If the forward and reverse rotation switches are both STF FWD EXT
set to ON, the inverter will not start. Also, if these
switches are both set to ON during operation, the
motor is decelerated to a stop.
4 Change the multi-speed frequency during running from the 4. Running frequency
PU. When high speed has been selected (RH signal ON), High speed
changing the Pr. 4 "three-speed setting (high speed)" value Mid speed
Low speed
varies the speed. SET 4
Note: The other multiple-speed settings not being used
WRITE
may also be changed during operation. READ
5 Switch off the multi-speed signal (RH, RM, RL or REX 5. Stop

signal) and set the start switch (STF or STR signal) to OFF. High speed
Mid speed
The motor stops running. Low speed
Forward rotation
OFF
Reverse
rotation
OFF
61
CHAPTER 4
SPECIFICATION
This chapter provides the "specifications" for use of this
product.
4.1 Specifications ･････････････････････････････････62

CHAPTER 2 FUNCTIONS
CHAPTER 3 OPERATION
4
4.1 Specifications
SPECIFICATIONS
4SPECIFICATIONS
4.1Specifications
4.1.1 Standard specifications

Item Specifications
Operating −10℃ to +50℃ (Note 1)
Ambient temperature
Storage −20℃ to +65℃
Ambient humidity 90%RH or less Non-condensing
Operating ambience No oil mist, corrosive gases, minimal dust and dirt.
Power supply Power is supplied from the inverter.
Connection Fitted to the inverter or connected to the inverter by the cable.
Display LCD (liquid crystal display, 16 characters × 4 lines)
Size 125 × (H) × 70 (W) × 15 (D)
Data retention Onboard E2ROM
Number of write
Max. 100,000 times
times
Note: 1. At the low temperatures of less than about 0℃, the liquid crystal display (LCD)
may be slower in operation. At high temperatures, the LCD life may become
shorter.
2. Do not expose the liquid crystal screen to direct sunlight.
3. During transportation, use care to avoid loading the liquid crystal display.
62
SPECIFICATIONS
4.1.2 Outline drawing
72 15 9.7 24
20
125
4.1.3 Panel cutting drawing
16.5
43.75
Panel cut area 11.75 5-φ4 hole
1.5
17
13
1.5
1.25
81.5
3.75 40 (Unit: mm)
63
REVISIONS
*The manual number is given on the bottom left of the back cover.
Print Date *Manual Number Revision

Oct., 1997 IB(NA)-66807-A First edition
SINGER PRESSURE REDUCING VALVE
SINGER
PRESSURE REDUCING VALVE
1-1/4”
MODEL
106/206 –2PR –2SC
IOM A-8509A Page 1 of 15 5 January 2001

CONTENTS
SINGER MODEL 106/206-2PR-2SC ................................................................. 3

DESCRIPTION: ............................................................................................................................... 3
DESCRIPTION OF OPERATION: ....................................................................................................... 3
INSTALLATION: .............................................................................................................................. 4
ADJUSTING PROCEDURE:............................................................................................................... 4
DRAWING A-8509A .......................................................................................... 5
MODEL 106/206-PG POWER OPERATED GLOBE VALVE ............................ 6

INSTALLATION, OPERATING AND MAINTENANCE INSTRUCTIONS:....................................................... 6
DRAWING A-0719A .......................................................................................... 7
MATERIAL SPECIFICATION FOR DRAWING A-0719A................................... 8
MODEL 160 PRESSURE REDUCING PILOT .................................................. 9

DESCRIPTION AND OPERATION: ..................................................................................................... 9
DRAWING A-0708B ........................................................................................ 10
SINGER MODEL 26 FLOW STABILIZER ....................................................... 11

DESCRIPTION: ............................................................................................................................. 11
DRAWING A-0273F......................................................................................... 12
DRAWING A-0618A ........................................................................................ 13
DRAWING A-0564B ........................................................................................ 14
LIMITED WARRANTY ..................................................................................... 15

SINGER MODEL 106/206-2PR-2SC

PRESSURE REDUCING VALVE with SOLENOID SELECTABLE PRESSURE
SETTING
See Drawing A-8509A
Description:
Model 106/206-2PR-2SC is a pilot operated pressure reducing valve designed to automatically
reduce a high inlet pressure into a lower outlet pressure. The valve will maintain a relatively
steady downstream pressure regardless of fluctuations in the supply pressure or flow rate. The
valve has two pressure reducing pilots and solenoid pilots that allows for selection between
the two pilot set points and to close the valve fully.
Unless otherwise specified, the valve will be assembled for service temperatures to 100 F (40
C). Higher temperature ratings are available - consult SINGER VALVE for details.
Description Of Operation:
The valve (1) is normally open when pressure is applied to the valve inlet. When the same
pressure is applied to the bonnet, the valve closes tight. Refer to ‘Installation, Operation and
Maintenance Instructions’. By controlling the pressure in the bonnet, the valve can be made to
open fully, close tight or open partially.
The bonnet pressure (and therefore the position of the valve) is controlled by a pilot circuit
consisting of a fixed restriction (3), two solenoid pilots (5 & 6) and two pressure-reducing pilots
(7 & 8).
When flow is required, the pressure reducing pilot senses a drop in its outlet pressure and
opens. The flow through the pilot is greater than flow through the fixed restriction. The bonnet
pressure is reduced and the valve opens to supply the demand. The speed of opening is
determined by the setting of the flow control (4). Refer to Model 26 instructions for details and
adjustment. Under flowing conditions the pressure-reducing pilot reacts to small changes in
pressure to modulate the bonnet pressure (and valve position) as required to keep the
downstream pressure constant. Note that the main valve position follows the position of the
pilot. When the pilot closes, the main valve closes. When the pilot opens, the main valve
opens.
A “high” pressure setting can be selected by energizing solenoid (5) and de-energizing
solenoid (6). A “low” pressure setting can be selected by energizing solenoid (6) and
energizing solenoid (5). In the event of a power failure solenoid (5) will be in its normally
closed state. This will direct inlet pressure to the cover causing the main valve to close. To
select a “low” pressure when there is a power failure, open by-pass ball valve (9) and close
pilot ball valve (10C). To select a “high” pressure when there is a power failure, open by-pass
ball valve (9) and close (10D). Note this will also “override” the solenoid selection when power
is available to both solenoids. Ensure ball valves (10C & 10D) are open and by-pass ball valve
(9) is closed when power is restored.

Installation:
1) For main valve installation refer to 106/206-PG IOM ‘Installation, Operation and
Maintenance Instructions’.
2) Check solenoid for correct voltage and pressure.
• WARNING: NEVER ENERGIZE AN AC SOLENOID COIL WHEN THE COIL IS
REMOVED FROM THE SOLENOID PILOT.
3) Wire the solenoid to the customer supplied controls and adhere to all local codes and
requirements.
Adjusting Procedure:
1) Open pilot ball valves (10A), (10B), (10C) and (10D)

2) Close by-pass ball valve (9).
3) DE-ENERGIZE solenoid (6) and ENERGIZE solenoid (5). By-pass ball valve (9) can
be opened in lieu of energizing solenoid (5).
4) Crack outlet mainline stop valve and slowly open mainline inlet stop valve wide.
5) Bleed air from main valve bonnet. See 106/206-PG ‘Installation, Operation and
Maintenance Instructions’.
6) Open mainline outlet stop valve wide.
7) Adjust setting of “high” pressure reducing pilot (7). Turn adjusting screw clockwise to
increase pressure setting. Turn counterclockwise to decrease pressure setting.
Tighten locknut after desired setting is obtained. See 160 instructions for further
details. THERE MUST BE FLOW THROUGH VALVE WHEN MAKING PILOT
ADJUSTMENTS.
8) Close pilot ball valve (10C).
9) Adjust setting of “low” pressure reducing pilot (8). Turn adjusting screw clockwise to
increase pressure setting. Turn counterclockwise to decrease pressure setting.
Tighten locknut after desired setting is obtained. See 160 instructions for further
details. THERE MUST BE FLOW THROUGH VALVE WHEN MAKING PILOT
ADJUSTMENTS.
10) Open pilot ball valve (10C).
11) Ensure by-pass ball valve (9) is closed.
12) If the valve does NOT open (pressure remains low), check the adjustment of Model 26
flow control. See model 26 instructions.
13) If valve begins to oscillate or hunt:
• Bleed air from main valve bonnet. See ‘Installation, Operation and Maintenance
Instructions’.
• Adjust Model 26 flow control. See model 26 instructions.

DRAWING A-8509A
Customized for Falcon Concentrators
8
9
2
3 4
7
6
11 5
10B
10C
10A
10D
Flow
1. Ductile iron model 106-PG or 206-PG main valve

* Hi-build internal epoxy coating
2. Model J0098A strainer
3. Fixed restriction - 1/16"
4. Model 26 opening speed control
5. Solenoid, 2-way N.C. (Supplied by Falcon Concentrators)
6. Solenoid, 2-way N.O. (Supplied by Falcon Concentrators)
7. Model 160 pressure reducing pilot (high setting)
8. Model 160 pressure reducing pilot (low setting)
9. Manual by-pass ball valve
10. Pilot isolation ball valve
11. Model X107 position indicator
SINGER VALVE INC
12850-87th Avenue
Surrey, BC
Canada. V3W-3H9
Dual Pilot Pressure Reducing Valve with Date: January 22, 2001 Appd. By:
Solenoid Selectable Pressure Setting Drawing
Drawn By: Scott Grover
A-8509A
Model 106 or 206-2PR-2SC

MODEL 106/206-PG POWER OPERATED GLOBE VALVE

Sizes 1/2" to 8" (106-PG) 4" to 10" (206-PG)
Installation, Operating and Maintenance Instructions:
DESCRIPTION: b) Valves installed in horizontal piping with bonnet up (WITH

LIMIT SWITCH): Refer to Drawing A0707A. Use bleed screw
This valve is the basic component used for most Singer Model (63) to vent air.
106/206 Automatic Valves. It is a hydraulically operated valve. c) Valves installed in vertical pipe: The pilot connection will be to
DESCRIPTION OF OPERATION: the highest point on the bonnet if the orientation and flow
direction were specified on the order. Some sizes vent
The valve opens when the bonnet (area above the diaphragm) is automatically. Some sizes are provided with a small screw to
connected to the downstream side of the valve AND a pressure facilitate bleeding (do not remove completely).
drop of 5 psi (35 kPa) is available across the valve. The valve d) Valves that do not have the bleed screw and do not bleed
also opens when the bonnet is vented to atmosphere, regardless completely from existing connections must be bled by
of pressure drop, provided that the line pressure is 5 psi (35 kPa) loosening the bonnet bolts.
or more.
SERVICE SUGGESTIONS:
The valve closes when the inlet pressure is directed to the
bonnet. POSSIBLE CAUSE / REMEDY
The valve can be made to modulate by varying the bonnet
FAILS TO OPEN
pressure between inlet pressure and outlet pressure. This is done
by the pilot circuit. 1. Insufficient inlet pressure. / Increase pressure
2. Pressure in the bonnet is not released:
In some cases the line media is unsuitable for use in the pilot
• Isolating valves on pilot lines closed. / Open valves
system. In these circumstances external water pressure can be
used in the pilot system. The external pressure must be equal to • Pilot components not functioning. / Refer to specific
or higher than the line pressure. instructions on pilot components
• Foreign material in pilot system. / Clear obstruction
If available pressure drop is less than 5 psi (35 kPa), spring lift
and external water pressure must be used. (consult factory) FAILS TO CLOSE
Unless otherwise specified, the valve is assembled with Lack of pressure in the bonnet due to:
components suitable for water service up to 120o F (50o C). For • Pilot components not functioning. / Refer to specific
other service conditions, contact your Singer Valve instructions on pilot components.
representative. • Foreign material in pilot system. / Clear obstructions.
INSTALLATION: • Ruptured diaphragm. / Replace worn parts.
• Obstruction in the valve. / Remove obstructions.
1. The valve will operate in any position but maintenance is • Worn main valve disc. / Replace disc.
easiest on valves installed in horizontal line with the bonnet
up. PULSATIONS
2. For most convenient operation and maintenance, line
• Air in the bonnet. / Vent air. Refer to "Installation (9)" above.
isolation valves should be installed.
3. A suitable bypass should be provided to allow for servicing • Improper adjustment to pilot components. / Refer to specific
of the valve without interrupting the flow. instructions on pilot components.
4. Install pressure gauges upstream and/or downstream of • Valve oversized. A smaller valve in parallel may be required.
valve as appropriate. This will facilitate ease of setting the MAINTENANCE:
pilot system.
5. A strainer with a suitable basket should be installed ahead of The SINGER Model 106/206-PG requires a minimum of
the valve to protect it from foreign material. maintenance. All parts are accessible for inspection and repair
6. Sufficient space should be provided around the valve for without removing the valve from the line.
disassembly. 1. Close upstream and downstream isolating gate valves.
7. Flush system of all foreign matter before installing the valve. 2. Disconnect body and bonnet pilot lines.
8. Check direction of flow (inlet of valve is marked OR an arrow 3. Remove bonnet. If bonnet does not come free readily, it can
on the side of body indicates flow direction) and install the be pried loose with a small pry-bar.
valve accordingly. 4. Remove main valve assembly for inspection. Do not remove
9. VENT AIR FROM THE BONNET After installation, when the seat ring unless inspection shows that it is damaged.
valve is pressurized, vent air from the bonnet: 5. Replace worn or defective parts and reassemble.
a) Valves installed in horizontal piping with bonnet up (NO
LIMIT SWITCH): NOTE REGARDING FREEZING:
This valve does not drain completely when inlet and outlet pipes
Sizes up to 2" where pilot connection is to the guide bushing are drained. Where freezing conditions are expected, one of the
at the center of the valve do not require venting (they vent following must be performed:
automatically).
• Drain valve and pilot system completely.
Sizes up to 2" with position indicator: use bleed-cock on
• Add suitable anti-freeze to valve and pilot system (Non-
indicator.
potable water service only).
Sizes 2-1/2" and larger, loosen pipe plug at the center of the • Provide insulation and/or heating to keep the valve from
bonnet to bleed air. If equipped with position indicator, use freezing.
bleed-cock on indicator.

DRAWING A-0719A
A0719A
SINGER MODEL 106PG
POWER OPERATED GLOBE VALVE
GLOBE AND ANGLE STYLE : SIZES 2-1/2" to 8"
20
18 3/8" NPT CONNECTION 13
12 16
11 15 8
10 49
'E'
9 7
6
46
3
17
44
45 5
'D' 19 'F'
14 4
'B'
'A'
A0719A
MATERIAL SPECIFICATION FOR DRAWING A-0719A

Sizes 2-1/2” To 8”
ITEM PART MATERIAL ITEM PART NAME MATERIAL
1 Body Ductile Iron ASTM A536 13 Stem Cap Ductile Iron (A536)
2 Bonnet Ductile Iron (A536) *14 Seat Ring Seal Buna-N
X3 Seat Ring S. St. AISI 303 *15 Stem Cap Seal Buna-N
4 Stem S. St. AISI 303 16 Body Capscrew Steel Cad-plated
!5 Disc Retainer Cast Iron ASTM A48 -17 Seat Ring Screws S. St. 18-8
*6 Resilient Disc Buna - N 18 Stem Cap Capscrew Steel Cad-plated
7 Inner Valve Cast Iron ASTM A48 -19 Bottom Guide Ductile Iron & Bronze
*8 Diaphragm Reinforced Neoprene 20 Stem Cap Plug Brass
9 Clamp Plate Cast Iron ASTM A48 -44 Retaining Washer S. St. AISI 303
10 Stem nut Brass B-16 *45 Diaphragm Seal Buna - N
11 Spring S. St. AISI 302 46 Locating Pin Steel
12 Guide Bushing Brass B-16 49 Disc Retainer Seal Buna-N
* Recommended spare parts are included in the standard repair kits.

+ For availability of other materials, consult factory
- Not required on size 2-1/2”, (One piece seat ring and guide, shown as item 3 ).
X On size 2-1/2” items 3 & 19 are one piece; material - bronze ASTM B-62 and S. St. AISI 303
! On sizes 2-1/2” to 4”, material is brass B-16 On size 3”, material is bronze B-62.
DIMENSIONS : SIZE 2-1/2” 3” 4” 6” 8”

GLOBE STYLE CV 86 120 210 520 815
ANSI 300 SCREWED A 11” 13-5/8

ANSI 150 FLANGED A 11” 12-1/2” 15” 20-1/8” 25”
ANSI 300 FLANGED A 11-5/8” 13-1/4” 15-5/8” 21” 26”
D 3-3/4” 4-1/8” 4-1/2” 5-3/4” 7-3/4”
C 7-5/8” 9-3/8” 11-1/2” 17” 20-1/2”
E 7-5/8” 8-1/8” 9-3/16” 11-7/8” 15-1/2”
Optional Pos. Ind. G 4” 4” 4-1/2” 4-1/2” 6”
ANGLE STYLE CV 90 135 260 635 1050
ANSI 300 SCREWED B 5-1/2” 6-5/8”

F 4” 4-7/8”
ANSI 150 FLANGED B 5-1/2” 6-1/16” 7-11/16” 10-1/4” 12-7/16”
F 4-1/8” 4-1/16” 6-1/8” 6-1/2” 8-15/16”
ANSI 300 FLANGED B 5-13/16” 6-7/16” 8” 10-5/8” 12-15/16”
F 4-5/16” 4-7/16” 6-7/16” 6-13/16” 9-7/16”
C 7-3/4” 9-3/8” 11-1/2” 17” 20-1/2”
E 7-5/8” 8-1/8” 9-3/16” 12-7/8” 15-1/2”
Optional Pos. Ind. G 4” 4” 4-1/2” 4-1/2” 6”
Sensing Connections (NPT) 3/8” 3/8” 3/8” 3/8” / ½” 3/8” / ½”

(Body/Bonnet, if applicable)

MODEL 160 PRESSURE REDUCING PILOT

See Drawing A-0708B
Description And Operation:
Model 160 is a direct acting, spring and diaphragm DIAPHRAGM REPLACEMENT:

type pressure-reducing valve. The valve is held • Note the orientation of the diaphragm to help
open by the spring. The outlet pressure acting on install the replacement diaphragm properly.
the diaphragm opposes the spring to close the valve.
• Hold the inner valve (5) HEX in a vise and use a
INSTALLATION: screwdriver that is a proper fit on slot on top of
the stem (4) to turn the stem counterclockwise. If
1. Install the valve as shown in the enclosed
required, use a second screwdriver or similar tool
schematic or drawing.
at the Yoke (6) to prevent the yoke from turning.
2. Note the direction of flow and install the valve BE CAREFUL NOT TO DAMAGE THE STEM
accordingly. GUIDING SURFACE.
3. The valve should be installed with the adjusting • Replace the diaphragm and orient it to straddle
screw pointing up. the legs of the yoke.
ADJUSTMENT: REASSEMBLY:
Turn the adjusting screw clockwise for increased Reassembly is the reverse of disassembly. Ensure
pressure, counterclockwise for reduced pressure that parts are replaced in the sequence shown on
setting. Range of adjustment is shown on the the drawing.
nameplate.
TEST PROCEDURE:
DISMANTLING: Connect a source of air or water to the inlet. Attach
1. Close upstream and downstream isolating valves. a 3/8" line with a pressure gauge and shut-off valve
2. Remove the valve from the pilot system. to the outlet. Back off the adjusting screw, then
proceed to turn it in. The gauge should show an
3. Remove the adjusting screw. increase within the range marked on the valve.
4. Remove the body screws (11) and remove the Open the shut-off valve slightly and bleed flow to
spring casing assembly. atmosphere. Pressure should drop slightly and
5. Loosen the diaphragm if it adheres to the body return to setting when the shut-off valve is closed.
and remove the Stem/Yoke assembly. Be careful This check should be performed at various settings.
to avoid damage to the stem as any interference SERVICE SUGGESTION:
or friction between the stem (4) and guide
bushing (10) can cause problems. POSSIBLE CAUSE / REMEDY
If further disassembly is required: FAILS TO OPEN:

Valve under-set./ Increase setting.
INNER VALVE REPLACEMENT:
FAILS TO CLOSE:
Hold the inner valve (5) HEX in a vise and use a
screwdriver or similar tool to turn the Yoke (6). Valve overset. / Reduce setting.
Obstruction on seat. / Clear obstruction.
Ruptured diaphragm. / Replace diaphragm.
Worn inner valve. / Replace inner valve.

DRAWING A-0708B
FILENAME:
A0708B ASSEMBLY/A0708B
SINGER MODEL 160

PRESSURE REDUCING PILOT SINGER MODEL 160
PRESSURE REDUCING PILOT
MATERIAL SPECIFICATION
17
ITEM PART NAME MATERIAL
1. BODY BRONZE ASTM B-62
16 2. DIAPHRAGM BUNA-N
3. OUTLET CONNECTOR BRASS
4. STEM STAINLESS STEEL 303
14 5. INNER VALVE AISI 303 & BUNA-N
6. YOKE SILICON BRONZE B-198
13 7. CLAMP PLATE BRASS B-16
8. SPRING CASING BRONZE ASTM B-62
9. RETAINING RING STAINLESS STEEL
8
10. GUIDE BUSHING DELRIN
11. SPRING CASING SCREW (8) 18-8 STAINLESS STEEL
4 12. CLAMP PLATE SEAL BUNA-N
13. SPRING SPRING STEEL
10 14. SPRING STEPS (2) 18-8 STAINLESS STEEL
16. LOCKNUT 18-8 STAINLESS STEEL
9 17. ADJUSTING SCREW 18-8 STAINLESS STEEL
11 18. SEAT RING AISI 303 STAINLESS STEEL
12 19. SEAT RING SEAL BUNA-N
9" MAX
2 20.** BUCKING SPRING AISI 302 STAINLESS STEEL
7 ** NOT SHOWN - USED ONLY WITH SPRING RANGE 5 - 50 PSI.
6 SPRING RANGES ADJUSTMENT (PSI/TURN)

INLET 3/8" NPT 19 5- 50 PSI 7
10 - 80 PSI 12
20 - 200 PSI 26
18 100 - 300 PSI 35
OUTLET 3/8" NPT 3
O3"
SINGER VALVE INC.

12850-87th avenue
surrey, bc
canada. v3w-3h9
Date: 04/05/96 Appd. By:
A0708B
Drawn By: KK
NOVEMBER 1999
MODEL:160

SINGER MODEL 26 FLOW STABILIZER
See Drawing A-0273F
Description:
Model 26 is a low flow stabilizer used on Model To dampen pulsations, loosen Locknut (7) and turn
106/206-PR pressure reducing valve and other the Adjusting Screw (2) COUNTERCLOCKWISE
valves that require low flow stabilizing. until pulsing is dampened. Lock the locknut.
DESCRIPTION OF OPERATION: Check that the main valve has sufficient opening
speed by increasing the demand rapidly. If the
Model 26 stabilizes the main valve by providing opening speed is too slow, turn the adjusting screw
relatively unrestricted closing speed and controlled clockwise a few degrees to find an acceptable
opening speed. Refer to Drawing A0273E. compromise between fast opening and good
Flow DOWN to port '1' is unrestricted. A very light pulsation damping.
spring (4) allows Inner Valve (3) to open (move ADJUSTMENT (OFF VALVE):
down). Flow UP from port '1' is restricted by Inner
Valve (3). Adjusting Screw (2) keeps the Inner Valve If above adjustment procedure fails to dampen the
(3) from closing tight. pulsations, remove Model 26 from the pilot system,
remove any fittings and clean.
INSTALLATION:
Blow (or connect a source of air or water pressure)
When installing Model 26 on Model 106/206-PR, the to port '1'. Loosen Locknut (7) and turn Adjusting
connections are: Screw (2) COUNTERCLOCKWISE until flow through
Port 1 - Bonnet of Main Valve. port '1' is very severely restricted. Lock the locknut
Port 2 - Inlet of Pilot Valve. and retest. Install the pilot system. Any further
Port 3 - Inlet of Main Valve adjustments required should be only a few degrees.
NOTE: There must be a RESTRICTION in the line NOTE: THE SLIGHTEST TRACE OF AIR IN THE
from the inlet of the main valve to Port 3 of the PILOT SYSTEM OR BONNET WILL CAUSE
Model 26. Refer to applicable schematic. INSTABILITY IN VERY LOW FLOW
SIZING OF RESTRICTION : APPLICATIONS. REPEATED BLEEDING AND
FLUSHING MAY BE NEEDED.
Valves 1/2" to 2": 1/16"
Valves 2-1/2" to 4”: 3/32” If the Model 26 does not close tight in above test,
Valves 4” and larger: 1/8" turn the Adjusting Screw (2) COUNTER-
CLOCKWISE (CCW) as far as it goes and using a
For connections on other models, refer to applicable 1/8" or 3/16" diameter punch through port '1' and
schematic. Spring Retainer (5), tap the Inner Valve (3) sharply to
ADJUSTMENT (ON VALVE): seat it.
If the main valve pulsates (hunts), check for air in the

bonnet of the main valve (see 106/206-PG
instructions). If the pulsations continue after
bleeding air from the main valve bonnet, adjust
Model 26.

DRAWING A-0273F
SINGER MODEL 26
A0273F
FLOW CONTROL
2
7
6
PORT 3 PORT 2
1
3
4
5
PORT 1
ITEM DESCRIPTION MATERIAL

1 BODY SST
2 ADJUSTING SCREW SST
3 INNER VALVE SST
4 SPRING SST
5 SPRING RETAINER BRASS
6 SCREW SEAL BUNA-N
7 LOCKNUT BRASS
FLOW DOW N TO PORT '1' FLOW UP FROM PORT '1' FLOW UP FROM PORT '1'
IS UNRESTRICTED IS RESTRICTED IS STOPPED
REVISED: FEB/2000
A0273F

DRAWING A-0618A
SINGER MODEL J0097A STRAINER

SENSING OR GAUGE FLOW OUT 3/8" NPT 3
CONNECTION, 1/4" NPT
1
1.50"
FLOW IN
4
2.75"
3/8" NPT
2
SINGER MODEL J0098A STRAINER

FLOW OUT 3
3/8" NPT
1.50"
FLOW IN
3/8" NPT 2.75"

2
ITEM DESCRIPTION MATERIAL

1. BODY BRASS
2. SCREEN RETAINER BRASS
3. SCREEN (40 Mesh) STAINLESS STEEL
4. BLOW DOW N PLUG BRASS
A0681A

DRAWING A-0564B
MODEL X107 POSITION INDICATOR

2-1/2" to 8" 106; 4" to 10" 206
29
23
21
25
'G' 22
27
25
24
28
18
12
15
26
ITEM PART NAME STANDARD MATERIAL

2 Bonnet Ductile iron ASTM A536
12 Guide bushing Brass B-36
15** Stem cap seal Buna-N
18 Stem cap capscrew Cad-plated steel
21 Indicator body Brass B-36
22 Sight tube Pyrex glass
23 Indicator cap Brass B-36
24 Stem cap Ductile iron ASTM A-536
25** Sight tube gasket Buna-N
26 Stem AISI 303 SST
27 Indicator rod AISI 303 SST
28 Retaining pin 18-8 SST
29 Bleed Valve Brass B-36 ** Recommended
spare parts
VALVE SIZE 2-1/2" 3" 4" 6" 8" 10"
DIM 'G'-106 4-1/2" 4-1/2" 4-3/4" 5" 6-1/2" N/A
DIM 'G'-206 N/A N/A 4-1/2" 4-3/4" 5" 6-1/2"
A0564B

LIMITED WARRANTY
This is a limited warranty

Automatic valves and controls as manufactured by SINGER VALVE, INC., (hereafter referred to as SINGER
VALVE) are warranted for THREE YEARS from date of shipment, against manufacturing defects in material and
workmanship which develop in the service for which they are designed, provided the products are installed and
used in accordance with all applicable instructions and limitations issued by SINGER VALVE.
We will repair or replace defective material, free of charge, if returned to our factory, transportation charges prepaid,
provided that, after inspections, the material is found to have been defective at time of shipment. This warranty is
expressly conditioned on the purchaser's giving SINGER VALVE immediate written notice upon discovery of the
defect. Repairs or parts replaced under this warranty are warranted throughout the remainder of the original
warranty period only.
Components used by SINGER VALVE, but manufactured by others, are warranted only to the extent of that
manufacturer's guarantee.
This warranty shall not apply if the product has been altered or repaired by others, and SINGER VALVE shall make
no allowances or credit for such repairs or alterations unless authorized in writing by SINGER VALVE.
Disclaimer Of Warranties And Limitations Of Liability

The foregoing warranty is exclusive and in lieu of all other warranties and representations, whether expressed,
implied, oral or written, statutory or otherwise, including but not limited to, any implied warranties of merchantability
or fitness for a particular purpose. All such other warranties and representations are hereby cancelled.
SINGER VALVE shall not be liable for any incidental or consequential loss, damage or expense (including loss of
use) caused by defects in the product or by repair of it or arising directly or indirectly from the use of the product or
otherwise. SINGER VALVE shall not be liable for any damages or charges for labor or expense in making
unauthorized repairs or adjustments to the product. SINGER VALVE shall not be liable for any damages or charges
sustained in the adaptation of use of its engineering data and services.
No representatives of SINGER VALVE may change any of the foregoing or assume any additional liability or
responsibility in connection with the product. The liability of SINGER VALVE is limited to material repairs or
replacements F.O.B. our factory.

Installation & Maintenance Instructions SERIES
8003G
8202G
OPEN-FRAME, GENERAL PURPOSE, WATERTIGHT/EXPLOSIONPROOF SOLENOIDS Form No.V6584R7
INSTALLATION
Ċ SERVICE NOTICE Ċ Check nameplate for correct catalog number, service, and wattage. Check
front of solenoid for voltage and frequency.
ASCO solenoid valves with design change letter G" or H" in the catalog
number (ex. 8210G 1) have an epoxy encapsulated ASCO Red Hat II WARNING: Electrical hazard from the accessibility
solenoid. This solenoid replaces some of the solenoids with metal enclosures of live parts. To prevent the possibility of death,ĂseriĆ
and open-frame constructions. Follow these installation and maintenance
instructions if your valve or operator uses this solenoid. ous injury or property damage, install the open -
frame solenoid in an enclosure.
See separate instructions for basic valve.
FOR BLACK ENCLOSURE TYPES 7 AND 9 ONLY
DESCRIPTION
CAUTION: To prevent fire or explosion, do not install solenoid
Catalog numbers 8003G and 8202G are epoxy encapsulated pull-type and/or valve where ignition temperature of hazardous atmosphere is
solenoids. The green solenoid with lead wires and 1/2Ăconduit connection is less than 165 C. On valves used for steam service or when a class
designed to meet Enclosure Type 1-General Purpose, Type 2-Dripproof, H" solenoid is used, do not install in hazardous atmosphere where
Types 3 and 3S-Raintight, and Types 4 and 4X-Watertight. The black ignition temperature is less than 180C. See nameplate/retainer for
solenoid on catalog numbers prefixed EF" or EV" is designed to meet service.
Enclosure Types 3 and 3S-Raintight, Types 4 and 4X-Watertight, Types 6 NOTE: These solenoids have an internal non-resetable thermal fuse to
and 6P-Submersible, Type 7 (A, B, C & D) Explosionproof Class I, Division limit solenoid temperature in the event that extraordinary conditions occur
1 Groups A, B, C, & D and Type 9 (E, F, & G)-Dust-Ignitionproof Class II, which could cause excessive temperatures. These conditions include high
Division 1 Groups E, F & G. The Class II, Groups F & G Dust Locations input voltage, a jammed core, excessive ambient temperature or a shorted
designation is not applicable for solenoids or solenoid valves used for steam solenoid, etc. This unique feature is a standard feature only in solenoids with
service or when a class H" solenoid is used. See Temperature Limitations black explosionproof/dust-ignitionproof enclosures (Types 7 & 9).
section for solenoid identification and nameplate/retainer for service. When
installed just as a solenoid and not attached to an ASCO valve, the core has
a 0.250-28 UNF-2B tapped hole, 0.38 or 0.63 minimum full thread.
CAUTION: To protect the solenoid valve or operator, install a
NOTE: Catalog number prefix EV" denotes stainless steel construction.
strainer or filter, suitable for the service involved in the inlet side as
Catalog numbers 8202G1, 8202G3, 8202G5 and 8202G7 are epoxy encapsuĆ close to the valve or operator as possible. Clean periodically dependĆ
lated push-type, reverse-acting solenoids having the same enclosure types ing on service conditions. See ASCO Series 8600, 8601, and 8602 for
as previously stated for Catalog numbers 8003G1 and 8003G2. strainers.
Series 8003G and 8202G solenoids are available in: Temperature Limitations
Open-Frame Construction: The green solenoid may be supplied with For maximum valve ambient temperatures, refer to chart. The temperature
1/4 spade, screw or DIN terminals. (Refer to Figure 4) limitations listed, only indicate maximum application temperatures for field
Panel Mounted Construction: These solenoids are specifically designed wiring rated at 90C. Check catalog number prefix and watt rating on
to be panel mounted by the customer through a panel having a .062 to .093 nameplate to determine maximum ambient temperature. See valve installaĆ
maximum wall thickness. Refer to Figure 1 and section on Installation of tion and maintenance instructions for maximum fluid temperature. NOTE:
Panel Mounted Solenoid. For steam service, refer to Wiring section, Junction Box for temperature
rating of supply wires.
Optional Features For Type 1 - General Purpose
Temperature Limitations For Series 8003G or 8202G Solenoids
Construction Only for use on Valves Rated at 10.1, 11.6, 17.1, or 22.6 Watts
Junction Box: This junction box construction meets Enclosure Types Watt Catalog Class of Maximum
2,3,3S,4, and 4X. Only solenoids with 1/4 spade or screw terminals may Rating Number Coil Prefix Insulation Ambient Temp.
have a junction box. The junction box provides a 1/2 conduit connection, None, FB, KF, KP
grounding and spade or screw terminal connections within the junction 10.1 & 17.1 F 125F (51.7C)
SC, SD, SF, & SP,
box (See Figure 5).
DIN Plug Connector Kit No.K236034:Ă Use this kit only for solenoids with HB, HT, KB, KH,
10.1 & 17.1 H 140F (60C)
DIN terminals. The DIN plug connector kit provides a two pole with SS, ST, SU,
grounding contact DIN Type 43650 construction (See Figure 6). None, FB,KF, KP,
11.6 & 22.6 F 104F (40C)
SC, SD, SF, & SP.
OPERATION HP, HT, KB, KH,
11.6 & 22.6 H 104F (40C)
Series 8003G - When the solenoid is energized, the core is drawn into the SS, ST, SU, & SV
solenoid base sub-assembly. IMPORTANT: When the solenoid is Minimum ambient temperature -40 F (-40 C).
de-energized, the initial return force for the core, whether developed by
spring, pressure, or weight, must exert a minimum force to overcome Positioning
residual magnetism created by the solenoid. Minimum return force for AC This solenoid is designed to perform properly when mounted in any position.
construction is 11 ounces, and 5 ounces for DC construction. However, for optimum life and performance, the solenoid should be
mounted vertically and upright to reduce the possibility of foreign matter
Series 8202G - When the solenoid is energized, the disc holder assembly accumulating in the solenoid base sub-assembly area.
seats against the orifice. When the solenoid is de-energized , the disc holder
assembly returns. IMPORTANT: Initial return force for the disc or disc Wiring
holder assembly, whether developed by spring, pressure, or weight, must Wiring must comply with local codes and the National Electrical Code. All
exert a minimum force to overcome residual magnetism created by the solenoids supplied with lead wires are provided with a grounding wire which
solenoid. Minimum return force is 1 pound, 5 ounces. is green or green with yellow stripes and a 1/2 conduit connection. To
Page 1 of 4
MCMXCIX All Rights Reserved Printed in U.S.A.
ASCO Valves 50-60 Hanover Road, Florham Park, New Jersey 07932
facilitate wiring, the solenoid may be rotated 360. For the watertight and Cleaning
explosionproof solenoid, electrical fittings must be approved for use in the All solenoid operators and valves should be cleaned periodically. The time
approved hazardous locations. between cleaning will vary depending on medium and service conditions. In
general, if the voltage to the solenoid is correct, sluggish valve operation,
CAUTION: Cryogenic Applications - Solenoid lead wire excessive noise or leakage will indicate that cleaning is required. Clean
insulation should not be subjected to cryogenic temperatures. strainer or filter when cleaning the valve.
Adequate lead wire protection and routing must be provided.
Preventive Maintenance
Additional Wiring Instructions For Optional Features: Keep the medium flowing through the solenoid operator or valve as free
Open-Frame solenoid with 1/4 spade terminals. from dirt and foreign material as possible.
For solenoids supplied with screw terminal connections use #12-18 AWG While in service, the solenoid operator or valve should be operated at least
stranded copper wire rated at 90C or greater. Torque terminal block screws once a month to insure proper opening and closing.
to 10 ± 2 in-lbs [1,0 ± 1,2 Nm]. A tapped hole is provided in the solenoid for Depending on the medium and service conditions, periodic inspection of
grounding, use a #10-32 machine screw. Torque grounding screw to 15 - 20 internal valve parts for damage or excessive wear is recommended.
in-lbs [1,7 - 2,3 Nm]. On solenoids with screw terminals, the socket head Thoroughly clean all parts. Replace any worn or damaged parts.
screw holding the terminal block to the solenoid is the grounding screw. Causes of Improper Operation
Torque the screw to 15 - 20 in-lbs [1,7 - 2,3 Nm] with a 5/32 hex key Faulty Control Circuit: Check the electrical system by energizing the
wrench. solenoid. A metallic click signifies that the solenoid is operating. Absence
Junction Box of the click indicates loss of power supply. Check for loose or blown fuses,
The junction box is used with spade or screw terminal solenoids only and is open-circuited or grounded solenoid, broken lead wires or splice
provided with a grounding screw and a 1/2 conduit connection. Connect connections.
#12-18 AWG standard copper wire only to the screw terminals. Within the Burned-Out Solenoid: Check for open-circuited solenoid. Replace if
junction box use field wire that is rated 90C or greater for connections. For necessary. Check supply voltage; it must be the same as specified on
steam service use 105C rated wire up to 50 psi or use 125C rated wire above nameplate/retainer and marked on the solenoid. Check ambient
50 psi. After electrical hookup, replace cover gasket, cover, and screws. temperature and check that the core is not jammed.
Tighten screws evenly in a crisscross manner. Low Voltage: Check voltage across the solenoid leads. Voltage must be at
DIN Plug Connector Kit No.K236034 least 85% of rated voltage.
1. The open-frame solenoid is provided with DIN terminals to Solenoid Replacement
accommodate the plug connector kit. 1. Disconnect conduit, coil leads, and grounding wire.
2. Remove center screw from plug connector. Using a small screwdriver, pry NOTE: Any optional parts attached to the old solenoid must be reinstalled
terminal block from connector cover. on the new solenoid. For 3-way construction, piping or tubing must be
3. Use #12-18 AWG stranded copper wire rated at 90C or greater for removed from pipe adapter.
connections. Strip wire leads back approximately 1/4 for installation in 2. Disassemble solenoids with optional features as follows:
socket terminals. The use of wire-end sleeves is also recommended for Spade or Screw Terminals
these socket terminals. Maximum length of wire-end sleeves to be Remove terminal connections, grounding screw, grounding wire, and
approximately 1/4.ĂTinning of the ends of the lead wires is not terminal block (screw terminal type only).
recommended. NOTE: For screw terminals, the socket head screw holding the terminal
4. Thread wire through gland nut, gland gasket, washer and connector cover. block serves as a grounding screw.
NOTE: Connector housing may be rotated in 90 increments from position Junction Box
shown for alternate positioning of cable entry. Remove conduit and socket head screw (use 5/32 hex key wrench) from
5. Check DIN connector terminal block for electrical markings. Then make center of junction box. Disconnect junction box from solenoid.
electrical hookup to terminal block according to markings on it. Snap DIN Plug Connector
terminal block into connector cover and install center screw. Remove center screw from DIN plug connector. Disconnect DIN plug
6. Position connector gasket on solenoid and install plug connector. Torque
connector from adapter. Remove socket head screw (use 5/32 hex key
center screw to 5 ± 1 in-lbs [0,6 ± 1,1 Nm].
wrench), DIN terminal adapter, and gasket from solenoid.
NOTE: Alternating current (AC) and direct current (DC) solenoids are built 3. Snap off red cap from top of solenoid base sub-assembly. For 3-way
differently. To convert from one to the other, it may be necessary to change construction with pipe adapter (Figure 3), remove pipe adapter, nameĆ
the complete solenoid including the core and solenoid base sub-assembly, plate and solenoid. Omit steps 4 and 5.
not just the solenoid. Consult ASCO. 4. Push down on solenoid. Then using a suitable screwdriver, insert blade
between solenoid and nameplate/retainer. Pry up slightly and push to
Installation of Solenoid remove.
Solenoids may be assembled as a complete unit. Tightening is accomplished NOTE: Series 8202G solenoids have a spacer between the nameplate/
by means of a hex flange at the base of the solenoid. retainer and solenoid.
Installation of Panel Mounted Solenoid (See Figure 1) 5. Remove solenoid from solenoid base sub-assembly.
1. Disassemble solenoid following instruction under Solenoid Replacement 6. Reassemble in reverse order of disassembly. Use exploded views for
then proceed. identification and placement of parts.
2. Install solenoid base sub-assembly through customer panel. 7. Torque pipe adapter to 90 inch-pounds maximum [10,2 Nm maximum].
3. Position spring washer on opposite side of panel over solenoid base sub- Then make up piping or tubing to pipe adapter on solenoid.
assembly. Disassembly and Reassembly of Solenoids
4. Replace solenoid, nameplate/retainer and red cap. 1. Remove solenoid, see Solenoid Replacement.
5. Make electrical hookup, see Wiring section. 2. Remove spring washer from solenoid base sub-assembly. For 3-way
construction, remove plugnut gasket.
Solenoid Temperature
3. Unscrew solenoid base sub-assembly from valve body.
Standard solenoids are designed for continuous duty service. When the
4. Remove internal solenoid parts for cleaning or replacement. Use
solenoid is energized for a long period, the solenoid becomes hot and can be
exploded views for identification and placement of parts.
touched by hand only for an instant. This is a safe operating temperature.
5. If the solenoid is part of a valve, refer to basic valve installation and
MAINTENANCE maintenance instructions for further disassembly.
6. Torque solenoid base sub-assembly and adapter to 175±25 in-lbs
WARNING: To prevent the possibility of death, [19,8±2,8 Nm].
serious injury or property damage, turn off electrical
ORDERING INFORMATION FOR ASCO SOLENOIDS
power, depressurize solenoid operator and/or valve, When Ordering Solenoids for ASCO Solenoid Operators or Valves, order
and vent fluid to a safe area before servicing. the number stamped on the solenoid. Also specify voltage and frequency.
Page 2 of 4 Form No.V6584R7
Torque Chart
Part Name Torque Value Inch-Pounds Torque Value Newton-Meters
solenoid base sub-assembly & adapter 175 ± 25 19,8 ± 2,8
pipe adapter 90 maximum 10,2 maximum
Remove red cap and

push solenoid down.
Then pry here to lift red cap Remove red cap and
nameplate/retainer push solenoid down.
and push to remove. nameplate/ Then pry here to lift
retainer nameplate/retainer
and push to remove.
grounding wire -
solenoid green or green with
with 1/2 NPT yellow stripes
.062 to .093 maximum finger washer

thickness of panel
for mounting
0.69 diameter
mounting hole Side View
finger
core core solenoid base washer
(AC) (DC) sub-assembly collar to face
Tapped hole in core 0.9375-26 UNS -2A valve body
0.250-28 UNF-2B thread
0.63 minimum full thread (AC) Alternate
0.38 minimum full thread (DC) Panel Mount Construction
Figure 1. Series 8003G solenoids
red cap Remove red cap and

push solenoid down.
Then pry here to lift
nameplate/ nameplate/retainer pipe adapter
retainer and push to remove.
spacer plugnut gasket
grounding wire -
green or green with
solenoid
yellow stripes
with 1/2 NPT
spring washer
solenoid base
sub-assembly
bonnet washer
cutaway view to core(small end up)
show positioning
of retainer in solenoid base gasket
gasket recess plugnut assembly
retainer gasket adapter
retainer gasket
adapter
stem
disc holder
disc assembly Air Only Construction
Without With Vent to Atmosphere
Adapter disc spring disc holder Adapter
spring
Figure 2. Series 8202G solenoids Figure 3. 3-Way Construction
Form No.V6584R7 Page 3 of 4
Torque Chart
Part Name Torque Value in Inch-Pounds Torque Value in Newton-Meters
terminal block screws 10 ± 2 1,1 ± 0,2
socket head screw 15 - 20 1,7 - 2,3
center screw 5±1 0,6 ± 0,1
Open-Frame Solenoid Open-Frame Solenoid

Open-Frame Solenoid with Screw Terminals. with DIN Terminals Indicates parts supplied
with 1/4 Spade Terminals Socket head screw is in Termination Module
used for grounding. Kit No. K256104
See
torque chart screw terminal gasket
above adapter
DIN terminal
adapter
terminal
block
screw
tapped hole for
socket head
socket head screw
#10-32 grounding screw grounding screw
(not included) (5/32 hex key wrench) (5/32 hex key wrench)
Figure 4. Open-frame solenoids

Junction Box Solenoid
screw terminal block cover screw
with 1/4 Spade Terminals (see note)
or Screw Terminals See
cover
torque chart
above
cover gasket
grounding screw
and cup washer
junction box gasket
Note:
Junction box with screw terminals
shown. With screw terminal
block removed, remaining parts junction box with
comprise the junction box for 1/2 conduit connection socket head screw
spade terminal construction. and grounding terminal (5/32 hex key wrench)
Figure 5. Junction box (optional feature)
Open-Frame Solenoid
with DIN Terminal Indicates that these parts are included
Plug Conector gasket in DIN plug connector Kit No. K236034
DIN terminal
adapter
See connector
gland nut
torque chart
above gasket
gland gasket
socket head screw

washer
(5/32 hex key wrench)
Notes:
1. Connector cover may be
rotated in 90 increments from DIN connector
position shown for alternate terminal block center screw
position of cable entry. (see note 2) connector cover
2. Refer to markings on DIN (see note 1)
connector for proper
electrical connections.
Figure 6. DIN plug connector kit No. K236034 (optional feature)

Page 4 of 4 Form No.V6584R7
$25.00
Integral Horsepower
AC Induction Motors
ODP Enclosure
TEFC Enclosure
Installation & Operating Manual
9/96 MN400
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section 2
Installation & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Doweling & Bolting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Conduit Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Coupled Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Jogging and Repeated Starts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Section 3
Maintenance & Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lubrication & Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Type of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lubrication Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
MN400 Table of Contents i

Section 1
General Information
Overview This manual contains general procedures that apply to Baldor Motor products. Be sure to read and
understand the Safety Notice statements in this manual. For your protection, do not install, operate or
attempt to perform maintenance procedures until you understand the Warning and Caution statements. A
Warning statement indicates a possible unsafe condition that can cause harm to personnel. A Caution
statement indicates a condition that can cause damage to equipment.
Important: This instruction manual is not intended to include a comprehensive listing of all details for all
procedures required for installation, operation and maintenance. This manual describes general
guidelines that apply to most of the motor products shipped by Baldor. If you have a question
about a procedure or are uncertain about any detail, Do Not Proceed. Please contact your Baldor
distributor for more information or clarification.
Before you install, operate or perform maintenance, become familiar with the following:
S NEMA Publication MG-2, Safety Standard for Construction and guide
for Selection, Installation and Use of Electric Motors and Generators.
S The National Electrical Code
S Local codes and Practices
Limited Warranty
1. Baldor Electric motors are warranted for a period of one (1) year, from date of shipment from the factory or factory
warehouse against defects in material and workmanship. To allow for stocking and/or fabrication period and to
provide one year of actual service, the warranty period is extended for an additional period of six (6) months for a
total of eighteen (18) months from the original date of shipment from the factory or factory warehouse stock. In no
case will the warranty period be extended for a longer period. Baldor extends this limited warranty to each buyer
of the electric motor for the purpose of resale and to the original purchaser for use.
2. Baldor will, at its option repair or replace a motor which fails due to defects in material or workmanship during the
warranty period if:
a. the purchaser presents the defective motor at or ships it prepaid to, the Baldor plant in Fort Smith, Arkansas
or one of the Baldor Authorized Service Centers and
b. the purchaser gives written notification concerning the motor and the claimed defect including the date
purchased, the task performed by the Baldor motor and the problem encountered.
3. Baldor will not pay the cost of removal of any electric motor from any equipment, the cost of delivery to Fort Smith,
Arkansas or a Baldor Authorized Service Center, or the cost of any incidental or consequential damages resulting
from the claimed defects. (Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above exclusion may not apply to you.) Any implied warranty given by laws shall be limited to
the duration of the warranty period hereunder. (Some states do not allow limitations on how long an implied
warranty lasts, so the above limitation may not apply to you.)
4. Baldor Authorized Service Centers, when convinced to their satisfaction that a Baldor motor developed defects in
material or workmanship within the warranty period, are authorized to proceed with the required repairs to fulfill
Baldor’s warranty when the cost of such repairs to be paid by Baldor does not exceed Baldor’s warranty repair
allowance. Baldor will not pay overtime premium repair charges without prior written authorization.
5. The cost of warranty repairs made by centers other than Baldor Authorized Service Centers WILL NOT be paid
unless first authorized in writing by Baldor.
6. Claims by a purchaser that a motor is defective even when a failure results within one hour after being placed into
service are not always justified. Therefore, Baldor Authorized Service Centers must determine from the condition
of the motor as delivered to the center whether or not the motor is defective. If in the opinion of a Baldor
Authorized Service Center, a motor did not fail as a result of defects in material or workmanship, the center is to
proceed with repairs only if the purchaser agrees to pay for such repairs. If the decision is in dispute, the
purchaser should still pay for the repairs and submit the paid invoice and the Authorized Service Center’s signed
service report to Baldor for further consideration.
7. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Note that Baldor Super–ER Premium Efficiency electric motors are warranted for a period of three (3) years.
All other terms and conditions of the Limited Warranty statement apply.
MN400 General Information 1-1

Safety Notice: This equipment contains high voltage! Electrical shock can cause serious or fatal injury.
Only qualified personnel should attempt installation, operation and maintenance of
electrical equipment.
Be sure that you are completely familiar with NEMA publication MG-2, safety standards
for construction and guide for selection, installation and use of electric motors and
generators, the National Electrical Code and local codes and practices. Unsafe
installation or use can cause conditions that lead to serious or fatal injury. Only qualified
personnel should attempt the installation, operation and maintenance of this equipment.
WARNING: Do not touch electrical connections before you first ensure that
power has been disconnected. Electrical shock can cause serious
or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
WARNING: Be sure the system is properly grounded before applying power.
Do not apply AC power before you ensure that all grounding
instructions have been followed. Electrical shock can cause
serious or fatal injury. National Electrical Code and Local codes
must be carefully followed.
WARNING: Avoid extended exposure to machinery with high noise levels. Be
sure to wear ear protective devices to reduce harmful effects to
your hearing.
WARNING: This equipment may be connected to other machinery that has
rotating parts or parts that are driven by this equipment. Improper
use can cause serious or fatal injury. Only qualified personnel
should attempt to install operate or maintain this equipment.
WARNING: Do not by-pass or disable protective devices or safety guards.
Safety features are designed to prevent damage to personnel or
equipment. These devices can only provide protection if they
remain operative.
WARNING: Avoid the use of automatic reset devices if the automatic restarting
of equipment can be hazardous to personnel or equipment.
WARNING: Be sure the load is properly coupled to the motor shaft before
applying power. The shaft key must be fully captive by the load
device. Improper coupling can cause harm to personnel or
equipment if the load decouples from the shaft during operation.
WARNING: Use proper care and procedures that are safe during handling,
lifting, installing, operating and maintaining operations.
Improper methods may cause muscle strain or other harm.
WARNING: Before performing any motor maintenance procedure, be sure that
the equipment connected to the motor shaft cannot cause shaft
rotation. If the load can cause shaft rotation, disconnect the load
from the motor shaft before maintenance is performed. Unexpected
mechanical rotation of the motor parts can cause injury or motor
damage.
WARNING: Disconnect all electrical power from the motor windings and
accessory devices before disassembly of the motor. Electrical
shock can cause serious or fatal injury.
WARNING: Do not use these motors in the presence of flammable or
combustible vapors or dust. These motors are not designed for
atmospheric conditions that require explosion proof operation.
1-2 General Information MN400

Section 1
General Information
Safety Notice Continued

Caution: To prevent premature equipment failure or damage, only qualified
maintenance personnel should perform maintenance.
Caution: Do not lift the motor and its driven load by the motor lifting
hardware. The motor lifting hardware is adequate for lifting only the
motor. Disconnect the load from the motor shaft before moving the
motor.
Caution: If eye bolts are used for lifting a motor, be sure they are securely
tightened. The lifting direction should not exceed a 20° angle from
the shank of the eye bolt or lifting lug. Excessive lifting angles can
cause damage.
Caution: To prevent equipment damage, be sure that the electrical service is
not capable of delivering more than the maximum motor rated amps
listed on the rating plate.
Caution: If a HI POT test (High Potential Insulation test) must be performed,
follow the precautions and procedure in NEMA MG-1 and MG-2
standards to avoid equipment damage.
If you have any questions or are uncertain about any statement or procedure, or if you
require additional information please contact your Baldor distributor or an Authorized
Baldor Service Center.
MN400 General Information 1-3

Section 1
General Information
Receiving Each Baldor Electric Motor is thoroughly tested at the factory and carefully packaged for
shipment. When you receive your motor, there are several things you should do
immediately.
1. Observe the condition of the shipping container and report any damage
immediately to the commercial carrier that delivered your motor.
2. Verify that the part number of the motor you received is the same as the part
number listed on your purchase order.
Storage If the motor is not put into service immediately, the motor must be stored in a clean, dry
and warm location. Several precautionary steps must be performed to avoid motor
damage during storage.
1. Use a “Megger” periodically to ensure that the integrity of the winding insulation
has been maintained. Record the Megger readings. Immediately investigate
any significant drop in insulation resistance.
2. Do not lubricate bearings during storage. Motor bearings are packed with
grease at the factory. Excessive grease can damage insulation quality.
3. Rotate motor shaft at least 10 turns every two months during storage (more
frequently if possible). This will prevent bearing damage due to storage.
4. If the storage location is damp or humid, the motor windings must be protected
from moisture. This can be done by applying power to the motors’ space
heater (if available) while the motor is in storage.
Unpacking Each Baldor motor is packaged for ease of handling and to prevent entry of
contaminants.
1. To avoid condensation inside the motor, do not unpack until the motor has
reached room temperature. (Room temperature is the temperature of the room
in which it will be installed). The packing provides insulation from temperature
changes during transportation.
2. When the motor has reached room temperature, remove all protective wrapping
material from the motor.
Handling The motor should be lifted using the lifting lugs or eye bolts provided.
1. Use the lugs or eye bolts provided to lift the motor. Never attempt to lift the
motor and additional equipment connected to the motor by this method. The
lugs or eye bolts provided are designed to lift only the motor. Never lift the
motor by the motor shaft.
2. If the motor must be mounted to a plate with the driven equipment such as
pump, compressor etc., it may not be possible to lift the motor alone. For this
case, the assembly should be lifted by a sling around the mounting base. The
entire assembly can be lifted as an assembly for installation. Do not lift using
the motor lugs or eye bolts provided.
If the load is unbalanced (as with couplings or additional attachments)

additional slings or other means must be used to prevent tipping. In any event,
the load must be secure before lifting.
1-4 General Information MN400

Section 2
Installation & Operation
Overview Installation should conform to the National Electrical Code as well as local codes and
practices. When other devices are coupled to the motor shaft, be sure to install
protective devices to prevent future accidents. Some protective devices include,
coupling, belt guard, chain guard, shaft covers etc. These protect against accidental
contact with moving parts. Machinery that is accessible to personnel should provide
further protection in the form of guard rails, screening, warning signs etc.
Location The motor should be installed in an area that is protected from direct sunlight, corrosives,
harmful gases or liquids, dust, metallic particles, and vibration. Exposure to these can
reduce the operating life and degrade performance. Be sure to allow clearance for
ventilation and access for cleaning, repair, service and inspections. Ventilation is
extremely important. Be sure the area for ventilation is not obstructed. Obstructions will
limit the free passage of air. Motors get warm and the heat must be dissipated to prevent
damage.
These motors are not designed for atmospheric conditions that require explosion proof
operation. They must NOT be used in the presence of flammable or combustible vapors
or dust.
1. ODP motors are suitable only for indoor applications.
2. TEFC motors are suitable for indoor or outdoor standard service applications.
Mounting The motor must be securely installed to a rigid foundation or mounting surface to
minimize vibration and maintain alignment between the motor and shaft load. Failure to
provide a proper mounting surface may cause vibration, misalignment and bearing
damage.
Foundation caps and sole plates are designed to act as spacers for the equipment they
support. If these devices are used, be sure that they are evenly supported by the
foundation or mounting surface.
After installation is complete and accurate alignment of the motor and load is
accomplished, the base should be grouted to the foundation to maintain this alignment.
The standard motor base is designed for horizontal or vertical mounting. Adjustable or
sliding rails are designed for horizontal mounting only. Consult your Baldor distributor or
authorized Baldor Service Center for further information.
Alignment Accurate alignment of the motor with the driven equipment is extremely important.
1. Direct Coupling
For direct drive, use flexible couplings if possible. Consult the drive or
equipment manufacturer for more information. Mechanical vibration and
roughness during operation may indicate poor alignment. Use dial indicators to
check alignment. The space between coupling hubs should be maintained as
recommended by the coupling manufacturer.
2. End-Play Adjustment
The axial position of the motor frame with respect to its load is also extremely
important. The motor bearings are not designed for excessive external axial
thrust loads. Improper adjustment will cause failure.
3. Pulley Ratio
The pulley ratio should not exceed 8:1.
4. Belt Drive
Align sheaves carefully to minimize belt wear and axial bearing loads (see
End-Play Adjustment). Belt tension should be sufficient to prevent belt slippage
at rated speed and load. However, belt slippage may occur during starting.
Caution: Do not over tension belts.
MN400 Installation & Operation 2-1

Section 1
General Information
Doweling & Bolting After proper alignment is verified, dowel pins should be inserted through the motor feet
into the foundation. This will maintain the correct motor position should motor removal be
required. (Baldor motors are designed for doweling.)
1. Drill dowel holes in diagonally opposite motor feet in the locations provided.
2. Drill corresponding holes in the foundation.
3. Ream all holes.
4. Install proper fitting dowels.
5. Mounting bolts must be carefully tightened to prevent changes in alignment.
Use a flat washer and lock washer under each nut or bolt head to hold the
motor feet secure. Flanged nuts or bolts may be used as an alternative to
washers.
Power Connection Motor and control wiring, overload protection, disconnects, accessories and grounding
should conform to the National Electrical Code and local codes and practices.
Conduit Box For ease of making connections, an oversize conduit box is provided. The box can be
rotated 360° in 90° increments. Auxiliary conduit boxes are provided on some motors for
accessories such as space heaters, RTD’s etc.
AC Power Connect the motor leads as shown on the connection diagram located on the name plate
or inside the cover on the conduit box. Be sure the following guidelines are met:
1. AC power is within ±10% of rated voltage with rated frequency. (See motor
name plate for ratings).
OR
2. AC power is within ±5% of rated frequency with rated voltage.
OR
3. A combined variation in voltage and frequency of ±10% (sum of absolute
values) of rated values, provided the frequency variation does not exceed ±5%
of rated frequency.
Performance within these voltage and frequency variations are shown in Figure 2-1.
2-2 Installation & Operation MN400

Section 1
General Information
Figure 2-1 Motor Performance VS Voltage Variations

+20
Maximum
Full -Load Torque
Current
+15
Changes in Motor Performance (%)
+10
Full -Load
Power Current
Factor
+5
Efficiency Efficiency
–5
–10
–15
Power
Maximum Factor
Torque
–20
–15 –10 –5 0 +5 +10 +15
Voltage Variations (%)
MN400 Installation & Operation 2-3

Section 1
General Information
First Time Start Up Be sure that all power to motor and accessories is off. Be sure the motor shaft is
disconnected from the load and will not cause mechanical rotation of the motor shaft.
1. Make sure that the mechanical installation is secure. All bolts and nuts are
tightened etc.
2. If motor has been in storage or idle for some time, check winding insulation
integrity with a Megger.
3. Inspect all electrical connections for proper termination, clearance, mechanical
strength and electrical continuity.
4. Be sure all shipping materials and braces (if used) are removed from motor
shaft.
5. Manually rotate the motor shaft to ensure that it rotates freely.
6. Replace all panels and covers that were removed during installation.
7. Momentarily apply power and check the direction of rotation of the motor shaft.
8. If motor rotation is wrong, be sure power is off and change the motor lead
connections. Verify rotation direction before you continue.
9. Start the motor and ensure operation is smooth without excessive vibration or
noise. If so, run the motor for 1 hour with no load connected.
10. After 1 hour of operation, disconnect power and connect the to load to the
motor shaft. Verify all coupling guards and protective devices are installed.
Ensure motor is properly ventilated.
Coupled Start Up This procedure assumes a coupled start up. Also, that the first time start up procedure
was successful.
1. Check the coupling and ensure that all guards and protective devices are
installed.
2. Check that the coupling is properly aligned and not binding.
3. The first coupled start up should be with no load. Apply power and verify that
the load is not transmitting excessive vibration back to the motor though the
coupling or the foundation. Vibration should be at an acceptable level.
4. Run for approximately 1 hour with the driven equipment in an unloaded
condition.
The equipment can now be loaded and operated within specified limits. Do not exceed
the name plate ratings for amperes for steady continuous loads.
Jogging and Repeated Starts Repeated starts and/or jogs of induction motors generally reduce the life of the motor
winding insulation. A much greater amount of heat is produced by each acceleration or
jog than than by the same motor under full load. If it is necessary to to repeatedly start or
jog the motor, it is advisable to check the application with your local Baldor distributor or
Heating - Duty rating and maximum ambient temperature are stated on the motor name
plate. Do not exceed these values. If there is any question regarding safe operation,
contact your local Baldor distributor or Baldor Service Center.
2-4 Installation & Operation MN400

Section 3
Maintenance & Troubleshooting
General Inspection Inspect the motor at regular intervals, approximately every 500 hours of operation or
every 3 months, whichever occurs first. Keep the motor clean and the ventilation
openings clear. The following steps should be performed at each inspection:
WARNING: Do not touch electrical connections before you first ensure that
power has been disconnected. Electrical shock can cause serious
or fatal injury. Only qualified personnel should attempt the
installation, operation and maintenance of this equipment.
1. Check that the motor is clean. Check that the interior and exterior of the motor
is free of dirt, oil, grease, water, etc. Oily vapor, paper pulp, textile lint, etc. can
accumulate and block motor ventilation. If the motor is not properly ventilated,
overheating can occur and cause early motor failure.
2. Use a “Megger” periodically to ensure that the integrity of the winding insulation
has been maintained. Record the Megger readings. Immediately investigate
any significant drop in insulation resistance.
3. Check all electrical connectors to be sure that they are tight.
Lubrication & Bearings Bearing grease will lose its lubricating ability over time, not suddenly. The lubricating
ability of a grease (over time) depends primarily on the type of grease, the size of the
bearing, the speed at which the bearing operates and the severity of the operating
conditions. Good results can be obtained if the following recommendations are used in
your maintenance program.
Type of Grease A high grade ball or roller bearing grease should be used. Recommended greases for
standard service conditions are:
Shell Dolium R (Factory Installed) or Chevron SRI.
Lubrication Intervals Recommended lubrication intervals are shown in Table 3-1. It is important to realize that
the recommended intervals of Table 3-1 are based on average use. Refer to additional
information contained in Tables 3-2 and 3-3.
Table 3-1 Lubrication Intervals
Rated Speed - RPM
NEMA / (IEC) Frame
F Size
Si 3600 1800 1200 900
Up to 210 incl. (132) 5500 Hrs. 12000 Hrs. 18000 Hrs. 22000 Hrs.
Over 210 to 280 incl. (180) 3600 Hrs. 9500 Hrs. 15000 Hrs. 18000 Hrs.
Over 280 to 360 incl. (225) * 2200 Hrs. 7400 Hrs. 12000 Hrs. 15000 Hrs.
Over 260 to 5000 incl. (300) *2200 Hrs. 3500 Hrs. 7400 Hrs. 10500 Hrs.
* Bearings in 360 through 5000 frame, 2 pole motors are either 6313 or 6314 bearings and lubrication interval is shown
in the table. If roller bearings are used, the bearings must be lubricated more frequently, divide the listed lubrication
interval by 2.
Table 3-2 Service Conditions
Severity of Service Ambient Temperature Atmospheric Type of Bearing
Maximum Contamination
Standard 40° C Clean, Little Corrosion Deep Groove Ball Bearing
Severe 50° C Moderate dirt, Corrosion Ball Thrust, Roller
Extreme >50° C* or Severe dirt, Abrasive dust, All Bearings
Class H Insulation Corrosion
Low Temperature <–30° C **
* Special high temperature grease is recommended (Darmex 707).
** Special low temperature grease is recommended (Arrowshell 7).
MN400 Maintenance & Troubleshooting 3-1

Table 3-3 Lubrication Interval Multiplier
Severity of Service Multiplier
Standard 1.0
Severe 0.5
Extreme 0.1
Table 3-4 Bearings Sizes and Types
Frame Size Bearing Description
NEMA (IEC) (These are the “Large” bearings (Shaft End) in each frame size)
Bearing OD Width Weight of Volume of grease
D mm B mm Grease to to be added
add
dd in3 tea-
oz (Grams) spoon
Up to 210 incl. (132) 6307 80 21 0.30 (8.4 ) 0.6 2.0
Over 210 to 280 incl. (180) 6311 120 29 0.61 (17.4 ) 1.2 3.9
Over 280 to 360 incl. (225) 6313 140 33 0.81 (23.1 ) 1.5 5.2
Over 360 to 5000 incl. (300) NU322 240 50 2.12 (60.0) 4.1 13.4
Weight in grams = .005 DB
Lubrication Procedure Be sure that the grease you are adding to the motor is compatible with the grease already
in the motor. Consult your Baldor distributor or an authorized service center if a grease
other than the recommended type is to be used.
Caution: To avoid damage to motor bearings, grease must be kept free of
dirt. For an extremely dirty environment, contact your Baldor
distributor or an authorized Baldor Service Center for additional
information.
1. Clean all grease fittings.
2. Remove grease outlet plug.
3. If motor is stopped, add the recommended amount of grease.
If motor is to be greased while running, a slightly greater quantity of grease will
have to be added. Add grease slowly until new grease appears at shaft hole in
the endplate or purge outlet plug.
4. Re-install grease outlet plug.
Sample Lubrication Determination
Assume - NEMA 286T (IEC 180), 1750 RPM motor driving an exhaust fan in an ambient
temperature of 43° C and the atmosphere is moderately corrosive.
1. Table 3-1 list 9500 hours for standard conditions.
2. Table 3-2 classifies severity of service as “Severe”.
3. Table 3-3 lists a multiplier value of 0.5 for Severe conditions.
4. Table 3-4 shows that 1.2 in3 or 3.9 teaspoon of grease is to be added.
Note: Smaller bearings in size category may require reduced amounts of grease.
3-2 Maintenance & Troubleshooting MN400

Section 1
General Information
Accessories The following is a partial list of accessories available from Baldor.

Contact your Baldor distributor for availability and pricing information.
Note: Space heaters and RTD’s are standard on some motors.
Bearing RTD
RTD (Resistance Temperature Detector) devices are used to measure or
monitor the temperature of the motor bearing during operation.
Bearing Thermocouples
Used to measure or monitor bearing temperatures.
Bearing Thermostat
Temperature device that activates when bearing temperatures are excessive.
Used with an external circuit to warn of excessive bearing temperature or to
shut down a motor.
Conduit Boxes
Optional conduit boxes are available in various sizes to accommodate
accessory devices.
Cord & Plug Assembly
Adds a line cord and plug for portable applications.
Drains and Breathers
Stainless steel drains with separate breathers are available.
Drip Covers
Designed for use when motor is mounted in a vertical position. Contact your
Baldor distributor to confirm that the motor is designed for vertical mounting.
Fan Cover & Lint Screen
To prevent build-up of debris on the cooling fan.
Nameplate
Additional stainless steel nameplates are available.
Roller Bearings
Recommended for belt drive applications with a speed of 1800 RPM or less.
Rotation Arrow Labels
Rotation arrows are supplied on motors designed to operate in one direction
only. Additional rotation arrows are available.
Space Heater
Added to prevent condensation of moisture within the motor enclosure during
periods of shut down or storage.
Stainless Hardware
Stainless steel hardware is available. Standard hardware is corrosion resistant
zinc plated steel.
Winding RTD
RTD (Resistance Temperature Detector) devices are used to measure or
monitor the temperature of the motor winding during operation.
Winding Thermocouples
Used to measure or monitor winding temperatures.
Winding Thermostat
Temperature device that activates when winding temperatures are excessive.
Used with an external circuit to warn of excessive winding temperature or to
shut down a motor.
Note: On some motors, leads for accessory devices are brought out to a separate
conduit box located on the side of the motor housing (unless otherwise
specified).
MN400 Maintenance & Troubleshooting 3-3

Section 1
General Information
Table 3-5 Troubleshooting Chart

Symptom Possible Causes Possible Solutions
Motor will not start Usually caused by line trouble, such Check source of power. Check overloads, fuses,
as, single phasing at the starter. controls, etc.
Excessive humming High Voltage. Check input line connections.
Eccentric air gap. Have motor serviced at local Baldor service center.
Motor Over Heating Overload. Compare actual amps Locate and remove source of excessive friction in
(measured) with nameplate rating. motor or load.
Reduce load or replace with motor of greater capacity.
Single Phasing. Check current at all phases (should be approximately
equal) to isolate and correct the problem.
Improper ventilation. Check external cooling fan to be sure air is moving
properly across cooling fins.
Excessive dirt build-up on motor. Clean motor.
Unbalanced voltage. Check voltage at all phases (should be approximately
equal) to isolate and correct the problem.
Rotor rubbing on stator. Check air gap clearance and bearings.
Tighten “Thru Bolts”.
Over voltage or under voltage. Check input voltage at each phase to motor.
Open stator winding. Check stator resistance at all three phases for balance.
Grounded winding. Perform dielectric test and repair as required.
Improper connections. Inspect all electrical connections for proper
termination, clearance, mechanical strength and
electrical continuity. Refer to motor lead connection
diagram.
Bearing Over Heating Misalignment. Check and align motor and driven equipment.
Excessive belt tension. Reduce belt tension to proper point for load.
Excessive end thrust. Reduce the end thrust from driven machine.
Excessive grease in bearing. Remove grease until cavity is approximately 3/4 filled.
Insufficient grease in bearing. Add grease until cavity is approximately 3/4 filled.
Dirt in bearing. Clean bearing cavity and bearing. Repack with correct
grease until cavity is approximately 3/4 filled.
Vibration Misalignment. Check and align motor and driven equipment.
Rubbing between rotating parts and Isolate and eliminate cause of rubbing.
stationary parts.
Rotor out of balance. Have rotor balance checked are repaired at your
Resonance. Tune system or contact your Baldor Service Center for
assistance.
Noise Foreign material in air gap or Remove rotor and foreign material. Reinstall rotor.
ventilation openings. Check insulation integrity. Clean ventilation openings.
Growling or whining Bad bearing. Replace bearing. Clean all grease from cavity and new
bearing. Repack with correct grease until cavity is
approximately 3/4 filled.
3-4 Maintenance & Troubleshooting MN400

BALDOR ELECTRIC COMPANY
P.O. Box 2400
Ft. Smith, AR 72902–2400
(501) 646–4711
Fax (501) 648–5792
 Baldor Electric Company Printed in USA
MN400 9/96
EAGLE Pd Sprocket and Belt Installation
Follow all safety policies and requirements of federal, state and local authorities, as well as the regulations of the employer,
when working on power equipment. Always lock out the power source to the machinery before performing any work. Drive
size and location may require different assembly methods than the one outlined here.
Preparation
Clean all mating surfaces of the sprocket, bushing, and shaft. No lubrication should be used on any of these surfaces.
Make sure the shafts are true and parallel by accurately measuring the distance between the shafts at three points along
the shaft. The distance between the shafts should be the same at all three points. Also make sure the shafts are rigidly
mounted. Shafts should not deflect when the belt is tensioned.
Sprocket and Bushing Installation

If the sprockets are supplied with a bushing then refer to the directions supplied with the bushing. Align the sprockets using
a straight edge. Check for contact in 4 places as shown. Do not use bearings or drive shafts as reference points for
sprocket alignment. The sprocket will draw onto the bushing during tightening. Always recheck alignment after tightening
the capscrews. Loosen the capscrews and realign if necessary.
If the sprockets are finished bore use the above alignment procedure
and then tighten the setscrews to the torque value listed at right.
Capscrew (in) 1/4 5/16 3/8 1/2 9/16 5/8 3/4

Seating Torque (ft-lb) 9 15 30 60 75 135 225
Contact
Points
Belt Installation and Tensioning
1. Inspect the belt for damage and verify that the sprockets are properly mounted with the teeth pointing in the same
direction. Place the belt on each sprocket and ensure proper engagement between the sprocket and belt teeth.
2. Lengthen the center distance or adjust the tensioning idler to remove any belt slack.
3. Using a tape measure, measure the span length of the drive. Refer to
Span Length
dimension “P” in the diagram.
D1 Diam. in.
4. Place a straight edge or reference line across the top of the belt.
F.Force (lbs)
5. Determine the proper deflection force from the tables below. x G. Deflection (in.) x
a) If using the Eagle Pd tension gauge the deflection scale is calibrated
in inches of span length. Refer to the instructions supplied with the gauge. D1 Diam. in.
b) If using other means to apply force to the belt then adjust the center
distance so that the belt is deflected 1/64” per inch of span length
when the proper deflection force is applied. C1Center Distance
6. After the belt is properly tensioned lock down the center distance adjust-ments
and recheck the sprocket alignment. Recheck the belt tension, alignment, and capscrew torque after 8 hours of
operation to ensure the drive has not shifted.
Deflection Force for Belt Tensioning (lbs)
Yellow Belts White Belts Blue Belts Green Belts Orange Belts Red Belts
Number of Teeth on Smaller Sprocket
RPM of 18 to 23 to 31 & 18 to 23 to 31 & 28 to 31 to 39 & 28 to 31 to 39 & 28 to 31 to 39 & 28 to 31 to 39 &
Small Sprocket 23 31 up 23 31 up 31 39 up 31 39 up 31 39 up 31 39 up
Under 100 13 16 17 26 32 34 54 58 61 81 87 92 108 116 122 162 174 183

100 to 300 12 14 16 24 28 32 50 54 56 75 81 84 100 108 112 150 162 168
300 to 600 11 13 14 22 26 28 45 49 51 68 74 77 90 98 102 135 147 153
600 to 900 10 12 13 20 24 26 42 45 47 63 68 71 84 90 94 126 135 141
900 to 1200 9 11 12 18 22 24 39 42 45 59 63 68 78 84 90 117 126 135
1200 to 2000 9 10 11 18 20 22 37 40 44 56 60 66 74 80 88 111 120 132
2000 to 3500 8 9 11 16 18 22 36 38 40 54 57 60 72 76 80 108 114 120
3500 & up 8 9 10 16 18 20 32 35 37 48 53 56 64 70 74 96 105 111
DEUBLIN GENERAL PURPOSE 55 SERIES UNIONS
Part No.’s 055-000-04, 355-000-002, 555-033-154, 655-502-116
For Falcon “SB” Concentrators
These compact, versatile unions can be used for Water, Intermittent Steam or Hot Oil.
Two precision ball bearings keep the seal faces in perfect alignment. Models 55 and 355
have stainless steel rotors. Models 555, and 655 have carbon steel rotors. All sizes are
available with 2 seal face combinations for both monoflow and duoflow service.
Falcon Concentrators Inc. provides these instructions as general guidelines. They do not
contain exhaustive information about the installation, use or maintenance of unions.
Purchasers and users of Deublin Unions should be certain that they have reviewed
Deublin’s catalog and have sufficient experience and training in the use of unions before
attempting installation or use of Deublin’s products.
“ALL PURPOSE” SEALS

The standard “All Purpose” seals are Carbon Graphite-to-Bronze with a TFE sealing
wedge. Then can be used for water filtered to 25 microns where low operating torque is
required and temperature does not exceed 395º F (200ºC). Unions used above 250º F
require periodic lubrication. Check with the Deublin Engineering Department for a
lubrication guide.
OPERATING DATA
Max Water Pressure Model 55-555 750 PSI 51 bar

Max Water Pressure Model 655 600 PSI 41 bar
Max Water Temp 300º F 150º C
Max RPM NPT Threads 1500 1500/min
Max RPM NPT Threads Model 655 750 750/min
Max RPM ST Threads Model 55-255 3500 3500/min
Max RPM ST Threads Model 355 3000 3000/min
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 1

E.L.S. (EXTENDED LIFE SEALING)
For applications where filtration is not possible and water may contain rust, scale, chips; or
where maximum union life is required, E.L. S. seals are capable of extending seal life 2 to
4 times and even more depending on the severity of your problem. The union features
Tungsten Carbide-to Ceramic Seals with a Fluor-Elastomer O-Ring.
OPERATING DATA
Max Water Pressure 150 PSI 10 bar

Max Water Temp 300º F 150º C
Max RPM NPT Threads Model 55-555 1500 1500/min
Max RPM NPT Threads Model 655 750 750/min
Max RPM ST Threads 55-255 3500 3500/min
D1 MONOFLOW LENGTH
F (3) 11/32 DIA VENTS

EQ. SPACED
1/16"
C
G
ROTOR HOLE
K
A
H
ACROSS
FLATS B
J
LOCK UP APPROX
B A
K
PORT MODEL ROTOR C D1 D2 E F G H J
NPT
NPT THREAD
3/8” 55-000-004 5/8”-18 UNF LH 1 ¾” 3 15/16” 4 13/16” 1” 5/8” 3/8” 7/8” 2 1/2” 1/4”
1” 355-000-002 1” NPT RH 3 1/4” 6 13/16” 8 5/16” 1 15/16” 1 1/8” 1” 1 1/2” 4 11/16” 3/4”
1 ½” 555-033-154 1 ½” NPT RH 4 1/4” 8 1/2” 10 5/16” 2 7/16” 1 3/16” 1 1/2” 2 1/8” 6” 1 1/4”
2” 655-502-116 2” NPT RH 4 5/8” 10 1/16” 11 3/4” 3” 1 1/2” 1 7/8” 2 1/4” 7” 1 1/4”
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 2

REPAIR INSTRUCTIONS FOR 55 SERIES
TOOLING - BY CUSTOMER
Spring Compressor
Truarc Pliers Rotor Assembly Removal Plate
(Length to span fork in base of H
Model Pliers No. arbor press) 1/2"
055 3
(5/8" Thick
355 5 for 555
GF E D
555 5R Series
Rotors)
655 J4 (Nylon)
B C
A
Disassembly Rod Drill and tap
to fit Rotor
A 6" Thread MODEL A B C D E F G H
(Steel) 055 3 1/2 1/4 1/2 3/4 .490 3/16 .370 1/2
B
.495 .375
355 6” 3/16 7/8 1 3/4 1.457 1/4 1.112 7/16
Model A. DIA. B Spring Retaining Pin
1.452 1.110
555 6 3/16 7/8 2 1/8 1.867 1/4 1.480 7/16
055 5/16" 5" 1.862 1.485
355 3/4" 8" 1/16
655 8 1/4 3/4 2 1/8 2 1/4 1 1/2 1 1/8
555 1" 10" 3/16

1/8 5"
655 1" 15" DIA.
DISASSEMBLY
1 Remove Housing Snap Ring & Plug Housing

2
Ram Thread
Remove Rotor Rotor into
Assembly Removal
Plate
Housing Snap
Ring
Rotor
Assembly
Deublin
Union
Rod Arbor
Press
Plug Bed
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 3

3 Remove Floating Seal, Teflon Wedge, Seal
Guide, Coil Spring & Plug
4 Check area of bore shown for wear or pitting.

The bore must be smooth (16 -20 RMS
finish) and may be enlarged to the diameters
in chart below.
Floating
Seal
Teflon
Wedge
Seal
Guide
Coil
{ A Model
055
A max.
.504
Spring 355 1.471
555 1.884
655 2.259
Plug
ASSEMBLY
Assemble Coil Spring. (Grease Bearing

1 Bore.) Compress Spring until Retaining Pin
can be inserted through entrance port as
REBUILDING KIT PARTS LIST shown.
Remove Spring Compressor.
Rotor (Pre Assembled) Floating Seal
(2) Ball Bearings Teflon Seal Wedge-
Bearing Spacer (or) 055 0-Ring
Rotor Snap Ring Seal Guide -
Coil Spring (055 (2) Required) Spring
Compressor Housing
NOTE:
When assembling Deublin Unions cleanliness is an
important factor. All parts must be free of dirt and Retaining
chips. The parts may be cleaned with clorothene, Pin
carbon tetra-chloride, alcohol or any good cleaning
solvent. Coil
Spring
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 4

Assemble Seal Guide, Teflon Seal Wedge Clean Rotor, Carbon Seal Face and
2 and Floating Seal 3
assemble.
NOTE: Rotor Assembly

(Clean Floating Seal face and lubricate with
light viscosity oil)
Ram
Rotor
Assembly
Teflon
Floating
Wedge
Seal
(055 O-Ring)
Seal
Guide
4 Assemble Housing Snap Ring
TESTING
Housing
Test union with 50 PSI minimum air pressure before
Snap
permanent installation.
Ring Replace After
Testing
Cap
Test Hole
Plug
Remove
Pin
Air Supply
Plug duoflow port and cap rotor. Apply air pressure.
Put soap water solution or bubble soap over test
hole. Rotate rotor by hand. If no bubble rises union
is o.k.
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 5

DEUBLIN GENERAL 3” UNION
Part No. 857-000-101
This union combines economical initial cost with low maintenance and repair cost. You
can now upgrade to a longer wearing, mechanically sealed union that’s competitively
priced compared to commonly used pressure type joints. It features special wear-resistant
keyed seals (Tungsten Carbide to Carbon Graphite) that are capable of long service life
even under contaminated water conditions. And, when seals eventually do wear, both
seals are easily replaced on the machine, so downtime and cost are held to a minimum.
The 857 is a modern “full flow” design that utilizes a stacked wave spring to provide
uniform seal pressure without interfering with media flow. The rotor turns smoothly on
widely spaced twin precision ball bearings. The vented housing protects the bearings from
grease washout so they seldom need to be replaced.
OPERATING DATA

Max. Water Temperature 300º F 150º C
Max Speed 500 RPM 500/min
Torque @ 150 PSI/10 bar 6 ft. lbs 8.2 Nm
G C
H (ACROSS FLATS) B
B A C
MODEL D E F G H J
PORT ROTOR THREAD DIA.
TYPE I
3” NPT
857-000-101 3” NPT RH 7 1/2” 13 3/4” 3 7/16” 1 7/8” 2 7/8” 4” 10 9/16”
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 6

DEUBLIN STAINLESS STEEL UNION
Part No. 354-050-117 & 554-051-112
All metal parts are 316 stainless steel. Standard seals are Carbon-Graphite-to-Ceramic.
The secondary seal is a spring loaded TFE “V” seal.
OPERATING DATA
Max Pressure and Max. Speed See Diagram
MODEL 54
Max Temperature 302º F 150º C 1800
Max. RPM NPT 1500 1500/min
PRESSURE IN P.S.I.
1500
Temperatures above 160º F (70º C) Pressure should not 1200 154
exceed 150 P.S.I. (10 bar) and media must be in liquid form. 254
900
354
600
300
1000 2000 3000 4000
SPEED IN R.P.M. (BSP THREADS)

D
E (3) VENT HOLES 11/32" DIA
F
1/16"
T G C
C
B
H ACROSS FLATS
J
B A
C D E F G H J T
NPT MODEL ROTOR THREAD
1“ 354-050-117 1” (NPT) RH 3 11/16” 6 9/16” 1 15/16” 1 1/8” 7/8” 1 7/16” 4 7/8” 1 25/32”
1 1/2“ 554-051-112 1 1/2” (NPT) RH 4 1/4” 7 15/16” 2 1/4” 1 13/32” 7/8” 1 5/16” 5 1/8” 2 6/16”
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 7

DEUBLIN 3” CARTRIDGE WATER UNION
Part No. 6300-015-157
Deublin’s exclusive “Cartridge” design allows on-the-machine replacement of seals. Seals

are replaced quick and easy. There’s no need to remove hose connections or use special
tools. Simply remove 6 hex bolts and end cap, then remove floating seal cartridge and
rotor seal face and replace with new seals. Rotor seal is keyed and sealed to the rotor with
a built-in O-Ring. Replace end cap and hex bolts, and safety wire.
The steel banded floating seal and widely spaced heavy duty ball bearings make this
union resistant to shock and vibration. E.L.S. SEALS are Silicon Carbide-to-Tungsten
Carbide. All unions have a Fluoro-Elastomer diaphragm secondary seal.
OPERATING DATA

Max Temperature 300º 150º C
Max. Speed 750 RPM 750/min
Torque for Model 6300 8 FT. LBS 10.9 Nm
J
LOCK UP
B A
MODEL E F J
PORT NPT ROTOR THREAD
3“ 6300-015-157 3” (NPT) RH 3 7/8” 1 7/8” 14”
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 8

Important
THE DEUBLIN UNION is a precision made piece of equipment and should be handled
accordingly. It is a rotating sealing device – not just a plumbing union. Improper use could
result in premature leakage or failure. While Deublin Unions are of the highest quality and
precision they are, by their very nature, a “wear and tear” item. It is important that they
should periodically be inspected and, as seals wear out, the rotating union must be
replaced or repaired to avoid the consequence of leakage.
Deublin Unions should never be used for applications other than specified in the
catalog. Deublin unions should not be used to seal hydrocarbons or other flammable
media as leakage may result in explosions or fires. The use of our product on exotic or
corrosive media is strictly forbidden. For applications other than stated in the catalog,
the Deublin Engineering Department should be contacted for recommendations.
These instructions are provided by Deublin as general guidelines. They do not contain
exhaustive information about the installation, use or maintenance of unions. Purchasers
and users of Deublin Unions should be certain that they have reviewed Deublin’s catalog
and have sufficient experience and training in the use of unions before attempting
installation or use of Deublin’s products. The principal responsibility for the safe and
effective use of Deublin Unions rests with the user and its employees. Deublin will provide,
upon request, whatever assistance it can to advise users about the use of its products and
about any difficulties or problems which are brought to its attention.
Factory Testing
All DEUBLIN Unions are factory tested under pressure before shipment. This thorough
check assures that each Deublin Union is completely leak proof when you receive it, and
can be installed with fullest confidence that it will operate to your complete satisfaction.
Installation
No exterior bracing should be used to prevent the housing of a ball bearing type union
from rotating. To compensate for any eccentricities occurring from installation, it is
imperative that a flexible connection be used. DO NOT PIPE SOLID. Use a 45-degree
elbow and pipe union on the riser, making certain there is a slight curve in the hose. Do
not install hose taut.
See following page.
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 9

Connect flexible hose to
Grasp the rear of the supply line. Use a 45°
1 housing in a bench vise
and install flexible hose
3 elbow and pipe union on
the riser. Be sure hose is
not installed taut.
2 Install rotating union into

machine shaft
Lubrication
Lubrication of the ball bearings or seal faces is periodically required. The models that are
not equipped with a grease fitting or oil cup are lubricated for life and require no
maintenance other than periodic inspection to determine if normal wear has caused the
union to leak. The unions equipped with oil cups should be lubricated periodically with four
to five drops of high quality SAE #30 motor oil, approximately once a month or in extreme
severe conditions where high rpm is encountered once a week.
Rotating unions that are equipped with grease fittings should be lubricated with a good
quality ball bearing grease. We recommend Kluber Lubrications’s Petamo GHY 133N for
temperatures to 300°F (150°C). Only enough grease should be applied to the ball
bearings to replace that which has been dissipated. Over-greasing can be as damaging to
the union as under-greasing. Particularly in high rpm applications, grease should be used
sparingly. The chart below provides the approximate frequency of lubrication depending
on temperature or as experience dictates.
OPERATING TEMPERATURE FREQUENCY OF LUBRICATION
0°F (-18°C) to 250°F (121°C) Once every three months
250°F (121°C) to 300°F (149°C) Once monthly
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 10

Warranty
For a period of one year from the date of shipment, Deublin warrants that the products
sold by it are free from defects in material and workmanship. The liability of Deublin is
expressly limited to the replacement or rebuilding of any article, or part thereof, proved
defective, when returned to the Deublin Company, transportation prepaid within a
reasonable time after the termination of the 365 day warranty period.
This warranty is void if the product is dismantled, modified, altered, or damaged from
improper maintenance, side-loading, excessive temperature, abrasive or chemical action,
or other abuse.
No representative, agent or employee of Deublin has any authority to modify the terms of
this warranty. Deublin will not be responsible for any consequential or resulting damage
which may be claimed to have occurred through the sale or use of such products or parts
thereof, which might be defective.
There are no warranties that extend beyond the description contained under this heading,
express or implied, including warranties of fitness for a particular purpose.
Phone: 1-847-689-8600 ● Fax: 1-847-689-8690 11

10. Miscellaneous
The following is a list of miscellaneous documents that may be included in this manual
• Pre-Commissioning Checklist
• Commissioning Checklist
• VFD (or AFD) Parameters
• Bill of Materials
• PLC Ladder Logic
• Operator Interface Program / Data Registers
• Other
FALCON CONCENTRATORS INC
CUSTOMER PRE-COMMISSIONING CHECKLIST
---- Please complete and send a copy of this list to Falcon 7-10 days before expected commissioning date ----
CUSTOMER INFORMATION
Company: Phone:
Contact: Fax:
Location of Mine / Project: Email:
Machine Serial # (s) and purpose
INSTALLATION - please check off as completed ([C] only for continuous machines)
Note: Use right column to record details, expected completion dates, etc. Refer to drawings and manuals for specifications.
Installation kits information received Tails sample point available

Installation kits ordered Concentrate piping installed
GA drawings received Rinse launder piping installed
Assembly drawings received Water connections made
P & I D drawing received Water supply pressure / volume
Reconnaissance trip planned Water supply free of fine solids
Operating manuals received Compressor tested [C]
Equipment on site Air connections made
Installation Kit(s) on site Air supply pressure [C]
Packing list(s) confirmed Air pressure to feed valve regulated
Equipment inspected for damage Power to AutoPAC
Machine foundation prepared Voltage / current to specifications
Machine mounted * Power to motor
AutoPAC mounted Solenoids connected
Compressor installed / working [C] Voltage to solenoids 110 – 120 VAC
Screening installed Vibration Switch connected
Maintenance access (lid, rotor, etc.) Pressure Switch (optional) connected
Feed piping installed Machine started
Feed bypass system Rotation (CCW from above)
Feed to specifications Air system free of leaks [C]
Feed sample point available Water system free of leaks
Tails piping installed
* Contact Falcon at this time to confirm commissioning date:
Comments:
FALCON CONCENTRATORS INC.

9663 – 199A STREET LANGLEY, B.C. CANADA VIM 2X7
TEL: 604-888-5568 FAX: 604-888-5521 EMAIL: falcon@concentrators.net
FALCON CONCENTRATORS INC
COMMISSIONING / SERVICE CHECKLIST
(SBSE CONCENTRATOR)
Description: Documentation for the commissioning and functional checks of a Falcon SBSE Concentrator.
This document defines a generalized checklist that can be applied during the field commissioning or servicing of a
Falcon SBSE gravity concentrator, including Falcon supplied automation and other supporting equipment. This
checklist does not include an assessment of the condition and functionality of site infrastructure – that includes
structures, circuits, instrumentation, communication, metallurgy, etc.
It is envisioned that the document will be applied following the initial field installation of a new (or in some cases
used) Falcon concentrator prior to acceptance by the buyer / renter. It is expected that the checklist will be employed
by engineers and/or field technicians, working on behalf of the seller, who seek to verify that the concentrator was
properly assembled and installed in the field and that all supplied systems and subsystems function as intended.
This document is primarily applicable to the Falcon SB “SE” models. However, the checklist is written in such a
manner that it permits evaluations and tests to be conducted on a wide variety of concentrator options
(instrumentation, motors, automation, etc.), therefore can be used for all Falcon SB models. The person that
executes the checklist must select those entries and factors that apply to the specific concentrator that is being
commissioned. The checklist includes several blank and/or additional spaces that allow the user to customize the
checklist in areas in which it is believed that a variety of different factors may be found by the user. In the case of
multiple units the applicable sections can be copied and filled in for each unit.
The person(s) executing the checklist should be qualified in testing this type of equipment (engineer, factory-certified
technician). This person(s) should enter appropriate parameters and values in the boxes in which the parameters
are sought. The user should also initial all lines in which the user has conducted a test, made an entry, or made a
determination about the effectiveness of the installation.
Following the acceptance of this checklist by the user, a Warranty Registration can be completed to ensure that the
parties involved are in full agreement regarding supply, operation, maintenance and spare parts liabilities.
Administration
Customer:
Responsible Company:
Commissioning Representative:
Customer Representative:
Customer Contact Person:
Date:
Equipment Details
Equipment Serial Numbers, etc.
Automation Description:
Application:
Circuit Description:
Falcon Concentrators Inc. 1

F AL C O N S B S E C O M M I S S I O N I N G / S E R V I C E C H E C K L I S T
Materials Needed
Commissioning Checklist – as many copies as needed to cover all the units.
Electrical Circuit Multi-Tester – should be capable of measuring AC and DC voltage including mA.
Temperature Gun – capable of measuring bearing housing temperatures.
Hand Tools – As needed to gain entry into maintenance hatch, removing the lid, and performing minor
maintenance procedures.
Installation
Checked Items Status / Comments Initials
Machine mounted correctly
AUTOPAC panels mounted correctly
Electrical connections correct
Rotor spins freely
Acceptable feed circuit
Trash or other screen installed
Concentrate piping (flex)
Tailings piping (flex)
Feed piping (flex)
Lid removal ease
Feed valve installed
Pre-Start Checks
Feed valve operation
Air / water leaks
Voltage supplied to AUTOPAC _________-(V) _________ (ph) ________ (Hz.)
Automation settings (see below)
Vibration monitor
Flow control valve
Flow meters
Pressure transmitters
Solenoids working
Process water treatment
3
Water pressure/volume available _________-(kPa) _________ (m /h)
Notes:

Cold Commissioning (water only)

3
Operating water flow ___________ (m /h)
3
Rinse water flow ___________ (m /h)
Run cycle ___________ (minutes)
Rinse delay ___________ (seconds)
Rinse cycle ___________ (seconds)
Rinsing operation
Complete run/rinse cycle
Manual valve(s) working and set
Rotating union temperature ___________ (deg C)
Rotor bearing temp. (upper, lower) Upper ___________ (deg C.) Lower ___________ (deg C.)
Motor bearing temp. (upper, lower) Upper ___________ (deg C.) Lower ___________ (deg C.)
Motor load (run speed) Run Speed ___________ (Hz.) Run Current ___________ (A)
Motor load (rinse speed) Rinse Speed __________ (Hz.) Rinse Current __________ (A)
Emergency and normal stop
Hot Commissioning (slurry feed)

3
Feed volume ___________ (m /h)
Feed pulp density ___________ (% solids)
Feed rate ___________ (t/h)
Feed consistency
Bed consistency - full run cycle
Concentrate rinse
Concentrate discharge
Wear surfaces
Slurry leakage
3
Fluidization flow (run) ___________ (m /h)
3
Fluidization flow (rinse) ___________ (m /h)
Fluidization bowl pressure (run) ___________ (kPa)
Motor load (run speed) Run Speed ___________ (Hz.) Run Current ___________ (A)
Motor load (rinse speed) Rinse Speed __________ (Hz.) Rinse Current __________ (A)
Notes:

Control
Feed valve force
Flow control valve force
DCS or remote control
Maintenance
Lubrication
Lid removal
Rotor basket removal
Rotor fluidization hose removal
Motor removal
Rotor bowl / shaft removal
Bearing replacement
General maintenance practices
Training seminar
Safety
Safety seminar
Optimization
Metallurgical target
Sampling procedures
Current metallurgical performance
Recommended actions
Notes:

Interlocks / Alarms
CHECKED
CALIBRATED NORMAL DELAY
DESCRIPTION ACTION TAG NUMBER
RANGE SETPOINT (sec)
Client Tech.
FEED VALVE OPEN / CLOSE AUTO INTERLOCK -
INTERLOCK / AUTORINSE, SHUTDOWN

RAW WATER FEED A (LO 0 – 700 kPa 170 60
OTHERWISE
RAW WATER FEED A ( HI) 0 – 700 kPa 650 START INTERLOCK / ALARM OTHERWISE 60
RAW WATER FD FILTER DP (A-B) 0 – 700 kPa 50 ALARM -
RAW WATER FD FILTER DP (A-B) 0 – 700 kPa 100 START INTERLOCK / ALARM OTHERWISE -
RAW WATER FEED C

0 – 50 m3/h 0.5 START INTERLOCK -
(should be < 0.5 to start)
RAW WATER FEED C (LO) AUTORINSE, SHUTDOWN - ONLY AT RUN

0 – 500 kPa 40 30
(bowl pressure) SPEED (enabled after feed on for >1 minute)
RAW WATER FEED C (LO) AUTORINSE, SHUTDOWN - ONLY AT RUN

0 – 500 kPa 250 30
(bowl pressure) SPEED
RAW WATER FEED LOW FLOW 0 – 50 m3/h 7.5 - -
RAW WATER FEED HIGH FLOW 0 – 50 m3/h 28.0 - -
RAW WATER FEED LOW FLOW

0 – 50 m3/h 2.5 SHUTDOWN 60
DEVIATION LO/HI
RAW WATER FEED HIGH FLOW

0 – 50 m3/h 5.0 AUTORINSE, SHUTDOWN 60
DEVIATION LO/HI
RAW WATER FEED (FCV position) 0 – 100% - - -
SOLENOID RINSE VLV OPEN / CLOSE AUTO - -
SOLENOID FLUSH VLV OPEN / CLOSE AUTO - -

ST
1 TIME – AUTORINSE, START TIMER
VIBRATION SWITCH
0 – 50 mm/s 75% 2ND TIME – AUTORINSE, SHUTDOWN – 90
(acknowledge for 1st time)
INTERLOCK
VIBRATION SWITCH 0 – 50 mm/s 100% AUTORINSE, SHUTDOWN - INTERLOCK 0
SPEED SET RINSE (rinse speed) 0 – 60 Hz. 2.0 - -
SPEED SET FEED (run speed) 0 – 60 Hz. 80.0 FEED ON INTERLOCK, MUST BE > 60% -
AUTORINSE, SHUTDOWN – ONLY AT RUN

DRIVE SYSTEM FAULT 0 – 140 Amps 18.0 60
SPEED
INTERLOCK FOR 20 MINUTES – LOSS OF
EMERGENCY STOP (local) OPEN / CLOSE CLOSE 0
READY
Notes:

Conclusion and Final Comments

Checked Items Status / Comments
Commissioning report
Close-out meeting
Comments:
Signed:
Person Company Position Signature

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FALCON SB CONCENTRATOR

(Including support manuals / documentation)

C.I. BALKANES S.A.

Equipment Name: Gravity Concentrator

Date of Shipping: March 2006

Falcon Reference Number: 05-2339 AUTOMATION 4

Vendor Manual Number: SB750 R3.0

Telephone (+1) (604) 888-5568

CONCENTRATOR SERIAL NUMBER(S):

AUTOPAC SERIAL NUMBER:

Contact Persons: Dave Robertson, Production Manager

Telephone (+1) (604) 888-5568

READ BEFORE OPERATING!

Always lock unit out!

8. Do not operate concentrator at speeds in excess of its rating.

1.1 Who is Falcon Concentrators? ................................................................. 1-1

1.4 Falcon’s Guarantee .................................................................................. 1-6

1.1 Who is Falcon Concentrators?

• Falcon ‘SB’ – semi-continuous concentrators

With over 250 installations worldwide and 15 years of experience in gravity

Thank you for purchasing your own Falcon Concentrator.

1.2 The Semi-Batch (SB) Concentrator

The Falcon ‘SB’ series of concentrators produces high-grade concentrates while

The Falcon Model ‘SB’ units work best for:

• Free gold, silver and platinum recovery.

Feed capacity 5 sizes to 433 USt/h

Falcon Concentrators 1-2

Drive Consists of the VFD, motor, belts and sheaves.

Process (see figure on next page)

Feed is screened at approximately 2mm. depending on the application and is introduced

Falcon Concentrators 1-3

Figure 1.3.1 Process Schematic

LIP FEED PIPE

Falcon Concentrators 1-4

Figure 1.3-2 Typical Installation of Model SB750 (Grinding Circuit)

FRACTION OF CYCLONE UNDERFLOW

FEED TO PRIMARY MILL

Falcon Concentrators 1-5

1.4 Falcon’s Guarantee

Falcon Two-Year or 5000 Hour Warranty

Falcon Warranty Return Policy

Falcon is willing to guarantee an operational availability of the equipment to be in excess

Falcon Concentrators 1-6

2. Specifications / Requirements ..........................................................2-1

2.1 Specifications ........................................................................................... 2-1

2.2 Electrical ................................................................................................... 2-2

Optimum results may not be obtained at maximum values.

MINIMUM RECOMMENDED MAXIMUM

Table 2.1-1 Tons Per Hour

S.G. Solids 2.9

Falcon Concentrators 2-1

Table 2.1-2 SB750 Specifications

Falcon Concentrators 2-2

2.3 Compressed Air

Feed Pinch Valve

Falcon Concentrators 2-3

3. Installing the Equipment ....................................................................3-1

3.1 Lifting ........................................................................................................ 3-1

3.2 Location .................................................................................................... 3-1

3.3 Mounting................................................................................................... 3-2

3.5 Water System ........................................................................................... 3-4

3.7 Air Connections ........................................................................................ 3-8