Making Things Dojo Textbook

ものづくり教科書 Company members only

Inverter (Elementary version)

Mitsubishi Motors Corporation

1
 Revision history

Prepared on Apr. 1, 2008

Prepared by Ozaki, Dojo master

Dojo Name （ Mizushima ） Maintenance Dojo

Rev. No. Rev. Date Reason for Revision/Revised Contents Revised by Dojo Name Rev. Page

Rev. 1 Month/day/year

Rev. 2 Month/day/year

Rev. 3 Month/day/year

Rev. 4 Month/day/year

Rev. 5 Month/day/year

Rev. 6 Month/day/year

Rev. 7 Month/day/year

Rev. 8 Month/day/year

Rev. 9 Month/day/year

Rev. 10 Month/day/year

Rev. 11 Month/day/year

Rev. 12 Month/day/year

Rev. 13 Month/day/year

Rev. 14 Month/day/year

2
 Purpose of This Training

To acquire the following skill or capabilities

１） Understand the theory of inverter.
２） Change various set values through PU operation.
３） Monitor various items through PU operation.
４） Replace a defective inverter.
５） Understand the reason for using a brake unit.

3
 Maintenance Training Schedule
Training Name Inverter Total of Training Time

1.Training Contents of Training Required time

item
1 What is inverter?
2 Installation of inverter power circuit and control circuit
3 Major operation procedures of parameter unit
4 Practical training of wiring connection and function of inverter and relay circuits
5 Function of brake unit
6

7
8

2. Training (1) Shop floor Textbook and Training materials

method
(2) Electric motor 0.75 KW, Magnet SW, Inverter （ FR-PU04) This textbook
(1) Place
- Inverter training
(2) Training
materials
(3) Method (3) Install inverter circuits and check the function.

3. Method for
judging the
completion 1 It is possible to install and set the parameter according to electrical drawings.
of training 2 It is possible to check the history of faults in case of occurrence of faults
(what and how
to be achieved) 3 It is possible to replace the faulty inverter.

4. Job of Judging Job and Job Name Operating time

judging the
completion 1 Install the standard circuit, set the required parameter through PU, and then operate it to check the value using the monitor.
of training
2 Replace inverter, assuming the faulty condition.

4
 Safety Precautions
1. If you touch the charged area, you may receive an electric shock. Be sure to
check whether or not to have been charged, then you must touch the area after
checking that it has not been charged.
2. Even if you disconnect the primary power supply, the internal condenser has
been charged. You must touch the internal area after the voltage between P–
N terminals has completely run out.
3. When you carry out a test by turning an electric motor, you must not touch
the output shaft of the electric motor to operate an inverter.
4. To prevent receiving an electric shock, be sure to wear safety gloves for the
power-on/off operation of NFB and conduct the operation with a hand opposite
to your heart, avoiding the front side.
5. If you should find an operator who has received an electric shock, keep the
operator away from the source of an electric shock and immediately rescue the
operator’s life. Never hastily touch the operator with bare hands.

5
 Procedure for Controlling Motor Speed
◎ How to obtain three-phase induction motor speed,

Frequency
Revolution speed = ( ×120 ) - Sliding
Pole No.

To change the revolution speed from the above formula, change any of
frequency, pole number or sliding.
◎ As for pole-change three-phase induction motor,
Change the above pole number in stages of 2, 4, 8, 12, etc. to control the speed.

◎ As for inverter,
(1) Change frequency to control the revolution speed.
Features:
1) Since an inverter produces power supply with the required frequency,
the frequency can be easily changed.
2) The motor can always be operated with the required revolution speed by the
command to the inverter, which provides the smooth control.

6
 Schematic Diagram of Inverter
Schematic diagram
Converter circuit Inverter circuit
Three-phase alternate
current power supply

Condenser

Alternate
current
Three-phase

Direct

current
electric
motor

N
command
Speed

Control circuit Faulty output

Command of normal or
inverse revolution
(1) Create direct current from the three-phase alternate current power supply
through the converter circuit.
(2) Create alternate current from the created direct current through the inverter circuit.
(3) Supply the electric motor with the voltage of the specified frequency by the speed
command, normal/inverse revolution command, etc. in the control circuit
to change the revolution direction and the speed.
7
 External View of Inverter

MELCO’s Inverter FR-A500 series

After installing FR-PU04 (parameter

unit) here, the following operations can
be done.

(1) Changeover of the operation method.

(2) Setting of the parameter.
(3) Check of the operation status.
(4) Check of the history of faults, etc.

8
 Wiring Installation of Main Circuits

NFB MG OCR
R U
S V IM
T W
power supply
Speed changeover signal

R1 Three-phase
Control

Parameter unit
S1 induction motor
P

N
RH
RM
RL RUN

Brake unit
Input the speed
command of RL, RM, MRS
RH, and then turn on RES Faulty
STF or STR signal to Since RL, RM or RH operates
make normal or STF at the set speed command, RH
inverse revolution at
respective speeds. STR terminal does not always
conduct the high-speed
SD operation.
9
 Wiring Installation of Control Circuits
SYM Name Function

R, S, T Power supply Provide power supply via NFB and magnet.

U, V, W Inverter output Output the frequency which has been set according to this output of inverter.
Power supply for Provide power supply individually or via the wiring connection from the primary side (R, S) of MG retaining faulty indication or faulty
R1, S1 control circuit output at the power supply for control circuit.

P, PR Brake resistance Connect to this terminal when using a brake resistor.

P, N Brake unit Brake unit connection terminal

Regular revolution Input terminal for starting normal revolution (ON: Revolve regularly OFF: Stop) The revolution stops by simultaneous switching
STF command ON

Inverse revolution
STR command
Input terminal for starting inverse revolution (ON: Revolve inversely OFF: Stop)

MRS Output stop If this signal turns ON, the inverter output will stop.

RES Reset Reset this inverter.

RUN Inverter operation Signal output terminal during the operation of inverter

A, B, C Faulty output It is used for disconnecting power supply because the contact point output will be done when any faults occur.

RH, RM, Multi-speed

Multi-speed can be selected according to the combination of RH, RM, RL signals.
RL selection
Power supply for
10 setting frequency DC5V

Frequency setting
2 (Voltage)
If DC0-5V is input, the maximum output frequency is obtained at 5V, and output and input becomes proportional.

Common terminal for

5 setting frequency Common terminal of frequency setting signal

10
 Inverter Speed Command Circuit (1)
Speed-change circuits according to speed command voltage

OCR
R U
S V IM

Parameter unit
T W
R1
Control
power
supply

S1
The inverter to be used this time does not have
P
R1, S1 terminals.

N
Speed command

10 (+5V)

2 (DC0-5V)
5
RUN

Brake unit
MRS
RES Faulty
STF
STR
SD 11
 Inverter Speed Command Circuit (2)
Speed-changeover circuits speed according to contact point input

OCR
R U
S V IM

Parameter unit
T W
R1
Control
power
supply

S1
P
The converter to be used this time does not
have R1, S1 terminals.
N
RH
RM
RL RUN

Brake unit
MRS
RES Faulty
STF
STR
SD
12
Wiring Connection Diagram of Power Circuit with Inverter Operation for Practical Training

Install power circuits as shown below for the practical training.

NFB MG
Inverter
R U
S V IM
T W
A

RA B
STF From control circuit
C
STR
RA RUN
RH
OL
Color of cable:
RM
Use the following colors for wiring
installation.
RL Power circuit Black
Alternate current control circuit Red
MRS Direct current control circuit Blue

RES

SD

P1 P N

During the operation, never put your hands on the motor revolving area or never touch the charged area.
13
Wiring Connection Diagram of Control Circuit with Inverter Operation for Practical Training

Install power circuits as shown below for the practical training.

NFB

AC110V

Operating preparation Operating preparation From inverter

OFF ON

MG C B

MG

MG Start/stop Operation

RA
RA

14
Practical Training of Parameter Unit Operation

FR-PU04

Connect the power supply to the inverter, and conduct the following
practical training of operation using the parameter unit.

1. Practical training of PU operation

Operation method to start or stop an inverter using the parameter
unit.

2. Practical training of external operation

Operation method to start or stop an inverter through the signals
of a control panel, etc.

15
 External View of Parameter Unit

Practical training of FR-PU04

The value is indicated in

the display area.

Keys:
Use these keys to select
respective functions and
input data.

Various operation methods are practiced on the next page and subsequent.

16
 Practice of Selecting Operation Mode
How to change over the PU operation mode and the external operation mode

(1) Change over the mode from the external Press the mode selection key: PU when the
operation mode to the PU operation mode. external input signal is OFF (STF, STR), then the
operation mode is changed over and a screen for
setting the frequency is displayed.

(2) Change over the mode from the PU operation
mode to the external operation mode.
First, check that the external input signal is OFF
(STF or STR is OFF) and that “- - -” is indicated in
the operation command display. Next, press the
mode selection key: EXT , then the mode is
changed over to the external operation mode and
”EXT” is indicated in the operation mode display.

(3) Combined operation mode ”PU + E” is indicated in the display.

When Pr.79 = “0”, an inverter can be operated by changing over “external operation” and “PU
operation”.
“External operation” is selected when the power is “ON”.
An inverter installed in the machine must not allow for the PU operation.

17
 Clear All of the Parameter
(1) Operation procedure (To clear all of the parameter)
(1) Press HELP key twice in 1 Monitor
the operation mode. 2 PU operation
3 Parameter
(2) Move a cursor using key 4 Clear parameter
to “4. Clear parameter”.
1 Monitor
2 PU operation
3 Parameter
4 Clear parameter
(3) Press key.
・
READ
1 Clear parameter
2 Clear all
3 Clear user
4 No to clear
(4) Press ・ key.
READ
< Clear parameter >
Execute Write
Delete ESC

(5) Press WRITE key.

< Clear parameter >
Completed

18
 Practice of Changing the Parameter Setting
(1) Operation procedure
(Example: How to read and write Pr.8, “Decelerating time”)
(1) Press PU key. A screen for setting frequency is displayed.
(2) Press SET key. The parameter setting mode is selected.
(3) Input the objective parameter No.“8”. The input value is indicated.

(4) Press ・ key. The set value is indicated in the display.

READ
(5) Input the number you wish to set, such A new set value is indicated in the display.
as
“180”. (Example: To set 180 seconds)
(6) Press Write key. The set value is preserved in the memory.
When an error occurs, check and
correct the indicated content.
(7) Press SHIFT key to move to the
next parameter and display the current
set value.
Press SHIFT key consecutively to
move the parameter forward one by one.

* In case of the wrong input, press ESC key to return to the previous screen and input the correct value.

19
 Practice of Normal Operation Using PU
Repeating the following procedures 2 and 3 during the operation of motor can change the revolution speed.
Safety precaution: Never place your hands on the motor area.

Order Operation procedure

Turn on the power, and then check that a screen for setting the frequency is displayed.
1 (If the screen is not displayed, change the mode to the “PU operation mode”.)

Set the operation frequency at 60Hz.

Set the operation frequency in either of the following methods and then fix it with WRITE key.
● Direct setting
Press PU key, and then input frequency with numeric keys directly.
2
● Skip setting
Press keys to change the frequency continuously.

Press FWD or REV key. The motor starts operating.

3 The monitor mode is selected automatically, and then the output frequency is displayed.

STOP
Press RESET key.
4 The motor decelerates to stop.

An inverter installed in the machine must not allow for the PU operation.
20
 Practice of PU JOG Operation
Safety precaution: Never put your hands on the motor area.
Order Operation procedure
Turn on the power, and then check that a screen for setting the frequency is displayed.
1 (If the screen is not displayed, change the mode to the “PU operation mode”.)

The JOG operation frequency and the acceleration/deceleration parameter can be set
2 by putting “JOG frequency” to Pr.15.
Pr.15: “JOG frequency”, Pr.16: ”JOG accelerating/decelerating time”

Press PU key, and then press SHIFT key.

3 The JOG operation mode is selected and a screen for setting the JOG PU frequency is displayed.
To change the frequency, input the numerical values, and then press WRITE key.

Press FWD or REV key.

The display changes over to the monitor screen, and the motor operates while the key is pressed
3 and then stops when the key is released. If a motor does not operate, check Pr. 13, “Starting
frequency”. If the value lower than the starting frequency is set to the JOG frequency, the motor
will not operate.
Press PU key.
4 The JOG operation mode is canceled, and then returns to the normal PU operation mode.
To return to the JOG operation, press SHIFT key.

An inverter installed in the machine must not allow for the PU operation.
21
 Shift Operation of Programming Unit Monitor
If Pr.52 [Data selection] is set to [0], change the monitor display sequentially with [SHIFT] key.
Output frequency monitor

Display all of the following

Output current items.
monitor - Output frequency
- Output current
- Output voltage monitor

Output voltage monitor Selection monitor Faulty contents monitor Output frequency monitor

<Other monitor> 1 f monitor

Other monitor is 2 I monitor
3 V monitor
Help
4 Alarm history

Move a cursor to the objective item

by pressing or key.

Faulty contents monitor Faulty contents monitor

<Alarm history>
Display Read

22
 FR-PU04 Parameter Unit
The parameter setting contents can be read and memorized into FR-
PU04, therefore, copy the memorized parameter set values to the
inverter of the same series and the same capacity.
<Before setting>
● Select the PU operation mode.
● Do not operate an inverter before it stops.
● The set value cannot be copied when the inverter to be copied
prohibits writing in parameter by setting Pr. 77 “Selection of
prohibition of writing in parameter” to “1”.
Note: Do not make unnecessary change of the setting during the
operation. Doing so may cause faulty inverter, resulting in the
free running (out-of-control) of motor.

23
 FR-PU04 Copying and Collating Function

(1) Practice of reading the parameter set value

(1) Connect FR-PU04 to an inverter.

(2) Press SET key. <Set mode>
Parameter NO. key-in
Pr. list Help
Whole operation

(3) Press key. --- Move to the ROM package

mode. Whole parameter operation
Reading READ
Writing WRITE
Collating

・
(4) Press READ key. ---
Memorize the parameter set value. Whole parameter operation

Reading has completed

24
 FR-PU04 Copying and Collating Function

(1) Practice of writing the parameter set value

(1) Connect FR-PU04 to an inverter.

<Set mode>
(2) Press SET key. Parameter NO. key-in
Pr. list Help
Whole operations

(3) Press key. --- Move to the ROM package

Whole parameter operation
mode. Reading READ
Writing WRITE
Collating

(4) Press WRITE key. --- The parameter set

value which has been memorized and saved Whole parameter operation
in FR-PU04 is copied to an inverter. Writing has completed
Reset the inverter.

After writing, reset the inverter.

25
 FR-PU04 Copying and Collating Function

（１） Practice of collating the parameter set value

(1) Connect FR-PU04 to an inverter.

<Set mode>
(2) Press SET key. Parameter NO. key-in
Pr. list Help
Whole operation

(3) Press key. --- Move to the ROM package

mode. Whole parameter operation
Reading READ
Writing WRITE
Collating
(4) Press key. --- Start collating the parameter

set value memorized in FR-PU04 and the Whole parameter operation

parameter set value in the inverter.
(If there are any errors while collating, Collating has completed.
Pr. with error is indicated.)

26
 Overview of Inverter Alarm History

1. Check the alarm history.

(1) Press HELP key twice in the operation mode.
(2) Simultaneously press SHIFT key and key.
(3) Check that a cursor is placed at “5. Alarm history”.
・
(4) Press READ key.
2. Since faults (alarm) over the past eight times are displayed in
abbreviated symbols, investigate the details of faults in the operation
manual.

27
 Main Parameter and Function Diagram

Respective parameters and function diagram

Revolution
High speed
speed Low
speed

Accelerating time Decelerating time

(1) Pr. 4 3rd-speed setting （ RH ）

(2) Pr. 5 3rd-speed setting （ RM ）
(3) Pr. 6 3rd-speed setting （ RL ）
(4) Pr. 7 Accelerating time
Refer to the next page.
(5) Pr. 8 Decelerating time

28
 Accelerating/Decelerating Time

Hz
Base frequency (60)
Frequency

40

4 sec. Time
6 sec.
It takes 6 seconds before it reaches the base frequency (60 Hz in this
example), provided the accelerating time is set to 6 seconds. If the frequency
has been set to 40 Hz, the accelerating time reaches the frequency in 4
seconds. (This also applies to the decelerating time.)

29
 Procedure for Replacing Inverter

1. Record the parameter of an inverter (to be replaced) in FR-PU04.

2. Turn off the primary power of an inverter, and then wait until the voltage

between P and N has completely run out.

3. Record the wiring connection status of an inverter.
4. Remove an inverter.
5. Install an inverter as described in the record of “3”.
5. Turn on the power, and then write the parameter according to the
memorized FR-PU04 to be collated.
6. Check that an inverter functions as specified.

30
 [Ref.] Operation of Brake Unit

The speed of inverter is controlled with output frequency and output

voltage.
When the inertia of the controlled object (drop lift, etc.) is greater though
the inverter has commanded the deceleration, the electric motor becomes
the power generator, and the inverter commands to reduce the output
voltage. However, the deceleration effect cannot be obtained because the
electric motor becomes the power generator and it is impossible to reduce
to the commanded voltage.
When the voltage between P and N of the inverter will not exceed 360V
(ex. 220V inverter), achieve the deceleration effect by flowing current to
the discharge resistance to keep the voltage so that the voltage will not
exceed 360V. (Voltage between P and N is normally DC300V.)

33
[Ref.] External View of Brake Unit

OCR reset button

While the brake unit is

operating, this lamp
comes on.

34
Internal Circuit of MELCO’s BU-type Brake Unit

P/+ Inverter N/ －

Discharge resistor

P HA HC HB TB PR

OCR

Constant
-
voltage
current +
Comparator

35
 Brake Unit Function Diagram

(1) When the load

Inverter OCR inertia at
R U
decelerating is
great, the motor
revolves faster
S V IM than the
command value to
T W become a power
generator.
power supply

R1
Control

S1 (2) The voltage rises because

P the motor generates electric
power though the voltage (4) As a result of
between P and N commands discharge in (3),
N to be reduced. it is possible to
RL (Normally about DC 300V) decelerate as
commanded.
RM
Parameter unit

RH RUN

Discharge
MRS

resistor
RES Faulty
(3) When the voltage between P
STF and N becomes 360V or more,
this contact point is closed and
STR then the discharging to the
discharge resistor reduces the
SD voltage.
36
[Ref.] Practical Training of Inverter Operation (Sequencer)
Hard-wiring connection diagram
NFB MG
Inverter
R U
S V IM
T W
R１
S1 1) Connect an inverter and a sequencer, and
SE then check the operation under the following
STF C
AY40A conditions.

STR Turning on the start-up SW

RUN
RL (1) Low-speed normal operation 5 sec.
OL (2) Middle-speed normal operation 10 sec.
(3) High-speed normal operation 5 sec.
RM
(4) Stop 3 sec.
(5) Low-speed inverse operation 5 sec.
RH
(6) Stop
MRS
Setting the inverter
RES
(1) High-speed frequency 60Hz
(2) Middle-speed frequency 40Hz
SD (3) Low-speed frequency 10Hz
(4) Accelerating/decelerating time setting 1 sec.
P1 P N

During the operation, never put your hands on the motor or never touch the charged area.
37
[Ref.] Job of judging the completion of training

1. Install hard-command circuits or sequencer command circuits.

2. The conditions are as follows:

1) Connect an inverter and a sequencer, 2) Hard-command circuit

and then check the operation under
the
following conditions.
Turning on the start-up SW
(1) Low-speed normal operation
sec.
(2) Middle-speed normal operation
(3) High-speed normal operation
sec.
(4) Stop
sec.
(5) Low-speed inverse operation
(6) Stop
Setting the inverter
(1) High-speed frequency 60Hz
(2) Middle-speed frequency 40Hz
(3) Lowe-speed frequency 10Hz
(4) Accelerating/decelerating time setting 1 sec.
5
Set the above items in the inverter, and then
10 sec. check the following items.
5
(1) Turn on normal revolution, and
3 (2) Turn on inverse revolution.
5 sec.

Setting the inverter

(1) High-speed frequency 60Hz
(2) Middle-speed frequency 40Hz
(3) Low-speed frequency 10Hz
(4) Accelerating/decelerating time setting 1
38
sec.