Contents of Inverter training

• Definition of Inverter
• About Mitsubishi Inverters
• Basics of Inverter
• Controls of Inverter(V/F)
• Basic functions of Inverter
• Parameter settings
• Use of FR-Configurator (Software)
 Definition of Inverter

A variable frequency drive is a system of

controlling the rotational speed of Motor by
controlling the frequency of the electrical power
supplied to the motor.
 Advantages of Inverter

• Variable speed
• Maintain constant speed
• Acceleration and deceleration
• Change of direction
• Saving energy.
 Specification of Inverter

FR-A 740-630-**
(1) (2) (3) (4) (5)
1 : FREQROL
2 : Series (A,F,E,D)
3 : 720S = Single phase 220V (for D,E series only)
710W = Single phase 110V (for D,E series only)
720 = Three phase 220V
740 = Three phase 440V
4 : Capacity = 0.1kw to 630kw
5 : Special case refer to catalogue
Mitsubishi Inverter and Capacity Overview

I FR-A700 0.4KW-630KW
N
V
E FR-F700 0.75KW-630KW
R
T
E 0.4KW-15KW
R FR-E700
0.4KW-7.5KW
0.1KW-2.2KW FR-D700
CAPACITY
 FR-D700 (The Standard Inverter)
1. Simple Operation: Quick setting with one-touch
digital dial, save time for setting.
2. Application like:

Pumps Power Range:

Fans FR-D720 = 0.1-2.2KW

Presses FR-D740 = 0.4-7.5KW

Conveyor belt

Industrial washing machine Output Frequency
3. Space Saving : Extremely compact Inverter with 0.2 – 400HZ
minimum size (128*108)mm available.
4. Safety Stop function : Emergency stop result high Control
reliable immediate shutoff drive output.(S1,S2) V/F, optimum excitation
5. Spring Clamp Terminal : Easy wiring, maintenance control, vector control
is unnecessary.
6. Power failure- time deceleration-to-stop function Integrated
7. Password function available(Pr.296,Pr.297). RS485, USB
8. Parameter unit FR-PU07 can be connected as
well. Internal Inputs/Output
DI = 5,DO = 2, AI=2, AO=1
 FR-E700
1. High torque: 200% /0.5Hz torque is realized(3.7kw
or less) Power Range:
2. Application like: 0.4-15KW

Textile Output Frequency

Door and gate actuators 0.2 – 400HZ

Elevators Control

Cranes V/F, optimum excitation

Material handling systems control, General purpose
3. Plug in option : External option card can be use. vector control, Advance
4. Support various network : various kind of magnetic flux vector
network can be use with this drive. Integrated
5. Long Life design : life of cooling fan has been RS485, USB
extended to 10 year. Optional Extras
6. Automatic Restart after instantaneous power CC-link, Ethernet, Profibus,
failure function with frequency search DeviceNet, CANopen, Lon
7. Short time overload capacity is increased (200% Works
in 3s) Internal Inputs/Output
8. Control terminal are selectable according to DI = 7,DO = 3, AI=2, AO=1
application.
 FR-F700 (Energy Saving Drive)

1. More Energy Saving

2. Application like:
Power Range:

Air Conditioning system
FR-F740 = 0.75-630KW

Fans and Blowers
FR-F746 = 0.75-55KW

Compressor
Output Frequency

Heat Pumps
0.5– 400HZ
3. Maintenance Timer can be used.
Control
4. Removable terminal blocks
V/F, OEC,SMFV
5. High torque in low speed by Simple magnetic flux
Integrated
control is possible
RS485, Modbus RTU
6. Adjustable 5 points V/F is possible.
Optional Extras
7. Monitor Energy saving parameter.
Analog+ Digital I/Os, CC-link,
8. Enhanced PID function
Ethernet, Profibus,
9. Holding starting time (Pr.13,Pr.571)
DeviceNet, CANopen, Lon
10. Frequency jump option(Pr.31-Pr.36)
Works
Internal Inputs/Output
DI = 12,DO = 7, AI=3, AO=2
 FR-A700 (HIGH END INVERTER)

1. Sensorless vector control: To control the speed

and torque without using Encoder.
2. Autotuning : Identify all the parameter within 1 Power Range:
min. Upto 2 motor data can be stored. FR-A740 = 0.4-630KW
3. PLC function: Output Frequency
4. Application like: 0.2– 400HZ

Conveyor technology Control

Chemical machines V/F, OEC, RSV, Closed Loop

Winding machine Vector Control

Printing machine Integrated

Cranes and lifting gear RS485, Modbus RTU,USB

Extruder Optional Extras
5. Removable terminal blocks Analog+ Digital I/O’s,
6. Pulse train I/O function is available Encoder feedback, Master-
Slave, CC-link, Ethernet,
Profibus, DeviceNet,
CANopen, Lon Works.
Internal Inputs/Output
DI = 12,DO = 7, AI=3, AO=2
Relation of (TORQUE,CURRENT and SPEED)
 Motor Slip

• When the Load is applied to the motor , it becomes mismatched with the
synchronous speed, so the gap between these two speed is called “SLIP”.

SLIP = Synchronous speed – Motor speed *100

Synchronous speed

Note:
1) When the load torque increase(Overload), the slip and the motor
current also increase.
2) When the slip becomes a minus value, it means motor speed exceed the
synchronous speed.
 Motor Current

At starting motor current becomes 6-7 times larger than the motor rated
current

The larger the slip is , the larger the current flows. Because the load torque
increase, the motor speed slows down.

So, the larger the load torque is , the larger the motor current becomes.
Configuration of Inverter
 Configuration of Inverter

The Converter consist of following parts:

1. CONVERTER
2. SMOOTHING CAPACITOR
3. INRUSH CURRENT CONTROL CIRCUIT
Operation of Converter
When a Sine wave voltage is supply to the converter,
the current flows through the diodes, doing so
conducts the diodes in the respective timing
allowing the input current to be make distorted
waveform.

The Diode rectified waveform of all the three phase

are further smoothed to DC with less pulsation by
the smoothing capacitor C.

When the inverter is stopped, the DC voltage can be

up to √2V Lmes larger.

When the Inverter is running, the DC voltage slightly

fluctuates depending on the output(torque/speed)
Operation of Capacitor
When the Inverter is turned on , a large current flow
for charging a smoothing capacitor. To control the
peak value of the Inrush current.
After the smoothing capacitor is charged, short the
both ends of the control resistor with a relay.
Operation of Inverter

After the smoothing the D.C voltage, the

converted D.C voltage is given to the Inverter
section.
Turn off the transistors in order, doing so obtain
pulse waveform at section U-V, V-W, W-U in the
same cycle, and applies a A.C voltage in a
rectangular waveform to a motor.
The method of changing the frequency is depend
upon the timing of ON/OFF the transistors by
given formula below:

F = 1/t0 [Hz]
 V/F Pattern

Constant torque
When the output frequency of an Inverter is
changed, the output must be changed.
The output Torque is defined as per the
formula(FLH rule) given below:
T=ɸ×I
= (V/F) × I
So as per the equation, if the voltage is fixed
and the frequency is decreased it increased
the magnetic flux and it cause the iron core
to magnetic saturation and then the current
increase cause overheat and burn.
By this method, the constant torque can be
obtained.
But in this method, we cannot obtained high
torque in low speed for this we have to
increase the value of torque boost(Pr.0).
 Energy Saving Concept

A variable speed drive regulates the speed of the motor, and in turn the speed of
the pump or fan, by controlling the energy that goes into the motor, rather than
restricting the flow of a process running constantly at full speed.
Running a motor at full speed while throttling the output is like driving a car with
one foot on the accelerator and the other on the brake; a part of the produced
output immediately goes to waste. A variable speed drive can save over 60% of the
energy. This is possible as it controls the energy at source, only using as much as is
necessary to run the motor with the required speed and torque . As acceptance of
the technology increases, variable speed drives are gaining market share across a
range of industries.
In particular, variable speed drives can dramatically reduce energy consumption in
fan and pump systems. A pump or fan running at half speed consumes only one-
eighth of the energy of one running at full speed. Or, put differently: the power
required to run a pump or a fan is proportional to the cube of the speed. This
means that if 100% flow requires full power, 75% requires (0.75)^3= 42% of full
power, and 50% flow requires (0.5)^3= 12.5% of the power.
 PWM (Pulse Modulation System)

The PWM system is a system that changes the output voltage by generating
switching pulses within one cycle and changing the pulse width.
Most of general-purpose inverters use the sine wave approximation PWM
system. The number of switching pulses generated per second is referred to as
carrier frequency. With the PWM system, the frequency components of the
generated motor vibration and motor noise are proportional to the carrier
frequency.
If there is a reference saying high carrier frequency PWM control, this means
that the carrier frequency is high.
Also note that the Soft-PWM control is a control system that suppresses the
increase of generated noise and reduces the motor magnetic noise by
preventing the carrier frequency from being higher and dispersing the
components of the motor magnetic noise.

The Minimum carrier frequency is 0.75KHz and Maximum is 14.5KHz.

PWM (Pulse Modulation System)
FR-D740 Wiring Diagram
FR-E (Safety Stop Function)
FR-F700
FR-A700
Sink/Source logic
 Wiring of Forward and Reverse Rotation

Forward Rotation Reverse Rotation

R
Multi speed setting

Can be used to change the preset speed given in

the parameter no. Pr.4 to Pr.6 and Pr.24 to Pr.27.

Pr.4 to Pr.6 = for 3 speed

Pr.24 to Pr. 27 = for 7(3+4) speed
Pr.232 to Pr.239 = for 15* speed.

* To use REX input assign this input in (Pr.178-

Pr.189)
 JOG setting

For JOG mode set the following parameter:-

Pr.15(Jog frequency) : 0-400Hz

Pr.16(Jog acc/dece time) : 0-3600sec
JOG setting from PU
 POTENTIOMETER setting

Potentiometer is used in the inverter is wire wound type 2W 1K ohm. It is used to vary
the speed of the output, this a analog process, used in EXT mode.
(Automatic Restart after power failure)

Pr. 57(Restart coasting time)

Pr. 58(Restart cushion time)

Pr. 162(Automatic Restart

after power failure
selection)
 Operation mode selection

To change the operation mode setting

Operation Pr.79 is used as follows:
mode
S.No Setting Description
PU Panel unit mode range
1 0 Switch between EXT/PU
2 1 Fixed to PU mode
EXT External mode 3 2 Fixed to EXT mode
Operation can be performed
by switching EXT/NET mode
4 3 EXT/PU combined mode 1
NET Network mode
5 4 EXT/PU combined mode 2
6 6 Switch between PU/EXT/NET
7 7 PU operation interlock(X12)

* Use Pr. 340 for NET mode.

(Parameter Settings)
(Parameter Clear)
(Parameters All Clear)
 PCPY
0 Cancel
1 Copy
Parameters
2 Write copy
Parameters
3 Verify
Parameters
(Error )
Error Clear
 Password protection

Pr.296 and Pr. 297 is used for password protection function.

Pr.296 = Password lock level

Pr.297 = Password lock/unlock

For putting a password:

1. Put the password on pr.297(1000- 9998).
2. Put Pr. 296 <> 9999 for valid the protection(Read/Write).
Regenerative Brake Function
 Parameters
Pr.0 (Torque Boost)
The Motor torque in the Low-frequency range is adjusted to the load.

Note: Do not increase the value of the manual torque boost because it also increase
the value of current. If the range of the current exceed the over current value,
Alarm occur.
 Parameters
Pr.1,Pr.2 (Maximum and Minimum frequency)
The Motor torque in the Low-frequency range is adjusted to the load.
 Parameters
Pr.3 (Base frequency)
This parameter is used to adjust the reference frequency of the inverter to the rating
of the motor. If the frequency given in the motor rating plate is “50Hz”, always set
to “50Hz”.
 Parameters
(Multi Speed Setting)
This parameter is used to change the preset speed in the parameter with the contact
terminal. Any speed can be selected by merely turning on/off the contact signals
(RH, RM, RL, REX).
For using this function parameters are: (Pr.4-Pr.6),(Pr.24-Pr.27),(Pr.232-Pr.239).
 Parameters
Pr.7, Pr.8 (Acc/dec time setting)
This parameter is used to change the preset speed in the parameter with the contact
terminal. Any speed can be selected by merely turning on/off the contact signals
(RH, RM, RL, REX).
For using this function parameters are: (Pr.4-Pr.6),(Pr.24-Pr.27),(Pr.232-Pr.239).
 Inverter Software (FR-Configurator)

Inverter Setup Software (FR-Configurator)

1) Functions:-

1.1) Parameter setting and edit

1.2) Monitoring
1.3) Test operation
1.4) Diagnosis
1.5) File
 Software overview (Step-1)
After click on the FR - Configurator software below window will appear:-
Troubleshooting and Alarms
 Troubleshooting and Alarms

1. Error Messages: If the below message is occur, operation will not stop.
 Troubleshooting and Alarms
1. Alarms: If the below message is occur, operation will stop.
 Troubleshooting and Alarms
1. Major Faults: The below message is some example of major faults , This could
stop the operation when occurs.

* In the major faults do not reset the alarm, first confirm the cause, resetting several
times may cause the failure of Inverter.
 Troubleshooting and Alarms
1. Motor does not rotate as commanded :

1) Check the Pr. 0 “Torque Boost” setting

2) Check the main circuit

2.1 Check that proper power supply voltage is applied
2.2 Check thar
Troubleshooting and Alarms
Troubleshooting and Alarms
Troubleshooting and Alarms
Troubleshooting and Alarms
Troubleshooting and Alarms
Protections Limits
THANKS