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Precision Zone Expertly Repairs Inverter-General Purpose Mitsubishi FR-Z220/Z240

Here at Precision Zone, one of our specialties is the repair services of Mitsubishi general purpose inverter units. One of the series that we often work on is the FR-Z220 and FR-Z240 series.

Mitsubishi offers quite a few different series of general purpose inverters and one of these series is this FR-Z220 and FR-Z240 series. These units are offered in 200VAC and 400VAC variants, designated in the model number by the FR-Z220 for 200V or FR-Z240 for the 400V option. This inverter series has sizes ranging from 0.4kW (0.5 HP) up to a 55kW (75 HP) and has an optional parameter unit, which should be denoted by the model number – FR-Z220-0.75KP is an example, where the P following the size means a parameter unit should be supplied. This parameter unit, model FR-PU01E, allows for quick parameter access, easy monitoring functions, and quick accessibility to any alarm faults to speed up the troubleshooting process.

These units offer a few different operation modes which will be determined by the application each unit is installed for. It can be controlled in external operation mode – utilizes external signals as the control method, PU operation mode – uses the parameter unit as the control method, or combined operation mode – allows external signals and the parameter unit to be used as the control method.

When assessing the functionality of a drive, our repair team typically conducts a four-step check:

    1. Visual Overview
    2. Static Test
    3. Checks Under Power
    4. Alarm Codes Verification

This overview is Precision Zone’s basic troubleshooting process. Once our repair team starts on the job, we use specialized and customized testing fixtures, Huntron trackers, signal generators, oscilloscopes, milli and megaohm meters, as well as any other necessary tools we have available to assure quality repair work. Most importantly, every repair is fully tested in our custom-built simulators under load with a motor to replicate real-life working environment.

Precision Zone goes as far as using heating chambers and overnight dynamic testing, when applicable, to guarantee performance of the repaired product when it arrives back with the customer.

Repair Process for Mitsubishi FR-Z220/Z240 General Purpose Inverter Drives

Visual Overview

When conducting a visual check, the technician inspects the drive for any mechanical damage to the drive itself and any printed circuit boards (PCB). The technician then proceeds to verify connections are tight and correct inside the drive and there are no loose screws, wires or debris. Additionally, the unit is checked for any burn marks on the components, PCBs or chassis. During the visual inspection, excessive dirt on cooling components is noted as well as the functionality of the heat sink.

Basic Static Check

Input Module Testing

The input modules on these units can be tested by use of a digital multimeter with diode checking capabilities. Upon removing the cover, all of these terminals can be located along the terminal strip found within the unit.

Positive Lead Negative Lead Reading
R 'P' Terminal 0.35V-0.50V
S 'P' Terminal 0.35V-0.50V
T 'P' Terminal 0.35V-0.50V
'N' Terminal R 0.35V-0.50V
'N' Terminal S 0.35V-0.50V
'N' Terminal T 0.35V-0.50V


Output Module Testing

Using the same type of test as above, the output modules can be checked as well. Our technicians are also equipped with huntron devices further verify their integrity. Module ratings change with drive capacity, so the biggest concern is that each reading is within 10% of one another.

Positive Lead Negative Lead Reading
U 'P' Terminal 0.32V-0.52V
V 'P' Terminal 0.32V-0.52V
W 'P' Terminal 0.32V-0.52V
'N' Terminal U 0.32V-0.52V
'N' Terminal V 0.32V-0.52V
'N' Terminal W 0.32V-0.52V

Common Alarms for the Mitsubishi FR-Z220/FR-Z240 General-Purpose Inverter Units

Alarm Code Description Checks
OC1
OC2
OC3		 Overcurrent detected during acceleration (OC1), constant speed (OC2), or deceleration (OC3)
  • Check cables for poor insulation
  • Perform magaohm test on motor
  • Use 'Output Module Testing' test to verify modules
  • Check for ground faults
OVT Overvoltage detected in DC output circuit
  • Verify load is not excessive
  • Verify deceleration time is not too quick
  • Check input voltage
  • Swap drive out with another if applicable
OHT External thermal relay has been switched on. Only applies when external thermal relay input is selected
  • Check motor for signs of overheating
  • Verify connections of thermal sensor
  • Reduce load and check if problem persists
GF Ground fault has occured on the output of unit
  • Check motor or wire for ground fault
  • Check input/output terminals to ground for leakage
  • Replace Drive


For a full list of Mistubishi FR-Z220/Z240 alarms, click below for a list directly from the manual:

https://s3.amazonaws.com/Icarus/DOCUMENTS/Mitsubishi_Alarms_Faults_3783.pdf

The list of alarms within the manual is a good starting point for troubleshooting the Mitsubishi General Purpose Inverters. If any additional troubleshooting assistance is needed for the FR-Z220 or FR-Z240, Precision Zone offers free technical support. Feel free to contact us via phone or email to get in touch with our experienced technical support team.

Learn the benefit of repairing your Mitsubishi FR-Z220/FR-Z240 General Purpose Inverters with Precision Zone

  • Quick and Flexible Service
  • Fully Refurbished, not just repaired
  • Decades of Industry Experience/li>
  • Superior Technology Knowledge and Support

Contact Us To Start Your Repair Today!


Recently Repaired Products

Mitsubishi FR-Z220-2.2K image FR-Z220-2.2K is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Output Transistors/SCRs, Bad Circuit Board Component(s), Bad Gate Section/Board
Series: FR-Z220; 200V
Capacity: 2.2kW; 3 HP
Parameter Unit: Parameter Unit Not installed
Version: Japanese

Mitsubishi FR-Z220-3.7K image FR-Z220-3.7K is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Power Section/Board, Bad Capacitor(s), Bad Circuit Board Component(s), Bad Cooling Fans, Leaky Capacitors (Open, Corroded Traces)
Series: FR-Z220; 200V
Capacity: 3.7kW; 5 HP
Parameter Unit: Parameter Unit Not installed
Version: Japanese

Mitsubishi FR-Z220-11K-UL image FR-Z220-11K-UL is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Circuit Board Component(s), Bad Control Section/Board, Bad Cooling Fans, Leaky Capacitors (Open, Corroded Traces), Bad Power Section/Board, Bad DCCT
Series: FR-Z220; 200V
Capacity: 11kW; 15 HP
Parameter Unit: Parameter Unit Not installed
Version: UL listed

Mitsubishi FR-Z220-5.5KP image FR-Z220-5.5KP is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Gate Section/Board, Bad Circuit Board Component(s), Bad Power Section/Board
Series: FR-Z220; 200V
Capacity: 5.5kW; 7.5 HP
Parameter Unit: Parameter Unit Installed
Version: Japanese

Mitsubishi FR-Z220-3.7K-UL image FR-Z220-3.7K-UL is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Cooling Fans, Leaky Capacitors (Open, Corroded Traces), Bad Magnetic Contactor, Relay
Series: FR-Z220; 200V
Capacity: 3.7kW; 5 HP
Parameter Unit: Parameter Unit Not installed
Version: UL listed

Mitsubishi FR-Z240-2.2K-ER image FR-Z240-2.2K-ER is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Magnetic Contactor, Relay, Bad Power Section/Board, Leaky Capacitors (Open, Corroded Traces), No Display
Series: FR-Z240; 400V
Capacity: 2.2kW; 3 HP
Parameter Unit: Parameter Unit Not installed
Version: European specification

Mitsubishi FR-Z220-3.7KP image FR-Z220-3.7KP is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Control Section/Board, Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Power Section/Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Series: FR-Z220; 200V
Capacity: 3.7kW; 5 HP
Parameter Unit: Parameter Unit Installed
Version: Japanese

Mitsubishi FR-Z220-1.5K image FR-Z220-1.5K is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Leaky Capacitors (Open, Corroded Traces), Bad Capacitor(s), Bad Circuit Board Component(s), Bad Gate Section/Board, Bad Power Section/Board
Series: FR-Z220; 200V
Capacity: 1.5kW; 2HP
Parameter Unit: Parameter Unit Not installed
Version: Japanese

Mitsubishi FR-Z220-7.5K image FR-Z220-7.5K is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Gate Section/Board, May Require Board Replacement
Series: FR-Z220; 200V
Capacity: 7.5kW; 10 HP
Parameter Unit: Parameter Unit Not installed
Version: Japanese

Mitsubishi FR-Z220-0.75K image FR-Z220-0.75K is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Gate Section/Board, Bad Power Section/Board
Series: FR-Z220; 200V
Capacity: 0.75kW; 1HP
Parameter Unit: Parameter Unit Not installed
Version: Japanese

Mitsubishi FR-Z240-3.7K-UL image FR-Z240-3.7K-UL is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Blown Circuit Board (Through Hole), May Require Board Replacement, Bad Capacitor(s), Bad Circuit Board Component(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Output Transistors/SCRs, Bad Power Section/Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces), No Display, Physical Damage to the Drive
Series: FR-Z240; 400V
Capacity: 3.7kW; 5 HP
Parameter Unit: Parameter Unit Not installed
Version: UL listed

Mitsubishi FR-Z220-0.4K image FR-Z220-0.4K is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Circuit Board Component(s), Bad Gate Section/Board, Bad Input Diodes/SCRs, Bad Output Transistors/SCRs, Bad Power Section/Board, Blown Input Power Components, May Require Board Replacement, No Display
Series: FR-Z220; 200V
Capacity: 0.4kW; 0.5HP
Parameter Unit: Parameter Unit Not installed
Version: Japanese

Mitsubishi FR-Z220-1.5KP image FR-Z220-1.5KP is an
Inverter-General Purpose manufactured by Mitsubishi
Discovered issues: Bad Control Section/Board, No Display
Series: FR-Z220; 200V
Capacity: 1.5kW; 2HP
Parameter Unit: Parameter Unit Installed
Version: Japanese