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Mitsubishi A800-E FR-A862-08500-E Inverter Instruction Manual PDF
en
Summary of Content for Mitsubishi A800-E FR-A862-08500-E Inverter Instruction Manual PDF
IN VER
TER A
800-E FR
-A 862-E IN
STR U
C TIO
N M
A N
U A
L (H A
R D
W A
R E)
B
HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
IB(NA)-0600639ENG-B(1903)MEE Printed in Japan Specifications subject to change without notice.
INVERTER
INTRODUCTION 1
A800-E FR-A862-E (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE)
FR-A862-05450 to 08500-E High functionality and high performance
INSTALLATION AND WIRING 2
PRECAUTIONS FOR USE OF THE INVERTER 3
PROTECTIVE FUNCTIONS 4
PRECAUTIONS FOR MAINTENANCE AND
INSPECTION 5
SPECIFICATIONS 6
Thank you for choosing this Mitsubishi Electric inverter. This Instruction Manual describes handling and cautions about the hardware, such as installation and wiring, for the FR-A862 (separated converter type) that are different from the FR-A860. Information about the software, such as basic operations and parameters, is described in the FR-A860 Instruction Manual (Detailed) in the CD-ROM enclosed with the product. For the details on Ethernet communication, refer to the FR-A800-E Ethernet Function Manual in the enclosed CD-ROM. In addition to this manual, please read the manuals in the enclosed CD-ROM carefully. Do not use this product until you have a full knowledge of the equipment, safety information and instructions. Please forward this Instruction Manual to the end user.
Electric Shock Prevention
Fire Prevention
Injury Prevention
Additional Instructions The following instructions must be also followed. If the product is handled incorrectly, it may cause unexpected fault, an injury, or an electric shock.
Safety Instructions Do not attempt to install, operate, maintain or inspect the 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. Installation, operation, maintenance and inspection must be performed by qualified personnel. Here, an expert means a person who meets all the conditions below. A person who took a proper engineering training. Such training may be available at your local Mitsubishi Electric office. Contact your local sales office for schedules and locations. A person who can access operating manuals for the protective devices (e.g. light curtain) connected to the safety control system. A person who has read and familiarized himself/herself with the manuals.
In this Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION"
Incorrect handling may cause hazardous conditions, resulting in death or severe injury. Incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause only material damage.
Note that even the level may even lead to a serious consequence according to conditions. Be sure to follow the instructions of both levels as they are critical to personal safety.
WARNING While the inverter power is ON, do not remove the front cover or
the wiring cover. Do not run the inverter with the front cover or the wiring cover removed, as accidental contact with exposed high-voltage terminals and internal components may occur, resulting in an electrical shock. Even if power is OFF, do not remove the front cover except for
wiring or periodic inspection. You may accidentally touch the charged inverter circuits and get an electric shock. Before wiring or inspection, power lamp must be switched OFF.
Any person who is involved in wiring or inspection shall wait for at least 10 minutes after the power supply has been switched OFF and check that there are no residual voltage using a tester or the like. The capacitor is charged with high voltage for some time after power OFF, and it is dangerous. This inverter must be earthed (grounded). Earthing (grounding)
must conform to the requirements of national and local safety regulations and electrical code (NEC section 250, IEC 61140 class 1 and other applicable standards). Any person who is involved in wiring or inspection of this
equipment shall be fully competent to do the work. The inverter must be installed before wiring. Otherwise you may
get an electric shock or be injured. Setting dial and key operations must be performed with dry
hands to prevent an electric shock. Otherwise you may get an electric shock. Do not subject the cables to scratches, excessive stress, heavy
loads or pinching. Doing so may cause an electric shock. Do not change the cooling fan while power is ON. It is dangerous
to change the cooling fan while power is ON. Do not touch the printed circuit board or handle the cables with
wet hands. Doing so may cause an electric shock. A PM motor is a synchronous motor with high-performance
magnets embedded in the rotor. Motor terminals holds high- voltage while the motor is running even after the inverter power is turned OFF. Before wiring or inspection, the motor must be confirmed to be stopped. In an application, such as fan and blower, where the motor is driven by the load, a low-voltage manual motor starter must be connected at the inverter's output side, and wiring and inspection must be performed while the motor starter is open. Otherwise you may get an electric shock.
WARNING
CAUTION
CAUTION
CAUTION Inverter must be installed on a nonflammable wall without holes
(so that nobody touches the inverter heat sink on the rear side, etc.). Mounting it to or near flammable material may cause a fire. If the inverter has become faulty, the inverter power must be
switched OFF. A continuous flow of large current may cause a fire. Be sure to perform daily and periodic inspections as specified in
the Instruction Manual. If a product is used without any inspection, a burst, breakage, or a fire may occur.
CAUTION The voltage applied to each terminal must be the ones specified
in the Instruction Manual. Otherwise an explosion or damage may occur. The cables must be connected to the correct terminals.
Otherwise an explosion or damage may occur. The polarity (+ and -) must be correct. Otherwise burst, damage,
etc. may occur. While power is ON or for some time after power-OFF, do not
touch the inverter as it will be extremely hot. Touching these devices may cause a burn.
CAUTION Transportation and installation Any person who is opening a package using a sharp object,
such as a knife and cutter, must wear gloves to prevent injuries caused by the edge of the sharp object. The product must be transported in correct method that
corresponds to the weight. Failure to do so may lead to injuries. Do not stand or rest heavy objects on the product. Do not stack the boxes containing inverters higher than the
number recommended. When carrying the inverter, do not hold it by the front cover; it
may fall off or fail. During installation, caution must be taken not to drop the inverter
as doing so may cause injuries. The product must be installed on the surface that withstands the
weight of the inverter. Do not install the product on a hot surface. The mounting orientation of the inverter must be correct. The inverter must be installed on a strong surface securely with
screws so that it will not drop. Do not install or operate the inverter if it is damaged or has parts
missing. Foreign conductive objects must be prevented from entering the
inverter. That includes screws and metal fragments or other flammable substance such as oil. As the inverter is a precision instrument, do not drop or subject it
to impact. The surrounding air temperature for LD and ND (initial setting)
models must be between -10 and +50C (non-freezing). The surrounding air temperature for SLD and HD models must be between -10 and +40C (non-freezing). Otherwise the inverter may be damaged. The ambient humidity must be 95%RH or less (non-
condensing). Otherwise the inverter may be damaged. (Refer to page 17 for details.)
Safety Instructions 1
CAUTION Transportation and installation The storage temperature (applicable for a short time, e.g. during
transit) must be between -20 and +65C. Otherwise the inverter may be damaged. The inverter must be used indoors (without corrosive gas,
flammable gas, oil mist, dust and dirt etc.) Otherwise the inverter may be damaged. The product must be used at an altitude of 2500 m or less, with
2.9 m/s2 or less vibration at 10 to 55 Hz (directions of X, Y, Z axes). Otherwise the inverter may be damaged. (For installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude.) If halogen-based materials (fluorine, chlorine, bromine, iodine,
etc.) infiltrate into a Mitsubishi Electric product, the product will be damaged. Halogen-based materials are often included in fumigant, which is used to sterilize or disinfest wooden packages. When packaging, prevent residual fumigant components from being infiltrated into Mitsubishi Electric products, or use an alternative sterilization or disinfection method (heat disinfection, etc.) for packaging. Sterilization of disinfection of wooden package should also be performed before packaging the product.
Wiring Do not install a power factor correction capacitor or surge
suppressor/capacitor type filter on the inverter output side. These devices on the inverter output side may be overheated or burn out. The output side terminals (terminals U, V, and W) must be
connected correctly. Otherwise the motor will rotate inversely. PM motor terminals (U, V, W) hold high-voltage while the PM
motor is running even after the power is turned OFF. Before wiring, the PM motor must be confirmed to be stopped. Otherwise you may get an electric shock. Never connect a PM motor to the commercial power supply.
Applying the commercial power supply to input terminals (U, V, W) of a PM motor will burn the PM motor. The PM motor must be connected with the output terminals (U, V, W) of the inverter.
Trial run Before starting operation, each parameter must be confirmed
and adjusted. A failure to do so may cause some machines to make unexpected motions.
WARNING Usage Everyone must stay away from the equipment when the retry
function is set as it will restart suddenly after a trip. Since pressing the STOP/RESET key may not stop output
depending on the function setting status, separate circuit and switch that make an emergency stop (power OFF, mechanical brake operation for emergency stop, etc.) must be provided. OFF status of the start signal must be confirmed before resetting
the inverter fault. Resetting inverter fault with the start signal ON restarts the motor suddenly. Do not use a PM motor for an application where the PM motor is
driven by its load and runs at a speed higher than the maximum motor speed. Use this inverter only with three-phase induction motors or with a
PM motor. Connection of any other electrical equipment to the inverter output may damage the equipment. Performing pre-excitation (LX signal and X13 signal) under
torque control (Real sensorless vector control) may start the motor running at a low speed even when the start command (STF or STR) is not input The motor may run also at a low speed when the speed limit value = 0 with a start command input. It must be confirmed that the motor running will not cause any safety problem before performing pre-excitation. Do not modify the equipment. Do not perform parts removal which is not instructed in this
manual. Doing so may lead to fault or damage of the product.
CAUTION Usage The electronic thermal relay function does not guarantee
protection of the motor from overheating. It is recommended to install both an external thermal and PTC thermistor for overheat protection. Do not use a magnetic contactor on the inverter input for
frequent starting/stopping of the inverter. Doing so may shorten the life of this product. The effect of electromagnetic interference must be reduced by
using a noise filter or by other means. Otherwise nearby electronic equipment may be affected. Appropriate measures must be taken to suppress harmonics.
Otherwise power supply harmonics from the inverter may heat/ damage the power factor correction capacitor and generator. When driving a 600V class motor by the inverter, the motor must
be an insulation-enhanced motor or measures must be taken to suppress surge voltage. Surge voltage attributable to the wiring constants may occur at the motor terminals, deteriorating the insulation of the motor. When parameter clear or all parameter clear is performed, the
required parameters must be set again before starting operations because all parameters return to their initial values. The inverter can be easily set for high-speed operation. Before
changing its setting, the performances of the motor and machine must be fully examined. Stop status cannot be hold by the inverter's brake function. In
addition to the inverters brake function, a holding device must be installed to ensure safety. Before running an inverter which had been stored for a long
period, inspection and test operation must be performed. Static electricity in your body must be discharged before you
touch the product. Only one PM motor can be connected to an inverter. A PM motor must be used under PM sensorless vector control.
Do not use a synchronous motor, induction motor, or synchronous induction motor. Do not connect a PM motor in the induction motor control
settings (initial settings). Do not use an induction motor in the PM sensorless vector control settings. It will cause a failure. In the system with a PM motor, the inverter power must be
turned ON before closing the contacts of the contactor at the output side. In order to protect this product and the system against
unauthorized access from external sources through Ethernet communication, take security measures such as setting up a firewall. Depending on the network environment, the inverter may not
operate as intended due to delays or disconnection in communication. Carefully consider what type of environment this product will be used in and any safety issues related to its use.
Emergency stop A safety backup such as an emergency brake must be provided
for devices or equipment in a system to prevent hazardous conditions in case of failure of this product or an external device controlling this product. When the breaker on the inverter input side trips, the wiring must
be checked for fault (short circuit), and internal parts of the inverter for a damage, etc. The cause of the trip must be identified and removed before turning ON the power of the breaker. When a protective function is activated, take an appropriate
corrective action, then reset the inverter, and resume the operation.
Maintenance, inspection and parts replacement Do not carry out a megger (insulation resistance) test on the
control circuit of the inverter. It will cause a failure. Disposal The inverter must be treated as industrial waste.
2 Safety Instructions
Application of caution labels Caution labels are used to ensure safety during use of the Mitsubishi Electric inverters. Apply the following labels to the inverter if the "retry function" and/ or "automatic restart after instantaneous power failure" have been enabled. For the retry function
For automatic restart after instantaneous power failure
Application of motor control labels Apply the following labels to the inverter to avoid connecting motors not intended for a particular motor control setting.
General instruction For clarity, illustrations in this Instruction Manual may be drawn
with covers or safety guards removed. Ensure all covers and safety guards are properly installed prior to starting operation. For details on the PM motor, refer to the Instruction Manual of the PM motor.
CAUTION Retry Function Has Been Selected
Stay away from the motor and machine. They will start suddenly (after given time has elapsed) when alarm occurs.
CAUTION Automatic Restart after Instantaneous Power Failure Has Been Selected
Stay away from the motor and machine. They will start suddenly (after reset time has elapsed) when instantaneous power failure occurs.
Induction motor setting
The inverter is set for the induction motor control. Do not connect a PM motor.
PM motor control setting
The inverter is set for the PM motor control. Do not connect an induction motor.
Safety Instructions 3
CONTENTS
1 INTRODUCTION 7 1.1 Product checking and accessories 8
1.2 Inverter component names 9
1.3 About the related manuals 10
2 INSTALLATION AND WIRING 11 2.1 Peripheral devices 12
2.1.1 Inverter and peripheral devices ...................................................................................................................... 12
2.1.2 Peripheral devices.......................................................................................................................................... 14
2.2 Removal and reinstallation of the front covers 15
2.3 Installation of the inverter and enclosure design 17 2.3.1 Inverter installation environment .................................................................................................................... 17
2.3.2 Amount of heat generated by the inverter ...................................................................................................... 19
2.3.3 Cooling system types for inverter enclosure .................................................................................................. 20
2.3.4 Inverter installation ......................................................................................................................................... 21
2.3.5 Protruding the heat sink through a panel ....................................................................................................... 23
2.4 Terminal connection diagrams 25
2.5 Main circuit terminals 27 2.5.1 Details on the main circuit terminals of the inverter........................................................................................ 27
2.5.2 Details on the main circuit terminals of the converter unit (FR-CC2) ............................................................. 27
2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor ..................................... 28
2.5.4 Applicable cables and wiring length ............................................................................................................... 29
2.5.5 Earthing (grounding) precautions ................................................................................................................... 31
2.6 Control circuit 32 2.6.1 Details on the control circuit terminals of the inverter..................................................................................... 32
2.6.2 Details on the control circuit terminals of the converter unit (FR-CC2) .......................................................... 35
2.6.3 Control logic (sink/source) change ................................................................................................................. 36
2.6.4 Wiring of inverter control circuit ...................................................................................................................... 38
2.6.5 Wiring precautions.......................................................................................................................................... 40
2.6.6 When using separate power supplies for the control circuit and the main circuit........................................... 41
2.6.7 When supplying 24 V external power to the control circuit............................................................................. 42
2.7 Communication connectors and terminals 44 2.7.1 PU connector.................................................................................................................................................. 44
2.7.2 Ethernet connector ......................................................................................................................................... 45
2.7.3 USB connector ............................................................................................................................................... 46
2.8 Connection of motor with encoder (Vector control) 48
2.9 Parameter settings for a motor with encoder 52
2.10 Installing a communication option 53
4 CONTENTS
3 PRECAUTIONS FOR USE OF THE INVERTER 55 3.1 Electro-magnetic interference (EMI) and leakage currents 56
3.1.1 Leakage currents and precautions .................................................................................................................56
3.1.2 Precautions against inverter-generated EMI ..................................................................................................57
3.2 Power supply harmonics 59 3.2.1 Power supply harmonics.................................................................................................................................59
3.3 Installation of a reactor 59
3.4 Power-OFF and magnetic contactor (MC) 60
3.5 Precautions against deterioration of the 600 V class motor insulation 61
3.6 Checklist before starting operation 62
3.7 Failsafe system which uses the inverter 64
4 PROTECTIVE FUNCTIONS 67 4.1 Inverter fault and indications 68
4.2 Reset method for the protective functions 68
4.3 List of fault displays 69
5 PRECAUTIONS FOR MAINTENANCE AND INSPECTION 71
5.1 Inspection item 72 5.1.1 Daily inspection...............................................................................................................................................72
5.1.2 Periodic inspection..........................................................................................................................................72
5.1.3 Daily and periodic inspection ..........................................................................................................................73
5.1.4 Checking the inverter and converter modules ................................................................................................74
5.1.5 Cleaning..........................................................................................................................................................75
5.1.6 Replacement of parts......................................................................................................................................75
5.1.7 Removal and reinstallation of the control circuit terminal block ......................................................................78
5.2 Measurement of main circuit voltages, currents and powers 79 5.2.1 Measurement of powers .................................................................................................................................81
5.2.2 Measurement of voltages ...............................................................................................................................81
5.2.3 Measurement of currents................................................................................................................................81
5.2.4 Example of measuring converter unit (FR-CC2) input power factor ...............................................................81
5.2.5 Measurement of converter output voltage (across terminals P and N)...........................................................81
5.2.6 Measurement of inverter output frequency .....................................................................................................82
5.2.7 Insulation resistance test using megger .........................................................................................................82
5.2.8 Withstand voltage test ....................................................................................................................................82
CONTENTS 5
6 SPECIFICATIONS 83 6.1 Inverter rating 84
6.2 Common specifications 85
6.3 Outline dimension drawings 87 6.3.1 Inverter outline dimension drawings............................................................................................................... 87
APPENDIX 89 Appendix 1 For customers replacing the conventional model with this inverter.................................. 90 Appendix 2 Comparison with FR-A860...................................................................................................... 92 Appendix 3 Instructions for UL and cUL ................................................................................................... 93 Appendix 4 Restricted Use of Hazardous Substances in Electronic and Electrical Products ............. 95
6 CONTENTS
1
INTRODUCTION 7
1 INTRODUCTION
This chapter contains the descriptions that must be read before using this product. Always read the instructions before using the equipment.
1.1 Product checking and accessories.........................................8 1.2 Inverter component names......................................................9 1.3 About the related manuals.......................................................10
A8TP (control terminal option) Pr. ..................................................Parameter number (Number assigned to function) PU operation ..................................Operation using the PU (operation panel/parameter unit) External operation ..........................Operation using the control circuit signals Combined operation ......................Combined operation using the PU (operation panel/parameter unit) and
External operation
Ethernet is a registered trademark of Fuji Xerox Co., Ltd.
Connection diagrams in this Instruction Manual suppose that the control logic of the input terminal is the sink
logic, unless otherwise specified. (For the control logic, refer to page 36.)
Product checking and accessories
1.1 Product checking and accessories Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model agrees with the
order and the product is intact.
Inverter model
How to read the SERIAL number
Accessory Earthing (grounding) cable (1): For connection with a communication option. (Refer to page 53.)
CD-ROM (1): Including the Instruction Manual (Detailed) and other documents.
Rating plate example The SERIAL consists of one symbol, two characters indicating the production
year and month, and six characters indicating the control number.
The last digit of the production year is indicated as the Year, and the Month is
indicated by 1 to 9, X (October), Y (November), or Z (December).
Symbol Year Month Control number
SERIAL
F R - A 8 6 2 - 05450 - E1 - 60
600 V class Symbol Voltage class
6
Symbol Circuit board coating (conforming to IEC 60721-3-3 3C2/3S2)
With With
Plated conductor
With Without
06 60
Symbol Description
05450 to 08500 SLD rated inverter current (A)
Symbol Structure, functionality Separated converter type2
Symbol Communication
type E1 Ethernet
Rating plate
Input rating
Output rating
SERIAL
Inverter model FR-A862-05450-E1-60
Country of origin
8 INTRODUCTION
Inverter component names
1
1.2 Inverter component names Component names are shown below.
Refer to the FR-A860 Instruction Manual (Detailed)
Symbol Name Description Refer to page
(a) Plug-in option connector 1 Connects a plug-in option or a communication option.
Instruction Manual of the option(b) Plug-in option connector 3
(c) Plug-in option connector 2
The connector 2 cannot be used because the Ethernet board is installed in the initial status. The Ethernet board must be removed to install a plug-in option to the connector 2. (However, Ethernet communication is disabled in that case.)
45
(d) Voltage/current input switch (SW2) Selects between voltage and current for terminal 2 and 4 inputs.
(e) Ethernet communication connector Connect the Ethernet dedicated cable for connection to the network. 45 (f) Control circuit terminal block Connects cables for the control circuit. 32
(g) PU connector Connects the operation panel or the parameter unit (FR-PU07). This connector also enables the RS-485 communication. 44
(h) USB A connector Connects a USB memory device. 46
(i) USB mini B connector Connects a personal computer and enables communication with FR Configurator2. 46
(j) Front cover (upper side) Remove this cover for the installation of the product, installation of a plug-in (communication) option, switching of the voltage/current input switch, etc. 15
(k) Power lamp Stays ON while the power is supplied to the control circuit (R1/L11, S1/L21). 28 (l) Alarm lamp Turns ON when the protective function of the inverter is activated. 67 (m) Charge lamp Stays ON while the power is supplied to the main circuit. 28 (n) Accessory cover Remove this cover for using the PU connector.
(o) Front cover (lower side) Remove this cover for wiring. 15 (p) Main circuit terminal block Connects cables for the main circuit. 27 (q) Cooling fan Cools the inverter. 76
(r) Switches for manufacturer setting (SW3 and SW4) Do not change the initial setting (OFF ).
(p)
(m)
(n)
(k) (l)
(j)
(o)
(q)(g)
(f)
(d)
(e)
(b)
(a)
(c)
(h) (i) (r)
OFF ON
INTRODUCTION 9
About the related manuals
1.3 About the related manuals The manuals related to FR-A862-E are shown below.
Manual name Manual number FR-A860 Instruction Manual (Detailed) IB-0600563ENG
FR-A800-E Ethernet Function Manual IB-0600628ENG
FR-CC2 (Converter unit) Instruction Manual IB-0600572ENG
FR Configurator 2 Instruction Manual IB-0600516ENG
FR-A800/F800 PLC Function Programming Manual IB-0600492ENG
10 INTRODUCTION
2
INSTALLATION AND WIRING 11
2 INSTALLATION AND WIRING
This chapter explains the "installation" and the "wiring" of this product. Always read the instructions before use.
2.1 Peripheral devices ....................................................................12 2.2 Removal and reinstallation of the front covers......................15 2.3 Installation of the inverter and enclosure design..................17 2.4 Terminal connection diagrams................................................25 2.5 Main circuit terminals ...............................................................27 2.6 Control circuit ...........................................................................32 2.7 Communication connectors and terminals ............................44 2.8 Connection of motor with encoder (Vector control)..............48 2.9 Parameter settings for a motor with encoder ........................52 2.10 Installing a communication option..........................................53
Peripheral devices
2.1 Peripheral devices
2.1.1 Inverter and peripheral devices
NOTE To prevent an electric shock, always earth (ground) the motor, the inverter, and the converter unit. Do not install a power factor correction capacitor, surge suppressor, or capacitor type filter on the inverter's output side. Doing so
will cause the inverter shut off or damage the capacitor or surge suppressor. If any of the above devices is connected, immediately remove it. When installing a molded case circuit breaker on the output side of the inverter, contact the manufacturer of the molded case circuit breaker.
Electromagnetic wave interference The input/output (main circuit) of the inverter or the converter unit includes high frequency components, which may interfere with the communication devices (such as AM radios) used near the inverter or the converter unit. Refer to page 57 for countermeasures.
For details of options and peripheral devices, refer to the respective Instruction Manual. A PM motor cannot be driven by the commercial power supply. A PM motor is a motor with permanent magnets embedded inside. High voltage is generated at the motor terminals while the
motor is running. Before closing the contactor at the output side, make sure that the inverter power is ON and the motor is stopped.
Earth (Ground)
R/L1 S/L2 T/L3 N/-N/- P/+P/+
: Install these options as required.
U V W U
Earth (Ground)
V W
(d) Molded case circuit breaker (MCCB) or earth leakage current breaker (ELB), fuse
(i) Noise filter
(k) Contactor Example) No-fuse switch (DSN type)
(l) PM motor
(g) Noise filter
(e) Magnetic contactor (MC)
(a) Inverter (FR-A862)
(b) Converter unit (FR-CC2)
(c) Three-phase AC power supply
(h) USB connector
Personal computer (FR Configurator2)
USB
USB host (A connector)
USB device (Mini B connector)
Communication status indicator (LED)(USB host)
Earth (Ground)
(j) Induction motor
(f) AC reactor
IM connection PM connection Earth
(Ground)
12 INSTALLATION AND WIRING
Peripheral devices
2
Symbol Name Overview Refer
to page
(a) Inverter (FR-A862)
The life of the inverter and the converter unit is influenced by the surrounding air temperature. The surrounding air temperature should be as low as possible within the permissible range. This must be noted especially when the inverter is installed in an enclosure. Incorrect wiring may lead to damage of the inverter and the converter unit. The control signal lines must be kept fully away from the main circuit lines to protect them from noise.
17 25
(b) Converter unit (FR-CC2)
(c) Three-phase AC power supply Must be within the permissible power supply specifications of the converter unit.
84
(d) Molded case circuit breaker (MCCB), earth leakage circuit breaker (ELB), or fuse
Must be selected carefully since an inrush current flows in the converter unit at power ON.
14
(e) Magnetic contactor (MC) Install this to ensure safety. Do not use this to start and stop the inverter. Doing so will shorten the life of the inverter and the converter unit.
60
(f) AC reactor
Install this to suppress harmonics and to improve the power factor. An AC reactor is required when installing the inverter near a large power supply system (1000 kVA or more). Under such condition, the inverter and the converter unit may be damaged if you do not use a reactor. Select a reactor according to the applied motor capacity.
59
(g) Noise filter Suppresses the noise radiated from the power supply side of the converter unit.
57
(h) USB connection
Connect between the inverter and a personal computer with a USB (ver. 1.1) cable. Use a USB memory device to copy parameter settings or use the trace function.
46
(i) Noise filter Install this to reduce the electromagnetic noise generated from the inverter and the converter unit. The noise filter is effective in the range from about 0.5 to 5 MHz.
57
(j) Induction motor Connect a squirrel-cage induction motor.
(k) Contactor Example) No-fuse switch (DSN type)
Connect this for an application where a PM motor is driven by the load even while the inverter power is OFF. Do not open or close the contactor while the inverter is running (outputting).
(l) PM motor A PM motor can be used. A PM motor cannot be driven by the commercial power supply.
INSTALLATION AND WIRING 13
Peripheral devices
2.1.2 Peripheral devices Selecting the converter unit (FR-CC2) Select the capacity of the FR-CC2 converter unit according to the connected motor capacity.
The motor capacity indicated is the maximum capacity applicable for use of the 4-pole standard motor.
Selecting the breaker/magnetic contactor Check the model of the inverter and the converter unit you purchased. Appropriate peripheral devices must be selected
according to the capacity.
Refer to the following table to prepare appropriate peripheral devices.
NOTE When the converter unit capacity is larger than the motor capacity, select an MCCB and a magnetic contactor according to
the converter unit model, and select cables and reactors according to the motor output.
When the breaker on the converter unit's input side trips, check for the wiring fault (short circuit), damage to internal parts of
the inverter and the converter unit, etc. The cause of the trip must be identified and removed before turning ON the power of
the breaker.
Converter unit
FR-CC2-[ ]
Inverter Model
FR-A862-[ ] Rated current
(A) Motor capacity
(kW)
C355K 05450
SLD 545 400
LD 496 355
ND 402 280
HD 304 220
C400K 06470
SLD 647 450
LD 589 400
ND 496 355
HD 402 280
C560K 08500
SLD 850 630
LD 773 560
ND 663 450
HD 589 400
Motor output (kW)
Applicable converter model
Applicable inverter model
Molded case circuit breaker (MCCB) or
earth leakage circuit breaker (ELB) (NF, NV type)
Input-side magnetic
contactor
280 FR-CC2-C355K FR-A862-05450 600 A 373 A
355 FR-CC2-C400K FR-A862-06470 800 A 469 A
450 FR-CC2-C560K FR-A862-08500 1000 A 617 A
Assumes the use of a Mitsubishi Electric 4-pole standard motor with the power supply voltage of 575 VAC 50 Hz.
Select an MCCB according to the power supply capacity.
Install one MCCB per converter.
(For the use in the United States or Canada, refer to page 93 to select an appropriate fuse.)
The magnetic contactor is selected based on the AC-1 class. The electrical durability of magnetic contactor is 500,000 times. When the
magnetic contactor is used for emergency stops during motor driving, the electrical durability is 25 times.
If using an MC for emergency stop during driving the motor, select an MC regarding the converter unit input side current as JEM 1038-AC-3
class rated current. When using an MC on the inverter output side for commercial-power supply operation switching using a general-purpose
motor, select an MC regarding the rated motor current as JEM 1038-AC-3 class rated current.
MCCB Converter unit
MCCB Converter unit
M
M
INV
INV
14 INSTALLATION AND WIRING
Removal and reinstallation of the front covers
2
2.2 Removal and reinstallation of the front covers
Removal of the front cover (lower side)
(a) When the mounting screws are removed, the front cover (lower side) can be removed. (The number of the mounting screws differs by the capacity.)
(b) With the front cover (lower side) removed, wiring of the main circuit terminals can be performed.
Removal of the front cover (upper side)
(a) With the front cover (lower side) removed, loosen the mounting screws on the front cover (upper side). These screws cannot be removed.
(b) While holding the areas around the installation hooks on the sides of the front cover (upper side), pull out the front cover (upper side) using its upper side as a support.
(c) With the front cover (upper side) removed, wiring of the control circuit and the RS-485 terminals, and installation of the plug-in option can be performed.
(a) (b)
(a) (b) (c)
Loosen
INSTALLATION AND WIRING 15
Removal and reinstallation of the front covers
Reinstallation of the front covers
(a) Insert the upper hooks of the front cover (upper side) into the sockets of the inverter. Securely install the front cover (upper side) to the inverter by fixing the hooks on the sides of the cover into place.
(b) Tighten the mounting screws at the lower part of the front cover (upper side). (c) Fasten the front cover (lower side) with the mounting screws. (The number of the mounting screws differs by the capacity.)
NOTE When installing the front cover (upper side), fit the connector of the operation panel securely along the guides of the PU
connector.
Fully make sure that the front cover has been reinstalled securely. Always tighten the installation screws of the front covers.
(b) (c)(a)
Fasten Fasten
16 INSTALLATION AND WIRING
Installation of the inverter and enclosure design
2
2.3 Installation of the inverter and enclosure design When designing or manufacturing an inverter enclosure, determine the structure, size, and device layout of the enclosure by
fully considering the conditions such as heat generation of the contained devices and the operating environment. An inverter
uses many semiconductor devices. To ensure higher reliability and long period of operation, operate the inverter in the
ambient environment that completely satisfies the equipment specifications.
2.3.1 Inverter installation environment The following table lists the standard specifications of the inverter installation environment. Using the inverter in an
environment that does not satisfy the conditions deteriorates the performance, shortens the life, and causes a failure. Refer to
the following points, and take adequate measures.
Standard environmental specifications of the inverter
Temperature applicable for a short time, for example, in transit.
For the installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude.
Surrounding Air Temperature is a temperature measured at a measurement position in an enclosure.
Ambient Temperature is a temperature outside an enclosure.
Temperature The permissible surrounding air temperature of the inverter is between -10C and +50C (-10C and +40C at the SLD and
HD ratings). Always operate the inverter within this temperature range. Operation outside this range will considerably shorten
the service lives of the semiconductors, parts, capacitors and others. Take the following measures to keep the surrounding air
temperature of the inverter within the specified range.
(a) Measures against high temperature
Use a forced ventilation system or similar cooling system. (Refer to page 20.)
Install the enclosure in an air-conditioned electric chamber.
Block direct sunlight.
Provide a shield or similar plate to avoid direct exposure to the radiated heat and wind of a heat source.
Ventilate the area around the enclosure well.
(b) Measures against low temperature
Provide a space heater in the enclosure.
Do not power OFF the inverter. (Keep the start signal of the inverter OFF.)
(c) Sudden temperature changes
Select an installation place where temperature does not change suddenly.
Avoid installing the inverter near the air outlet of an air conditioner.
If temperature changes are caused by opening/closing of a door, install the inverter away from the door.
NOTE For the amount of heat generated by the inverter unit, refer to page 19.
Item Description
Surrounding air temperature
LD, ND (initial setting) -10 to +50C (non-freezing)
SLD, HD -10 to +40C (non-freezing)
Surrounding air humidity 95% RH or less (non-condensing)
Storage temperature -20 to + 65C
Atmosphere Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)
Altitude Maximum 2500 m
Vibration 2.9 m/s2 or less at 10 to 55 Hz (directions of X, Y, Z axes)
Measurement position
Measurement position
Inverter 5 cm 5 cm
5 cm
Enclosure
INSTALLATION AND WIRING 17
Installation of the inverter and enclosure design
Humidity Operate the inverter within the ambient air humidity of usually 45 to 95%. Too high humidity will pose problems of reduced
insulation and metal corrosion. On the other hand, too low humidity may cause a spatial electrical breakdown. The humidity
conditions for the insulation distance defined in JEM 1103 standard "Insulation Distance from Control Equipment" is 45 to
85%.
(a) Measures against high humidity
Make the enclosure enclosed, and provide it with a hygroscopic agent.
Provide dry air into the enclosure from outside.
Provide a space heater in the enclosure.
(b) Measures against low humidity
Air with proper humidity can be blown into the enclosure from outside. Also when installing or inspecting the unit, discharge
your body (static electricity) beforehand, and keep your body away from the parts and patterns.
(c) Measures against condensation
Condensation may occur if frequent operation stops change the in-enclosure temperature suddenly or if the outside air
temperature changes suddenly.
Condensation causes such faults as reduced insulation and corrosion.
Take the measures against high humidity in (a).
Do not power OFF the inverter. (Keep the start signal of the inverter OFF.)
Dust, dirt, oil mist Dust and dirt will cause such faults as poor contacts, reduced insulation and cooling effect due to the moisture-absorbed
accumulated dust and dirt, and in-enclosure temperature rise due to a clogged filter. In an atmosphere where conductive
powder floats, dust and dirt will cause such faults as malfunction, deteriorated insulation and short circuit in a short time.
Since oil mist will cause similar conditions, it is necessary to take adequate measures.
Precautions
Place the inverter in a totally enclosed enclosure.
Take measures if the in-enclosure temperature rises. (Refer to page 20.)
Purge air.
Pump clean air from outside to make the in-enclosure air pressure higher than the outside air pressure.
Corrosive gas, salt damage If the inverter is exposed to corrosive gas or to salt near a beach, the printed board patterns and parts will corrode or the
relays and switches will result in poor contact.
In such places, take the measures given above.
Explosive, flammable gases As the inverter is non-explosion proof, it must be contained in an explosion-proof enclosure. In places where explosion may
be caused by explosive gas, dust or dirt, an enclosure cannot be used unless it structurally complies with the guidelines and
has passed the specified tests. This makes the enclosure itself expensive (including the test charges). The best way is to
avoid installation in such places and install the inverter in a non-hazardous place.
High altitude Use the inverter at an altitude of within 2500 m. For use at an altitude above 1000 m, consider a 3% reduction in the rated
current per 500 m increase in altitude.
If it is used at a higher place, it is likely that thin air will reduce the cooling effect and low air pressure will deteriorate dielectric
strength.
18 INSTALLATION AND WIRING
Installation of the inverter and enclosure design
2
Vibration, impact The vibration resistance of the inverter is up to 2.9 m/s2 at 10 to 55 Hz frequency and 1 mm amplitude for the directions of X,
Y, Z axes. Applying vibration and impacts for a long time may loosen the structures and cause poor contacts of connectors,
even if those vibration and impacts are within the specified values.
Especially when impacts are applied repeatedly, caution must be taken because such impacts may break the installation feet.
Precautions
Provide the enclosure with rubber vibration isolators.
Strengthen the structure to prevent the enclosure from resonance.
Install the enclosure away from the sources of the vibration.
2.3.2 Amount of heat generated by the inverter Regarding the amount of heat generated in the FR-A860 series inverter The amount of heat generated by the inverter unit and converter unit is shown in the following tables.
NOTE The amount of heat generated shown assumes that the output current is inverter rated current, and carrier frequency is 2
kHz.
Inverter model Amount of heat generated (W)
SLD LD ND HD FR-CC2-C355K 2500
7300 2300
6600 1750
5100 1300
3750 FR-A862-05450 4800 4300 3350 2450
FR-CC2-C400K 3000 8600
2600 7700
2200 6500
1700 5000
FR-A862-06470 5600 5100 4300 3300
FR-CC2-C560K 3700 11400
3200 10200
2700 8500
2300 7400
FR-A862-08500 7700 7000 5800 5100
INSTALLATION AND WIRING 19
Installation of the inverter and enclosure design
2.3.3 Cooling system types for inverter enclosure From the enclosure that contains the inverter, the heat of the inverter and other equipment (transformers, lamps, resistors,
etc.) and the incoming heat such as direct sunlight must be dissipated to keep the in-enclosure temperature lower than the
permissible temperatures of the in-enclosure equipment including the inverter.
The cooling systems are classified as follows in terms of the cooling calculation method.
(a) Cooling by natural heat dissipation from the enclosure surface (totally enclosed type)
(b) Cooling by heat sink (aluminum fin, etc.)
(c) Cooling by ventilation (forced ventilation type, pipe ventilation type)
(d) Cooling by heat exchanger or cooler (heat pipe, cooler, etc.)
Cooling system Enclosure structure Comment
Natural
Natural ventilation (enclosed type / open type)
This system is low in cost and generally used, but the enclosure size increases as the inverter capacity increases. This system is for relatively small capacities.
Natural ventilation (totally enclosed type)
Being a totally enclosed type, this system is the most appropriate for hostile environment having dust, dirt, oil mist, etc. The enclosure size increases depending on the inverter capacity.
Forced air
Heat sink cooling This system has restrictions on the heat sink mounting position and area. This system is for relatively small capacities.
Forced ventilation This system is for general indoor installation. This is appropriate for enclosure downsizing and cost reduction, and often used.
Heat pipe This is a totally enclosed for enclosure downsizing.
INV
INV
INV Heat sink
INV
INV
Heat pipe
20 INSTALLATION AND WIRING
Installation of the inverter and enclosure design
2
2.3.4 Inverter installation Inverter placement
Install the inverter on a strong surface securely with screws.
Leave enough clearances and take cooling measures.
Avoid places where the inverter is subjected to direct sunlight, high temperature and high humidity.
Install the inverter on a nonflammable wall surface.
When encasing multiple inverters in an enclosure, install them in parallel as a cooling measure.
For heat dissipation and maintenance, keep clearance between the inverter and the other devices or enclosure surface.
The clearance below the inverter is required as a wiring space, and the clearance above the inverter is required as a heat
dissipation space.
When designing or building an enclosure for the inverter, carefully consider influencing factors such as heat generation of
the contained devices and the operating environment.
For replacing the cooling fan, 30 cm or more of space is necessary in front of the inverter. Refer to page 76 for fan replacement.
Installation orientation of the inverter Install the inverter on a wall as specified. Do not mount it horizontally or in any other way.
Above the inverter Heat is blown up from inside the inverter by the small fan built in the unit. Any equipment placed above the inverter should be
heat resistant.
Vertical
Allow clearance.
Clearances (side)Clearances (front)
Inverter
5 cm or more 1
10 cm or more
10 cm or more
20 cm or more
20 cm or more
INSTALLATION AND WIRING 21
Installation of the inverter and enclosure design
Arrangement of multiple inverters and converter units
Arrangement of the ventilation fan and inverter
When multiple inverters and converter units are placed in the
same enclosure, generally arrange them horizontally as shown
in the figure on the right.
Do not place multiple products vertically. The exhaust air
temperature of the inverter and the converter unit may be
increased.
When mounting multiple inverters and converter units, fully take
caution not to make the surrounding air temperature of the
inverter and the converter unit higher than the permissible value
by providing ventilation and increasing the enclosure size. Arrangement of multiple inverters and converter units
Heat generated in the inverter is blown up from the bottom of
the unit as warm air by the cooling fan. When installing a
ventilation fan for that heat, determine the place of ventilation
fan installation after fully considering an air flow. (Air passes
through areas of low resistance. Make an airway and airflow
plates to expose the inverter to cool air.)
Arrangement of the ventilation fan and inverter
Enclosure
InverterConverter unit
InverterConverter unit
InverterConverter unit
Inverter
Inverter
22 INSTALLATION AND WIRING
Installation of the inverter and enclosure design
2
2.3.5 Protruding the heat sink through a panel When encasing an inverter to an enclosure, the heat generated in the enclosure can be greatly reduced by protruding the
heat sink of the inverter.
When installing the inverter in a compact enclosure, etc., this installation method is recommended.
Panel cutting Cut the panel of the enclosure according to the inverter capacity.
FR-A862-05450
(Unit: mm)
FR-A862-06470
FR-A862-08500
(Unit: mm)
6-M10 screw520
Hole
200
15 15
12 70
13 00
200 660
Hole
240 240 6-M10 screw
15 15
20 15
15 50
INSTALLATION AND WIRING 23
Installation of the inverter and enclosure design
Removal of the rear installation frame
Installation of the inverter Push the inverter heat sink portion outside the enclosure and fix the enclosure and inverter with upper and lower
installation frame.
NOTE Having a cooling fan, the cooling section which comes out of the enclosure cannot be used in the environment of water drops,
oil, mist, dust, etc.
Be careful not to drop screws, dust etc. into the inverter and cooling fan section.
Two installation frames are attached to each of the upper and lower
parts of the inverter. Remove the rear side installation frame on the top
and bottom of the inverter as shown on the right. Upper installation frame (rear side)
Lower installation frame (rear side)
185 mm
Exhausted air
There are finger guards behind the enclosure. Therefore, the thickness of the panel should be less than 10 mm (1) and also do not place anything around finger guards to avoid contact with the finger guards.
140 mm
6 m
m
Inverter
Inside the enclosure
Enclosure
Installation frame
Dimension of the outside of the enclosure
Cooling wind
Enclosure
Finger guard10 mm1
24 INSTALLATION AND WIRING
Terminal connection diagrams
2
2.4 Terminal connection diagrams
R1/L11 S1/L21
PC
Frequency setting signals (Analog) 10E(+10V)
10(+5V)
2
(Analog common)
2 3
1
Auxiliary input
Terminal 4 input (Current input)
1
4
Frequency setting potentiometer 1/2W1k
Running
Up to frequency
Overload
Frequency detection
Open collector output common Sink/source common
F/C (FM)
SD
Motor
Relay output 1 (Fault output)
C1
B1
A1
U V W
Indicator (Frequency meter, etc.)
+ -
(-)
(+) Analog signal output (0 to 10VDC)
Earth (Ground)
AM
5
0 to 5VDC selectable
0 to 10VDC
Open collector output
Moving-coil type 1mA full-scale
Calibration resistor
Main circuit terminal
Control circuit terminal
0 to 5VDC 0 to 10VDC
C2
B2
A2 Relay output 2
Relay output
M
0 to 20mADC
0 to 5VDC 0 to 10VDC
selectable
4 to 20mADC
S IN
K
S O
U R
C E
Connector for plug-in option connection
STF
STR
STP(STOP)
RH
RM
RL
JOG
RT
MRS X10
RES
AU
CS
SD
RUN
SU
IPF
OL
FU
SE
(+) (-)
5
(+) (-)
Sink logic
Earth (Ground)
N/-
P/+
Initial value
ON OFF
42
For manufacturer
So (SO)
SOC
Shorting wire
S1
S2
PC
SD
SIC
+24
SD
Jumper
Connector 1 Connector 2
Connector 3
24V external power supply input
Common terminal
24VDC power supply (Common for external power supply transistor)
Forward rotation start
Reverse rotation start
Start self-holding selection
Middle speed
High speed
Low speed
Jog operation
Second function selection
Reset
Terminal 4 input selection Selection of automatic restart
after instantaneous power failure
Control input signals (No voltage input allowed)
Multi-speed selection
Contact input common
Main circuit
Control circuit
PU connector
USB A connector
USB mini B connector
Voltage/current input switch
selectable
Initial value
Initial value
Output stop RDA
RDI
Converter unit
RSO
SE
N/-
P/+
IPF
RDB
FAN
R/L1 S/L2 T/L3
OH
RES
SD
PC
+24
C1
B1
A1
Ethernet connector
24V
INSTALLATION AND WIRING 25
Terminal connection diagrams
A jumper is installed across terminal R1/L11 and terminal P/+, and across terminal S1/L21 and terminal N/-. When using a separate power
supply for the control circuit, remove the jumpers from R1/L11 and S1/L21.
The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). Terminal JOG is also used as the pulse train input terminal. Use Pr.291 to choose JOG or pulse.
The X10 signal (NC contact input specification) is assigned to terminal MRS in the initial setting. Set Pr.599 = "0" to change the input
specification of the X10 signal to NO contact.
Terminal input specifications can be changed by analog input specification switchover (Pr.73, Pr.267). To input a voltage (0 to 5 V/0 to 10 V), set
the voltage/current input switch OFF. To input a current (4 to 20 mA), set the voltage/current input switch ON. Terminals 10 and 2 are also used
as a PTC input terminal. (Pr.561) It is recommended to use 2 W 1 k when the frequency setting signal is changed frequently.
The function of these terminals can be changed with the output terminal assignment (Pr.195, Pr.196). The function of these terminals can be changed with the output terminal assignment (Pr.190 to Pr.194). No function is assigned in the initial setting. Use Pr.192 for function assignment.
Terminal FM can be used to output pulse trains as open collector output by setting Pr.291.
Not required when calibrating the scale with the operation panel.
The option connector 2 cannot be used because the Ethernet board is installed in the initial status. The Ethernet board must be removed to
install a plug-in option to the option connector 2. (However, Ethernet communication is disabled in that case.)
NOTE To prevent a malfunction due to noise, keep the signal cables 10 cm or more away from the power cables. Also, keep the
cables of the main circuit for input and output separated.
After wiring, wire offcuts must not be left in the inverter.
Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter clean.
When drilling mounting holes in an enclosure etc., take caution not to allow chips and other foreign matter to enter the
inverter.
Set the voltage/current input switch correctly. Incorrect setting may cause a fault, failure or malfunction.
Terminals S1, S2, SIC, So (SO), and SOC are for manufacturer setting. Do not remove the shorting wires across terminals S1
and PC, terminals S2 and PC, and terminals SIC and SD. When the shorting wires are removed, the inverter does not
operate.
Connection between the converter unit and the inverter Perform wiring so that the commands sent from the converter unit are transmitted to the inverter without fail. Incorrect
connection may damage the converter unit and the inverter.
For the wiring length, refer to the table below.
For the cable gauge of the cable across the main circuit terminals P/+ and N/- (P and P, N and N), refer to page 29.
Do not install an MCCB across terminals P/+ and N/- (across terminals P and P/+ or across N and N/-). Connecting the opposite polarity of terminals N/- and P/+ will damage the inverter.
For the terminal used for the X10 signal input, set "10" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function. (The X10 signal is assigned to terminal MRS in the initial setting.) For the X10 signal, NC contact input specification is selected in the initial setting. Set Pr.599 = "0" to change the input specification to NO contact.
For the terminal used for the X11 signal input, set "11" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function. For RS-485 or any other communication where the start command is only transmitted once, use the X11 signal to save the operation mode at the time of an instantaneous power failure.
Always connect terminal RDA of the converter unit and terminal MRS (X10) of the inverter, and terminal SE of the converter unit and terminal SD (sink logic) of the inverter. Not connecting these terminals may damage the converter unit.
Total wiring length
Across terminals P and P and terminals N and N 50 m or lower
Other control signal cables 30 m or lower
Inverter Converter unit
(FR-CC2)
M R1/L11 S1/L21
R/L1
S/L2
T/L3
Power supply
MCCB MC U V W
R1/L11 S1/L21
P/+P/+ N/-N/-
X11
RES
SD
IPF
RSO
SE
MRS(X10) 2
RDA 4
4
1
3
RDB
26 INSTALLATION AND WIRING
Main circuit terminals
2
2.5 Main circuit terminals
2.5.1 Details on the main circuit terminals of the inverter
2.5.2 Details on the main circuit terminals of the converter unit (FR-CC2)
Terminal symbol Terminal name Terminal function description Refer
to page U, V, W Inverter output Connect these terminals to a three-phase squirrel cage motor or a PM motor. -
R1/L11, S1/L21
Power supply for the control circuit
Connected to terminals P/+ and N/-. To retain the fault display and fault output, or to use the converter unit (FR-CC2), remove the jumpers installed across terminals R1/L11 and S1/L21, and supply external power to these terminals. The power capacity necessary when separate power is supplied from terminals R1/L11 and S1/L21 is 80 VA.
41
P/+, N/- Converter unit connection Connect the converter unit (FR-CC2). 25
Earth (ground) For earthing (grounding) the inverter chassis. This must be earthed (grounded).
31
Terminal symbol Terminal name Terminal function description Refer
to page R/L1, S/L2, T/L3
AC power input Connect these terminals to the commercial power supply. -
R1/L11, S1/L21
Power supply for the control circuit
Connected to the AC power supply terminals R/L1 and S/L2. To retain the fault display and fault output, remove the jumpers across terminals R/L1 and R1/L11 and across S/L2 and S1/L21, and supply external power to these terminals. When using a separate power supply from R1/L11 and S1/L21, the necessary power capacity of the separate power supply is 80 VA.
41
P/+, N/- Inverter connection Connect to terminals P/+ and N/- of the inverter. 25
Earth (ground) For earthing (grounding) the converter unit chassis. Be sure to earth (ground) the converter.
31
INSTALLATION AND WIRING 27
Main circuit terminals
2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor
NOTE Make sure the power cables are connected to terminals R/L1, S/L2, and T/L3 of the converter unit. (Phase need not be
matched.) Never connect the power cable to terminals U, V, and W of the inverter. Doing so will damage the inverter.
Connect the motor to terminals U, V, and W of the inverter. (The phases must be matched.)
When wiring the main circuit conductor, tighten a nut from the right side of the conductor.
When wiring two wires, place wires on both sides of the conductor. (Refer to the diagram below.)
For wiring, use bolts (nuts) provided with the inverter.
When wiring the main circuit conductor (terminals R/L1, S/L2, T/L3) of the converter unit (FR-CC2), use the bolts (nuts) for
main circuit wiring, which are provided on the front side of the conductor.
FR-CC2-C355K to FR-CC2-C560K FR-A862-05450 to FR-A862-08500
Jumper
Charge lamp
P/+N/-
To inverter
R1/L11 S1/L21
R/L1 S/L2 T/L3
Power supply
Charge lamp
Jumper
M Motor
N/-
P/+
To converter unit
R1/L11 S1/L21
FR-CC2-C355K FR-CC2-C400K, C560K
Connect the cables here. Connect the cables here.
28 INSTALLATION AND WIRING
Main circuit terminals
2
2.5.4 Applicable cables and wiring length Select a recommended cable size to ensure that the voltage drop ratio is within 2%.
If the wiring distance is long between the inverter and motor, the voltage drop in the main circuit will cause the motor torque to
decrease especially at a low speed.
The following table shows a selection example for the wiring length of 20 m (575 V input power supply, 150% overload current
rating for 1 minute).
Converter unit (FR-CC2)
Inverter
It is the gauge of the cable with the continuous maximum permissible temperature of 90C or higher. (LMFC (heat resistant flexible cross-linked
polyethylene insulated cable), etc.). It assumes a surrounding air temperature of 50C or lower and in-enclosure wiring.
It is the gauge of the cable with continuous maximum permissible temperature of 90C (THHN cable). It assumes a surrounding air temperature
of 40C or lower and in-enclosure wiring.
(For the use in the United States or Canada, refer to page 93.)
The terminal screw size indicates the size of a terminal screw for R/L1, S/L2, T/L3, U, V, W, P/+, N/-, and a screw for earthing (grounding).
The screw size for earthing (grounding) terminal is indicated in parentheses.
The line voltage drop can be calculated by the following formula:
Line voltage drop [V] =
Use a larger diameter cable when the wiring distance is long or when it is desired to decrease the voltage drop (torque
reduction) in the low speed range.
NOTE Tighten the terminal screw to the specified torque.
A screw that has been tightened too loosely can cause a short circuit or malfunction.
A screw that has been tightened too tightly can cause a short circuit or malfunction due to the unit breakage.
Use crimp terminals with insulation sleeves to wire the power supply and motor.
Converter model
FR-CC2-[ ]
Terminal screw size
Tightening torque
Nm
Crimp terminal Cable gauge
HIV cables, etc. (mm2) AWG/MCM R/L1, S/L2, T/L3
P/+, N/- Earthing
(grounding) cable
R/L1, S/L2, T/L3
P/+, N/-
Earthing (grounding)
cable
R/L1, S/L2, T/L3
P/+, N/-
Earthing (grounding)
cable C355K M12 (M10) 46 280-12 2100-12 100-10 280 2100 100 24/0 2300 4/0
C450K M12 (M10) 46 2125-12 2150-12 100-10 2125 2150 100 2300 2350 300
C560K M12 (M10) 46 2200-12 2250-12 100-10 2200 2250 100 2400 2500 300
Inverter model
FR-A862-[ ]
Terminal screw size
Tightening torque
Nm
Crimp terminal Cable gauge
HIV cables, etc. (mm2) AWG/MCM
U, V, W P/+, N/- Earthing
(grounding) cable
U, V, W
P/+, N/-
Earthing (grounding)
cable
U, V, W
P/+, N/-
Earthing (grounding)
cable 05450 M12 (M10) 46 280-12 2100-12 100-10 280 2100 100 2250 2300 4/0
06470 M12 (M10) 46 2125-12 2150-12 100-10 2125 2150 100 2300 2350 300
08500 M12 (M10) 46 2200-12 2250-12 100-10 2200 2250 100 2400 2500 300
wire resistance [m/m] wiring distance [m] current [A] 1000
INSTALLATION AND WIRING 29
Main circuit terminals
Total wiring length With induction motor Connect one or more general-purpose motors within the total wiring length 500 m. (The wiring length should be 100 m or
less under vector control.)
With PM motor Use the wiring length of 100 m or shorter when connecting a PM motor.
Use one PM motor for one inverter. Multiple PM motors cannot be connected to an inverter.
When the wiring length exceeds 50 m for a 600 V class motor driven by an inverter under PM sensorless vector control,
set "9" (6 kHz) or less in Pr.72 PWM frequency selection.
NOTE Especially for long-distance wiring, the inverter may be affected by a charging current caused by the stray capacitances of the
wiring, leading to a malfunction of the overcurrent protective function or fast response current limit function or a malfunction or
fault of the equipment connected on the inverter output side. If the fast-response current limit function malfunctions, disable
this function. (For the details of Pr.156 Stall prevention operation selection, refer to the Instruction Manual (Detailed) of the
FR-A860.)
For the details of Pr.72 PWM frequency selection, refer to the Instruction Manual (Detailed) of the FR-A860.
The carrier frequency is limited during PM sensorless vector control. (Refer to the Instruction Manual (Detailed) of the FR-
A860.)
Total wiring length
500 m or less
300 m
300 m
300 m + 300 m = 600 m
30 INSTALLATION AND WIRING
Main circuit terminals
2
2.5.5 Earthing (grounding) precautions Always earth (ground) the motor, the inverter, and the converter unit.
Purpose of earthing (grounding) Generally, an electrical apparatus has an earth (ground) terminal, which must be connected to the ground before use.
An electrical circuit is usually insulated by an insulating material and encased. However, it is impossible to manufacture an
insulating material that can shut off a leakage current completely, and actually, a slight current flows into the case. The
purpose of earthing (grounding) the case of an electrical apparatus is to prevent operators from getting an electric shock from
this leakage current when touching it.
To avoid the influence of external noises, the earthing (grounding) is important to EMI-sensitive equipment that handle low
level signals or operate very fast such as audio equipment, sensors, computers.
Earthing (grounding) system to be established As described previously, the purpose of earthing (grounding) is roughly classified into the electrical shock prevention and the
prevention of malfunction due to the influence of electromagnetic noise. These two purposes should be clearly distinguished,
and the appropriate earth (ground) system must be established to prevent the leakage current having the inverter's high
frequency components from reversing through another earth (ground) point for malfunction prevention by following these
instructions.
Make the separate earth (ground) connection (I) for high frequency products such as the inverter from any other devices
(EMI-sensitive devices described above) wherever possible.
Establishing adequate common (single-point) earth (ground) system (II) shown in the following figure is allowed only in
cases where the separate earth (ground) system (I) is not feasible. Do not make inadequate common (single-point) earth
(ground) connection (III).
As leakage currents containing many high frequency components flows into the earthing (grounding) cables of the inverter
and peripheral devices the inverter must also be earthed (grounded) separately from the EMI-sensitive devices described
above.
In a high building, it may be effective to use its iron structure frames as earthing (grounding) electrode for EMI prevention in
order to separate from the earth (ground) system for electric shock prevention.
Earthing (Grounding) must conform to the requirements of national and local safety regulations and electrical codes
(NEC section 250, IEC 61140 class 1 and other applicable standards).
A neutral-point earthed (grounded) power supply in compliance with EN standard must be used.
Use the thickest possible earthing (grounding) cable. The earthing (grounding) cable should be equal to the size
indicated in the table on page 29.
The earthing (grounding) point should be as close as possible to the inverter, and the earth (ground) cable length should
be as short as possible.
Run the earthing (grounding) cable as far away as possible from the I/O wiring of the EMI-sensitive devices and run
them in parallel in the minimum distance.
Inverter/ converter
unit EMI-sensitive
devices
(I) Separate earthing (grounding): Good
EMI-sensitive devices
(II) Common (single-point) earthing (grounding): OK
Inverter/ converter
unit
Inverter/ converter
unit
EMI-sensitive devices
(III) Inadequate common (single-point) earthing (grounding): Bad
INSTALLATION AND WIRING 31
Control circuit
2.6 Control circuit
2.6.1 Details on the control circuit terminals of the inverter
The input signal function of the terminals in can be selected by setting Pr.178 to Pr.196 (I/O terminal function selection). For the parameter details, refer to the FR-A860 Instruction Manual (Detailed).
Input signal
Ty pe Terminal
symbol Terminal name Terminal function description Rated specification
C on
ta ct
in pu
t
STF Forward rotation start Turn ON the STF signal to start forward rotation and turn it OFF to stop.
When the STF and STR signals are turned ON simultaneously, the stop command is given.
Input resistance: 4.7 k Voltage when contacts are open: 21 to 27 VDC Current when contacts are short- circuited: 4 to 6 mADC
STR Reverse rotation start Turn ON the STR signal to start reverse rotation and turn it OFF to stop.
STOP Start self-holding selection
Turn ON the STOP signal to self-hold the start signal.
RH RM RL
Multi-speed selection Multi-speed can be selected according to the combination of the RH, RM and RL signals.
JOG
Jog mode selection Turn ON the JOG signal to enable JOG operation (initial setting) and turn ON the start signal (STF or STR) to start JOG operation.
Pulse train input Terminal JOG is also used as the pulse train input terminal. To use as a pulse train input terminal, change the Pr.291 setting. (maximum input pulse: 100k pulses/s)
Input resistance: 2 k Current when contacts are short- circuited: 8 to 13 mADC
RT Second function selection
Turn ON the RT signal to enable the second function. When the second function such as "second torque boost" and "second V/F (base frequency)" is set, turning ON the RT signal enables the selected function.
Input resistance: 4.7 k Voltage when contacts are open: 21 to 27 VDC Current when contacts are short- circuited: 4 to 6 mADC
MRS (X10)
Output stop (Inverter operation enable)
Connect to terminal RDA of the converter unit (FR-CC2). When the RDA signal is turned OFF, the inverter output is shut off. The X10 signal (NC contact) is assigned to terminal MRS in the initial setting. Use Pr.599 to change the specification to NO contact.
RES Reset
Use this signal to reset a fault output provided when a protective function is activated. Turn ON the RES signal for 0.1 second or longer, then turn it OFF. In the initial setting, reset is always enabled. By setting Pr.75, reset can be enabled only at an inverter fault occurrence. The inverter recovers about 1 second after the reset is released.
AU Terminal 4 input selection
The terminal 4 function is available only when the AU signal is ON Turning ON the AU signal disables the terminal 2 function.
CS
Selection of automatic restart after instantaneous power failure
When the CS signal is left ON, the inverter restarts automatically at power restoration. Note that restart setting is necessary on both the inverter and the converter unit for this operation. In the initial setting, a restart is disabled.
SD
Contact input common (sink)
Common terminal for the contact input terminal (sink logic) and terminal FM
External transistor common (source)
Connect this terminal to the power supply common terminal of a transistor output (open collector output) device, such as a programmable controller, in the source logic to avoid malfunction by undesirable current.
24 VDC power supply common
Common terminal for the 24 VDC power supply (terminal PC, terminal +24) Isolated from terminals 5 and SE.
PC
External transistor common (sink)
Connect this terminal to the power supply common terminal of a transistor output (open collector output) device, such as a programmable controller, in the source logic to avoid malfunction by undesirable current.
Power supply voltage range: 19.2 to 28.8 VDC Permissible load current: 100 mA
Contact input common (source)
Common terminal for contact input terminal (source logic).
24 VDC power supply common
Can be used as a 24 VDC 0.1 A power supply.
32 INSTALLATION AND WIRING
Control circuit
2
Set Pr.73, Pr.267, and the voltage/current input switch correctly, then input an analog signal in accordance with the setting. Applying a voltage with the voltage/current input switch ON (current input is selected) or a current with the switch OFF (voltage input is selected)
could cause component damage of the inverter or analog circuits of output devices. (For the details, refer to the Instruction Manual (Detailed) of
the FR-A860.)
Sink logic is initially set.
Output signal
F re
qu en
cy s
et tin
g
10E Frequency setting power supply
When connecting the frequency setting potentiometer at an initial status, connect it to terminal 10. Change the input specifications of terminal 2 using in Pr.73 when connecting it to terminal 10E.
10 V 0.4 VDC Permissible load current: 10 mA
10 5 V0.5 VDC Permissible load current: 10 mA
2 Frequency setting (voltage)
Inputting 0 to 5 VDC (or 0 to 10 V, 0 to 20 mA) provides the maximum output frequency at 5 V (10 V, 20 mA) and makes input and output proportional. Use Pr.73 to switch among input 0 to 5 VDC (initial setting), 0 to 10 VDC, and 0 to 20 mA. Set the voltage/current input switch in the ON position to select current input (0 to 20 mA).
For voltage input, Input resistance: 10 1 k Maximum permissible voltage: 20 VDC For current input, Input resistance: 245 5 Permissible maximum current: 30 mA
4 Frequency setting (current)
Inputting 4 to 20 mADC (or 0 to 5 V, 0 to 10 V) provides the maximum output frequency at 20 mA and makes input and output proportional. This input signal is valid only when the AU signal is ON (terminal 2 input is invalid). Use Pr.267 to switch among input 4 to 20 mA (initial setting), 0 to 5 VDC, and 0 to 10 VDC. Set the voltage/current input switch in the OFF position to select voltage input (0 to 5 V/0 to 10 V). Use Pr.858 to switch terminal functions.
1 Frequency setting auxiliary
Input 0 to 5 VDC or 0 to 10 VDC to add this signal to the frequency setting signal input via terminal 2 or 4. Use Pr.73 to switch between input 0 to 5 VDC and 0 to 10 VDC (initial setting). Use Pr.868 to switch terminal functions.
Input resistance: 10 1 k Permissible maximum voltage: 20 VDC
5 Frequency setting common
Common terminal for the frequency setting signal input via terminal 2 or 4 frequency setting signal (via terminal 2, 1 or 4) for the and analog output terminal AM. Do not earth (ground).
T he
rm is
to r
10 2
PTC thermistor input For receiving PTC thermistor outputs. When PTC thermistor is valid (Pr.561 "9999"), terminal 2 is not available for frequency setting.
Applicable PTC thermistor specification Overheat detection resistance: 0.5 to 30 k (Set by Pr.561)
E xt
er na
l p ow
er s
u pp
ly in
pu t
+24 24 V external power supply input
For connecting a 24 V external power supply. If a 24 V external power supply is connected, power is supplied to the control circuit while the main power circuit is OFF.
Input voltage: 23 to 25.5 VDC Input current: 1.4 A or less
Ty pe Terminal
symbol Terminal name Terminal function description Rated specification
R el
ay
A1, B1, C1
Relay output 1 (fault output)
1 changeover contact output that indicates that an inverter's protective function has been activated and the outputs are stopped. Fault: discontinuity across B and C (continuity across A and C), Normal: continuity across B and C (discontinuity across A and C)
Contact capacity: 230 VAC 0.3 A (power factor = 0.4) 30 VDC 0.3 AA2,
B2, C2
Relay output 2 1 changeover contact output
Ty pe Terminal
symbol Terminal name Terminal function description Rated specification
Voltage/current input switch
2 4
switch1 switch2
INSTALLATION AND WIRING 33
Control circuit
Communication
O pe
n co
lle ct
or
RUN Inverter running The output is in LOW state when the inverter output frequency is equal to or higher than the starting frequency (initial value: 0.5 Hz). The output is in HIGH state during stop or DC injection brake operation.
Permissible load: 24 VDC (maximum 27 VDC) 0.1 A (The voltage drop is 2.8 V at maximum while the signal is ON.) The open collector transistor is ON (conductive) in LOW state. The transistor is OFF (not conductive) in HIGH state.
SU Up to frequency
The output is in LOW state when the output frequency is within the set frequency range 10% (initial value). The output is in HIGH state during acceleration/deceleration and at a stop.
Fault code (4 bits) output.
OL Overload alarm
The output is in LOW state when stall prevention is activated by the stall prevention function. The output is in HIGH state when stall prevention is canceled.
IPF Open collector output No function is assigned in the initial setting. The function can be assigned by setting Pr.192.
FU Frequency detection
The output is in LOW state when the inverter output frequency is equal to or higher than the preset detection frequency, and is in HIGH state when it is less than the preset detection frequency.
SE Open collector output common
Common terminal for terminals RUN, SU, OL, IPF, FU
P ul
se FM
For meter Among several monitor items such as output frequency, select one to output it via these terminals. The signal is not output during an inverter reset. The size of output signal is proportional to the magnitude of the corresponding monitoring item. Use Pr.55, Pr.56, and Pr.866 to set full scales for the monitored output frequency, output current, and torque.
Output item: Output frequency (initial setting)
Permissible load current: 2 mA For full scale: 1440 pulses/s
NPN open collector output
This terminal can be used for open collector outputs by setting Pr.291.
Maximum output pulse: 50k pulses/s Permissible load current: 80 mA
A na
lo g
AM Analog voltage output Output item: Output frequency (initial setting)
Output signal 0 to 10 VDC, Permissible load current: 1 mA (load impedance 10 k or more) Resolution: 8 bits
Ty pe Terminal
symbol Terminal
name Terminal function description
E th
er ne
t
Ethernet connector
Communication can be made via Ethernet.
Category: 100BASE-TX/10BASE-T Data transmission speed: 100 Mbps (100BASE-TX) / 10 Mbps (10BASE-T) Transmission method: Baseband Maximum segment length: 100 m between the hub and the inverter Number of cascade connection stages: Up to 2 (100BASE-TX) / up to 4 (10BASE-T) Interface: RJ-45 Number of interfaces available: 1 IP version: IPv4
R S
-4 85
PU connector
With the PU connector, communication can be made through RS-485. (For connection on a 1:1 basis only) Conforming standard: EIA-485 (RS-485) Transmission format: Multidrop link Communication speed: 4800 to 115200 bps Wiring length: 500 m
U S
B
USB A connector
A connector (receptacle). Plug a USB memory device into this connector to copy parameter settings or use the trace function. Interface: Conforms to USB 1.1
(USB 2.0 full speed compatible) Transmission speed: 12 MbpsUSB B
connector
Mini B connector (receptacle). By connecting an inverter to the personal computer through USB, FR Configurator2 can be used for setting the inverter, monitoring, and testing the operation.
Ty pe Terminal
symbol Terminal name Terminal function description Rated specification
34 INSTALLATION AND WIRING
Control circuit
2
Terminals for manufacturer setting
2.6.2 Details on the control circuit terminals of the converter unit (FR-CC2)
The input signal function of the terminals in can be selected by setting Pr.178, Pr.187, Pr.189 to Pr.195 (I/O terminal function selection). For the parameter details, refer to the Instruction Manual of the FR-CC2-C.
Input signal
Terminal symbol Terminal function description
S1, S2, SIC, So (SO), SOC
Terminals S1, S2, SIC, So (SO), and SOC are for manufacturer setting. Do not connect anything to there. Doing so may cause an inverter failure. Do not remove the shorting wires across terminals S1 and PC, terminals S2 and PC, and terminals SIC and SD. Removing either shorting wire disables the inverter operation.
Ty pe Terminal
symbol Terminal name Terminal function description Rated specification
C on
ta ct
in pu
t
RES Reset
Use this signal to reset a fault output provided when a protective function is activated. Turn ON the RES signal for 0.1 second or longer, then turn it OFF. In the initial setting, reset is always enabled. By setting Pr.75, reset can be set enabled only at fault occurrence of the converter unit. The inverter recovers about 1 second after the reset is released.
Input resistance: 4.7 k Voltage when contacts are open: 21 to 27 VDC Current when contacts are short- circuited: 4 to 6 mADC
OH External thermal relay input
The External thermal relay input (OH) signal is used when using an external thermal relay or a thermal protector built into the motor to protect the motor from overheating. When the thermal relay is activated, the inverter is shut off due to the fault occurrence of the external thermal relay operation (E.OHT).
RDI Contact input The function can be assigned by setting Pr.178.
SD
Contact input common (sink)
Common terminal for contact input terminal (sink logic) and terminal FM
External transistor common (source)
Connect this terminal to the power supply common terminal of a transistor output (open collector output) device, such as a programmable controller, in the source logic to avoid malfunction by undesirable current.
24 VDC power supply common
Common terminal for the 24 VDC power supply (terminal PC, terminal +24) Isolated from terminals 5 and SE.
PC
External transistor common (sink)
Connect this terminal to the power supply common terminal of a transistor output (open collector output) device, such as a programmable controller, in the source logic to avoid malfunction by undesirable current.
Power supply voltage range: 19.2 to 28.8 VDC Permissible load current: 100 mA
Contact input common (source)
Common terminal for contact input terminal (source logic).
24 VDC power supply common
Can be used as a 24 VDC 0.1 A power supply.
P ow
er s
up pl
y in
pu t
+24 24 V external power supply input
For connecting a 24 V external power supply. If a 24 V external power supply is connected, power is supplied to the control circuit while the main power circuit is OFF.
Input voltage: 23 to 25.5 VDC Input current: 1.4 A or less
INSTALLATION AND WIRING 35
Control circuit
Output signal
2.6.3 Control logic (sink/source) change Switch the control logic of input signals as necessary.
To change the control logic, change the jumper connector position on the control circuit board.
Connect the jumper connector to the connector pin of the desired control logic.
The control logic of input signals is initially set to the sink logic (SINK).
(The output signals may be used in either the sink or source logic independently of the jumper connector position.)
NOTE Make sure that the jumper connector is installed correctly.
Never change the control logic while power is ON.
Ty pe Terminal
symbol Terminal name Terminal function description Rated specification
R el
a y
A1, B1, C1
Relay output 1 (fault output)
1 changeover contact output that indicates that the protective function of the converter unit has been activated and the outputs are stopped. Fault: discontinuity across B and C (continuity across A and C), Normal: continuity across Band C (discontinuity across A and C)
Contact capacity: 230 VAC 0.3 A (power factor = 0.4) 30 VDC 0.3 A
88R, 88S
For manufacturer setting. Do not use.
O pe
n co
lle ct
or
RDA Inverter operation enable (NO contact)
The output is in LOW state when the converter unit operation is ready. Assign the signal to terminal MRS (X10) of the inverter. The inverter can be started when the RDA status is LOW.
Permissible load: 24 VDC (27 VDC at maximum) 0.1 A (The voltage drop is 2.8 V at maximum while the signal is ON.) The open collector transistor is ON (conductive) in LOW state. The transistor is OFF (not conductive) in HIGH state.
RDB Inverter operation enable (NC contact)
The output is in LOW state when a converter unit fault occurs or the converter is reset. The inverter can be started when the RDB status is HIGH.
RSO Inverter reset The output is in LOW state when the converter is reset (RES-ON). Assign the signal to terminal RES of the inverter. The inverter is reset when it is connected with the RSO status LOW.
IPF Instantaneous power failure
The output is in LOW state when an instantaneous power failure is detected.
FAN Cooling fan fault The output is in LOW state when a cooling fan fault occurs.
SE Open collector output common
Common terminal for terminals RDA, RDB, RSO, IPF, FAN Connect this terminal to terminal SD (sink logic) or PC (source logic) of the inverter.
CAUTION Do not use the empty terminals (NCs) of the control circuit. Doing so may lead to damage of the converter unit
and the inverter. Always connect between terminal RDA of the converter unit and terminal MRS (X10) of the inverter, and between
terminal SE of the converter unit and terminal SD (terminal PC in the source logic) of the inverter. Failure to do so may lead to damage of the converter unit.
Jumper connector For sink logic
SOURCE
SINK
36 INSTALLATION AND WIRING
Control circuit
2
Sink logic and source logic In the sink logic, a signal turns ON when a current exits from the corresponding signal input terminal.
Terminal SD is common to the contact input signals. Terminal SE is common to the open collector output signals.
In the source logic, a signal turns ON when a current enters into the corresponding signal input terminal.
Terminal PC is common to the contact input signals. Terminal SE is common to the open collector output signals.
When using an external power supply for transistor output
Sink logic
Use terminal PC as a common terminal, and perform
wiring as follows. (Do not connect terminal SD on the
inverter with terminal 0 V for the external power supply.
When using terminals PC-SD as a 24 VDC power supply,
do not install an external power supply in parallel with the
inverter. Doing so may cause a malfunction in the inverter
due to undesirable currents.)
Source logic
Use terminal SD as a common terminal, and perform
wiring as follows. (Do not connect terminal PC on the
inverter with terminal +24 V for the external power supply.
When using terminals PC-SD as a 24 VDC power supply,
do not install an external power supply in parallel with the
inverter. Doing so may cause a malfunction in the inverter
due to undesirable currents.)
Current
PC
STF R
STR R
Source logic
Source connector
Current
SD
STF R
STR R
Sink connector
Sink logic
Current flow concerning the input/output signal when sink logic is selected
Current flow concerning the input/output signal when source logic is selected
DC input (source type)
24 VDC
RUN
SE
TB1
TB18
R
Inverter
R
Current flow
+ -+-
DC input (sink type)
Inverter
24 VDC
RUN
SE
TB1
TB17
R
R
Current flow
QY40P type transistor output unit
TB1
TB2
TB17
TB18
24 VDC SD
PC
STR
STF
Inverter
24 VDC (SD)
Current flow
Constant voltage circuit
QY80 type transistor output unit
Constant voltage circuit
PC
TB1
TB2
TB17Fuse
TB18
STF
STR
SD
Inverter
24 VDC (SD)
24 V
D C
Current flow
INSTALLATION AND WIRING 37
Control circuit
2.6.4 Wiring of inverter control circuit Control circuit terminal layout
This terminal functions as terminal FM.
The X10 signal is assigned in the initial setting.
No signal is assigned in the initial setting.
Wiring method Power supply connection
Use crimp terminals and stripped wire for the control circuit wiring. For single wire, the stripped wire can be used without crimp
terminal.
Connect the end of wires (crimp terminal or stranded wire) to the terminal block.
(1) Strip the signal wires as shown below. If too much of the wire is stripped, a short circuit may occur with neighboring wires.
If not enough of the wire is stripped, wires may become loose and fall out. Twist the stripped end of wires to prevent them
from fraying. Do not solder it.
(2) Use appropriate crimp terminals (ferrules, blade terminals, etc.).
Insert wires to the crimp terminal, and check that the wires come out for about 0 to 0.5 mm from a sleeve.
Check the condition of the crimp terminals after crimping. Do not use the crimp terminals of which the crimping is
inappropriate, or the face is damaged.
Crimp terminals commercially available (as of January 2017)
Phoenix Contact Co., Ltd.
Wire strip length
Wire gauge (mm2)
Ferrule part No. Crimping tool model No.With insulation sleeve Without insulation sleeve For UL wire
0.3 AI 0,34-10TQ - -
CRIMPFOX 6
0.5 AI 0,5-10WH - AI 0,5-10WH-GB
0.75 AI 0,75-10GY A 0,75-10 AI 0,75-10GY-GB
1 AI 1-10RD A 1-10 AI 1-10RD/1000GB
1.25, 1.5 AI 1,5-10BK A 1,5-10 AI 1,5-10BK/1000GB
0.75 (for two wires) AI-TWIN 2 0,75-10GY - -
A ferrule terminal with an insulation sleeve compatible with the MTW wire which has a thick wire insulation.
Applicable for terminals A1, B1, C1, A2, B2, and C2 only.
AM
2 5 4 1 F/C +24 SD SD S1 S2 PC A1 B1 C1 A2 B2 C2SICSo SOC
5 10E 10 SE SE SURUN IPF OL FU PC RL RM RH RT AU SD SD CSSTP MRS (X10)2
RES STF STR JOG
1
3
10 mm
Crumpled tip Wires are not inserted into the sleeve
Unstranded wires
Damaged
Wire
Sleeve
0 to 0.5 mm
38 INSTALLATION AND WIRING
Control circuit
2
NICHIFU Co., Ltd.
NOTE When using stranded wires without a blade terminal, twist enough to avoid short circuit with a nearby terminals or wires.
Place the flathead screwdriver vertical to the open/close button. In case the blade tip slips, it may cause an inverter damage
or injury.
Wire removal
Common terminals of the control circuit (SD, PC, 5, SE) Terminals SD (sink logic), PC (source logic), 5, and SE are common terminals (0 V) for I/O signals. (All common terminals
are isolated from each other.) Do not earth (ground) these terminals. Avoid connecting terminal SD (sink logic) with terminal
5, terminal PC (source logic) with terminal 5, and terminal SE with terminal 5.
In the sink logic, terminal SD is a common terminal for the contact input terminals (STF, STR, STOP, RH, RM, RL, JOG, RT,
MRS, RES, AU, and CS) and the pulse train output terminal (FM). The open collector circuit is isolated from the internal
control circuit by photocoupler.
In the source logic, terminal PC is a common terminal for the contact input terminals (STF, STR, STOP, RH, RM, RL, JOG,
RT, MRS, RES, AU, and CS). The open collector circuit is isolated from the internal control circuit by photocoupler.
Terminal 5 is a common terminal for the frequency setting terminals (2, 1, and 4) and the analog output terminals (AM). It
should be protected from external noise using a shielded or twisted cable.
Terminal SE is a common terminal for the open collector output terminals (RUN, SU, OL, IPF, and FU). The contact input
circuit is isolated from the internal control circuit by photocoupler.
Wire gauge (mm2) Blade terminal
part No. Insulation cap
part No. Crimping tool
model No. 0.3 to 0.75 BT 0.75-11 VC 0.75 NH 69
(3) Insert the wires into a socket. When using a single wire or stranded wires without a blade terminal, push the
open/close button all the way down with a flathead screwdriver, and insert the
wire.
Pull the wire while pushing the open/close button all
the way down firmly with a flathead screwdriver.
Flathead screwdriver
Open/close button
Flathead screwdriver
Open/close button
NOTE Pulling out the wire forcefully without pushing the open/close
button all the way down may damage the terminal block.
Use a small flathead screwdriver (tip thickness: 0.4 mm/tip
width: 2.5 mm).
If a flathead screwdriver with a narrow tip is used, terminal
block may be damaged.
Commercially available products (as of February 2016)
Place the flathead screwdriver vertical to the open/close
button. In case the blade tip slips, it may cause an inverter
damage or injury.
Name Model Manufacturer
Screwdriver SZF 0- 0,4 2,5
Phoenix Contact Co., Ltd.
INSTALLATION AND WIRING 39
Control circuit
Signal inputs by contactless switches The contact input terminals of the inverter (STF, STR, STOP, RH, RM, RL, JOG, RT, MRS, RES, AU, CS) can be controlled
using a transistor instead of a contact switch as shown below.
2.6.5 Wiring precautions It is recommended to use a cable of 0.75 mm2 for the connection to the control circuit terminals.
The wiring length should be 30 m (200 m for terminal FM) at the maximum.
Use two or more parallel micro-signal contacts or twin contacts to prevent
contact faults when using contact inputs since the control circuit input signals
are micro-currents.
To suppress EMI, use shielded or twisted cables for the control circuit
terminals and run them away from the main and power circuits (including the
200 V relay sequence circuit). For the cables connected to the control circuit terminals, connect their shields to the common
terminal of the connected control circuit terminal. When connecting an external power supply to terminal PC, however,
connect the shield of the power supply cable to the negative side of the external power supply. Do not directly earth
(ground) the shield to the enclosure, etc.
Always apply a voltage to the fault output terminals (A1, B1, C1, A2, B2, C2) via a relay coil, lamp, etc.
Separate the wiring of the control circuit away from the wiring of the main circuit.
Make cuts in rubber bush of the inverter side and lead the wires through.
+24 V
STF, etc.
SD Inverter
External signal input using transistor (sink logic)
PC
RSTF, etc.
+24 V
Inverter
External signal input using transistor (source logic)
Micro signal contacts Twin contacts
Rubber bush (viewed from inside)
Make cuts along the lines on the inside with a cutter knife
40 INSTALLATION AND WIRING
Control circuit
2
2.6.6 When using separate power supplies for the control circuit and the main circuit
Cable size for the control circuit power supply (terminals R1/L11 and S1/ L21)
Terminal screw size: M4
Cable gauge: 0.75 mm2 to 2 mm2
Tightening torque: 1.5 Nm
Connection method When a fault occurs, opening of the electromagnetic contactor (MC) on the inverter power supply side results in power loss in
the control circuit, disabling the fault output signal retention. Terminals R1/L11 and S1/L21 are provided to hold a fault signal.
In this case, connect the power supply terminals R1/L11 and S1/L21 of the control circuit to the input side of the MC.
Terminals R1/L11 and S1/L21 are connected to terminals P/+ and N/- with a jumper respectively. Do not connect the power
cable to incorrect terminals. Doing so may damage the inverter.
(a) Remove the upper screws. (b) Remove the lower screws. (c) Pull the jumper toward you to remove. (d) Connect the separate power supply cable for the control circuit to the upper terminals (R1/L11, S1/L21).
NOTE When using separate power supplies, always remove the jumpers from terminals R1/L11 and S1/L21. The inverter may be
damaged if the jumpers are not removed.
The voltage should be the same as that of the main control circuit when the control circuit power is supplied from other than
the input side of the MC.
When using a separate power supply from R1/L11 and S1/L21, the necessary power capacity of the separate power supply is
80 VA.
If the main circuit power is switched OFF (for 0.1 s or more) then ON again, the inverter is reset and a fault output will not be
held.
InverterConverter unitMC R/L1
S/L2
P/+
N/-
T/L3
R1/L11
S1/L21
P/+
N/-
Remove the jumper
R1/L11 S1/L21
Power supply terminal block for the control circuit
(c)
(d)
(a) (b)
Power supply terminal block for the control circuit
INSTALLATION AND WIRING 41
Control circuit
2.6.7 When supplying 24 V external power to the control circuit
Connect a 24 V external power supply across terminals +24 and SD. Connecting a 24 V external power supply enables I/O terminal ON/OFF operation, operation panel displays, control functions, and communication during communication operation even during power-OFF of inverter's main circuit power supply. When the main circuit power supply is turned ON, the power supply changes from the 24 V external power supply to the main circuit power supply.
Specification of the applied 24 V external power supply
Commercially available products (as of February 2015)
Starting and stopping the 24 V external power supply operation Supplying 24 V external power while the main circuit power is OFF starts the 24 V external power supply operation.
Likewise, turning OFF the main circuit power while supplying 24 V external power starts the 24 V external power supply
operation.
Turning ON the main circuit power stops the 24 V external power supply operation and enables the normal operation.
NOTE When the 24 V external power is supplied while the main circuit power supply is OFF, the inverter operation is disabled.
In the initial setting, when the main power supply is turned ON during the 24 V external power supply operation, a reset is
performed in the inverter, then the power supply changes to the main circuit power supply. (The reset can be disabled using
Pr.30.)
Confirming the 24 V external power supply input During the 24 V external power supply operation, the alarm lamp blinks.
During the 24 V external power supply operation, the 24 V external power supply operation signal (EV) is output. To use the
EV signal, set "68 (positive logic) or 168 (negative logic)" in one of Pr.190 to Pr.196 (output terminal function selection) to assign function to an output terminal.
Item Rated specification Input voltage 23 to 25.5 VDC
Input current 1.4 A or lower
Model Manufacturer S8JX-N05024C Specifications: Capacity 50 W, output voltage 24 VDC, output current 2.1 A Installation method: Front installation with cover
or
S8VS-06024 Specifications: Capacity 60 W, output voltage 24 VDC, output current 2.5 A Installation method: DIN rail installation
For the latest information about OMRON power supply, contact OMRON corporation.
OMRON Corporation
42 INSTALLATION AND WIRING
Control circuit
2
Operation while the 24 V external power is supplied Fault records and parameters can be read and parameters can be written (when the parameter write from the operation
panel is enabled) using the operation panel keys.
The safety stop function is disabled during the 24 V external power supply operation.
During the 24 V external power supply operation, monitored items and signals related to inputs to main circuit power supply,
such as output current and converter output voltage, are invalid.
The alarms, which have occurred when the main circuit power supply is ON, continue to be output after the power supply is
changed to the 24 V external power supply. Perform the inverter reset or turn OFF then ON the power to reset the faults.
The output data is retained when "1 or 11" is set in Pr.495 Remote output selection.
NOTE Inrush current equal to or higher than the 24 V external power supply specification may flow at power-ON. Confirm that the
power supply and other devices are not affected by the inrush current and the voltage drop caused by it. Depending on the
power supply, the inrush current protection may be activated to disable the power supply. Select the power supply and
capacity carefully.
When the wiring length between the external power supply and the inverter is long, the voltage often drops. Select the
appropriate wiring size and length to keep the voltage in the rated input voltage range.
In a serial connection of several inverters, the current increases when it flows through the inverter wiring near the power
supply. The increase of the current causes voltage to drop further. Use the inverter after confirming that the input voltage of
each converter unit is within the rated input voltage range. Depending on the power supply, the inrush current protection may
be activated to disable the power supply. Select the power supply and capacity carefully.
"E.SAF" or "E.P24" may appear when the start-up time of the 24 V power supply is too long (less than 1.5 V/s) in the 24 V
external power supply operation.
"E.P24" may appear when the 24 V external power supply input voltage is low. Check the external power supply input.
Do not touch the control circuit terminal block (circuit board) during the 24 V power supply operation (when conducted).
Otherwise you may get an electric shock or burn.
INSTALLATION AND WIRING 43
Communication connectors and terminals
2.7 Communication connectors and terminals
2.7.1 PU connector Removal and reinstallation of the accessory cover
Mounting the operation panel (FR-LU08) or parameter unit (FR-PU07) on the enclosure surface
The operation panel can be used for setting the inverter parameters, monitoring various items, and checking fault
indications.
Having an operation panel (FR-LU08) or a parameter unit (FR-PU07) on the enclosure surface is convenient. With a
connection cable, the operation panel (FR-LU08) or the parameter unit (FR-PU07) can be mounted to the enclosure
surface and connected to the inverter.
Use the option FR-CB2[ ], or connectors and cables available on the market.
(To install the operation panel (FR-LU08), the optional connector (FR-ADP) is required.)
Securely insert one end of the connection cable until the stoppers are fixed.
NOTE Refer to the following table when fabricating the cable on the user side. Keep the total cable length within 20 m.
Commercially available products (as of February 2015)
For the details of the FR-LU08, refer to the FR-LU08 Instruction Manual.
Loosen the two screws on the accessory cover.
(These screws cannot be removed.)
Push the upper part of the accessory cover and pull the
accessory cover to remove.
To install the accessory cover, fit it securely and tighten the screws. (Tightening torque: 0.40 to 0.45 Nm)
Name Model Manufacturer Communication cable SGLPEV-T (Cat5e/300 m) 24AWG 4P Mitsubishi Cable Industries, Ltd.
RJ-45 connector 5-554720-3 Tyco Electronics
Parameter unit connection cable (FR-CB2[ ]) (option)
Operation panel connection connector (FR-ADP) (option)
STF FWD PU
Operation panel (FR-LU08) (option)
Parameter unit (FR-PU07) (option)
44 INSTALLATION AND WIRING
Communication connectors and terminals
2
Communication operation Using the PU connector enables communication operation from a personal computer, etc. When the PU connector is
connected with a personal, FA or other computer by a communication cable, a user program can run to monitor the inverter
or read and write parameters.
Communication can be performed with the Mitsubishi inverter protocol (computer link operation).
(For details, refer to the Instruction Manual (Detailed) of the FR-A860.)
2.7.2 Ethernet connector Ethernet communication specifications
Connection cable Use Ethernet cables compliant with the following standards.
Hub Use a hub that supports transmission speed of the Ethernet.
Item Description Category 100BASE-TX/10BASE-T
Data transmission speed 100 Mbps (100BASE-TX) / 10 Mbps (10BASE-T)
Transmission method Baseband
Maximum segment length 100 m between the hub and the inverter
Number of cascade connection stages Up to 2 (100BASE-TX) / up to 4 (10BASE-T)
Interface RJ-45
Number of interfaces available 1
IP version IPv4
Communication speed Cable Connector Standard 100 Mbps Category 5 or higher, (shielded / STP) straight cable
RJ-45 connector
100BASE-TX
10M bps Category 3 or higher, (shielded / STP) straight cable
10BASE-T Category 3 or higher, (UTP) straight cable
INSTALLATION AND WIRING 45
Communication connectors and terminals
2.7.3 USB connector
USB host communication
Different inverter data can be saved in a USB memory device.
The USB host communication enables the following functions.
The operating status of the USB host can be checked on the LED display of the inverter.
When a device such as a USB battery charger is connected to the USB connector and an excessive current (500 mA or
more) flows, USB host error (UF warning) is displayed on the operation panel.
If a UF warning occurs, disconnect the USB device and set Pr.1049 = "1" to cancel the USB error. (The UF warning can
also be canceled by resetting the inverter power or resetting with the RES signal.)
NOTE Do not connect devices other than a USB memory device to the inverter.
If a USB device is connected to the inverter via a USB hub, the inverter cannot recognize the USB memory device properly.
For the details of usage, refer to the Instruction Manual (Detailed) of the FR-A860.
Interface Conforms to USB 1.1
Transmission speed 12 Mbps
Wiring length Maximum 5 m
Connector USB A connector (receptacle)
Compatible USB memory
(Format) FAT32
Capacity 1 GB or more (used in the recorder mode of the trace function)
Encryption function Not available
Function Description
Parameter copy
Copies the parameter setting from the inverter to the USB memory device. A maximum of 99 parameter setting files can be saved in a USB memory device.
The parameter setting data copied in the USB memory device can be copied to other inverters. This function is useful in backing up the parameter setting or for sharing the parameter setting among multiple inverters.
The parameter setting file can be copied onto a personal computer from the USB memory device and edited using FR Configurator2.
Trace The monitored data and output status of the signals can be saved in a USB memory device. The saved data can be imported to FR Configurator2 to diagnose the operating status of the inverter.
PLC function data copy
This function copies the PLC function project data to a USB memory device when the PLC function is used. The PLC function project data copied in the USB memory device can be copied to other inverters. This function is useful in backing up the parameter setting and for allowing multiple inverters to operate by the same sequence programs.
LED display status Operating status
OFF No USB connection.
ON The communication is established between the inverter and the USB device.
Fast blinking The USB memory device is being accessed. (Do not remove the USB memory device.)
Slow blinking Error in the USB connection.
Place a flathead screwdriver, etc. in a slot and push up the cover to open.
USB host (A connector)
USB device (Mini B connector)
Communication status indicator (LED)
Personal computer (FR Configurator2)
USB
46 INSTALLATION AND WIRING
Communication connectors and terminals
2
USB device communication A USB (Ver. 1.1) cable connects the inverter with a personal computer.
Parameter setting and monitoring can be performed by FR Configurator2.
NOTE For the details of FR Configurator2, refer to the Instruction Manual of FR Configurator2.
Interface Conforms to USB 1.1
Transmission speed 12 Mbps
Wiring length Maximum 5 m
Connector USB mini B connector (receptacle)
Power supply Self-powered
INSTALLATION AND WIRING 47
Connection of motor with encoder (Vector control)
2.8 Connection of motor with encoder (Vector control)
Using encoder-equipped motors together with a vector control compatible option enables speed, torque, and positioning
control operations under orientation control, encoder feedback control, and full-scale vector control.
This section explains wiring for use of the FR-A8AP.
Appearance and parts name of the FR-A8AP
Terminals of the FR-A8AP
NOTE When the encoder's output voltage differs from its input power supply voltage, the signal loss detection (E.ECT) may occur.
Incorrect wiring or faulty setting to the encoder will cause a fault such as an overcurrent (E.OC[ ]) and an inverter
overload (E.THT).
Correctly perform the encoder wiring and setting.
Symbol Name Description Refer to page
a Mounting hole Used for installation to the inverter.
b Terminal block Connected with the encoder. 50 c Encoder type selection switch (SW3) Switches the encoder type (differential line driver/complementary). 49 d CON2 connector Used for extension
e Terminating resistor selection switch (SW1)
Switches ON or OFF the internal terminating resistor. 49
f Switch for manufacturer setting (SW2) Do not change from the initially-set status. (Switches 1 and 2 are OFF .)
g Connector Connected to the option connector of the inverter. 9 h LED for manufacturer check Not used.
Terminal symbol Terminal name Description
PA1 Encoder A-phase signal input terminal
A-, B- and Z-phase signals are input from the encoder.
PA2 Encoder A-phase inverse signal input terminal
PB1 Encoder B-phase signal input terminal
PB2 Encoder B-phase inverse signal input terminal
PZ1 Encoder Z-phase signal input terminal
PZ2 Encoder Z-phase inverse signal input terminal
PG Encoder power supply (positive side) input terminal
Input terminal for the encoder power supply. Connect the external power supply (5 V, 12 V, 15 V, 24 V) and the encoder power cable. When the encoder output is the differential line driver type, only 5 V can be input. Make the voltage of the external power supply same as the encoder output voltage. (Check the encoder specification.)
SD Encoder power supply ground terminal
PIN Not used.
PO
Front view Rear view
Terminal layout
PA 2
PB 2
PZ 2
SD SD PO
PA 1
PB 1
PZ 1
PG PG PI N
PIN and PO are not used.
1 2 3 4
O N 1 2
O N
SW2
SW3
SW 1
(a)
(a)
(a)(b)
(a)(a)
(a)
(e)
(d)
(f)
(c)
(h)
1 2
O N
48 INSTALLATION AND WIRING
Connection of motor with encoder (Vector control)
2
Switches of the FR-A8AP Encoder type selection switch (SW3)
Selects either the differential line driver or complementary setting.
It is initially set to the differential line driver. Switch its position according to the
output circuit.
Terminating resistor selection switch (SW1)
Selects ON/OFF of the internal terminating resistor.
Set the switch to ON (initial status) when an encoder output type is
differential line driver, and set to OFF when complementary.
ON: with internal terminating resistor (initial status)
OFF: without internal terminating resistor
NOTE Set all switches to the same setting (ON/OFF).
Set the switch "OFF" when sharing an encoder with another unit (NC (computerized numerical controller), etc.) having a
terminating resistor under the differential line driver setting.
Prepare an encoder's power supply (5 V/12 V/15 V/24 V) according to the encoder's output voltage. When the encoder output
is the differential line driver type, only 5 V can be input.
The SW2 switch is for manufacturer setting. Do not change the setting.
Encoder specification Item Specification
Resolution 0 to 4096 pulses/rev (setting by Pr. 369)
Power supply voltage 5 V, 12 V, 15 V, 24 V
Output signal form A, B phases (90 phase shift) Z phase: 1 pulse/rev
Output circuit Differential line driver or complementary
Complementary
Differential line driver (initial status)
1 2 3 4
O N
1 2
O N
SW2
SW3
SW 1
Internal terminating resistor-ON (initial status)
Internal terminating resistor-OFF
1 2 3 4
O N
1 2
O N
SW2
SW3
SW 1
INSTALLATION AND WIRING 49
Connection of motor with encoder (Vector control)
Encoder cable As the terminal block of the FR-A8AP is an insertion type, cables need to be treated when the encoder cables of the
inverter have crimp terminals. Cut the crimp terminal of the encoder cable and strip its sheath to make its cable wires loose.
Also, treat the shielding wires of the shielded twisted pair cable to ensure that they will not contact conductive areas.
Wire the stripped cable after twisting it to prevent it from becoming loose. In addition, do not solder it.
NOTE Crimp terminals
Commercially available (as of January 2017)
Phoenix Contact Co., Ltd.
NICHIFU Co., Ltd.
When using a blade terminal (without insulation sleeve),
take caution that the twisted wires do not come out.
Wiring example Speed control
Terminal screw size
Wire gauge (mm2)
Ferrule part No. Crimping tool model(With insulation sleeve) (Without insulation sleeve)
M2 0.3, 0.5 AI 0,5-6WH A 0,5-6 CRIMPFOX 6
Terminal screw size
Wire gauge (mm2)
Blade terminal part No. Insulation cap part No. Crimping tool model
M2 0.3 to 0.75 BT 0.75-7 VC 0.75 NH 69
5 V differential line driver
The pin number differs according to the encoder used.
Speed, control, torque control, and position control by pulse train input are available with or without the Z-phase being connected.
Connect the encoder so that there is no looseness between the motor and motor shaft. Speed ratio must be 1:1.
Earth (ground) the shield of the encoder cable to the enclosure using a tool such as a P-clip. (Refer to page 51.)
For the complementary, set the terminating resistor selection switch to OFF position. (Refer to page 49.)
A separate power supply of 5 V / 12 V / 15 V / 24 V is necessary according to the encoder power specification.
When the encoder output is the differential line driver type, only 5 V can be input.
Make the voltage of the external power supply the same as the encoder output voltage, and connect the external power supply between
PG and SD.
5 mm
Wire strip length
Motor with encoder
U V W
U V W E
C
3
1
2
4
R PA1
FR-A8AP
PA2
PB1 PB2
PZ1 PZ2
PG
PG SD
SD
Differential
Terminating resistor ON
OFF
Complementary
A N
B P
H K
IM
Forward rotation start Reverse rotation start
Contact input common
STF STR
SD
PLG
Earth (Ground)
Inverter
10
2 2
3
1
Torque limit command
(10V)
1
Frequency command Frequency setting
potentiometer 1/2W1k 5
(+) (-)
5VDC power supply(+) (-) 5
To converter unit P/+ N/-
50 INSTALLATION AND WIRING
Connection of motor with encoder (Vector control)
2
Instructions for encoder cable wiring Use shielded twisted pair cables (0.2 mm2 or larger) to connect the FR-A8AP. For wiring to terminals PG and SD, use
several cables in parallel or use a thick cable, according to the wiring length.
To protect the cables from noise, run them away from any source of noise (such as the main circuit and power supply
voltage).
When differential line driver is set and a wiring length is 30 m or more.
The wiring length can be extended to 100 m by increasing the 5 V power supply (approximately to 5.5 V) while using six or more 0.2 mm2 gauge
cables in parallel or a 1.25 mm2 or larger gauge cable. The voltage applied must be within power supply specifications of encoder.
To reduce noise of the encoder cable, earth (ground) the encoder's shielded cable to the enclosure
(as close as possible to the inverter) with a P-clip or U-clip made of metal.
When one encoder is shared between FR-A8AP and CNC (computerized numerical controller), its output signal should be
connected as shown below. In this case, the wiring length between FR-A8AP and CNC should be as short as possible,
within 5 m.
Wiring length Parallel connection Larger-size cable Within 10 m At least two cables in parallel
Cable gauge 0.2 mm2
0.4 mm2 or larger
Within 20 m At least four cables in parallel 0.75 mm2 or larger
Within 100 m At least six cables in parallel 1.25 mm2 or larger
PZ2 PZ1
PA1 PA2 FB1 FB2
SD PG
G F D C B A
R S
Encoder
2 mm2
FR-A800 (FR-A8AP)
Example of parallel connection with two cables
(with complementary encoder output)
Encoder cable Shield
P-clip
Earthing (grounding) example using a P-clip
NC Maximum 5 m
(two parallel cables)
Inverter (FR-A8AP) Encoder
INSTALLATION AND WIRING 51
Parameter settings for a motor with encoder
2.9 Parameter settings for a motor with encoder
Parameter for the encoder (Pr.359, Pr.369, Pr.851, Pr.852) Set the encoder specifications.
The following table shows parameters to be set according to a vector control compatible option to be used.
Parameter settings for the motor under vector control
Pr. Name Initial value
Setting range Description
359 C141
852 C241
Encoder rotation direction 1
0 Set when using a motor for which forward rotation (encoder) is clockwise (CW) viewed from the shaft.
Set for the operation at 120 Hz or less.
100 Set for the operation at a frequency higher than 120 Hz.
1
Set when using a motor for which forward rotation (encoder) is counterclockwise (CCW) viewed from the shaft.
Set for the operation at 120 Hz or less.
101 Set for the operation at a frequency higher than 120 Hz.
369 C140
851 C240
Number of encoder pulses 1024 0 to 4096
Set the number of encoder pulses output. Set the number of pulses before it is multiplied by 4.
The parameters above can be set when a vector control compatible option is installed.
Item FR-A8AP/FR-A8AL
/FR-A8APA parameter
FR-A8APR parameter
FR-A8APS parameter
FR-A8TP parameter
Encoder/Resolver rotation direction Pr.359 Pr.852
Number of detector pulses Pr.369 (fixed 1024 pulses) (Obtained via communication from the encoder)
Pr.851
Motor name
Pr.9 Electronic
thermal O/L relay
Pr.71 Applied motor
Pr.80 Motor
capacity
Pr.81 Number of
motor poles
Pr.359/ Pr.852
Encoder rotation direction
Pr.369/ Pr.851
Number of encoder pulses
Standard motor (thermal characteristic: standard)
Rated motor current
0 Motor capacity Number of motor poles
1 1024
Constant-torque motor (thermal characteristic: constant torque)
Rated motor current
1 Motor capacity 4 1 1024
Vector control dedicated motor 0 30 Motor capacity 4 1 2048
Other manufacturer's standard motor
Rated motor current
0 (3) Motor capacity Number of motor poles
Other manufacturer's constant- torque motor
Rated motor current
1 (13) Motor capacity Number of motor poles
Offline auto tuning is required (Refer to the FR-A860 Instruction Manual (Detailed))
Set this parameter according to the motor.
Use the thermal protector input provided with the motor.
CW
CCW
52 INSTALLATION AND WIRING
Installing a communication option
2
2.10 Installing a communication option To use a communication option, the enclosed earthing (grounding) cable needs to be installed. Install the cable according
to the following procedure.
NOTE The number and shape of the spacers used differ depending on the communication option type. Refer to the Instruction
Manual of each communication option for details.
The earth plate enclosed with a communication option is not used.
No. Installation procedure 1 Insert spacers into the mounting holes that will not be tightened with the option mounting screws.
2 Fit the connector of the communication option to the guide of the connector of the inverter, and insert the option as far as it goes. (Insert it to the inverter option connector 1.)
3 Remove the mounting screw (lower) of the Ethernet board earth plate. Fit the one terminal of the earthing (grounding) cable on the Ethernet board earth plate and fix it securely to the inverter with the mounting screw. (tightening torque 0.33 Nm to 0.40 Nm)
4
Fix the left part of the communication option securely with the option mounting screw, and place another terminal of the earthing (grounding) cable on the right part of the option and fix the cable terminal and the option with the option mounting screw. (tightening torque 0.33 Nm to 0.40 Nm) If the screws are not tightened properly, the connector may not be inserted deep enough. Check the connector.
Ethernet board earth plate
Ethernet board earth plate
Spacer
Spacer
Option connector 1
Example of FR-A8NC
Spacer
Spacer
Mounting screw
Mounting screw
Mounting screw
Earth cable
Earth cable
INSTALLATION AND WIRING 53
MEMO
54
3
PRECAUTIONS FOR USE OF THE INVERTER 55
3 PRECAUTIONS FOR USE OF THE INVERTER
This chapter explains the precautions for use of this product. Always read the instructions before using the equipment.
3.1 Electro-magnetic interference (EMI) and leakage currents ..56 3.2 Power supply harmonics .........................................................59 3.3 Installation of a reactor ............................................................59 3.4 Power-OFF and magnetic contactor (MC) ..............................60 3.5 Precautions against deterioration of the 600 V class motor
insulation...................................................................................61 3.6 Checklist before starting operation ........................................62 3.7 Failsafe system which uses the inverter ................................64
Electro-magnetic interference (EMI) and leakage currents
3.1 Electro-magnetic interference (EMI) and leakage currents
3.1.1 Leakage currents and precautions Capacitances exist between the inverter I/O cables, other cables and earth and in the motor, through which a leakage current
flows. Since its value depends on the static capacitances, carrier frequency, etc., low acoustic noise operation at the
increased carrier frequency of the inverter will increase the leakage current. Therefore, take the following precautions. Select
the earth leakage current breaker according to its rated sensitivity current, independently of the carrier frequency setting.
To-earth (ground) leakage currents Leakage currents may flow not only into the inverter's own line but also into the other lines through the earthing (grounding)
cable, etc. These leakage currents may operate earth leakage circuit breakers and earth leakage relays unnecessarily.
Precautions
If the carrier frequency setting is high, decrease the Pr.72 PWM frequency selection setting.
Note that motor noise increases. Selecting Pr.240 Soft-PWM operation selection makes the sound inoffensive.
By using earth leakage circuit breakers designed for harmonic and surge suppression in the inverter's own line and other
line, operation can be performed with the carrier frequency kept high (with low noise).
To-earth (ground) leakage currents
Take caution as long wiring will increase the leakage current. Decreasing the carrier frequency of the inverter reduces the
leakage current.
Increasing the motor capacity increases the leakage current.
Line-to-line leakage currents Harmonics of leakage currents flowing in static capacitances between the inverter output cables may operate the external
thermal relay unnecessarily.
Precautions
Use Pr.9 Electronic thermal O/L relay.
If the carrier frequency setting is high, decrease the Pr.72 PWM frequency selection setting.
Note that motor noise increases. Selecting Pr.240 Soft-PWM operation selection makes the sound inoffensive.
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.
Installation and selection of the molded case circuit breaker
Install a molded case circuit breaker (MCCB) on the power receiving side to protect the wiring at the inverter input side.
Select an MCCB according to the inverter input side power factor, which depends on the power supply voltage, output
frequency and load. Especially for a completely electromagnetic MCCB, a slightly large capacity must be selected since its
operation characteristic varies with harmonic currents. (Check it in the data of the corresponding breaker.)
Power supply
Thermal relay
Line-to-line static capacitances
MCCB MC
Line-to-line leakage currents path
Motor
Inverter M
56 PRECAUTIONS FOR USE OF THE INVERTER
Electro-magnetic interference (EMI) and leakage currents
3
3.1.2 Precautions against inverter-generated EMI Some electromagnetic noises enter the inverter or the converter unit to cause its malfunction, and others are radiated by the
inverter or the converter unit to cause the peripheral devices to malfunction. Though the inverter or the converter unit is
designed to have high immunity performance, it handles low-level signals, so it requires the following basic techniques. Also,
since the inverter chops outputs at high carrier frequency, that could generate electromagnetic noises. To prevent peripheral
devices from malfunctioning due to electromagnetic noise, take precautions to suppress EMI. These techniques differ slightly
depending on EMI paths.
Basic techniques
- Do not run the power cables (I/O cables) and signal cables of the inverter or the converter unit in parallel with each other
and do not bundle them.
- Use shielded twisted pair cables for the detector connecting and control signal cables and connect the sheathes of the
shielded cables to terminal SD.
- Ground (Earth) the inverter or the converter unit, motor, etc. at one point.
Techniques to reduce electromagnetic noises that enter and cause a malfunction of the inverter or the converter unit (EMI
precautions)
When devices that generate many electromagnetic noises (which use magnetic contactors, electromagnetic brakes, many
relays, for example) are installed near the inverter or the converter unit and it may malfunction due to electromagnetic
noises, the following precautions must be taken:
- Provide surge suppressors for devices that generate many electromagnetic noises to suppress electromagnetic noises.
- Install data line filters (page 58) to signal cables.
- Ground (Earth) the shields of the detector connection and control signal cables with cable clamp metal.
Techniques to reduce electromagnetic noises that are radiated by the inverter or converter unit to cause the peripheral
devices to malfunction (EMI precautions)
Noises generated from the inverter or the converter unit are largely classified into those radiated by the cables connected to
the inverter or the converter unit and its main circuits (I/O), those electromagnetically and electrostatically induced to the
signal cables of the peripheral devices close to the main circuit power supply, and those transmitted through the power
supply cables.
Noise directly radiated from the inverter or the converter unit
Inverter generated electromagnetic noise
Air propagated noise
Electrical path propagated noise
Electromagnetic induction noise
Electrostatic induction noise
Path (c)
Path (b)
Path (a)
Path (h)
Path (g)
Path (d), (e)
Path (f)
Noise propagated through power supply cable
Noise radiated from power supply cable
Noise radiated from motor connection cable
Noise from earthing (grounding) cable due to leakage current
M
(a)
(b)
(c)
(c)
(h)
(g)
(e)
(g)
(d) (f)
Converter unit
Inverter (a)
Motor
Telephone
Sensor
Instrument Receiver
Sensor power supply
PRECAUTIONS FOR USE OF THE INVERTER 57
Electro-magnetic interference (EMI) and leakage currents
Data line filter Data line filter is effective as an EMI precautions. Provide a data line filter for the detector cable, etc.
EMI precautions example
Noise propagation path Countermeasure
(a)(b)(c)
When devices that handle low-level signals and are liable to malfunction due to electromagnetic noises, e.g. instruments, receivers and sensors, are contained in the enclosure that contains the inverter or the converter unit, or when their signal cables are run near the inverter, the devices may malfunction due to by air-propagated electromagnetic noises. The following precautions must be taken: Install easily affected devices as far away as possible from the inverter or the converter unit. Run easily affected signal cables as far away as possible from the inverter or the converter unit, and its I/O cables.
Do not run the signal cables and power cables (inverter or converter unit I/O cables) in parallel with each other and do not bundle them.
Inserting a line noise filter into the output suppresses the radiated noise from the cables. Use shielded cables as signal cables and power cables and run them in individual metal conduits to produce further effects.
(d)(e)(f)
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 to cause malfunction of the devices and the following precautions must be taken: Install easily affected devices as far away as possible from the inverter or the converter unit. Run easily affected signal cables as far away as possible from the inverter or the converter unit, and its I/O cables.
Do not run the signal cables and power cables (inverter or converter unit I/O cables) in parallel with each other and do not bundle them.
Use shielded cables as signal cables and power cables and run them in individual metal conduits to produce further effects.
(g)
When the power supplies of the peripheral devices are connected to the power supply of the inverter or the converter unit in the same line, its generated noises may flow back through the power supply cables to cause malfunction of the devices and the following precautions must be taken: Install the line noise filter to the power cables (output cables) of the inverter.
(h)
When a closed loop circuit is formed by connecting the peripheral device wiring to the inverter or the converter unit, leakage currents may flow through the earthing (grounding) cable of the inverter or the converter unit to cause the device to malfunction. In that case, disconnecting the earthing (grounding) cable from the device may stop the malfunction of the device.
Converter unit
Line noise filter
Install filter on inverter output side.Install filter on converter unit input side.
Inverter
Sensor Use a twisted pair shielded cable
Enclosure Decrease carrier frequency
Motor Inverter power supply
Separate inverter, converter unit and power line by more than 30 cm (at least 10 cm) from sensor circuit.
Control power supply
Do not earth (ground) enclosure directly. Do not earth (ground) control cable.
Use 4-core cable for motor power cable and use one cable as earth (ground) cable.
Do not earth (ground) shield but connect it to signal common cable.
Line noise filter M
Power supply for
sensor
58 PRECAUTIONS FOR USE OF THE INVERTER
Power supply harmonics
3
3.2 Power supply harmonics
3.2.1 Power supply harmonics The inverter may generate power supply harmonics from its converter circuit to affect the power generator, power factor
correction capacitor etc. Power supply harmonics are different from noise and leakage currents in source, frequency band and
transmission path. Take the following precaution suppression techniques.
The differences between harmonics and noises
Precautions
NOTE The power factor improving capacitor and surge suppressor on the inverter output side may be overheated or damaged by
the harmonic components of the inverter output. Also, since an excessive current flows in the inverter to activate overcurrent
protection, do not provide a capacitor and surge suppressor on the inverter output side when the motor is driven by the
inverter. For power factor improvement, install a reactor on the inverter input side or in the DC circuit.
3.3 Installation of a reactor When the inverter is connected near a large-capacity power transformer (1000 kVA or more) or when a power factor
correction capacitor is to be switched over, an excessive peak current may flow in the power input circuit, damaging the
converter circuit. To prevent this, always install an AC reactor.
Item Harmonics Noise
Frequency Normally 40th to 50th degrees or less (3 kHz or less).
High frequency (several 10 kHz to 1 GHz order).
Environment To-electric channel, power impedance. To-space, distance, wiring path,
Quantitative understanding Theoretical calculation possible. Random occurrence, quantitative grasping difficult.
Generated amount Nearly proportional to the load capacity. Changes with the current variation ratio. (Gets larger as switching speed increases.)
Affected equipment immunity Specified by standards per equipment. Different depending on maker's equipment specifications.
Precaution Provide a reactor. Increase distance.
The harmonic current generated from the inverter
to the input side differs according to various
conditions such as the wiring impedance,
whether a reactor is used or not, and output
frequency and output current on the load side.
For the output frequency and output current, we
understand that this should be calculated in the
conditions under the rated load at the maximum
operating frequency.
The converter unit (FR-CC2) is equipped with the DC reactor.
DC reactor 1
Inverter with converter unit
R
S
T Z
Y
X U
V
W
R/L1
S/L2
T/L3
M
AC reactor Do not insert power factor improving capacitor.
MCCB MC
P ow
er s
up pl
y
MCCB MC
Inverter with converter unit
R
S
T Z
Y
X U
V
W
R/L1
S/L2
T/L3
M
5000 5300
4000
3000
2000
1000
110 165 247 330 420 550 kVA
AC reactor
Power supply
Capacities requiring installation of AC reactor
Inverter capacity
P ow
er s
up pl
y sy
st em
ca
pa ci
ty (k
V A
)
PRECAUTIONS FOR USE OF THE INVERTER 59
Power-OFF and magnetic contactor (MC)
3.4 Power-OFF and magnetic contactor (MC)
Converter unit input side magnetic contactor (MC) On the converter unit input side, it is recommended to provide an MC for the following purposes:
(Refer to page 14 for selection.)
To disconnect the inverter from the power supply at activation of a protective function or at malfunctioning of the driving
system (emergency stop, etc.).
To prevent any accident due to an automatic restart at power restoration after an inverter stop made by a power failure.
To separate the inverter from the power supply to ensure safe maintenance and inspection work.
If using an MC for emergency stop during operation, select an MC regarding the converter unit input side current as JEM
1038-AC-3 class rated current.
NOTE Since repeated inrush currents at power ON will shorten the life of the converter circuit (switching life is about 1,000,000
times), frequent starts and stops of the magnetic contactor must be avoided. Turn ON/OFF the inverter start controlling
terminals (STF, STR) to run/stop the inverter.
Inverter start/stop circuit example
As shown below, always use the start signal (ON or OFF of STF(STR) signal) to make a start or stop.
Install a stepdown transformer.
Connect the power supply terminals R1/L11, S1/L21 of the control circuit to the input side of the MC to hold an alarm signal when the inverter's
protective circuit is activated. At this time, remove jumpers across terminals R1/L11 and S1/L21. (Refer to page 41 for removal of the jumper.)
Handling of the magnetic contactor on the inverter's output side Switch the magnetic contactor between the inverter and motor only when both the inverter and motor are at a stop. When the
magnetic contactor is turned ON while the inverter is operating, overcurrent protection of the inverter and such will activate.
When an MC is provided to switch to a commercial power supply, for example, it is recommended to use the electronic bypass
function Pr.135 to Pr.139. (The commercial power supply operation is not available with vector control dedicated motors nor
with PM motors.)
Handling of the manual contactor on the inverter's output side A PM motor is a synchronous motor with high-performance magnets embedded inside. High-voltage is generated at the motor
terminals while the motor is running even after the inverter power is turned OFF. In an application where the PM motor is
driven by the load even after the inverter is powered OFF, a low-voltage manual contactor must be connected at the inverter's
output side.
MCCB
Converter unit
Power supply
To the motor
Inverter
Stop
Start
Operation preparation
Start/Stop
P/+
N/-
P/+
N/-
A1
B1
C1
RDA
MC R/L1
S/L2
T/L3 R1/L11
S1/L21
OFF ON
MC
RA
MC RA
MC
RA
U
V
A1
B1
C1
W
SD STF/STR
R1/L11
S1/L21
X10
SE SD
T 1
2 2
60 PRECAUTIONS FOR USE OF THE INVERTER
Precautions against deterioration of the 600 V class motor insulation
3
NOTE Before wiring or inspection for a PM motor, confirm that the PM motor is stopped. In an application, such as fan and blower,
where the motor is driven by the load, a low-voltage manual contactor must be connected at the inverter's output side, and
wiring and inspection must be performed while the contactor is open. Otherwise you may get an electric shock.
Do not open or close the contactor while the inverter is running (outputting).
3.5 Precautions against deterioration of the 600 V class motor insulation
In the PWM type inverter, a surge voltage attributable to wiring constants is generated at the motor terminals. Especially for a 600 V class motor, the surge voltage may deteriorate the insulation.
Surge voltage at a motor terminal by motor wiring length (reference)
When the 600 V class motor is driven by the inverter, consider the following measures:
Measures Inverter duty motor
Select an inverter duty motor. Many motor manufacturers sell motors with insulation systems designed to withstand the
stress imposed by PWM inverters
AC reactor
For added protection, install an AC reactor on the inverter output
100%
0
200
150
Vo lta
ge a
t a m
ot or
te rm
in al
(% )
10 20 30 40 50 60 70 80 90 100 Motor wiring length (m)
PRECAUTIONS FOR USE OF THE INVERTER 61
Checklist before starting operation
3.6 Checklist before starting operation The FR-A860 series inverter and FR-CC2 converter unit are highly reliable products, but incorrect peripheral circuit making or
operation/handling method may shorten the product life or damage the products.
Before starting operation, always recheck the following points.
Checkpoint Countermeasure Refer to page
Check by user
Crimp terminals are insulated. Use crimp terminals with insulation sleeves to wire the power supply and the motor.
-
The wiring between the power supply (R/L1, S/L2, T/L3) and the motor (U, V, W) is correct.
Application of power to the output terminals (U, V, W) of the inverter will damage the inverter. Never perform such wiring.
28
No wire offcuts are left from the time of wiring.
Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter and the converter unit clean. When drilling mounting holes in an enclosure etc., take caution not to allow chips and other foreign matter to enter the inverter and the converter unit.
-
The main circuit cable gauge is correctly selected.
Use an appropriate cable gauge to suppress the voltage drop to 2% or less. If the wiring distance is long between the inverter and motor, the voltage drop in the main circuit will cause the motor torque to decrease especially during the output of a low frequency.
29
The total wiring length is within the specified length.
Keep the total wiring length is within the specified length. In long distance wiring, charging currents due to stray capacitance in the wiring may degrade the fast-response current limit operation or cause the equipment on the inverter's output side to malfunction. Pay attention to the total wiring length.
29
Precautions are taken against EMI.
The input/output (main circuit) of the inverter and the converter unit includes high frequency components, which may interfere with the communication devices (such as AM radios) used near the inverter and the converter unit. In such case, install a noise filter to minimize interference.
57
On the inverter's output side, there is no power factor correction capacitor, surge suppressor, or radio noise filter installed.
Doing so will cause the inverter to trip or the capacitor and surge suppressor to be damaged. If any of the above devices is connected, immediately remove it.
-
When performing an inspection or rewiring on the product that has been energized, the operator has waited long enough after shutting off the power supply.
For a short time after the power-OFF, a high voltage remains in the smoothing capacitor, and it is dangerous. Before performing an inspection or rewiring, wait 10 minutes or longer after the power supply turns OFF, then confirm that the voltage across the main circuit terminals P/+ and N/- of the inverter is low enough using a tester, etc.
-
The inverter's output side has no short circuit or ground fault occurring.
A short circuit or earth (ground) fault on the inverter's output side may damage the inverter module.
Fully check the insulation resistance of the circuit prior to inverter operation since repeated short circuits caused by peripheral circuit inadequacy or an earth (ground) fault caused by wiring inadequacy or reduced motor insulation resistance may damage the inverter module.
Fully check the to-earth (ground) insulation and phase-to-phase insulation of the inverter's output side before power-ON. Especially for an old motor or use in hostile atmosphere, securely check the motor insulation resistance, etc.
-
The circuit is not configured to use the converter unit's input-side magnetic contactor to start/stop the inverter frequently.
Since repeated inrush currents at power ON will shorten the life of the inverter and the converter unit, frequent starts and stops of the magnetic contactor must be avoided. Turn ON/OFF the inverter's start signals (STF, STR) to run/ stop the inverter.
60
The voltage applied to the I/O signal circuits of the inverter and the converter unit is within the specifications.
Application of a voltage higher than the permissible voltage to the I/O signal circuits of the inverter and the converter unit or opposite polarity may damage the I/O devices. Especially check the wiring to prevent the speed setting potentiometer from being connected incorrectly to short circuit terminals 10E and 5.
32
The converter unit and the inverter are correctly connected.
Make sure that terminal P/+ of the converter unit and terminal P/+ of the inverter, and terminal N/- of the converter unit and terminal N- of the inverter are correctly connected. Connecting the opposite polarity of terminals N/- and P/+ will damage the inverter. Also, do not install an MCCB across terminals P/+ and N/- (across terminals P and P/+ or across N and N/-).
Always connect terminal RDA of the converter unit and terminal MRS (X10) of the inverter, and terminal SE of the converter unit and terminal SD (terminal PC for source logic) of the inverter. Not connecting these terminals may damage the converter unit.
26
62 PRECAUTIONS FOR USE OF THE INVERTER
Checklist before starting operation
3
When using the electronic bypass operation, electrical and mechanical interlocks are provided between the electronic bypass contactors MC1 and MC2.
When using a switching circuit as shown below, chattering due to mis- configured sequence or arc generated at switching may allow undesirable current to flow in and damage the inverter. Mis-wiring may also damage the inverter. (The commercial power supply operation is not available with vector control dedicated motors nor with PM motors.)
If switching to the commercial power supply operation while a failure such as an output short circuit has occurred between the magnetic contactor MC2 and the motor, the damage may further spread. If a failure has occurred between the MC2 and the motor, a protection circuit such as using the OH signal input must be provided.
-
Precautions are taken for power restoration after a power failure.
If the machine must not be restarted when power is restored after a power failure, provide an MC in the converter unit's input side 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.
-
When using the vector control, the encoder is properly installed.
The encoder must be directly connected to a motor shaft without any backlash. (Real sensorless vector control, PM sensorless vector control do not require an encoder.)
48
A magnetic contactor (MC) is installed on the converter unit's input side.
On the converter unit's input side, connect an MC for the following purposes: To disconnect the inverter and the converter unit from the power supply at activation of a protective function or at malfunctioning of the driving system (emergency stop, etc.).
To prevent any accident due to an automatic restart at power restoration after an inverter stop made by a power failure.
To separate the inverter and the converter unit from the power supply to ensure safe maintenance and inspection work.
If using an MC for emergency stop during operation, select an MC regarding the converter unit input side current as JEM 1038-AC-3 class rated current.
60
The magnetic contactor on the inverter's output side is properly handled.
Switch the magnetic contactor between the inverter and motor only when both the inverter and motor are at a stop.
60
When using a PM motor, a low- voltage manual contactor is installed on the inverter's output side.
A PM motor is a synchronous motor with high-performance magnets embedded inside. High-voltage is generated at the motor terminals while the motor is running even after the inverter power is turned OFF. In an application, such as fan and blower, where the motor is driven by the load, a low-voltage manual contactor must be connected at the inverter's output side, and wiring and inspection must be performed while the contactor is open. Otherwise you may get an electric shock.
60
EMC precautions are taken for the frequency setting signals.
If electromagnetic noise generated from the inverter and the converter unit causes frequency setting signal to fluctuate and the motor rotation speed to be unstable when changing the motor speed with analog signals, the following precautions are effective: Do not run the signal cables and power cables (inverter and converter unit I/ O cables) in parallel with each other and do not bundle them.
Run signal cables as far away as possible from power cables (inverter and converter I/O cables).
Use shielded cables. Install a ferrite core on the signal cable.
-
A countermeasure is provided for an overload operation.
When performing frequent starts/stops by the inverter, rise/fall in the temperature of the transistor element of the inverter will repeat due to a repeated flow of large current, shortening the life from thermal fatigue. Since thermal fatigue is related to the amount of current, the life can be increased by reducing current at locked condition, starting current, etc. Reducing current may extend the service life but may also cause torque shortage, which leads to a start failure. Adding a margin to the current can eliminate such a condition. For an induction motor, use the inverter and the converter unit of a higher capacity (up to two ranks). For a PM motor, use the inverter and the converter unit, and PM motor of higher capacities.
-
The specifications and rating match the system requirements.
Make sure that the specifications and rating match the system requirements. -
Countermeasures are taken against electrical corrosion on the motor bearing.
When a motor is driven by the inverter, axial voltage is generated on the motor shaft, which may cause electrical corrosion of the bearing in rare cases depending on the wiring, load, operating conditions of the motor or a specific inverter setting (high carrier frequency). Contact your sales representative to take appropriate countermeasures for the motor. The following shows examples of countermeasures for the inverter. Decrease the carrier frequency. Provide a common mode choke on the output side of the inverter.
Recommended common mode choke: FT-3KM F series FINEMET
common mode choke cores manufactured by Hitachi Metals, Ltd.
FINEMET is a registered trademark of Hitachi Metals, Ltd.
-
Checkpoint Countermeasure Refer to page
Check by user
Inverter with converter unit
MC2
MC1
U V W
R/L1 S/L2 T/L3
IM Power supply
Undesirable current
Interlock
PRECAUTIONS FOR USE OF THE INVERTER 63
Failsafe system which uses the inverter
3.7 Failsafe system which uses the inverter When a fault is detected by the protective function, the protective function is activated to output a fault signal. However, a fault
signal may not be output at an inverter's fault occurrence when the detection circuit or output circuit fails, etc. Although
Mitsubishi Electric assures the best quality products, provide an interlock which uses inverter status output signals to prevent
accidents such as damage to the machine when the inverter fails for some reason. Also at the same time consider the system
configuration where a failsafe from outside the inverter, without using the inverter, is enabled even if the inverter fails.
Interlock method which uses the inverter status output signals By combining the inverter output signals to provide an interlock as shown below, an inverter failure can be detected.
No. Interlock method Check method Used signals
a Inverter protective function operation
Operation check of an alarm contact. Circuit error detection by negative logic.
Fault (ALM) signal
b Inverter operating status Operation ready signal check. Inverter operation ready (RY) signal
c Inverter running status Logic check of the start signal and running signal. Start (STF/STR) signal Inverter running (RUN) signal
d Inverter running status Logic check of the start signal and output current. Start (STF/STR) signal Output current detection (Y12) signal
(a) Checking by the output of the inverter fault signal
When the inverter's protective function is activated and
the inverter trips, the Fault (ALM) signal is output. (The
ALM signal is assigned to terminal A1B1C1 in the initial
setting).
With this signal, check that the inverter operates
properly.
In addition, negative logic can be set. (ON when the
inverter is normal, OFF when the fault occurs.)
(b) Checking the inverter operating status by the inverter
operation ready completion signal
The Inverter operation ready (RY) signal is output when
the inverter power is ON and the inverter becomes
operative.
Check if the RY signal is output after powering ON the
inverter.
(c) Checking the inverter operating status by the start signal
input to the inverter and inverter running signal
The Inverter running (RUN) signal is output when the
inverter is running. (The RUN signal is assigned to
terminal RUN in the initial setting.)
Check if the Y12 signal is being output while inputting a
start signal to the inverter. (The STF signal is a forward
rotation signal, and the STR signal is a reverse rotation
signal.) Even after the start signal is turned OFF, the
RUN signal is kept output until the inverter makes the
motor to decelerate and to stop. For the logic check,
configure a sequence considering the inverter's
deceleration time.
ON
OFF RES
OFF
ON
Reset ON
O ut
pu t f
re qu
en cy
ALM (when output
at NC contact)
Inverter fault occurrence (trip)
Time
(about 1 s) Reset processing
STF
RH
RY
ON OFF
ON OFF
ON OFF
ON
RUN ON OFF
Time
Power supply
O ut
pu t f
re qu
en cy
Pr. 13 Starting frequency
DC injection brake operation point
DC injection brake operation
Reset processing
64 PRECAUTIONS FOR USE OF THE INVERTER
Failsafe system which uses the inverter
3
NOTE Changing the terminal assignment using Pr.190 and Pr.196 (Output terminal function selection) may affect the other
functions. Set parameters after confirming the function of each terminal.
For the details of the parameters and signals, refer to the Instruction Manual (Detailed) of the FR-A860.
Backup method outside the inverter Even if the interlock is provided by the inverter status signal, enough failsafe is not ensured depending on the failure status of
the inverter itself. For example, if an inverter CPU fails in a system interlocked with the inverter's fault, STF/STR, and RUN
signals, no fault signal will be output and the RUN signal will be kept ON because the inverter CPU is down.
Provide a speed detector to detect the motor speed and current detector to detect the motor current and consider the backup
system such as performing a check as below according to the level of importance of the system.
(a) Start signal and actual operation check
Check the motor running and motor current while the start signal is input to the inverter by comparing the start signal to
the inverter and detected speed of the speed detector or detected current of the current detector. Note that the current
is flowing through the motor while the motor coasts to stop, even after the inverter's start signal is turned OFF. For the
logic check, configure a sequence considering the inverter's deceleration time. In addition, it is recommended to check
the three-phase current when using the current detector.
(b) Command speed and actual operation check
Check for a gap between the actual speed and commanded speed by comparing the inverter's speed command and
the speed detected by the speed detector.
(d) Checking the motor operating status by the start signal input to the inverter and inverter output current detection signal
The Output current detection (Y12) signal is output when the inverter operates and current flows into the motor.
Check if the Y12 signal is being output while inputting a start signal to the inverter. (The STF signal is a forward rotation
signal, and the STR signal is a reverse rotation signal.) The Y12 signal is initially set to be output at 150% rated inverter
current. Adjust the level to around 20% using no load current of the motor as reference with Pr.150 Output current detection level. Like the Inverter running (RUN) signal, even after the start signal is turned OFF, the Y12 signal is kept output until the
inverter stops the output to a decelerating motor. For the logic check, configure a sequence considering the inverter's
deceleration time.
When using various signals, assign the functions to Pr.190 and Pr.196 (Output terminal function selection) referring to the
table on the left.
Output signal
Pr.190 to Pr.196 setting Positive logic Negative logic
ALM 99 199
RY 11 111
RUN 0 100
Y12 12 112
Inverter
Controller
System failure
To the alarm detection sensor
Sensor (speed, temperature,
air volume, etc.)
PRECAUTIONS FOR USE OF THE INVERTER 65
MEMO
66
4
PROTECTIVE FUNCTIONS 67
4 PROTECTIVE FUNCTIONS
This chapter explains the "PROTECTIVE FUNCTIONS" that operates in
this product.
Always read the instructions before using the equipment.
4.1 Inverter fault and indications...................................................68 4.2 Reset method for the protective functions.............................68 4.3 List of fault displays .................................................................69
Inverter fault and indications
68 PROTECTIVE FUNCTIONS
4.1 Inverter fault and indications When a fault occurs in the inverter, a protective function is automatically activated to shut off the inverter output and show
an indication on the operation panel of the inverter.
When any fault occurs, take an appropriate corrective action, then reset the inverter, and resume the operation. Restarting
the operation without a reset may break or damage the inverter.
When a protective function is activated, note the following points.
Inverter fault or alarm indications are categorized as below.
NOTE For the details of fault displays and other malfunctions, refer to the Instruction Manual (Detailed) of the FR-A860.
The past eight faults can be displayed on the operation panel. (Fault history) (For the operation, refer to the operation panel
or the parameter unit Instruction Manual.)
4.2 Reset method for the protective functions Reset the inverter by performing any of the following operations. Note that the accumulated heat value of the electronic
thermal relay function and the number of retries are cleared (erased) by resetting the inverter.
The inverter recovers about 1 s after the reset is released.
NOTE OFF status of the start signal must be confirmed before resetting the inverter fault. Resetting an inverter fault with the start
signal ON restarts the motor suddenly.
Item Description
Fault output signal Opening the magnetic contactor (MC) provided on the input side of the inverter at a fault occurrence shuts off the control power to the inverter, therefore, the fault output will not be retained.
Fault or alarm indication When a protective function is activated, the operation panel displays a fault indication.
Operation restart method While a protective function is activated, the inverter output is kept shutoff. Reset the inverter to restart the operation.
Displayed item Description
Error message A message regarding an operational fault and setting fault by the operation panel and parameter unit is displayed. The inverter output is not shut off.
Warning The inverter output is not shut off even when a warning is displayed. However, failure to take appropriate measures will lead to a fault.
Alarm The inverter output is not shut off. An Alarm (LF) signal can also be output with a parameter setting.
Fault A protective function is activated to shut off the inverter output and output a Fault (ALM) signal.
On the operation panel, press the STOP/RESET key to reset the
inverter. (This may only be performed when a fault occurs.)
Switch power OFF once, then switch it ON again.
Turn ON the Inverter reset (RES) signal for 0.1 s or more. (If the
RES signal is kept ON, "Err" appears (blinks) to indicate that the
inverter is in a reset status.)
ON
OFF
SD
Inverter
RES
List of fault displays
PROTECTIVE FUNCTIONS 69
4
4.3 List of fault displays For details, refer to the Instruction Manual (Detailed) of the FR-A860.
If faults other than the above appear, contact your sales
representative.
Abbreviation Name
E rr
or m
es sa
ge
HOLD Operation panel lock LOCD Password locked Er1 to Er4 Er8
Parameter write error
rE1 to rE8 Copy operation error Err. RES signal ON or communication circuit fault
W ar
ni ng
OL Stall prevention (overcurrent) oL Stall prevention (overvoltage) TH Electronic thermal relay function pre-alarm PS PU stop
SL Speed limit indication (output during speed limit)
CF Continuous operation during communication fault
CP Parameter copy SA SA MT1 to MT3 Maintenance timer 1 to 3 UF USB host error HP1 Home position return setting error HP2 Home position return uncompleted HP3 Home position return parameter setting error EHR Ethernet communication fault
A la
rm FN Fan alarm
F au
lt
E.OC1 Overcurrent trip during acceleration E.OC2 Overcurrent trip during constant speed E.OC3 Overcurrent trip during deceleration or stop
E.OV1 Regenerative overvoltage trip during acceleration
E.OV2 Regenerative overvoltage trip during constant speed
E.OV3 Regenerative overvoltage trip during deceleration or stop
E.THT Inverter overload trip (electronic thermal relay function)
E.THM Motor overload trip (electronic thermal relay function)
E.FIN Heat sink overheat
F au
lt
E.OLT Stall prevention stop E. SOT Loss of synchronism detection E.GF Output side earth (ground) fault overcurrent E.LF Output phase loss E.OHT External thermal relay operation E.PTC PTC thermistor operation E.OPT Option fault E.OP1 to E.OP3
Communication option fault
E.16 to E.20 User definition error by the PLC function E.PE Parameter storage device fault E.PUE PU disconnection E.RET Retry count excess E.PE2 Parameter storage device fault E.CPU E. 5 to E. 7
CPU fault
E.CTE Operation panel power supply short circuit E.P24 24 VDC power fault E.CDO Abnormal output current detection E.AIE Analog input fault E.USB USB communication fault E.SAF Safety circuit fault E.PBT E.13
Internal circuit fault
E.OS Overspeed occurrence E.OSD Speed deviation excess detection E.ECT Signal loss detection E.OD Excessive position fault E.MB1 to E.MB7
Brake sequence fault
E.EP Encoder phase fault E.MP Magnetic pole position unknown E.EF External fault during output operation E.LCI 4 mA input fault E.PCH Pre-charge fault E.PID PID signal fault E. 1 to E. 3 Option fault E.11 Opposite rotation deceleration fault E.EHR Ethernet communication fault
O th
er s E.0 No fault history
RD Backup in progress WR Restoration in progress
Abbreviation Name
MEMO
70
5
PRECAUTIONS FOR MAINTENANCE AND INSPECTION 71
5 PRECAUTIONS FOR MAINTENANCE AND INSPECTION
This chapter explains the "PRECAUTIONS FOR MAINTENANCE AND
INSPECTION" for this product.
Always read the instructions before using the equipment.
5.1 Inspection item..........................................................................72 5.2 Measurement of main circuit voltages, currents and
powers .......................................................................................79
Inspection item
The inverter is a static unit mainly consisting of semiconductor devices. Daily inspection must be performed to prevent any
fault from occurring due to the adverse effects of the operating environment, such as temperature, humidity, dust, dirt and
vibration, changes in the parts with time, service life, and other factors.
Precautions for maintenance and inspection When accessing the inverter for inspection, wait for at least 10 minutes after the power supply has been switched OFF, and
then make sure that the voltage across the main circuit terminals P/+ and N/- of the inverter is not more than 30 VDC using a
tester, etc.
5.1 Inspection item
5.1.1 Daily inspection Basically, check for the following faults during operation.
Motor operation fault
Improper installation environment
Cooling system fault
Abnormal vibration, abnormal noise
Abnormal overheat, discoloration
5.1.2 Periodic inspection Check the areas inaccessible during operation and requiring periodic inspection.
Consult us for periodic inspection.
Check and clean the cooling system. .......... Clean the air filter, etc.
Check the tightening and retighten.............. The screws and bolts may become loose due to vibration, temperature
changes, etc. Check and tighten them.
Tighten them according to the specified tightening torque. (Refer to page 29.)
Check the conductors and insulating materials for corrosion and damage.
Measure the insulation resistance.
Check and change the cooling fan and relay.
72 PRECAUTIONS FOR MAINTENANCE AND INSPECTION
Inspection item
5
5.1.3 Daily and periodic inspection
Oil component of the heat dissipation grease used inside the inverter may leak out. The oil component, however, is not flammable, corrosive, nor
conductive and is not harmful to humans. Wipe off such oil component.
It is recommended to install a voltage monitoring device for checking the voltage of the power supplied to the inverter.
One to two years of periodic inspection cycle is recommended. However, it differs according to the installation environment.
Consult us for periodic inspection.
NOTE Continuous use of a leaked, deformed, or degraded smoothing aluminum electrolytic capacitor (as shown in the table above)
may lead to a burst, breakage or fire. Replace such capacitor without delay.
Area of inspection Inspection item Description
Inspection interval Corrective action at
fault occurrence
Check by the userDaily Periodic
General
Surrounding environment
Check the surrounding air temperature, humidity, dirt, corrosive gas, oil mist, etc.
Improve the environment.
Overall unit Check for unusual vibration and noise.
Check fault location and retighten.
Check for dirt, oil, and other foreign material. Clean.
Power supply voltage
Check that the main circuit voltages and control voltages are normal.
Inspect the power supply.
Main circuit
General
(1) Check with megger (across main circuit terminals and earth (ground) terminal).
Contact the manufacturer.
(2) Check for loose screws and bolts. Retighten.
(3) Check for overheat traces on the parts. Contact the manufacturer.
(4) Check for stain. Clean.
Conductors, cables (1) Check conductors for distortion. (2) Check cable sheaths for breakage and
deterioration (crack, discoloration, etc.).
Contact the manufacturer.
Contact the manufacturer.
Transformer/ reactor
Check for unusual odor and abnormal increase of whining sound.
Stop the equipment and contact the manufacturer.
Terminal block Check for a damage. Stop the equipment and contact the manufacturer.
Smoothing aluminum electrolytic capacitor
(1) Check for liquid leakage. Contact the manufacturer.
(2) Check for safety valve projection and bulge. Contact the manufacturer.
(3) Judge by visual check
Relay/contactor Check that the operation is normal and no chattering sound is heard.
Contact the manufacturer.
Control circuit, protective circuit
Operation check
(1) Check that the output voltages across phases are balanced while operating the inverter alone.
Contact the manufacturer.
(2) Check that no fault is found in protective and display circuits in a sequence protective operation test.
Contact the manufacturer.
C om
po ne
nt s
ch ec
k
Overall (1) Check for unusual odor and discoloration.
Stop the equipment and contact the manufacturer.
(2) Check for serious rust development. Contact the manufacturer.
Aluminum electrolytic capacitor
(1) Check for liquid leakage in a capacitor and deformation trace.
Contact the manufacturer.
(2) Visual check and judge by the life check of the control circuit capacitor. (Refer to the Instruction Manual (Detailed) of the FR-A860.)
Cooling system
Cooling fan
(1) Check for unusual vibration and noise. Replace the fan.
(2) Check for loose screws and bolts. Fix with the fan cover fixing screws
(3) Check for stain. Clean.
Heat sink (1) Check for clogging. Clean.
(2) Check for stain. Clean.
Display Indication
(1) Check that indications are correct. Contact the manufacturer.
(2) Check for stain. Clean.
Meter/counter Check that readouts are correct. Stop the equipment and contact the manufacturer.
Load motor Operation check Check for vibration and abnormal increase in operation noise.
Stop the equipment and contact the manufacturer.
PRECAUTIONS FOR MAINTENANCE AND INSPECTION 73
Inspection item
5.1.4 Checking the inverter and converter modules Preparation Disconnect the external power supply cables (R/L1, S/L2, T/L3) and motor cables (U, V, W). (The inverter and the converter
unit (FR-CC2) can be measured with those cables connected.)
Prepare a continuity tester. (For the resistance measurement, use the 100 range.)
Checking method Change the polarity of the tester alternately at a semiconductor device (transistor) on an electrical path between two terminals
among the inverter main circuit terminals R/L1, S/L2, T/L3, U, V, W, P/+, and N/- to check the electric continuity.
NOTE Before measurement, check that the smoothing capacitor is discharged.
At the time of electric discontinuity, the measured value is almost . When there is an instantaneous electric continuity, due to
the smoothing capacitor, the tester may not indicate . At the time of electric continuity, the measured value is several to
several tens of . When all measured values are almost the same (although values may not be constant depending on the
tester type), it shows that there are no electrical paths with problems.
Device number and target terminal
(Assuming that an analog meter is used.)
Tester polarity Continuity
Tester polarity Continuity
C on
ve rt
er
m od
ul e
D1 R/L1, P/+ No
D4 R/L1, N/- Yes
P/+ R/L1, Yes N/- R/L1, No
D2 S/L2, P/+ No
D5 S/L2, N/- Yes
P/+ S/L2, Yes N/- S/L2, No
D3 T/L3 P/+ No
D6 T/L3 N/- Yes
P/+ T/L3 Yes N/- T/L3 No
In ve
rt er
m od
u le
TR1 U P/+ No
TR4 U N/- Yes
P/+ U Yes N/- U No
TR3 V P/+ No
TR6 V N/- Yes
P/+ V Yes N/- V No
TR5 W P/+ No
TR2 W N/- Yes
P/+ W Yes N/- W No
Converter module Inverter module
D1 D2 D3
D4 D5 D6
TR1 TR3 TR5
TR4 TR6 TR2
U
V
W
R/L1
S/L2
T/L3
C C
P/+
N/-
P/+
N/-
74 PRECAUTIONS FOR MAINTENANCE AND INSPECTION
Inspection item
5
5.1.5 Cleaning Always run the inverter in a clean status.
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 these will cause the inverter surface paint to peel off.
The display, etc. of the operation panel and parameter unit are vulnerable to detergent and alcohol. Therefore, avoid using
them for cleaning.
5.1.6 Replacement of parts The inverter consists of many electronic parts such as semiconductor devices.
The following parts may deteriorate with age because of their structures or physical characteristics, leading to reduced
performance or fault of the inverter. For preventive maintenance, the parts must be replaced periodically.
Use the life check function as a guidance of parts replacement.
Estimated lifespan for when the yearly average surrounding air temperature is 40C.
(without corrosive gas, flammable gas, oil mist, dust and dirt etc.)
Output current (80% of the inverter rating)
NOTE For parts replacement, contact the nearest Mitsubishi Electric FA center.
Inverter parts life display The inverter diagnoses the control circuit capacitor and the cooling fan by itself, and estimates their lives.
The self-diagnostic warning is output when the life span of each part is near its end. It gives an indication of replacement time.
The life warning output can be used as a guideline for life judgment.
NOTE Refer to the Instruction Manual (Detailed) of the FR-A860 to perform the life check of the inverter parts.
Part name Estimated lifespan Description Cooling fan 10 years Replace (as required)
Main circuit smoothing capacitor 10 years Replace (as required)
On-board smoothing capacitor 10 years Replace the board (as required)
Relays As required
Main circuit fuse 10 years Replace (as required)
Parts Judgment level Control circuit capacitor Estimated remaining life 10%
Cooling fan Not more than the specified speed
PRECAUTIONS FOR MAINTENANCE AND INSPECTION 75
Inspection item
Replacement procedure of the cooling fan The replacement interval of the cooling fan used for cooling the parts generating heat such as the main circuit semiconductor
is greatly affected by the surrounding air temperature. When unusual noise and/or vibration are noticed during inspection, the
cooling fan must be replaced immediately.
Removal 1) Remove the fan cover fixing screws, and remove the fan cover.
2) Disconnect the fan connector and remove the fan block.
3) Remove the fan fixing screws, and remove the fan.
The number of cooling fans differs according to the inverter capacity.
Reinstallation 1) Before installing the new fan, check the orientation of the fan to be sure that the "AIR FLOW" arrow printed on the side
of the fan points upward.
2) For reconnection of the fan, refer to the above figure.
NOTE Installing the fan in the opposite direction of air flow can cause the inverter life to be shorter.
Prevent the cable from being caught when installing a fan.
Switch the power OFF before replacing fans. Since the inverter circuits are charged with voltage even after power OFF,
replace fans only when the inverter cover is on the inverter to prevent an electric shock accident.
1)
2)
3)
Fan
Fan connection connector
Fan cover
Fan block
AIR FLOW
76 PRECAUTIONS FOR MAINTENANCE AND INSPECTION
Inspection item
5
Smoothing capacitors A large-capacity aluminum electrolytic capacitor is used for smoothing in the DC section of the main circuit, and an aluminum
electrolytic capacitor is used for stabilizing the control power in the control circuit. Adverse effects from ripple currents
deteriorate capacitors. Replacement intervals of capacitors vary greatly with surrounding temperatures and operating
conditions. Replace them roughly every 10 years when used in normal air-conditioned environments.
Inspecting the product visually:
Case: Check that the sides and bottom of the capacitor have not ruptured.
Rubber seal: Check for any noticeable bulging or severe cracks.
Check for external cracks, discoloration, leakage, etc. It is assumed that the capacitor has reached the end of its life when
its capacity has dropped below 80% of its rated capacity.
NOTE The inverter diagnoses the control circuit capacitor by itself and can estimate its remaining life. (Refer to the FR-A860
Instruction Manual (Detailed).)
Relay output terminals The contacts of relays deteriorate over time. To prevent faults from occurring, relays must be replaced when they have
reached the maximum of switching operations (switching life).
The control terminal block must be replaced (refer to page 78) in case of failure of either relay connected to the relay output
terminals A1, B1, and C1, or A2, B2, and C2. (After replacing the control terminal block, connect the jumper connector to
the correct position in accordance with the control logic of input signals. (Refer to page 36.))
Main circuit fuse A fuse is used inside the inverter. Replacement intervals of fuses vary with surrounding temperatures and operating
conditions. Replace them roughly every 10 years when used in normal air-conditioned environments.
PRECAUTIONS FOR MAINTENANCE AND INSPECTION 77
Inspection item
5.1.7 Removal and reinstallation of the control circuit terminal block
The FR-A800 series inverter has a removable control circuit terminal block, which can be replaced with a new one or a control
terminal option.
Removal and reinstallation 1) Loosen the two mounting screws at the both side of the control circuit terminal block. (These screws cannot be removed.)
Slide down the control circuit terminal block to remove it.
2) Be careful not to bend the pins of the inverter's control circuit connector, reinstall the control circuit terminal block and fix it
with the mounting screws.
NOTE Before starting the replacement, power OFF the inverter, wait for at least 10 minutes, and then check that the charge lamp is
OFF to ensure safety.
Removal and reinstallation precautions Precautions to be taken when removing or reinstalling the control circuit terminal block are shown below.
Observe the following precautions and handle the inverter properly to avoid malfunctions or failures.
To remove or reinstall the control circuit terminal block, keep it upright so that it is parallel with the inverter.
To install the control circuit terminal block, slide it upward so that the tongues on the inverter slot into the grooves on the terminal block.
Check that the terminal block is parallel to the inverter and the pins on the inverter control circuit connector are not bent.
After checking proper connection, fix the terminal block in place with two screws.
NOTE Do not tilt the terminal block while tightening the screws or removing it from the inverter. (Otherwise, stress applied to the
control circuit terminal block or the control circuit connector may damage the pins.)
After replacing the control terminal block, connect the jumper connector to the correct position in accordance with the control
logic of input signals. (Refer to page 36.)
Loosen the screws
Fasten the screws.
Control circuit terminal blockInverter's control circuit connector
A
Slot the tongue into the groove.
Insert the terminal block parallel to the
inverter.
View from side A
Control circuit terminal blockInverter's control circuit connector
78 PRECAUTIONS FOR MAINTENANCE AND INSPECTION
Measurement of main circuit voltages, currents and powers
5
5.2 Measurement of main circuit voltages, currents and powers
Since the voltages and currents on the inverter power supply and output sides include harmonics, measurement data
depends on the instruments used and circuits measured.
When instruments for commercial frequency are used for measurement, measure the following circuits with the instruments
given on the next page.
NOTE When installing meters etc. on the inverter output side
When the wiring length between the inverter and the motor is large, the meters and CTs may generate heat due to line-to-line
leakage current. Therefore, choose the equipment which has enough allowance for the current rating.
To measure and display the output voltage and output current of the inverter, it is recommended to use terminal AM and FM
output functions of the inverter.
+ -
Ar
As
At
Vr
Vs
Vt
Au
Av
Aw
Vu
Vv
Vw
W21
V
U
V
W
Inverter/ converter unit
Three-phase power supply To the motor
Input voltage
Input current
Output voltage
Output current
R/L1
S/L2
T/L3
P/+ N/-
W11
W12
W13 W22
PRECAUTIONS FOR MAINTENANCE AND INSPECTION 79
Measurement of main circuit voltages, currents and powers
Measuring points and instruments Item Measuring point Measuring instrument Remarks (reference measured value)
C on
ve rt
er u
ni t (
F R
-C C
2)
Power supply voltage V1
Across R/L1 and S/L2, S/L2 and T/L3, T/L3 and R/L1
Digital power meter (for inverter)
Commercial power supply Within permissible AC voltage fluctuation (Refer to page 84.)
Power supply side current I1
R/L1, S/L2, T/L3 line current
Power supply side power P1
R/L1, S/L2, T/L3 and Across R/L1 and S/L2, S/L2 and T/L3, T/L3 and R/L1
P1 = W11 + W12 + W13 (3-wattmeter method)
Power supply side power factor Pf1
Calculate after measuring power supply voltage, power supply side current and power supply side power.
Converter output Across P/+ and N/- Such as tester Inverter LED is lit. 1.35 V1
Operation enable signal External thermal relay signal Reset signal
Across RDI, OH, RES(+) and SD (for sink logic)
Digital multimeter or other tester, or moving-coil type instrument (internal resistance 50 k or more)
When open 20 to 30 VDC ON voltage: 1 V or less
"SD" is common
Alarm signal Across A1 and C1 Across B1 and C1
Digital multimeter or other tester
Continuity check [Normal] [Fault]
Across A1 and C1 Discontinuity Continuity Across B1 and C1 Continuity Discontinuity
In ve
rt er
Output side voltage V2
Across U and V, V and W, and W and U
Digital power meter (for inverter)
Difference between the phases is within 1% of the maximum output voltage.
Output side current I2
U, V and W line currents
Difference between the phases is 10% or lower of the rated inverter current.
Output side power P2
U, V, W and across U and V, V and W
Digital power meter (for inverter) P2 = W21 + W22 2-wattmeter method (or 3-wattmeter method)
Output side power factor Pf2
Calculate in similar manner to power supply side power factor.
Frequency setting signal
Across 2, 4(+) and 5
Digital multimeter or other tester, or moving-coil type instrument (internal resistance 50 k or more)
0 to 10 VDC, 4 to 20 mA
"5" is common
Across 1(+) and 5 0 to 5 VDC and 0 to 10 VDC Frequency setting power supply
Across 10(+) and 5 5.2 VDC Across 10E(+) and 5 10 VDC
Frequency meter signal Start signal Select signal Reset signal Output stop signal
Across AM(+) and 5 Approximately 10 VDC at maximum frequency (without frequency meter)
Across FM(+) and SD
Approximately 5 VDC at maximum frequency (without frequency meter)
Pulse width T1: Adjust with Pr.900. Pulse cycle T2: Set with Pr.55. (frequency monitor only)
"SD" is common
Across STF, STR, RH, RM, RL, JOG, RT, AU, STOP, CS, RES, MRS(+) and SD (for sink logic)
When open 20 to 30 VDC ON voltage: 1 V or less
Fault signal Across A1 and C1 Across B1 and C1
Digital multimeter or other tester
Continuity check [Normal] [Fault]
Across A1 and C1 Discontinuity Continuity Across B1 and C1 Continuity Discontinuity
Pf1 P1
3V1 I 1
----------------------- 100= %
Pf2 P2
3V2 I2 ------------------------ 100= %
8VDC
T1
80 PRECAUTIONS FOR MAINTENANCE AND INSPECTION
Measurement of main circuit voltages, currents and powers
5
Use an FFT to measure the output voltage accurately. A tester or general measuring instrument cannot measure accurately.
When the carrier frequency exceeds 5 kHz, do not use this instrument since using it may increase eddy current losses produced in metal parts
inside the instrument, leading to burnout. In this case, use an approximate-effective value type.
When the setting of Pr.195 ABC1 terminal function selection is the positive logic
5.2.1 Measurement of powers Use a digital power meter (for inverter) for the input side of the converter unit (FR-CC2) and the output side of the inverter.
5.2.2 Measurement of voltages Converter unit (FR-CC2) input side Use a digital power meter for inverters for the input side voltage.
Inverter output side Always use a digital power meter for inverter for measurement as the output side voltage has a PWM-controlled rectangular
wave. The value monitored on the operation panel is the inverter-controlled voltage itself. Hence, that value is accurate and it
is recommended to monitor values (analog output) using the operation panel.
5.2.3 Measurement of currents Use digital power meters (for converter) for the both of inverter input and output side.
Since current on the converter unit input side tends to be unbalanced, measurement of three phases is recommended.
Correct value cannot be obtained by measuring only one or two phases. On the other hand, the unbalanced ratio of each
phase of the output side current should be within 10%.
The inverter output current can be monitored on the operation panel. The value monitored on the operation panel is accurate
if the output frequency varies, and it is recommended to monitor values (provide analog output) using the operation panel.
5.2.4 Example of measuring converter unit (FR-CC2) input power factor
Calculate using effective power and apparent power. A power-factor meter cannot indicate an exact value.
5.2.5 Measurement of converter output voltage (across terminals P and N)
The output voltage of the converter is output across terminals P and N, and can be measured with a voltmeter such as a
digital multimeter. Although the voltage varies according to the power supply voltage, approximately 800 to 900 V is output
when no load is connected and voltage decreases during driving load operation.
When energy is regenerated from the motor during deceleration, for example, the converter output voltage rises to nearly
1100 to 1300 V maximum.
Total power factor of the converter unit = Effective power
Apparent power
= Three-phase input power found by the 3-wattmeter method
V (power supply voltage) I (input current effective value)3
PRECAUTIONS FOR MAINTENANCE AND INSPECTION 81
Measurement of main circuit voltages, currents and powers
5.2.6 Measurement of inverter output frequency In the initial setting, a pulse train proportional to the output frequency is output across the pulse train output terminals FM and
SD of the inverter. This pulse train output can be counted by a frequency counter, or a meter can be used to read the mean
value of the pulse train output voltage. When a meter is used to measure the output frequency, approximately 5 VDC is
indicated at the maximum frequency.
For detailed specifications of the pulse train output terminal FM, refer to the FR-A860 Instruction Manual (Detailed).
5.2.7 Insulation resistance test using megger For the inverter and the converter unit (FR-CC2), 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 500 VDC megger.)
NOTE Before performing the insulation resistance test on the external circuit, disconnect the cables from all terminals of the inverter
and the converter unit so that the test voltage is not applied to the inverter and the converter unit.
For the continuity test of the control circuit, use a tester (high resistance range) and do not use the megger or buzzer.
5.2.8 Withstand voltage test Do not conduct a withstand voltage test. Deterioration may occur.
500 VDC megger
Power supply
Motor P/+ N/-Converter
unit U V W
Inverter IM R/L1 S/L2 T/L3
P/+ N/-
Earth (ground) terminal Earth (ground) terminal
500 VDC megger
82 PRECAUTIONS FOR MAINTENANCE AND INSPECTION
6
SPECIFICATIONS 83
6 SPECIFICATIONS
This chapter explains the "SPECIFICATIONS" of this product.
Always read the instructions before using the equipment.
6.1 Inverter rating............................................................................84 6.2 Common specifications ...........................................................85 6.3 Outline dimension drawings....................................................87
Inverter rating
6.1 Inverter rating Inverter
The applicable motor capacity indicated is the maximum capacity applicable for use of the 4-pole standard motor.
The rated output capacity indicated assumes that the output voltage is 575 V.
When an operation is performed with the carrier frequency set to 3 kHz or more, and the inverter output current reaches the value indicated in
the parenthesis, the carries frequency is automatically lowered. The motor noise becomes louder accordingly.
The % value of the overload current rating indicated is the ratio of the overload current to the 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.
The maximum output voltage does not exceed the power supply voltage. The maximum output voltage can be changed within the setting range.
However, the maximum point of the voltage waveform at the inverter output side is the power supply voltage multiplied by about .
ND rating reference value
Model FR-A862-[ ] 05450 06470 08500
Applicable motor capacity (kW)
SLD 400 450 630
LD 355 400 560
ND (initial setting) 280 355 450
HD 220 280 400
O ut
pu t
Rated capacity (kVA)
SLD 543 645 847
LD 494 587 770
ND (initial setting) 401 494 661
HD 303 401 578
Rated current (A)
SLD 545 (463) 647 (549) 850 (722)
LD 496 (421) 589 (500) 773 (657)
ND (initial setting) 402 (341) 496 (421) 663 (563)
HD 304 (258) 402 (341) 589 (500)
Overload current rating
SLD 110% 60 s, 120% 3 s (inverse-time characteristics) at surrounding air temperature of 40C
LD 120% 60 s, 150% 3 s (inverse-time characteristics) at surrounding air temperature of 50C
ND (initial setting) 150% 60 s, 200% 3 s (inverse-time characteristics) at surrounding air temperature of 50C
HD 200% 60 s, 250% 3 s, 280% 0.5 s (inverse-time characteristics) at surrounding air temperature of 40C
Rated voltage Three-phase 525 to 600 V
Regenerative braking torque (When the converter unit (FR- CC2) is used)
Maximum brake torque
10% torque/continuous
In pu
t p ow
e r DC power supply voltage 618 to 933 VDC
Control power supply auxiliary input Single phase 525 to 600 V 50 Hz/60 Hz
Permissible control power supply auxiliary input fluctuation
Frequency 5%, voltage 10%
Protective structure (IEC 60529) Open type (IP00)
Cooling system Forced air cooling
Approx. mass (kg) 163 163 243
84 SPECIFICATIONS
Common specifications
6
6.2 Common specifications C
on tr
ol s
pe ci
fic at
io ns
Control method Soft-PWM control, high carrier frequency PWM control (selectable among V/F control, Advanced magnetic flux vector control, Real sensorless vector control), Optimum excitation control, Vector control, and PM sensorless vector control
Output frequency range 0.2 to 590 Hz (The upper-limit frequency is 400 Hz under Advanced magnetic flux vector control, Real sensorless vector control, Vector control, and PM sensorless vector control.)
Frequency setting resolution
Analog input
0.015 Hz/60 Hz (terminal 2, 4: 0 to 10 V/12 bits) 0.03 Hz/60 Hz (0 to 5 V/11 bits or 0 to 20 mA/approx. 11 bits for terminals 2 and 4, 0 to 10 V/12 bits for terminal 1) 0.06 Hz/60 Hz (0 to 5 V/11 bits for terminal 1)
Digital input 0.01 Hz Frequency accuracy
Analog input Within 0.2% of the max. output frequency (25C 10C) Digital input Within 0.01% of the set output frequency
Voltage/frequency characteristics
Base frequency can be set from 0 to 590 Hz. Constant-torque/variable-torque pattern or adjustable 5 points V/F can be selected.
Starting torque SLD rating: 120% 0.3 Hz, LD rating: 150% 0.3 Hz, ND rating: 200% 0.3 Hz, HD rating: 250% 0.3 Hz (under Real sensorless vector control or vector control)
Torque boost Manual torque boost Acceleration/deceleration time setting
0 to 3600 s (acceleration and deceleration can be set individually), linear or S-pattern acceleration/ deceleration mode, backlash countermeasures acceleration/deceleration can be selected.
DC injection brake (induction motor) Operation frequency (0 to 120 Hz), operation time (0 to 10 s), operation voltage (0 to 30%) variable
Stall prevention operation level
Activation range of stall prevention operation (SLD rating: 0 to 120%, LD rating: 0 to 150%, ND rating: 0 to 220%, HD rating: 0 to 280%). Whether to use the stall prevention or not can be selected. (V/F control, Advanced magnetic flux vector control)
Torque limit level Torque limit value can be set (0 to 400% variable). (Real sensorless vector control, Vector control, PM sensorless vector control)
O pe
ra tio
n sp
ec ifi
ca tio
ns
Frequency setting signal
Analog input Terminals 2 and 4: 0 to 10 V, 0 to 5 V, 4 to 20 mA (0 to 20 mA) are available. Terminal 1: -10 to +10 V, -5 to 5 V are available.
Digital input Input using the setting dial of the operation panel or parameter unit Four-digit BCD or 16-bit binary (when used with option FR-A8AX)
Start signal Forward and reverse rotation or start signal automatic self-holding input (3-wire input) can be selected.
Input signals (twelve terminals)
Low-speed operation command, Middle-speed operation command, High-speed operation command, Second function selection, Terminal 4 input selection, Jog operation selection, Selection of automatic restart after instantaneous power failure, flying start, Output stop, Start self-holding selection, Forward rotation command, Reverse rotation command, Inverter reset The input signal can be changed using Pr.178 to Pr.189 (Input terminal function selection).
Pulse train input 100k pulses/s
Operational functions
Maximum and minimum frequency settings, multi-speed operation, acceleration/deceleration pattern, thermal protection, DC injection brake, starting frequency, JOG operation, output stop (MRS), stall prevention, regeneration avoidance, increased magnetic excitation deceleration, frequency jump, rotation display, automatic restart after instantaneous power failure, electronic bypass sequence, remote setting, automatic acceleration/deceleration, retry function, carrier frequency selection, fast-response current limit, forward/reverse rotation prevention, operation mode selection, slip compensation, droop control, load torque high-speed frequency control, speed smoothing control, traverse, auto tuning, applied motor selection, gain tuning, RS-485 communication, Ethernet communication, PID control, PID pre-charge function, easy dancer control, cooling fan operation selection, stop selection (deceleration stop/coasting), stop-on-contact control, PLC function, life diagnosis, maintenance timer, current average monitor, multiple rating, orientation control, speed control, torque control, position control, pre-excitation, torque limit, test run, 24 V power supply input for control circuit, safety stop function, anti-sway control
Output signal Open collector output (five terminals) Relay output (two terminals)
Inverter running, Up to frequency, Overload warning, Output frequency detection, Fault The output signal can be changed using Pr.190 to Pr.196 (Output terminal function selection). Fault codes of the inverter can be output (4 bits) from the open collector.
Pulse train output 50k pulses/s
In di
ca tio
n
For meter
Pulse train output
Max. 2.4 kHz: one terminal (output frequency) The monitored item can be changed using Pr.54 FM/CA terminal function selection.
Voltage output
Max. 10 VDC: one terminal (output voltage) The monitored item can be changed using Pr.158 AM terminal function selection.
SPECIFICATIONS 85
Common specifications
Protective/ warning function
Protective function
Overcurrent trip during acceleration, Overcurrent trip during constant speed, Overcurrent trip during deceleration or stop, Regenerative overvoltage trip during acceleration, Regenerative overvoltage trip during constant speed, Regenerative overvoltage trip during deceleration or stop, Inverter overload trip (electronic thermal relay function), Motor overload trip (electronic thermal relay function), Heat sink overheat, Stall prevention stop, Loss of synchronism detection, Output side earth (ground) fault overcurrent, Output short circuit, Output phase loss, External thermal relay operation, PTC thermistor operation, Option fault, Communication option fault, Parameter storage device fault, PU disconnection, Retry count excess, CPU fault, Operation panel power supply short circuit, 24 VDC power fault, Abnormal output current detection, Ethernet communication fault, Analog input fault, USB communication fault, Overspeed occurrence, Speed deviation excess detection, Signal loss detection, Excessive position fault, Brake sequence fault, Encoder phase fault, 4 mA input fault, Pre-charge fault, PID signal fault, Opposite rotation deceleration fault, Internal circuit fault, Magnetic pole position unknown, External fault during output operation
Warning function
Fan alarm, Stall prevention (overcurrent), Stall prevention (overvoltage), Electronic thermal relay function pre-alarm, PU stop, Speed limit indication (output during speed limit), Parameter copy, Maintenance timer 1 to 3, USB host error, Home position return setting error, Home position return uncompleted, Home position return parameter setting error, Operation panel lock, Password locked, Parameter write error, Copy operation error, 24 V external power supply operation, Continuous operation during communication fault, Ethernet communication fault
En vi
ro nm
en t
Surrounding air temperature
-10C to +50C (non-freezing) (LD, ND ratings) -10C to +40C (non-freezing) (SLD, HD ratings)
Surrounding air humidity With circuit board coating (conforming to IEC 60721-3-3 3C2/3S2): 95% RH or less (non-condensing) Storage temperature -20C to +65C Atmosphere Indoors (without corrosive gas, flammable gas, oil mist, dust and dirt, etc.)
Altitude/vibration Maximum 2500 m (For the installation at an altitude above 1000 m, consider a 3% reduction in the rated
current per 500 m increase in altitude.), 2.9 m/s2 or less at 10 to 55 Hz (directions of X, Y, Z axes) Available only when a Vector control compatible option is mounted.
In the initial setting, it is limited to 150% by the torque limit level.
Temperature applicable for a short time, e.g. in transit.
This protective function is not available in the initial status.
86 SPECIFICATIONS
Outline dimension drawings
6
6.3 Outline dimension drawings
6.3.1 Inverter outline dimension drawings FR-A862-05450
FR-A862-06470, FR-A862-08500
(Unit: mm)
(Unit: mm)
185
185
23
12 70 200
540 440
4.5 4.5 200 (70)
(1 5)
13 00
(1 7)
17 12
96
15 13
30
3-12 hole 8-25 hole
185
185
23
12 100 240
680 440
4.5 4.5 240 (100)
(1 5)
15 50
(1 7)
17 15
46
15 15
80
3-12 hole 8-25 hole
SPECIFICATIONS 87
MEMO
88
APPENDIX 89
APPENDIX
APPENDIX provides the reference information for use of this product. Refer to APPENDIX as required.
Appendix 1 For customers replacing the conventional model with this inverter ...........................................................90
Appendix 2 Comparison with FR-A860 ...........................................92 Appendix 3 Instructions for UL and cUL.........................................93 Appendix 4 Restricted Use of Hazardous Substances in
Electronic and Electrical Products..............................95
Appendix 1 For customers replacing the conventional model with this inverter
Appendix 1.1 Replacement of the FR-A700 series Difference and compatibility with FR-A700 series
Item FR-A760 FR-A862
Control method V/F control Advanced magnetic flux vector control Real sensorless vector control Vector control (with plug-in option used)
V/F control Advanced magnetic flux vector control Real sensorless vector control Vector control (with plug-in option used) PM sensorless vector control (IPM motor/SPM motor)
M ax
im um
o ut
pu t f
re qu
en cy V/F control 400 Hz 590 Hz
Advanced magnetic flux vector control
120 Hz 400 Hz
Real sensorless vector control 120 Hz 400 Hz
Vector control 120 Hz 400 Hz
PM sensorless vector control 400 Hz
PID control Turn the X14 signal ON to enable PID control.
When the X14 signal is not assigned, just set a value other than "0" in Pr.128 to enable PID control. When the X14 signal is assigned, turn the X14 signal ON while Pr.128 "0" to enable PID control. The PID pre-charge function and dancer control are added.
Automatic restart after instantaneous power
failure Turn the CS signal ON to enable restart.
CS signal assignment not required. (Restart is enabled with the Pr.57 setting only.)
Number of motor poles V/F control switching
The V/F switchover (X18) signal is valid when Pr.81 = "12 to 20 (2 to 10 poles)".
Pr.81 = "12 (12 poles)" X18 is valid regardless of the Pr.81 setting. (The Pr.81 settings "14 to 20" are not available.)
PTC thermistor input Input from terminal AU (The function of terminal AU is switched by a switch.)
Input from terminal 2. (The function of terminal 2 is switched by the Pr.561 setting.)
USB connector B connector Mini B connector
Control circuit terminal block Removable terminal block (screw type) Removable terminal block (spring clamp type)
Terminal response level The FR-A800's I/O terminals have better response level than the FR-A700's terminals. By setting Pr.289 Inverter output terminal filter and Pr.699 Input terminal filter, the terminal response level can be compatible with that of FR-A700. Set to approximately 5 to 8 ms and adjust the setting according to the system.
PU Standard FR-DU07 (4-digit LED) None (FR-DU07 is not supported.)
Optional FR-PU07 FR-LU08 (LCD) FR-PU07 (Some functions are unavailable.)
Plug-in option Dedicated plug-in options (not interchangeable)
Communication option Connected to the connector 3. Connected to the connector 1.
Installation size Installation size is not compatible. (New mounting holes are required.)
Converter Built in for all capacities The converter unit (FR-CC2) is required.
DC reactor DC reactor is provided. Built in the converter unit (FR-CC2)
Brake unit FR-BU2, MT-BU5 FR-BU2
90 APPENDIX
Installation precautions Removal procedure of the front cover is different. (Refer to page 15.)
Plug-in options of the FR-A700 series are not compatible.
The operation panel (FR-DU07) cannot be used.
Wiring precautions The spring clamp type terminal block has changed to the screw type. Use of blade terminals is recommended.
Instructions for continuous use of the FR-PU07 (parameter unit) manufactured in September 2015 or earlier
For the FR-A800 series, many functions (parameters) have been added. When setting these parameters, the parameter
names and setting ranges are not displayed.
Only the parameter with the numbers up to "999" can be read and set. The parameters with the numbers after "999" cannot
be read or set.
Many protective functions have been added for the FR-A800 series. These functions are available, but all faults are
displayed as "Fault". When the fault history is checked, "ERR" appears. Added faults will not appear on the parameter unit.
(However, MT1 to MT3 are displayed as MT.)
Parameter copy/verification function are not available.
Copying parameter settings Not supported by the setup software FR-SW3-SETUP or older.
Appendix 1.2 Replacement of the FR-A500(L) series Installation precautions Installation size is not compatible. (New mounting holes are required.)
The optional converter unit (FR-CC2) is required.
APPENDIX 91
Appendix 2 Comparison with FR-A860
Item FR-A860 FR-A862
Pr.30 Regenerative function selection
Setting ranges "0 to 2, 10, 11, 20, 21, 100 to 102, 110, 111, 120, 121" Initial value "0"
Setting ranges "2, 10, 11, 102, 110, 111" Initial value "10"
Pr.70 Special regenerative brake duty With the parameter Without the parameter
Monitor function (Pr.52, Pr.54, Pr.158, Pr.774 to Pr.776, Pr.992, Pr.1027 to Pr.1034)
Regenerative brake duty With (Acceptable)
Regenerative brake duty Without (Unacceptable)
Input terminal function selection (Pr.178 to Pr.189)
DC feeding operation permission (X70), DC feeding cancel (X71) With (Acceptable)
DC feeding operation permission (X70), DC feeding cancel (X71) Without (Unacceptable)
Pr.187 MRS terminal function selection Initial value "24" (MRS) Initial value "10" (X10)
Output terminal function assignment selection (Pr.190 to Pr.196, Pr.313 to Pr.322)
Instantaneous power failure/undervoltage (IPF), Regenerative brake pre-alarm (RBP), DC current feeding (Y85), Main circuit capacitor life (Y87), Inrush current limit circuit life (Y89) With (Acceptable)
Instantaneous power failure/undervoltage (IPF), Regenerative brake pre-alarm (RBP), DC current feeding (Y85), Main circuit capacitor life (Y87), Inrush current limit circuit life (Y89) Without (Unacceptable)
Pr.192 IPF terminal function selection Initial value "2" (IPF) Initial value "9999" (No function)
Inrush current limit circuit life display, Main circuit capacitor life display (Pr.256, Pr.258, Pr.259)
With the parameter Without the parameter
Pr.599 X10 terminal input selection Initial value "0" (NO contact specification) Initial value "1" (NC contact specification)
Pr.872 Input phase loss protection selection With the parameter Without the parameter
Warning, protective functions
Regenerative brake pre-alarm (RB), Instantaneous power failure (E.IPF), Undervoltage (E.UVT), Input phase loss (E.ILF), Brake transistor alarm detection (E.BE), Inrush current limit circuit fault (E.IOH) Available
Regenerative brake pre-alarm (RB), Instantaneous power failure (E.IPF), Undervoltage (E.UVT), Input phase loss (E.ILF), Brake transistor alarm detection (E.BE), Inrush current limit circuit fault (E.IOH) Not available
92 APPENDIX
Appendix 3 Instructions for UL and cUL (Standard to comply with: UL 508C, CSA C22.2 No.274-13)
General Precaution CAUTION - Risk of Electric Shock -
The bus capacitor discharge time is 10 minutes. Before starting wiring or inspection, switch power off, wait for more than 10
minutes, and check for residual voltage between terminal P/+ and N/- with a meter etc., to avoid a hazard of electrical shock.
ATTENTION - Risque de choc lectrique -
La dure de dcharge du condensateur de bus est de 10 minutes. Avant de commencer le cblage ou linspection, mettez
lappareil hors tension et attendez plus de 10 minutes.
Installation The FR-A802 inverters with the below types of converter unit have been approved as products for use in enclosure.
Design the enclosure so that the surrounding air temperature, humidity and ambience of the inverter will satisfy the
specifications. (Refer to page 17.)
Wiring protection For installation in the United States, Class T, Class J, Class CC, or Class L fuse must be provided, in accordance with the
National Electrical Code and any applicable local codes.
For installation in Canada, Class T, Class J, Class CC, or Class L fuse must be provided, in accordance with the Canadian
Electrical Code and any applicable local codes.
Wiring to the power supply and the motor Refer to the National Electrical Code (Article 310) regarding the allowable current of the cable. Select the cable size for 125%
of the rated current according to the National Electrical Code (Article 430).
For wiring the input (R/L1, S/L2, T/L3) terminals of the converter unit and output (U, V, W) terminals of the inverter, use the UL
listed copper, stranded wires (rated at 75C) and round crimp terminals. Crimp the terminals with the crimping tool
recommended by the terminal manufacturer.
Short circuit ratings Suitable for use in a circuit capable of delivering not more than 100 kA rms symmetrical amperes, 600 V maximum.
FR-CC2-[ ] C355K C400K C560K Rated fuse voltage (V) 575 V or more
Fuse allowable rating (A) 700 800 1000
APPENDIX 93
Motor overload protection When using the electronic thermal relay function as motor overload protection, set the rated motor current in Pr.9 Electronic thermal O/L relay.
NOTE The internal accumulated heat value of the electronic thermal relay function is reset by inverter power reset and reset signal
input. Avoid unnecessary reset and power-OFF.
Install an external thermal relay (OCR) between the inverter and motors to operate several motors, a multi-pole motor or a
dedicated motor with one inverter. Note that the current indicated on the motor rating plate is affected by the line-to-line
leakage current (refer to page 56) when selecting the setting for an external thermal relay.
The cooling effect of the motor drops during low-speed operation. Use a thermal protector or a motor with built-in thermistor.
When the difference between the inverter and motor capacities is large and the setting is small, the protective characteristics
of the electronic thermal relay function will be deteriorated. In such case, use an external thermal relay.
A dedicated motor cannot be protected by an electronic thermal O/L relay. Use an external thermal relay.
Motor over temperature sensing is not provided by the drive.
Operation characteristics of electronic thermal relay function This function detects the overload (overheat) of the motor
and trips the inverter by stopping the operation of the
transistor at the inverter output side. (The operation
characteristic is shown on the left.)
When a value 50% of the inverter rated output current
(current value) is set in Pr.9 The % value denotes the percentage to the rated inverter
current. It is not the percentage to the rated motor current.
Transistor protection is activated depending on the
temperature of the heat sink. The protection may be
activated even with less than 150% depending on the
operating conditions.230
52.5% 105%
50 100 150
60
120
180
240
50
60
70
Pr.9 = 50% setting of inverter rating1, 2
Pr.9 = 100% setting of inverter rating2
6 Hz
20 Hz 10 Hz
6 Hz
0.5 Hz
30 Hz or more30 Hz
or more 20 Hz 10 Hz
0.5 Hz
Range for the transistor protection3
Se co
nd d
is pl
ay in
th is
ra ng
e M
in ut
e di
sp la
y in
th is
ra ng
e
O pe
ra tio
n tim
e (m
in )
O pe
ra tio
n tim
e (s
)
Characteristic when electronic thermal relay function for motor protection is turned off (When Pr.9 setting is 0(A))
Inverter output power (%) (% to the inverter rated current)
Operation region Region on the right of characteristic curve Non-operation region Region on the left of characteristic curve
94 APPENDIX
APPENDIX 95
Appendix 4 Restricted Use of Hazardous Substances in Electronic and Electrical Products
The mark of restricted use of hazardous substances in electronic and electrical products is applied to the product as follows
based on the Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic
Products of the People's Republic of China.
SJ/T11364 GB/T26572
GB/T26572
(Pb)
(Hg)
(Cd)
(Cr(VI))
(PBB)
(PBDE)
96
WARRANTY
When using this product, make sure to understand the warranty described below.
1. Warranty period and coverage We will repair any failure or defect (hereinafter referred to as "failure") in our FA equipment (hereinafter referred to as the "Product") arisen during warranty period at no charge due to causes for which we are responsible through the distributor from which you purchased the Product or our service provider. However, we will charge the actual cost of dispatching our engineer for an on-site repair work on request by customer in Japan or overseas countries. We are not responsible for any on-site readjustment and/or trial run that may be required after a defective unit are repaired or replaced.
[Term] The term of warranty for Product is twelve months after your purchase or delivery of the Product to a place designated by you or eighteen months from the date of manufacture whichever comes first ("Warranty Period"). Warranty period for repaired Product cannot exceed beyond the original warranty period before any repair work.
[Limitations] (1) You are requested to conduct an initial failure diagnosis by yourself, as a general rule. It can also be carried out by us or our service company upon your
request and the actual cost will be charged. However, it will not be charged if we are responsible for the cause of the failure.
(2) This limited warranty applies only when the condition, method, environment, etc. of use are in compliance with the terms and conditions and instructions that are set forth in the instruction manual and user manual for the Product and the caution label affixed to the Product.
(3) Even during the term of warranty, the repair cost will be charged on you in the following cases; a failure caused by your improper storing or handling, carelessness or negligence, etc., and a failure caused by your hardware or software problem a failure caused by any alteration, etc. to the Product made on your side without our approval a failure which may be regarded as avoidable, if your equipment in which the Product is incorporated is equipped with a safety device required by
applicable laws and has any function or structure considered to be indispensable according to a common sense in the industry a failure which may be regarded as avoidable if consumable parts designated in the instruction manual, etc. are duly maintained and replaced any replacement of consumable parts (condenser, cooling fan, etc.) a failure caused by external factors such as inevitable accidents, including without limitation fire and abnormal fluctuation of voltage, and acts of
God, including without limitation earthquake, lightning and natural disasters a failure generated by an unforeseeable cause with a scientific technology that was not available at the time of the shipment of the Product from our
company any other failures which we are not responsible for or which you acknowledge we are not responsible for
2. Term of warranty after the stop of production (1) We may accept the repair at charge for another seven (7) years after the production of the product is discontinued. The announcement of the stop of
production for each model can be seen in our Sales and Service, etc. (2) Please note that the Product (including its spare parts) cannot be ordered after its stop of production.
3. Service in overseas Our regional FA Center in overseas countries will accept the repair work of the Product; however, the terms and conditions of the repair work may differ depending on each FA Center. Please ask your local FA center for details.
4. Exclusion of loss in opportunity and secondary loss from warranty liability Regardless of the gratis warranty term, Mitsubishi Electric shall not be liable for compensation to: (1) Damages caused by any cause found not to be the responsibility of Mitsubishi Electric. (2) Loss in opportunity, lost profits incurred to the user by Failures of Mitsubishi Electric products. (3) Special damages and secondary damages whether foreseeable or not, compensation for accidents, and compensation for damages to products other
than Mitsubishi Electric products. (4) Replacement by the user, maintenance of on-site equipment, start-up test run and other tasks.
5. Change of Product specifications Specifications listed in our catalogs, manuals or technical documents may be changed without notice.
6. Application and use of the Product (1) For the use of our product, its applications should be those that may not result in a serious damage even if any failure or
malfunction occurs in product, and a backup or fail-safe function should operate on an external system to product when any failure or malfunction occurs.
(2) Our product is designed and manufactured as a general purpose product for use at general industries. Therefore, applications substantially influential on the public interest for such as atomic power plants and other power plants of electric power companies, and also which require a special quality assurance system, including applications for railway companies and government or public offices are not recommended, and we assume no responsibility for any failure caused by these applications when used. In addition, applications which may be substantially influential to human lives or properties for such as airlines, medical treatments, railway service, incineration and fuel systems, man-operated material handling equipment, entertainment machines, safety machines, etc. are not recommended, and we assume no responsibility for any failure caused by these applications when used. We will review the acceptability of the abovementioned applications, if you agree not to require a specific quality for a specific application. Please contact us for consultation.
97
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Before using the enclosed CD-ROM The copyright and other rights of the enclosed CD-ROM all belong to Mitsubishi Electric Corporation.
No part of the enclosed CD-ROM may be copied or reproduced without the permission of Mitsubishi Electric Corporation.
Specifications of the enclosed CD-ROM are subject to change for modification without notice.
We are not responsible for any damages and lost earnings, etc. from use of the enclosed CD-ROM.
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Any trade names and product names of companies herein are all trademarks or registered trademarks of those respective
companies.
Warranty
We do not provide a warranty against defects in the enclosed CD-ROM and related documents.
NOTE This is a personal computer dedicated CD-ROM. Do not attempt to play it on ordinary audio devices. The loud volume may
damage hearing and speakers.
System requirements for the enclosed CD-ROM The following system is required to read instruction manuals contained in the enclosed CD-ROM.
Operating method of the enclosed CD-ROM How to read instruction manuals
Step 1. Start a personal computer and place the enclosed CD-ROM in the CD-ROM drive.
Step 2. The main window automatically opens by the web browser.
Step 3. Choose your language from a language select menu.
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Step 5. PDF manual you clicked opens.
Manual opening of the enclosed CD-ROM
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Step 3. The main window opens by the web browser. Follow the instructions from Step 3 of "How to read instruction
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PDF data of the instruction manual are stored in "MANUAL" folder on the enclosed CD-ROM.
Item Specifications OS Microsoft Windows 10, Windows 8.1, Windows 8, Windows 7, Windows Vista
CPU Intel Pentium or better processor
Memory 128 MB of RAM
Hard disk 90 MB of available hard-disk space
CD-ROM drive Double speed or more (more than quadruple speed is recommended)
Monitor 800600 dots or more
Application Adobe Reader 7.0 or higher
Internet Explorer 6.0 or higher
98
REVISIONS
*The manual number is given on the bottom left of the back cover.
Revision Date *Manual Number Revision May 2016 IB(NA)-0600639ENG-A First edition
Mar. 2019 IB(NA)-0600639ENG-B Addition Application of caution labels
Modification Removal and reinstallation of the control circuit terminal block
IB(NA)-0600639ENG-B
1 BCN-C22005-971
FR-A800/A800 Plus Series Instruction Manual Supplement
1 Internal storage device fault (E.PE6) The operation of the storage device in the inverter can be checked. If a data fault occurs in the storage device in the inverter, the protective function (E.PE6) is activated. When the read value of Pr.890 is "7" or smaller, an inverter reset after All parameter clear can return the operation to normal. (The parameters that had been changed before All parameter clear must be set again.)
*1 For example, when parameter clear, All parameter clear, Parameter copy, or offline auto tuning is performed in the inverter, or when parameter batch write is performed in FR Configurator2.
NOTE "E.PE6" does not activate the retry function. "E.PE6" outputs the Fault output 3 (Y91) signal. "E.PE6" turns OFF the Safety monitor output (SAFE) signal. "E.PE6" is not cleared by turning ON the Fault clear (X51) signal. "E.PE6" is not activated during emergency drive operation. The communication data code for "E.PE6" is 172 (HAC).
Checking faulty area in the internal storage device When E.PE6 occurs, faulty area in the internal storage device can be checked by reading Pr.890.
Use the read value of Pr.890 to check the faulty area. The following table shows faulty areas indicated by the read value of Pr.890. Some read values indicate that there are multiple
faulty areas. (For example, the read value "7" indicates that all the areas described in No. 1 to No. 3 are faulty.)
Operation panel indication E.PE6 FR-LU08
indication Fault
Name Internal storage device fault
Description This protective function is activated by an inverter reset if writing data fails due to power-OFF or a data fault occurs in the storage device during parameter operations*1.
Check point Check if the power was turned OFF during parameter operations.
Corrective action
Check the power supply or the devices on the power system to check that the devices have no fault. When E.PE6 occurs due to power-OFF during parameter operations:
Check the read value of Pr.890. When the value is "7" or smaller, perform All parameter clear and then an inverter reset. The parameters that had been changed before All parameter clear must be set again.
When E.PE6 occurs due to other reason (such as turning OFF/ON the power or an inverter reset): Contact your sales representative.
Pr. Name Initial value Setting range Description 890 H325
Internal storage device status indication 0 (0 to 9999) A faulty area detected by self-check function can be
indicated in the internal storage device.
No. Read value Description
1 1, 3, 5, 7
Storage area other than the area for parameter settings is faulty (such as area for the set frequency). (When All parameter clear is performed, the set frequency, remotely-set frequency, host name for Ethernet communication, position pulse, multi-revolution counter, and offline auto tuning data are cleared.)
2 2, 3, 6, 7 Storage area for standard parameter settings is faulty. 3 4, 5, 6, 7 Storage area for communication parameter settings is faulty. 4 8 to 9999 Area for manufacturer setting
Pr.890 read Pr.890 setting read
BCN-C22005-971_ENG.fm 1
INVERTER
IN VER
TER A
800-E FR
-A 862-E IN
STR U
C TIO
N M
A N
U A
L (H A
R D
W A
R E)
B
INTRODUCTION 1
INSTALLATION AND WIRING 2
PRECAUTIONS FOR USE OF THE INVERTER 3
PROTECTIVE FUNCTIONS 4
PRECAUTIONS FOR MAINTENANCE AND
INSPECTION 5
SPECIFICATIONS 6
HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
IB(NA)-0600639ENG-B(1903)MEE Printed in Japan Specifications subject to change without notice.
A800-E FR-A862-E (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE)
FR-A862-05450 to 08500-E High functionality and high performance
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