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Mitsubishi A800-GF FR-A842-12120-500K-GF Inverter Instruction Manual PDF

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Summary of Content for Mitsubishi A800-GF FR-A842-12120-500K-GF Inverter Instruction Manual PDF

INVE

IN VER

TER A

800 FR

-A 802-G

F IN STR

U C

TIO N

M A

N U

A L (H

A R

D W

A R

E)

CIB(NA)-0600602ENG-C(1905)MEE Printed in Japan Specifications subject to change without notice.

A800 FR-A80 INSTR FR-A842

HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

RTER -GF 2-GF (SEP UCTION

-07700(315K)

INTRODUCTION 1

INSTALLATION AND WIRING 2

PRECAUTIONS FOR USE OF THE INVERTER 3

PROTECTIVE FUNCTIONS 4

PRECAUTIONS FOR MAINTENANCE AND

INSPECTION 5

SPECIFICATIONS 6

ARATED CONVERTER TYPE) MANUAL (HARDWARE)

to 12120(500K)-GF

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-A802 (separated converter type) that are different from the FR-A800. Information about the software, such as basic operations and parameters, is described in the FR-A800 Instruction Manual (Detailed) in the CD-ROM enclosed with the product. 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 this product until you have read through this Instruction Manual (Detailed) and supplementary documents carefully and can use the equipment correctly. Do not use this product until you have a full knowledge of this product mechanism, 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 (Detailed), 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.

The level may even lead to a serious consequence according to conditions. Both instruction levels must be followed because these are important to personal safety.

WARNING Do not remove the front cover or the wiring cover while the

power of this product is ON, and do not run this product with the front cover or the wiring cover removed as the exposed high voltage terminals or the charging part of the circuitry can be touched. Otherwise you may get an electric 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, LED indication of the operation

panel 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 product 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). A neutral-point earthed (grounded) power supply inverter in compliance with EN standard must be used. Any person who is involved in wiring or inspection of this product

shall be fully competent to do the work. This product body must be installed before wiring. Otherwise you

may get an electric shock or be injured. Do not touch the setting dial or keys with wed hands. Doing so

may cause 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 as 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. Before wiring or inspection for a PM motor, confirm that the PM

motor is stopped as a PM motor is a synchronous motor with high-performance magnets embedded inside and high-voltage is generated at the motor terminals while the motor is running even after the power of this product is turned OFF. In an application, such as fan and blower, that the motor may be driven by the load, connect a low-voltage manual contactor at this product output side and keep it open during wiring and inspection of this product. 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.). Installing it to or near flammable material may cause a fire. If the inverter becomes 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. There is a possibility of explosion, damage, or fire if this product is used without inspection.

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 an explosion or

damage 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 burns.

CAUTION Transportation and installation To prevent injury, wear cut-resistant gloves when opening

packaging with sharp tools. Use proper lifting techniques or a trolley when carrying products. 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 a surface that withstands the

weight of the inverter. Do not install the product on a hot surface. Ensure the mounting orientation of this product is correct. Ensure this product is mounted securely in its enclosure. 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, ND (initial setting), and

HD models must be between 0 and +50C (non-freezing). The surrounding air temperature for SLD must be between 0 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. Do not use this product at an altitude above 2500 m. Vibration

should not exceed 2.9 m/s2 at 10 to 55 Hz in X, Y, and Z directions. Otherwise this product may be damaged. (For the installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude.) If halogens (including fluorine, chlorine, bromine, and iodine)

contained in fumigants for wood packages enter this product, the product may be damaged. Prevent the entry of fumigant residuals or use an alternative method such as heat disinfection. Note that sterilization or disinfection of wood packages should be performed before packing the product.

Wiring Do not install a power factor correction capacitor, surge

absorber, or radio noise filter on the output side of this product. These devices may overheat or burn out. The output terminals (terminals U, V, and W) must be connected

to a motor 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 a commercial power supply.

Connecting a commercial power supply to the input terminals (U, V, W) of a PM motor will burn it out. The PM motor must be connected with the output terminals (U, V, W) of the inverter.

Test operation 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 Stay away from the equipment when the retry function is set as it

will restart suddenly after a trip.

Since pressing a 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. Otherwise the life of the inverter decreases. 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 precautions 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 400V class motor with the inverter, the motor

must be an insulation-enhanced motor or measures must be taken to suppress surge voltage. Otherwise surge voltage, which is attributed to the length and thickness of wire, may occur at the motor terminals, causing the motor insulation to deteriorate. 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. This product's brake function cannot be used as a mechanical

brake. Use a separate device instead. Perform an inspection and test operation of this product if it has

been stored for a long period of time. Static electricity in your body must be discharged beforeyou

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.

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. If the breaker installed on the input side of this product trips,

check for wiring faults (short circuits etc.) and damage to internal parts of this product. Identify and remove the cause of the trip before resetting the tripped breaker and applying the power to the product again. When a protective function activates, 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 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 a motor different from those intended for the 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. IM LED is ON during induction motor control. Do not drive a PM motor.

PM motor control setting The inverter is set for the PM motor control. PM LED is ON during PM motor control. Do not drive 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 operation panel or the front covers 15

2.3 Installation and enclosure design 17 2.3.1 Inverter installation environment .................................................................................................................... 17

2.3.2 Amount of heat generated by the inverter ...................................................................................................... 20

2.3.3 Cooling system types for inverter enclosure .................................................................................................. 21

2.3.4 Inverter installation ......................................................................................................................................... 22

2.3.5 Protruding the heat sink through the panel .................................................................................................... 24

2.4 Terminal connection diagrams 26

2.5 Main circuit terminals 30 2.5.1 Details on the main circuit terminals of the inverter........................................................................................ 30

2.5.2 Details on the main circuit terminals of the converter unit (FR-CC2) ............................................................. 30

2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor ..................................... 31

2.5.4 Applicable cables and wiring length ............................................................................................................... 32

2.5.5 Earthing (grounding) precautions ................................................................................................................... 35

2.6 Control circuit 36 2.6.1 Details on the control circuit terminals of the inverter..................................................................................... 36

2.6.2 Details on the control circuit terminals of the converter unit (FR-CC2) .......................................................... 40

2.6.3 Control logic (sink/source) change ................................................................................................................. 41

2.6.4 Wiring of inverter control circuit ...................................................................................................................... 43

2.6.5 Wiring precautions.......................................................................................................................................... 45

2.6.6 When using separate power supplies for the control circuit and the main circuit........................................... 46

2.6.7 When supplying 24 V external power to the control circuit............................................................................. 47

2.6.8 Safety stop function........................................................................................................................................ 49

2.7 Communication connectors and terminals 51 2.7.1 PU connector.................................................................................................................................................. 51

2.7.2 CC-Link IE Field Network function ................................................................................................................. 52

2.7.3 USB connector ............................................................................................................................................... 54

2.7.4 RS-485 terminal block .................................................................................................................................... 55

2.8 Connection of motor with encoder (vector control) 56

2.9 Parameter settings for a motor with encoder 62

2.10 Connection of stand-alone option units 63 2.10.1 Connection of the brake unit (FR-BU2) .......................................................................................................... 63

4 CONTENTS

2.10.2 Connection of the high power factor converter (FR-HC2) ..............................................................................64

2.10.3 Connection of the power regeneration converter (MT-RC).............................................................................65

3 PRECAUTIONS FOR USE OF THE INVERTER 67 3.1 Electro-magnetic interference (EMI) and leakage currents 68

3.1.1 Leakage currents and countermeasures ........................................................................................................68

3.1.2 Countermeasures against inverter-generated EMI.........................................................................................71

3.1.3 Converter unit (FR-CC2) built-in EMC filter ....................................................................................................74

3.2 Power supply harmonics 75 3.2.1 Power supply harmonics.................................................................................................................................75

3.2.2 Harmonic Suppression Guidelines in Japan...................................................................................................76

3.3 Installation of a reactor 78

3.4 Power-OFF and magnetic contactor (MC) 79

3.5 Countermeasures against deterioration of the 400 V class motor insulation 80

3.6 Checklist before starting operation 81

3.7 Failsafe system which uses the inverter 84

4 PROTECTIVE FUNCTIONS 87 4.1 Inverter fault and alarm indications 88

4.2 Reset method for the protective functions 88

4.3 Check and clear of the fault history 89

4.4 List of fault displays 91

5 PRECAUTIONS FOR MAINTENANCE AND INSPECTION 93

5.1 Inspection item 94 5.1.1 Daily inspection...............................................................................................................................................94

5.1.2 Periodic inspection..........................................................................................................................................94

5.1.3 Daily and periodic inspection ..........................................................................................................................95

5.1.4 Checking the inverter and converter semiconductor devices .........................................................................96

5.1.5 Cleaning..........................................................................................................................................................97

5.1.6 Replacement of parts......................................................................................................................................97

5.1.7 Removal and reinstallation of the control circuit terminal block ......................................................................99

5.2 Measurement of main circuit voltages, currents and powers 101 5.2.1 Measurement of powers ...............................................................................................................................103

5.2.2 Measurement of voltages .............................................................................................................................103

5.2.3 Measurement of currents..............................................................................................................................103

CONTENTS 5

5.2.4 Example of measuring converter unit (FR-CC2) input power factor............................................................. 103

5.2.5 Measurement of converter output voltage (across terminals P and N) ........................................................ 103

5.2.6 Measurement of inverter output frequency................................................................................................... 104

5.2.7 Insulation resistance test using megger ....................................................................................................... 104

5.2.8 Pressure test ................................................................................................................................................ 104

6 SPECIFICATIONS 105 6.1 Inverter rating 106

6.2 Common specifications 107

6.3 Outline dimension drawings 109

APPENDIX 111 Appendix 1 For customers replacing the conventional model with this inverter................................ 112 Appendix 2 Comparison with FR-A840.................................................................................................... 114 Appendix 3 Instructions for compliance with the EU Directives........................................................... 115 Appendix 4 Instructions for UL and cUL ................................................................................................. 118 Appendix 5 Instructions for EAC.............................................................................................................. 120 Appendix 6 Restricted Use of Hazardous Substances in Electronic and Electrical Products ........... 121 Appendix 7 Referenced Standard (Requirement of Chinese standardized law).................................. 121

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

DU...................................................Operation panel (FR-DU08)

Operation panel ..............................Operation panel (FR-DU08) and LCD operation panel (FR-LU08)

Parameter unit ................................Parameter unit (FR-PU07)

PU...................................................Operation panel and parameter unit

Inverter............................................Mitsubishi Electric inverter FR-A800 series (Separated converter type)

Vector control compatible option.....FR-A8AP/FR-A8AL/FR-A8APA/FR-A8APR/FR-A8APS (plug-in option), FR-

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 Corporation.

MODBUS is a registered trademark of SCHNEIDER ELECTRIC USA, INC.

Other company and product names herein are the trademarks and registered trademarks of their respective

owners.

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 41.)

Harmonic Suppression Guidelines All the models of the inverters used by specific consumers are covered by "the Harmonic Suppression Guidelines for Consumers Who Receive High Voltage or Special High Voltage". For the details, refer to page 76.

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.

Applicable inverter model

Specification differs by the type as follows.

Conforming to IEC 60721-3-3 3C2/3S2

NOTE In this Instruction Manual, the inverter model name consists of the applicable motor capacity and the rated current.

(Example) FR-A842-07700(315K)

How to read the SERIAL number

Type Monitor output Initial setting

Control logic Rated frequency

Pr.19 Base frequency voltage

FM (terminal FM equipped model)

Terminal FM (pulse train output) Terminal AM (analog voltage output (0 to 10 VDC))

Sink logic 60 Hz 9999 (same as the power supply voltage)

CA (terminal CA equipped model)

Terminal CA (analog current output (0 to 20 mA DC)) Terminal AM (analog voltage output (0 to 10 VDC))

Source logic 50 Hz 8888 (95% of the power supply voltage)

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

Rating plate

Input rating

Output rating

SERIAL

Inverter model

GF

Country of origin

F R - A 8 4 2 - 07700 - 1 -

400 V class Symbol Voltage class

4 CA

Symbol Type1

FM 2 1

Symbol Circuit board coating2

WithoutNone

With With

Plated conductor Without

With Without

06 60

Symbol Description

315K to 500K Inverter ND rated capacity (kW) 07700 to 12120 Inverter SLD rated current (A)

Symbol Structure, functionality Separated converter type2

Symbol

GF

Structure, functionality With built-in CC-Link IE Field Network function

8 INTRODUCTION

Inverter component names

1

1.2 Inverter component names Component names are shown below.

Symbol Name Description Refer to page

(a) RS-485 terminals Enables RS-485 communication. 55 (b) Plug-in option connector 2

Connects a plug-in option or a communication option. Instruction Manual of the option(c) Plug-in option connector 3

(d) Voltage/current input switch Selects between voltage and current for the terminal 2 and 4 inputs.

(e) Control circuit terminal block Connects cables for the control circuit. 36

(f) PU connector Connects the operation panel (FR-DU08) or the parameter unit (FR- PU07). This connector also enables the RS-485 communication.

51

(g) USB A connector Connects a USB memory device. 54

(h) USB mini B connector Connects a personal computer and enables communication with FR Configurator2.

54

(i) Upper front cover Remove this cover for the installation of the product, installation of a plug-in (communication) option, RS-485 terminal wiring, switching of the voltage/current input switch, etc.

15

(j) Power lamp Stays ON while the power is supplied to the control circuit (R1/L11, S1/ L21).

31

(k) Alarm lamp Turns ON when the protective function of the inverter is activated. 87 (l) Charge lamp Stays ON while the power is supplied to the main circuit. 31 (m) Operation panel (FR-DU08) Operates and monitors the inverter.

(n) Lower front cover Remove this cover for wiring. 15 (o) Main circuit terminal block Connects cables for the main circuit. 30 (p) Cooling fan Cools the inverter. 98

(q) CC-Link IE Field Network communication connector

For an Ethernet cable which connects to the network. 53

(r) Operation status indication LED Indicates the CC-Link IE Field Network communication status. 10

(f)

(e)

(d)

(o)

(j)

(l)

(a)

(c)

(q)

(b)

(m)

(k)

(i)

(n)

(g) (h)

(p)

(s)

(r)

INTRODUCTION 9

About the related manuals

Refer to the FR-A800 Instruction Manual (Detailed)

Operation status LEDs

1.3 About the related manuals The manuals related to FR-A800 are shown below.

(s) Switches for manufacturer setting (SW3) Do not change the initial setting (OFF ).

Manual name Manual number FR-A800 Instruction Manual (Detailed) IB-0600503ENG

FR-CC2 Instruction Manual IB-0600543ENG

FR Configurator2 Instruction Manual IB-0600516ENG

FR-A800/F800 PLC Function Programming Manual IB-0600492ENG

FR-A800/F800 Safety stop function instruction manual BCN-A23228-001

Symbol Name Description Refer to page

OFF ON

SD ERR L.ERRRD

D LINKRUN

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 using the equipment.

2.1 Peripheral devices ....................................................................12 2.2 Removal and reinstallation of the operation panel or the

front covers ...............................................................................15 2.3 Installation and enclosure design...........................................17 2.4 Terminal connection diagrams................................................26 2.5 Main circuit terminals ...............................................................30 2.6 Control circuit ...........................................................................36 2.7 Communication connectors and terminals ............................51 2.8 Connection of motor with encoder (vector control) ..............56 2.9 Parameter settings for a motor with encoder ........................62 2.10 Connection of stand-alone option units .................................63

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 or surge suppressor or capacitor type filter on the inverter's output side. 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 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. In this case, activating the EMC filter of the converter unit may minimize interference. (Refer to page 74.)

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/+ N/-P/+

P/+ P/+ PR

PR

: 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

(l) Noise filter (FR-BSF01, FR-BLF)

(n) Contactor Example) No-fuse switch (DSN type)

(o) PM motor

(g) Noise filter

(h) High power factor converter (FR-HC2)

(j) Resistor unit (MT-BR5)

(i) Brake unit (FR-BU2)

(e) Magnetic contactor (MC)

(a) Inverter (FR-A802)

(b) Converter unit (FR-CC2)

(c) Three-phase AC power supply

(k) USB connector

Personal computer (FR Configurator 2)

USB

USB host (A connector)

USB device (Mini B connector)

Communication status indicator (LED)(USB host)

Earth (Ground)

(m) Induction motor

(f) AC reactor (FR-HAL)

IM connection PM connection Earth

(Ground)

(P) Programmable controller (QJ71GF11-T2, etc.)

Ethernet cable

12 INSTALLATION AND WIRING

Peripheral devices

2

Symbol Name Overview Refer

to page

(a) Inverter (FR-A802)

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. The converter unit built-in EMC filter can reduce the noise.

17 26 74

(b) Converter unit (FR-CC2)

(c) Three-phase AC power supply Must be within the permissible power supply specifications of the converter unit.

106

(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.

79

(f) AC reactor (FR-HAL)

Install this to suppress harmonics and to improve the power factor. An AC reactor (FR-HAL) (option) 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.

78

(g) Noise filter Suppresses the noise radiated from the power supply side of the converter unit.

71

(h) High power factor converter (FR-HC2) Suppresses the power supply harmonics significantly. Install these options as required. When FR-HC2 is used, FR-CC2 is not required.

64

(i) Brake unit (FR-BU2) Allows the inverter to provide the optimal regenerative braking capability. Install these options as required.

63 (j) Resistor unit (MT-BR5)

(k) USB connection A USB (Ver. 1.1) cable connects the inverter with a personal computer. A USB memory device enables parameter copies and the trace function.

54

(l) 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 MHz to 5 MHz.

71

(m) Induction motor Connect a squirrel-cage induction motor.

(n) 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).

(o) PM motor A PM motor can be used. A PM motor cannot be driven by the commercial power supply.

(p) Programmable controller (QJ71GF11-T2, etc.)

Allows the inverter to be operated or monitored, or the parameter setting to be changed via the CC-Link IE Field Network.

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 Mitsubishi Electric 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 table below to prepare appropriate peripheral devices.

400 V class

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.

Motor capacity (kW)

Converter unit

FR-CC2-[ ]

Inverter

SLD (superlight duty) LD (light duty) ND (normal duty, initial value) HD (heavy duty)

Model FR-A842-[ ]

Rated current

(A)

Model FR-A842-[ ]

Rated current

(A)

Model FR-A842-[ ]

Rated current

(A)

Model FR-A842-[ ]

Rated current

(A) 280 H315 - - - - - - - - - 315K 07700 547

315 H315K - - - - - - 315K 07700 610 355K 08660 610

355 H355K - - - 315K 07700 683 355K 08660 683 400K 09620 683

400 H400K 315K 07700 770 355K 08660 770 400K 09620 770 450K 10940 770

450 H450K 355K 08660 866 400K 09620 866 450K 10940 866 500K 12120 866

500 H500K 400K 09620 962 450K 10940 962 500K 12120 962 - - -

560 H560K 450K 10940 1094 500K 12120 1094 - - - - - -

630 H630K 500K 12120 1212 - - - - - - - - -

Motor output (kW)

Applicable converter model

Molded case circuit breaker (MCCB) or

earth leakage circuit breaker (ELB) (NF, NV type)

Input-side magnetic contactor

315 FR-CC2-H315K 700 A S-N600

355 FR-CC2-H355K 800 A S-N600

400 FR-CC2-H400K 900 A S-N800

450 FR-CC2-H450K 1000 A 1000 A rated product

500 FR-CC2-H500K 1200 A 1000 A rated product

560 FR-CC2-H560K 1500 A 1200 rated product

630 FR-CC2-H630K 2000 A 1400 rated product

Assumes the use of a Mitsubishi Electric 4-pole standard motor with the power supply voltage of 400 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 118, and select the 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 operation panel or the front covers

2

2.2 Removal and reinstallation of the operation panel or the front covers

Removal and reinstallation of the operation panel

Removal of the lower front cover

(a) When the mounting screws are removed, the lower front cover can be removed. (The number of the mounting screws differs by the capacity.)

(b) With the lower front cover removed, the main circuit terminals can be wired.

Loosen the two screws on the operation panel.

(These screws cannot be removed.)

Push the upper part of the operation panel and pull the

operation panel to remove.

To reinstall the operation panel, align its connector on the back with the PU connector of the inverter, and insert the operation

panel. After confirming that the operation panel is fit securely, tighten the screws. (Tightening torque: 0.40 to 0.45 Nm)

(a) (b)

INSTALLATION AND WIRING 15

Removal and reinstallation of the operation panel or the front covers

Removal of the upper front cover

(a) With the lower front cover removed, loosen the mounting screws on the upper front cover. (These screws cannot be removed.) (b) While holding the areas around the installation hooks on the sides of the upper front cover, pull out the cover using its upper side

as a support. (c) With the upper front cover removed, the control circuit can be wired and the plug-in option can be installed.

Reinstallation of the front cover

(a) Clip on the upper front cover as illustrated. Check that it is properly secured. (b) Tighten the screws on the lower part of the upper front cover. (c) Attach the lower front cover using the screws. The number of screws differs depending on the capacity of the inverter.

NOTE When installing the upper front cover, 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 cover.

(a) (b) (c)

Loosen

(b) (c)(a)

Tighten Tighten

16 INSTALLATION AND WIRING

Installation and enclosure design

2

2.3 Installation 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, e.g. in transit. For installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude.

Temperature The permissible surrounding air temperature of the inverter is between 0C and +50C (0C and +40C at the SLD rating).

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 21.)

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 20.

Item Description

Surrounding air temperature

LD, ND (initial setting), HD 0 to +50C (non-freezing)

SLD 0 to +40C (non-freezing)

Surrounding air humidity With circuit board coating (conforming to class 3C2/3S2 in IEC 60721-3-3): 95% RH or less (non-condensing) Without circuit board coating 90% 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

INSTALLATION AND WIRING 17

Installation and enclosure design

Humidity Operate the inverter within the ambient air humidity of usually 45 to 90% (up to 95% with circuit board coating). 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 insulation distance defined in JEM 1103 "Control Equipment Insulator" is humidity of 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.

Countermeasure

Place the inverter in a totally enclosed enclosure.

Take measures if the in-enclosure temperature rises. (Refer to page 21.)

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 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.

Countermeasure

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.

INSTALLATION AND WIRING 19

Installation and enclosure design

2.3.2 Amount of heat generated by the inverter Installing the heat sink inside the enclosure When the heat sink is installed inside the enclosure, 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 the inverter rated current, and the carrier frequency

is 2 kHz.

Installing the heat sink outside the enclosure When the heat sink is protruded through a panel, the amount of heat generated by the inverter unit and converter unit is

shown in the following tables. (For the details on protruding the heat sink through a panel, refer to page 24.)

NOTE The amount of heat generated shown assumes that the output current is the inverter rated current, and the carrier frequency

is 2 kHz.

Converter FR-CC2-H[] Amount of heat generated (W)

315K 2350 355K 2600 400K 3050 450K 3400 500K 3800 560K 4400 630K 4920

Inverter FR-A842-[]

Amount of heat generated (W) SLD LD ND HD

315K 5800 5050 4450 3900 355K 6690 5800 5100 4410 400K 7370 6480 5650 4930 450K 8600 7340 6500 5650 500K 9810 8630 7400 6490

Converter FR-CC2-H[]

Amount of heat generated (W) Heat sink section (outside of enclosure) Control section (inside of enclosure)

315K 1640 710 355K 1820 780 400K 2130 920 450K 2380 1020 500K 2660 1140 560K 3080 1320 630K 3440 1480

Inverter FR-A842-[]

Amount of heat generated (W) Heat sink section (outside of enclosure) Control section (inside of enclosure)

SLD LD ND HD SLD LD ND HD 315K 4060 3530 3110 2730 1740 1520 1340 1170 355K 4680 4060 3570 3080 2010 1740 1530 1330 400K 5160 4530 3950 3450 2210 1950 1700 1480 450K 6020 5140 4550 3950 2580 2200 1950 1700 500K 6860 6040 5180 4540 2950 2590 2220 1950

20 INSTALLATION AND WIRING

Installation and enclosure design

2

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 cooling

Natural ventilation (enclosed, 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 cooling

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

INSTALLATION AND WIRING 21

Installation and enclosure design

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.

There needs to be a space of at least 30 cm in front of the inverter to replace the cooling fan. Refer to page 98 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

22 INSTALLATION AND WIRING

Installation and enclosure design

2

Encasing multiple inverters and converter units

Arrangement of the ventilation fan and inverter

When multiple inverters and converter units are placed in the

same enclosure, 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

INSTALLATION AND WIRING 23

Installation and enclosure design

2.3.5 Protruding the heat sink through the 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 through the panel.

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-A842-07700(315K),

FR-A842-08660(355K)

(Unit: mm)

FR-A842-09620(400K), FR-A842-10940(450K),

FR-A842-12120(500K)

(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

24 INSTALLATION AND WIRING

Installation and enclosure design

2

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

INSTALLATION AND WIRING 25

Terminal connection diagrams

2.4 Terminal connection diagrams

FM type

Fuse

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

TXD+

TXD-

RXD+

RXD-

Data transmission

GND

RS-485 terminals

S IN

K

S O

U R

C E

STF

STR

STP(STOP)

RH

RM

RL

JOG

RT

MRS X10

RES

AU

CS

SD

RUN

SU

IPF

OL

FU

SE

Data reception

(+) (-)

5

VCC

(+) (-)

5V

Sink logic

Earth (Ground)

N/-

P/+

Initial value

ON OFF

42

Safety stop signal

Safety monitor output

Safety monitor output common

So (SO)

SOC

Safety stop input (Channel 1)

Shorting wire

Safety stop input common

Safety stop input (Channel 2)

S1

S2

PC

SD

SIC

+24

SD

Brake unit (Option)

Jumper

(Permissible load current 100mA)

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

Terminating resistor

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

CC-Link IE Field Network communication connector

Connector for plug-in option connection

PORT2

PORT1

Connector 2

Connector 3

GND (SG)

24V

24V

Output shutoff circuit

26 INSTALLATION AND WIRING

Terminal connection diagrams

2

The terminals R1/L11 and S1/L21 are connected to the terminals P/+ and N/- with a jumper respectively. When using 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 the 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.

The 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.

NOTE To prevent a malfunction due to noise, keep the signal cables 10 cm or more away from the power cables. Also, separate the

main circuit cables at the input side from the main circuit cables at the output side.

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.

INSTALLATION AND WIRING 27

Terminal connection diagrams

CA type

PU connector

USB A connector

USB mini B connector

CC-Link IE Field Network communication connector

Connector for plug-in option connection

PORT2

PORT1

Connector 2

Connector 3

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

Motor

Relay output 1 (Fault output)

C1

B1

A1

U V W

Earth (Ground)

0 to 5VDC selectable

0 to 10VDC

Open collector output

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

TXD+

TXD-

RXD+

RXD-

Data transmission

GND

RS-485 terminals

S IN

K

S O

U R

C E

STF

STR

STP(STOP)

RH

RM

RL

JOG

RT

MRS X10

RES

AU

CS

SD

RUN

SU

IPF

OL

FU

SE

Data reception

(+) (-)

5

VCC

(+) (-)

5V

Sourse logic

Earth (Ground)

N/-

P/+

Initial value

ON OFF

42

Safety stop signal

Safety monitor output

Safety monitor output common

So (SO)

SOC

Safety stop input (Channel 1)

Shorting wire

Safety stop input common

Safety stop input (Channel 2)

S1

S2

PC

SD

SIC

+24

SD

Brake unit (Option)

Jumper

(Permissible load current 100mA)

24V external power supply input

Common terminal

24VDC power supply

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

Voltage/current input switch

selectable

Terminating resistor

Initial value

Initial value

Output stop

24V

24V

Output shutoff circuit

Common for external power supply transistor

(-)

(+) Analog signal output (0 to 10VDC)

(-)

(+) Analog current output (0 to 20mADC)

AM

5

F/C (CA)

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

GND (SG)

Fuse

28 INSTALLATION AND WIRING

Terminal connection diagrams

2

The terminals R1/L11 and S1/L21 are connected to the terminals P/+ and N/- with a jumper respectively. When using 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 the 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.

NOTE To prevent a malfunction due to noise, keep the signal cables 10 cm or more away from the power cables. Also, separate the

main circuit cables at the input side from the main circuit cables at the output side.

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.

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 32.

Do not install an MCCB across the 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 the 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 the terminal RDA of the converter unit and the terminal MRS (X10) of the inverter, and the terminal SE of the converter unit and

the terminal SD (sink logic) of the inverter. Not connecting these terminals may damage the converter unit.

Total wiring length

Across the terminals P and P and the 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

INSTALLATION AND WIRING 29

Main circuit terminals

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 the terminals P/+ and N/-. To retain the fault display and fault output, or to use the converter unit (FR-CC2), remove the jumpers installed in terminals R1/L11 and S1/L21, and apply external power supply to these terminals. The power capacity necessary when separate power is supplied from R1/L11 and S1/L21 is 80 VA.

46

P/+, N/- Converter unit connection Connect the converter unit (FR-CC2), brake unit (FR-BU2), or high power factor converter (FR-HC2).

26, 63

Earth (ground) For earthing (grounding) the inverter chassis. This must be earthed (grounded).

35

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. (When the converter unit is connected to the12-phase rectifier power transformer, refer to the Instruction Manual of the FR-CC2.)

-

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. The power capacity necessary when separate power is supplied from R1/L11 and S1/L21 is 80 VA.

46

P/+, N/- Inverter connection Connect to terminals P/+ and N/- of the inverter. 26

Earth (ground) For earthing (grounding) the converter unit chassis. This must be earthed (grounded).

35

30 INSTALLATION AND WIRING

Main circuit terminals

2

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 the R/L1, S/L2, and T/L3 of the converter unit. (Phase need not be matched.)

Never connect the power cable to the U, V, and W of the inverter. Doing so will damage the inverter.

Connect the motor to the 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 (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.

Converter unit Inverter

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-H315K, H355K FR-CC2-H400K to H500K

Connect the cables here. Connect the cables here.

INSTALLATION AND WIRING 31

Main circuit terminals

2.5.4 Applicable cables and wiring length Select a recommended cable size to ensure that the voltage drop will be 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 at a low speed.

The following table indicates a selection example for the wiring length of 20 m (440 V input power supply).

Converter unit (FR-CC2)

Inverter (ND rating)

Inverter (SLD rating)

Converter model

FR-CC2-H[ ]

Terminal screw Size

Tightening Torque

Nm

Crimping terminal

Cable gauge

HIV cables, etc. (mm2) AWG/MCM

PVC cables, etc. (mm2)

R/L1, S/L2, T/L3

R/L1, S/L2, T/L3

P/+, N/- Earthing

(grounding) cable

R/L1, S/L2, T/L3

R/L1, S/L2, T/L3

Earthing (grounding)

cable 315K M12 (M10) 46 150-12 2150 2150 100 2300 2150 150

355K M12 (M10) 46 C2-200 2200 2200 100 2350 2185 295

400K M12 (M10) 46 C2-200 2200 2200 100 2400 2185 295

450K M12 (M10) 46 C2-250 2250 2250 100 2500 2240 2120

500K M12 (M10) 46 C2-200 3200 3200 2100 2500 2240 2120

560K M12 (M10) 46 C2-200 3200 3200 2100 3350 3185 2150

630K M12 (M10) 46 C2-200 3200 3200 2100 3400 3185 2150

Inverter model

FR-A842-[ ]

Terminal screw size

Tightening Torque

Nm

Crimping terminal

Cable gauge

HIV cables, etc. (mm2) AWG/MCM PVC cables, etc.

(mm2)

U, V, W U, V, W P/+, N/- Earthing

(grounding) cable

U, V, W U, V, W Earthing

(grounding) cable

07700(315K) M12 (M10) 46 150-12 2150 2150 100 2300 2150 150

08660(355K) M12 (M10) 46 C2-200 2200 2200 100 2350 2185 295

09620(400K) M12 (M10) 46 C2-200 2200 2200 100 2400 2185 295

10940(450K) M12 (M10) 46 C2-250 2250 2250 100 2500 2240 2120

12120(500K) M12 (M10) 46 C2-250 2250 3200 2100 2500 2240 2120

Inverter model

FR-A842-[ ]

Terminal screw size

Tightening Torque

Nm

Crimping terminal

Cable gauge

HIV cables, etc. (mm2) AWG/MCM PVC cables, etc.

(mm2)

U, V, W U, V, W P/+, N/- Earthing

(grounding) cable

U, V, W U, V, W Earthing

(grounding) cable

07700(315K) M12 (M10) 46 C2-200 2200 2200 100 2400 2185 295

08660(355K) M12 (M10) 46 C2-250 2250 2250 100 2500 2240 2120

09620(400K) M12 (M10) 46 C2-250 2250 3200 2100 2500 2240 2120

10940(450K) M12 (M10) 46 C2-200 3200 3200 2100 3350 3185 2150

12120(500K) M12 (M10) 46 C2-200 3200 3200 2100 3400 3185 2150

32 INSTALLATION AND WIRING

Main circuit terminals

2

Inverter (LD rating)

Inverter (HD rating)

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 40C or lower and in-enclosure wiring.

The recommended cable size is that of the cable (THHN cable) with continuous maximum permissible temperature of 90C. 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 118.)

The cable size is that of the cable (XLPE cable) with continuous maximum permissible temperature of 90C. It assumes a surrounding air

temperature of 40C or lower and in-enclosure wiring.

(Selection example for use mainly in Europe.

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).

Screw size for earthing (grounding) 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 crimping terminals with insulation sleeves to wire the power supply and motor.

Inverter model

FR-A842-[ ]

Terminal screw size

Tightening Torque

Nm

Crimp terminal

Cable gauge

HIV cables, etc. (mm2) AWG/MCM PVC cables, etc.

(mm2)

U, V, W U, V, W P/+, N/- Earthing

(grounding) cable

U, V, W U, V, W Earthing

(grounding) cable

07700(315K) M12 (M10) 46 C2-200 2200 2200 100 2350 2185 295

08660(355K) M12 (M10) 46 C2-200 2200 2200 100 2400 2185 295

09620(400K) M12 (M10) 46 C2-250 2250 2250 100 2500 2240 2120

10940(450K) M12 (M10) 46 C2-250 2250 3200 2100 2500 2240 2120

12120(500K) M12 (M10) 46 C2-200 3200 3200 2100 3350 3185 2150

Inverter model

FR-A842-[ ]

Terminal screw size

Tightening Torque

Nm

Crimp terminal

Cable gauge

HIV cables, etc. (mm2) AWG/MCM PVC cables, etc.

(mm2)

U, V, W U, V, W P/+, N/- Earthing

(grounding) cable

U, V, W U, V, W Earthing

(grounding) cable

07700(315K) M12 (M10) 46 150-12 2125 2150 100 2250 2120 150

08660(355K) M12 (M10) 46 150-12 2150 2150 100 2300 2150 150

09620(400K) M12 (M10) 46 C2-200 2200 2200 100 2350 2185 295

10940(450K) M12 (M10) 46 C2-200 2200 2200 100 2400 2185 295

12120(500K) M12 (M10) 46 C2-250 2250 2250 100 2500 2240 2120

wire resistance[m/m] wiring distance[m] current[A] 1000

INSTALLATION AND WIRING 33

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.)

When driving a 400 V class motor by the inverter, surge voltages attributable to the wiring constants may occur at the

motor terminals, deteriorating the insulation of the motor. In this case, take one of the following measure.

Use a "400 V class inverter-driven insulation-enhanced motor" and set Pr.72 PWM frequency selection according to

the wiring length.

If the motor capacity is 280 kW or lower, connect the sine wave filter (MT-BSL/BSC) to the output side.

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 400 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 FR-A800 Instruction Manual

(Detailed))

A sine wave filter (MT-BSL/BSC) can be used under V/F control. Do not use the filters under different control methods.

For the details of Pr.72 PWM frequency selection, refer to the Instruction Manual (Detailed).

Refer to page 80 to drive a 400 V class motor by an inverter.

The carrier frequency is limited during PM sensorless vector control. (Refer to the Instruction Manual (Detailed))

Total wiring length

Wiring length 100 m or shorter Wiring length longer than 100 m 6 (6 kHz) or lower 4 (4 kHz) or lower

500 m or less

300 m

300 m

300 m+300 m=600 m

34 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, this earthing (grounding) is important to audio equipment, sensors, computers and

other apparatuses that handle low-level signals or operate very fast.

Earthing (grounding) methods and earthing (grounding) work As described previously, earthing (grounding) is roughly classified into an electrical shock prevention type and a noise-

influenced malfunction prevention type. Therefore, these two types should be clearly distinguished, and the following work

must be done to prevent the leakage current having the inverter's high frequency components from entering the malfunction

prevention type earthing (grounding):

Whenever possible, use the independent earthing (grounding) for the inverter.

If independent earthing (grounding) (I) is not available, use (II) common earthing (grounding) in the figure below where the

inverter is connected with the other equipment at an earthing (grounding) point. Do not use the other equipment's earthing

(grounding) cable to earth (ground) the inverter as shown in (III).

A leakage current containing many high frequency components flows into the earthing (grounding) cables of the inverter

and peripheral devices. Because of this, the inverter must be earthed (grounded) separately from EMI-sensitive devices.

In a high building, it may be effective to use the EMI prevention type earthing (grounding) connecting to an iron structure

frame, and electric shock prevention type earthing (grounding) with the independent earthing (grounding) together.

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 the size indicated in the

table on page 32.

The earthing (grounding) point should be as close as possible to the inverter, and the earth (ground) wire length should

be as short as possible.

Run the earthing (grounding) cable as far away as possible from the I/O wiring of equipment sensitive to noises and run

them in parallel in the minimum distance.

NOTE To be compliant with the EU Directive (Low Voltage Directive), refer to page 115.

InverterConverter unit

Other equipment

(I) Independent earthing (grounding).......Good (II) Common earthing (grounding).......Good

InverterConverter unit

Other equipment

(III) Common earthing (grounding) cable.......Not allowed

InverterConverter unit

Other equipment

INSTALLATION AND WIRING 35

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-A800 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 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 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 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 When contacts are short-circuited: 4 to 6 mADC

MRS (X10)

Output stop (Inverter run enable)

Connect to the 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 the 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 0.1s 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 1s 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.

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.

36 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 FR-A800 Instruction Manual

(Detailed).)

The sink logic is initially set for the FM-type inverter. The source logic is initially set for the CA-type inverter.

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 the terminal 10. Change the input specifications of the terminal 2 in Pr.73 when connecting it to the terminal 10E.

10 VDC 0.4 V Permissible load current 10 mA

10 5 VDC0.5 V 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).

When voltage is input: Input resistance 10 k 1 k Maximum permissible voltage 20 VDC When current is 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

Inputting 0 to 5 VDC or 0 to 10 VDC adds this signal to terminal 2 or 4 frequency setting signal. 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 k 1 k Permissible maximum voltage 20 VDC

5 Frequency setting common

Common terminal for frequency setting signal (terminal 2, 1 or 4) and analog output terminal AM. Do not earth (ground).

T h

er m

is to

r

10 2

PTC thermistor input For receiving PTC thermistor outputs. When PTC thermistor is valid (Pr.561 "9999"), the terminal 2 is not available for frequency setting.

Applicable PTC thermistor specification Overheat detection resistance: 0.5 to 30 k (Set by Pr.561)

P o

w 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

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 Band 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 37

Control circuit

Terminal FM is provided in the FM-type inverter.

Terminal CA is provided in the CA-type inverter.

O pe

n co

lle ct

or

RUN Inverter running Switched to LOW when the inverter output frequency is equal to or higher than the starting frequency (initial value 0.5 Hz). Switched to HIGH 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.) LOW is when the open collector output transistor is ON (conducted). HIGH is when the transistor is OFF (not conducted).

SU Up to frequency

Switched to LOW when the output frequency is within the set frequency range 10% (initial value). Switched to HIGH during acceleration/ deceleration and at a stop.

Fault code (4 bits) output.

OL Overload alarm

Switched to LOW when stall prevention is activated by the stall prevention function. Switched to HIGH when stall prevention is canceled.

IPF Open collector output No function is assigned in the initial setting. The function can be assigned setting Pr.192.

FU Frequency detection

Switched to LOW when the inverter output frequency is equal to or higher than the preset detection frequency, and to HIGH 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

Outputs a selected monitored item (such as output frequency) among several monitored items. The signal is not output during an inverter reset. The 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

CA

Analog current output

Load impedance 200 to 450 Output signal 0 to 20 mADC

Ty pe Terminal

symbol Terminal name Terminal function description Rated specification

38 INSTALLATION AND WIRING

Control circuit

2

Communication

Safety stop signal For the safety stop function, refer to page 49.

Ty pe Terminal

symbol Terminal

name Terminal function description

C C

-L in

k IE

PORT 1

Communication can be made via the CC-Link IE Field Network.

PORT 2

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

R S

-4 85

te rm

in al

s

TXD+ Inverter transmission terminal The RS-485 terminals enable the communication by RS-485.

Conforming standard: EIA-485 (RS-485) Transmission format: Multidrop link Communication speed: 300 to 115200 bps Overall length: 500 m

TXD-

RXD+ Inverter reception terminalRXD-

GND (SG)

Earthing (grounding)

U S

B

USB A connector

A connector (receptacle) A USB memory device enables parameter copies and the trace function. Interface: Conforms to USB1.1

(USB2.0 fullspeed compatible) Transmission speed: 12 MbpsUSB B

connector

Mini B connector (receptacle) Connected to a personal computer via USB to enable setting, monitoring, test operations of the inverter by FR Configurator2.

Terminal symbol Terminal name Terminal function description Rated

specification

S1 Safety stop input (Channel 1)

The terminals S1 and S2 are used for the safety stop input signal for the safety relay module. The terminals S1 and S2 are used at the same time (dual channel). Inverter output is shutoff by shortening/opening between terminals S1 and SIC, or between S2 and SIC. In the initial status, terminal S1 and S2 are shorted with the terminal PC by shorting wires. The terminal SIC is shorted with the terminal SD. Remove the shorting wires and connect the safety relay module when using the safety stop function.

Input resistance 4.7 k Input current 4 to 6 mADC (with 24 VDC input)S2

Safety stop input (Channel 2)

SIC Safety stop input terminal common

Common terminal for terminals S1 and S2.

So (SO) Safety monitor output Open collector output

Indicates the safety stop input signal status. Switched to LOW when the status is other than the internal safety circuit failure. Switched to HIGH during the internal safety circuit failure status. LOW is when the open collector output transistor is ON (conducted). HIGH is when the transistor is OFF (not conducted). Refer to the Safety stop function instruction manual (BCNA23228-001) when the signal is switched to HIGH while both terminals S1 and S2 are open. (Please contact your sales representative for the manual.)

Permissible load 24 VDC (27 VDC at maximum), 0.1 A (The voltage drop is 3.4 V at maximum while the signal is ON.)

SOC Safety monitor output terminal common

Common terminal for terminal So (SO).

INSTALLATION AND WIRING 39

Control circuit

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 FR-CC2 Instruction Manual.

Input signal

Ty pe Terminal

symbol Terminal name Terminal function description Rated specification

C o

nt ac

t 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 s 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 1s after the reset is released.

Input resistance 4.7 k Voltage when contacts are open: 21 to 27 VDC 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 trips by 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

40 INSTALLATION AND WIRING

Control circuit

2

Output signal

2.6.3 Control logic (sink/source) change Change the control logic of input signals as necessary.

To change the control logic, change the jumper connector position on the control circuit board. Remove the control circuit

terminal block and change the control logic. (Refer to page 99 for details on how to remove the control circuit terminal block.)

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) for the FM type inverter.

The control logic of input signals is initially set to the source logic (SOURCE) for the CA type inverter.

(The output signals may be used in either the sink or source logic independently of the jumper connector position.)

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)

Switched to LOW when the converter unit operation is ready. Assign the signal to the terminal MRS (X10) of the inverter. The inverter can be started when the RDA status is LOW.

Permissible load 24 VDC (maximum 27 VDC) 0.1 A (The voltage drop is 2.8 V at maximum while the signal is ON.) LOW is when the open collector output transistor is ON (conducted). HIGH is when the transistor is OFF (not conducted).

RDB Inverter operation enable (NC contact)

Switched to LOW 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 Switched to LOW when the converter is reset (RES-ON). Assign the signal to the terminal RES of the inverter. The inverter is reset when it is connected with the RSO status LOW.

IPF Instantaneous power failure

Switched to LOW when an instantaneous power failure is detected.

FAN Cooling fan fault Switched to LOW when a cooling fan fault occurs.

SE Open collector output common

Common terminal for terminals RDA, RDB, RSO, IPF, FAN Connect this terminal to the terminal SD (sink logic) or PC (source logic) of the inverter.

CAUTION Do not use the empty terminals (NC) of the control circuit. Doing so may lead to damage of the converter unit

and the inverter. Always connect the terminal RDA of the converter unit and the terminal MRS (X10) of the inverter, and the

terminal SE of the converter unit and the terminal SD (terminal PC in the source logic) of the inverter. Not doing so may lead to damage of the converter unit.

For sink logic

SOURCE

SINK

Jumper connector

INSTALLATION AND WIRING 41

Control circuit

NOTE Make sure that the jumper connector is installed correctly.

Never change the control logic while power is ON.

After changing the jumper connector position, reinstall the control circuit terminal block securely in place.

Sink logic and source logic In the sink logic, a signal switches ON when a current flows 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 switches ON when a current flows 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 the terminal PC as a common terminal, and perform

wiring as shown below. (Do not connect terminal SD of the

inverter with the terminal 0 V of 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 the terminal SD as a common terminal, and perform

wiring as shown below. (Do not connect terminal PC of the

inverter with the terminal +24 V of 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

24VDC 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

42 INSTALLATION AND WIRING

Control circuit

2

2.6.4 Wiring of inverter control circuit Control circuit terminal layout

This terminal operates as the terminal FM for the FM type, and as the terminal CA for the CA type.

Represents the terminal STOP.

The X10 signal is assigned in the initial setting.

No signal is assigned in the initial setting.

Wiring method Power supply connection

For the control circuit wiring, strip off the sheath of a cable, and use it with a blade terminal. For a single wire, strip off the

sheath of the wire and apply directly.

Insert the blade terminal or the single wire into a socket of the terminal.

(1) Strip off the sheath for the below length. If the length of the sheath peeled is too long, a short circuit may occur with

neighboring wires. If the length is too short, wires might come off.

Wire the stripped cable after twisting it to prevent it from becoming loose. In addition, do not solder it.

(2) Crimp the blade terminal.

Insert wires to a blade terminal, and check that the wires come out for about 0 to 0.5 mm from a sleeve.

Check the condition of the blade terminal after crimping. Do not use a blade terminal of which the crimping is inappropriate,

or the face is damaged.

Blade terminals commercially available (as of January 2017)

Phoenix Contact Co., Ltd.

Cable sheath stripping length

Cable gauge (mm2)

Ferrule terminal model Crimping tool nameWith 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 the 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)3

RES STF STR JOG

1

24

10 mm

Crumpled tip Wires are not inserted into the sleeve

Unstranded wires

Damaged

Wire

Sleeve

0 to 0.5mm

INSTALLATION AND WIRING 43

Control circuit

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 (0V) for I/O signals. (All common terminals

are isolated from each other.) Do not earth (ground) these terminals. Avoid connecting the terminal SD (sink logic) with 5,

the terminal PC (source logic) with 5, and the terminal SE with 5.

In the sink logic, terminal SD is a common terminal for the contact input terminals (STF, STR, STP (STOP), RH, RM, RL,

JOG, RT, MRS, RES, AU, 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, STP (STOP), RH, RM, RL,

JOG, RT, MRS, RES, AU, 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 or 4) and the analog output terminals (AM, CA).

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, FU). The contact input circuit

is isolated from the internal control circuit by photocoupler.

Terminal FM is provided in the FM-type inverter.

Terminal CA is provided in the CA-type inverter.

Cable gauge (mm2)

Blade terminal product number

Insulation cap product number

Crimping tool product number

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

Driver SZF 0- 0,4 2,5

Phoenix Contact Co., Ltd. Contact Co., Ltd.

44 INSTALLATION AND WIRING

Control circuit

2

Signal inputs by contactless switches The contact input terminals of the inverter (STF, STR, STP (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 0.3 to 0.75 mm2 for the connection to the control circuit terminals.

The wiring length should be 30 m (200 m for the 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 200V 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 the 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

INSTALLATION AND WIRING 45

Control circuit

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

Connected to 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.

The terminals R1/L11 and S1/L21 are connected to the 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.

The power capacity necessary when separate power is supplied from R1/L11 and S1/L21 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

46 INSTALLATION AND WIRING

Control circuit

2

2.6.7 When supplying 24 V external power to the control circuit

Connect the 24 V external power supply across terminals +24 and SD. The 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 April 2019)

For the latest information about OMRON power supply, contact OMRON corporation.

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, "EV" flickers on the operation panel. The alarm lamp also flickers. Thus,

the 24 V external power supply operation can be confirmed even when the operation panel is removed.

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 DC23 to 25.5 V

Input current 1.4 A or lower

Model Product overview Manufacturer

S8FS-G05024C

Specifications: Capacity 50 W, output voltage 24 VDC, output current 2.2 A Installation method: Direct installation, screw type terminal block with a cover Input: Single-phase 100 to 240 VAC

OMRON CorporationS8VK-S06024 Specifications: Capacity 60 W, output voltage 24 VDC, output current 2.5 A Installation method: DIN rail installation, push-in (spring) type terminal block Input: Single-phase 100 to 240 VAC

S8VK-WA24024 Specifications: Capacity 240 W, output voltage 24 VDC, output current 10 A Installation method: DIN rail installation, push-in (spring) type terminal block Input: Three-phase 200 to 240 VAC

POWER ALARM

Flickering

Flickering

INSTALLATION AND WIRING 47

Control circuit

Operation while the 24 V external power is supplied Fault history 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 occured 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.

48 INSTALLATION AND WIRING

Control circuit

2

2.6.8 Safety stop function Function description The terminals related to the safety stop function are shown below.

In the initial status, terminals S1 and PC, S2 and PC, and SIC and SD are respectively shorted with shorting wires. To use the safety stop

function, remove all the shorting wires, and then connect to the safety relay module as shown in the connection diagram.

At an internal safety circuit failure, the operation panel displays one of the faults shown on the next page.

NOTE Use the terminal So (SO) to output a fault and to prevent restarting of the inverter. The signal cannot be used as safety stop

input terminal to other devices.

Connection diagram To prevent restart at fault occurrence, connect terminals So (SO) and SOC to the reset button, which are the feedback input

terminals of the safety relay module.

Terminal symbol Terminal function description

S1 For input of the safety stop channel 1. Between S1 and SIC, S2 and SIC Open: In safety stop mode Short: Other than the safety stop mode.S2 For input of the safety stop channel 2.

SIC Common terminal for terminals S1 and S2.

So (SO) Outputs when an alarm or failure is detected. The signal is output when no internal safety circuit failure exists.

OFF: Internal safety circuit failure ON: No internal safety circuit failure

SOC Open collector output (terminal So (SO)) common

R/L1 S/L2 T/L3

U V W

M

So (SO)

SOC

S1

S2 G G

ASIC

Inverter

SIC

SD

Logic

PC CPU

+24V

RESET

Emergency stop button

Safety relay module / Safety programmable controller

Gate Driver

IGBTs

Fuse Gate Driver

INSTALLATION AND WIRING 49

Control circuit

Safety stop function operation

ON: The transistor is conducted. OFF: The transistor is not conducted. When not using the safety stop function, short across terminals S1 and PC, S2 and PC, and SIC and SD to use the inverter. (In the initial status,

terminals S1 and PC, S2 and PC, and SIC and SD are respectively shorted with shorting wires.) If any of the faults shown in the following table occurs, terminal So (SO) and the SAFE signal turns OFF.

When the internal safety circuit is operated normally (no faults occurs), terminal So (SO) and the SAFE signal remain ON until "E.SAF" is displayed. Terminal So (SO) and the SAFE signal turn OFF when "E.SAF" is displayed.

SA is displayed when terminals S1 and S2 are identified as OFF due to the internal safety circuit failure. If another fault occurs at the same time as E.SAF, the other fault can be displayed. If another warning occurs at the same time as SA, the other warning can be displayed. The ON/OFF state of the output signal is the one for the positive logic. The ON and OFF are reversed for the negative logic. To assign the function of the SAFE signal to an output terminal, set either value shown in the following table in any parameter from Pr.190 to

Pr.196 (Output terminal function selection).

The use of SAFE signal has not been certified for compliance with safety standards.

For more details, refer to the Safety stop function instruction manual. (A PDF copy can be found in the enclosed CD-ROM. For how to use this CD-ROM, refer to page 123.)

Input power

Internal safety circuit status

Input terminal ,

Output terminal

Output signal ,,

Inverter running status

Operation panel indication

S1 S2 So (SO) SAFE E.SAF SA OFF OFF OFF Output shutoff (Safe state) Not displayed Not displayed

ON

Normal ON ON ON OFF Drive enabled Not displayed Not displayed Normal ON OFF OFF OFF Output shutoff (Safe state) Displayed Displayed Normal OFF ON OFF OFF Output shutoff (Safe state) Displayed Displayed Normal OFF OFF ON ON Output shutoff (Safe state) Not displayed Displayed Fault ON ON OFF OFF Output shutoff (Safe state) Displayed Not displayed Fault ON OFF OFF OFF Output shutoff (Safe state) Displayed Displayed Fault OFF ON OFF OFF Output shutoff (Safe state) Displayed Displayed Fault OFF OFF OFF OFF Output shutoff (Safe state) Displayed Displayed

Output signal

Pr.190 to Pr.196 setting Positive logic Negative logic

SAFE 80 180

Fault type Operation panel indication

Option fault E.OPT Communication option fault E.OP1 to E.OP3 Parameter storage device fault (control circuit board)

E.PE

Retry count excess E.RET Parameter storage device fault (main circuit board)

E.PE2

Operation panel power supply short circuit/RS-485 terminals power supply short circuit

E.CTE

24 VDC power fault E.P24

Safety circuit fault E.SAF Overspeed occurrence E.OS Speed deviation excess detection E.OSD Signal loss detection E.ECT Excessive position fault E.OD Brake sequence fault E.MB1 to E.MB7 Encoder phase fault E.EP Magnetic pole position unknown E.MP

CPU fault E.CPU E.5 to E.7

Internal circuit fault E.13

Fault type Operation panel indication

50

IN
STALLATION AND WIRING

Communication connectors and terminals

2

2.7 Communication connectors and terminals

2.7.1 PU connector Mounting the operation panel or parameter unit on the enclosure surface Having an operation panel or a parameter unit on the enclosure surface is convenient. With a connection cable, the

operation panel or the parameter unit 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, 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)

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 FR-A800 Instruction Manual (Detailed).)

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-DU08)

Operation panel (FR-LU08) (option)

Parameter unit (FR-PU07) (option)

INSTALLATION AND WIRING 51

Communication connectors and terminals

2.7.2 CC-Link IE Field Network function CC-Link IE Field Network communication specifications

Parts

NOTE Do not remove the CC-Link IE Field Network communication circuit board or the earth plate.

Connection cable For wiring, use the 1000BASE-T compliant Ethernet cables.

NOTE For CC-Link IE Field Network wiring, use the recommended wiring components by CC-Link Partner Association.

Cables for CC-Link IE Controller Network cannot be used for CC-Link IE Field Network.

Some cable connector shapes are not compatible with CC-Link IE Field Network communication connector.

Item Description Transmission speed 1 Gbps

Communication method Token passing

Number of units connected 120 units at max. (64 units when all stations are inverters handling 128-word transmissions.) Different devices can be connected together.

Maximum distance between nodes

100 m

Maximum number of branches

No upper limit within the same Ethernet system

Topology Line, star, ring, or a combination of line and star

Connection cable Ethernet cable (IEEE 802.3 1000BASE-T compliant cable or ANSI/TIA/EIA-568-B (Category 5e) compliant shielded 4-pair branched cable)

Connector Shielded RJ-45

Node type Intelligent device station Maximum cyclic size (of one node)

RX 64 bits

RY 64 bits

RWr 128 words

RWw 128 words

Ethernet cable Connector Type

Category 5e or higher (Double shielded/STP) Straight cable

RJ-45 connector The following conditioning cables: IEEE802.3 (1000BASE-T) ANSI/TIA/EIA-568-B (Category 5e)

RUN D LINK

SD ERR

RD L.ERR

Connector for communication (PORT2)

Operation status indication LED

Connector for communication (PORT1)

CC-Link IE Field Network communication circuit board

Earth plate

52 INSTALLATION AND WIRING

Communication connectors and terminals

2

Hubs Use hubs that meet the conditions listed below:

Compliance with the IEEE802.3 (1000BASE-T)

Support of the auto MDI/MDI-X function

Support of the auto-negotiation function

Switching hub (layer 2 switch)

A repeater hub is not available.

Operation is not guaranteed if the hubs do not meet these conditions.

Industrial switching hub

Ethernet cable connection Connect or remove an Ethernet cable after switching the power of the inverter OFF.

PORT1 and PORT2 do not need to be distinguished.

When only one connector is used in star topology, either PORT1 or PORT2 is applicable.

When using two connectors for line topology and ring topology, an Ethernet cable can be connected to the connectors

in any combination. For example, the cable can be connected between PORT1s or between PORT1 and PORT2.

NOTE Ethernet is a registered trademark of Xerox Corporation of the United States.

For the CC-Link IE Field Network, refer to the FR-A800 Instruction Manual (Detailed).

Type Manufacturer NZ2EHG-T8 Mitsubishi Electric Corporation

Connection between PORT1 and PORT1, PORT2 and PORT2

Connection between PORT1 and PORT2

To the next connector for communication (PORT2)

To the next connector for communication (PORT2)

Connector for

communication (PORT2)

Connector for

communication (PORT1)

Connector for

communication (PORT2)

Connector for

communication (PORT1)

Connector for

communication (PORT2)

Connector for

communication (PORT1)

Connector for

communication (PORT2)

Connector for

communication (PORT1)

INSTALLATION AND WIRING 53

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.

When the inverter recognizes the USB memory device without any problem, is briefly displayed on the

operation panel.

When the USB memory device is removed, is briefly displayed on the operation panel.

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 FR-A800 Instruction Manual (Detailed).

Interface Conforms to USB1.1

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 data copied in the USB memory device can be saved in a personal computer and edited in FR Configurator 2.

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.

Flickering rapidly The USB memory device is being accessed. (Do not remove the USB memory device.)

Flickering slowly Error in the USB connection.

USB host (A connector)

USB device (Mini B connector)

Communication status indicator (LED)Place a flathead screwdriver,

etc. in a slot and push up the cover to open.

Personal computer (FR Configurator2)

USB memory device

54 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 Configurator 2.

NOTE For the details of FR Configurator2, refer to the Instruction Manual of FR Configurator2.

2.7.4 RS-485 terminal block Communication operation

The RS-485 terminals 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) and MODBUS RTU protocol.

(For details, refer to the FR-A800 Instruction Manual (Detailed).)

NOTE To avoid malfunction, keep the RS-485 terminal wires away from the control circuit board.

For wiring of the RS-485 terminals used with a plug-in option, lead the wires on the left side of the plug-in option.

Interface Conforms to USB1.1

Transmission speed 12 Mbps

Wiring length Maximum 5 m

Connector USB mini B connector (receptacle)

Power supply Self-powered

Conforming standard EIA-485 (RS-485)

Transmission format Multidrop link

Communication speed 115200 bps maximum

Overall length 500 m

Connection cable Twisted pair cable (4 pairs)

Terminating resistor switch Initially-set to "OPEN". Set only the terminating resistor switch of the remotest inverter to the "100" position.

OPEN

100

+ -+ TXD RXD-VCC GND

+ -+ TXD RXD-VCC GND

RDA1 (RXD1+)

RDB1 (RXD1-)

RDA2 (RXD2+)

RDB2 (RXD2-)

SDA1 (TXD1+)

SDB1 (TXD1-)

SDA2 (TXD2+)

SDB2 (TXD2-)

P5S (VCC)

SG (GND)

P5S (VCC)

SG (GND)

INSTALLATION AND WIRING 55

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 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. 59 c Encoder type selection switch (SW3) Switches the encoder type (differential line driver/complementary). 57 d CON2 connector Used for extension.

e Terminating resistor selection switch (SW1)

Switches ON or OFF the internal terminating resistor. 57

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.

Termina l 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

56 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 control

terminal option FR-A8TP is installed, 24 V power supply can be provided from the FR-A8TP. 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.

When the power supply of the inverter is turned OFF, also turn off the power supply of the encoder. Otherwise, the plug-in

option may be damaged.

Encoder specification Item Specification

Resolution 0 to 4096 Pulse/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 57

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 are crimping terminals. Cut the crimping 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 Information on blade terminals

Commercially available products (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.

FR-JCBL FR-V7CBL

As the terminal block of the FR-A8AP is an insertion type, cables need to be treated. (Refer to the following description.)

Terminal screw size

Cable gauge (mm2)

Ferrule terminal model Crimping tool name(With insulation sleeve) (Without insulation sleeve)

M2 0.3 AI 0,34-6TQ A 0,34-7

CRIMPFOX 6 0.5 AI 0,5-6WH A 0,5-6

Terminal screw size

Cable gauge (mm2)

Blade terminal product number

Insulation cap product number

Crimping tool product number

M2 0.3 to 0.75 BT 0.75-7 VC 0.75 NH 69

F-DPEVSB 12P 0.2 mm2

Earth cable Approx. 140 mm

60 mm L

D/MS3057-12A

D/MS3106B20-29S

11 m

m

Model Length L (m) FR-JCBL5 5

FR-JCBL15 15

FR-JCBL30 30

PZ2 PZ1 PB2 PB1 PA2 PA1

PG SD

P B N A R C

H K

PLG

2 mm2

A B C

D

EK

FGH J

L M

S

N

R

PT

D/MS3106B20-29S (As viewed from wiring side)

Positioning keyway

FR-A800 (FR-A8AP)

Earth cable

F-DPEVSB 12P 0.2 mm2

L D/MS3106B20-29S

D/MS3057-12A

11 m

m

60 mm

Approx. 140 mm

Model Length L (m) FR-V7CBL5 5

FR-V7CBL15 15

FR-V7CBL30 30

Shield earthing P-clip is

included.

PZ2 PZ1 PB2 PB1 PA2 PA1

SD PG

G F D C B A

R S

PLG

2 mm2

FR-A800 (FR-A8AP)

A B C D EK

FGHJ

L M

S

N

R

PT

D/MS3106B20-29S (As viewed from wiring side)

Positioning keyway

5 mm

Cable stripping size

58 INSTALLATION AND WIRING

Connection of motor with encoder (vector control)

2

Connection terminal compatibility table

Wiring example Speed control

Torque control

Encoder cable FR-V7CBL FR-JCBL

FR-A8AP terminal

PA1 PA PA

PA2 Do not connect anything to this. PAR

PB1 PB PB

PB2 Do not connect anything to this. PBR

PZ1 PZ PZ

PZ2 Do not connect anything to this. PZR

PG PG 5E

SD SD AG2

Standard motor with encoder, 5 V differential line driver Vector control dedicated motor, 12 V complementary

Standard motor with encoder, 5 V differential line driver Vector control dedicated motor, 12 V complementary

Motor with encoder

U V W

U V W E

C

3

1

2

4 6

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 1/2 W 1 k 5

(+) (-)

5 VDC power supply(+) (-) 5

To converter unit P/+ N/-

4 6 3

PA1 FR-A8AP

PA2

PB1 PB2

PZ1 PZ2

PG

1

OFF

Vector control dedicated motor

U V W

U V W E

A

2

B

PG SD

SD

C D

F G

S R

IM

PLG

(+) (-) 5

Earth (Ground)

Inverter

12 VDC power supply

Differential

Terminating resistor

ON

Complementary

Motor with encoder

U V W

U V W E

C

*3

1

2

4 6

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

1

5

(+) (-)

5 VDC power supply(+) (-) 5

To converter unit P/+ N/-

Torque command

(10V)

Speed limit command Frequency setting

potentiometer 1/2 W 1 k

4 6 3

PA1 FR-A8AP

PA2

PB1 PB2

PZ1 PZ2

PG

1

OFF

Vector control dedicated motor

U V W

U V W E

A

2

B

PG SD

SD

C D

F G

S R

IM

PLG

(+) (-) 5

Earth (Ground)

Inverter

12 VDC power supply

Differential

Terminating resistor

ON

Complementary

INSTALLATION AND WIRING 59

Connection of motor with encoder (vector control)

Position control

Vector control dedicated motor, 12 V complementary

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 61.)

For the complementary, set the terminating resistor selection switch to OFF position. (Refer to page 57.)

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.

For terminal compatibility of the FR-JCBL, FR-V7CBL, and FR-A8AP, refer to page 59.

Assign the function using Pr.178 to Pr.184, Pr.187 to Pr.189 (input terminal function selection). When position control is selected, terminal JOG function is invalid and simple position pulse train input terminal

becomes valid.

Assign the function using Pr.190 to Pr.194 (output terminal function selection).

Vector control dedicated motor

Torque limit command (10 V)

1

5

(+) (-)

4 6

3

PA1 FR-A8AP

PA2

PB1 PB2

PZ1 PZ2

PG

PG SD

SD

Forward stroke end Reverse stroke end

Pre-excitation/servo on

Clear signal

Pulse train

Sign signal

Preparation ready signal

STF STR LX 7

CLR 7CLEAR

JOG 8

NP 7

1

Differential line driver

Terminating resistor

ON

OFF

U V W

U V W E

A

Earth (ground)

2

B

C D

F G

S R

IM

PLG

Inverter

Positioning unit MELSEC-Q QD75P[]N/QD75P[]

MELSEC-L LD75P[]

12 VDC power supply(+) (-) 5

PULSE F

PULSE R

PULSE COM

CLRCOM

RDYCOM

READY

PC

RDY 9

SE

FLS RLS

DOG STOP

COM

24 VDC power supply

Complementary

P/+ N/-

To converter unit

60 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 the wiring to the 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.

NOTE For the details of the optional encoder dedicated cable (FR-JCBL/FR-V7CBL), refer to page 58.

The FR-V7CBL is provided with a P-clip for earthing (grounding) shielded cables.

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 61

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 Rated motor current 0 (3) Motor capacity Number of motor poles

Constant-torque motor Rated motor current 1 (13) Motor capacity Number of motor poles

Offline auto tuning is required (Refer to the FR-A800 Instruction Manual (Detailed))

Set this parameter according to the motor.

CW

CCW

62 INSTALLATION AND WIRING

Connection of stand-alone option units

2

2.10 Connection of stand-alone option units The inverter accepts a variety of stand-alone option units as required.

Incorrect connection will cause inverter damage or accident. Connect and operate the option unit carefully in accordance with

the corresponding option unit manual.

2.10.1 Connection of the brake unit (FR-BU2) Connect the brake unit (FR-BU2) as shown below to improve the braking capability during deceleration.

After making sure that the wiring is correct and secure, set "11 or 111" in Pr.30 Regenerative function selection.

Set Pr.0 Brake mode selection = "2" in the brake unit FR-BU2.

NOTE The warning "oL" of the stall prevention (overvoltage) is disabled while Pr.30 Regenerative function selection = "11 or 111".

For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

When wiring, make sure to match the terminal symbol (P/+, N/-) at the inverter side and at the brake unit (FR-

BU2) side. (Incorrect connection will damage the inverter and brake unit.)

For the FR-A842-08660(355K) or lower, up to two cables can be connected to terminals P/+ and N/-. For the

FR-A842-09620(400K) or higher, up to four cables can be connected. To use more cables, use a bus bar.

When the power supply is 400 V class, install a stepdown transformer.

The wiring distance between the inverter, brake unit (FR-BU2) and resistor unit (MT-BR5) must be within 5 m

each. Even when the cable is twisted, the wiring length must be within 10 m.

The contact between TH1 and TH2 is open in the normal status and is closed at a fault.

The CN8 connector used with the MT-BU5 type brake unit is not used.

P PR

10 m or less

TH1

TH2

CR1P N

BUE SD

P

PR

Brake unit FR-BU2

Resistor unit MT-BR5

TH1

TH2

Resistor unit MT-BR5

P PR

TH1

TH2

Resistor unit MT-BR5

P PR

MC R/L1 Motor

M

Inverter/ converter

S/L2 T/L3

U V

P/+ N/-

W

Three phase AC power supply

MCCB

MC

OFFON

MC

CR1

T

CR2

CR4

CR2 CR3 CR4

A B C

4

5

5

5

5

12

3

TH1

TH2

Resistor unit MT-BR5

P PR

CR3

6

INSTALLATION AND WIRING 63

Connection of stand-alone option units

2.10.2 Connection of the high power factor converter (FR-HC2)

When connecting the high power factor converter (FR-HC2) to suppress power harmonics, perform wiring securely as shown

below. Incorrect connection will damage the high power factor converter and the inverter.

After making sure that the wiring is correct and secure, set the rated motor voltage in Pr.19 Base frequency voltage (under

V/F control) or Pr.83 Rated motor voltage (under other than V/F control) and "2 or 102" in Pr.30 Regenerative function selection.

Remove jumpers installed in terminals R1/L11 and S1/L21 of the inverter, and connect the power supply for the control circuit to terminals

R1/L11 and S1/L21.

The voltage phases of terminals R4/L14, S4/L24, and T4/L34 and the voltage phases of terminals R/L1, S/L2, and T/L3 must be matched.

Do not install an MCCB across the 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.

When using the FR-HC2 with the FR-A802 series, installation of a fuse is not required.

Change the FR-HC2 parameter setting to Pr.10 RDY signal logic selection = "0" (positive logic).

Use Pr.178 to Pr.189 (input terminal function selection) to assign the terminals used for the X10 signal.

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.

Assign the IPF signal to an FR-HC2 terminal. (Refer to the Instruction Manual of FR-HC2.)

Always connect the FR-HC2 terminal RDY to the inverter terminal MRS(X10), and the FR-HC2 terminal SE to the inverter terminal SD. Not

connecting these terminals may damage the FR-HC2.

Always connect the R/L1, S/L2, and T/L3 terminals of FR-HC2 to the power supply. Operating the inverter without connecting them will

damage the FR-HC2.

Do not install an MCCB or MC between the reactor 1 terminals (R/L1, S/L2, T/L3) and the FR-HC2 terminals (R4/L14, S4/L24, T4/L34). It

will not operate properly.

Securely perform grounding (earthing) by using the grounding (earthing) terminal.

The number of connected peripheral devices differs according to the capacity. For the detail, refer to the FR-HC2 Instruction Manual.

MC1

MC2

MC3 M

R1/L11 S1/L21

R4/L14

S4/L24

T4/L34

R4/ L14 S4/ L24 T4/ L34

R3/ L13 S3/ L23 T3/ L33

R2/ L12 S2/ L22

T2/ L32

R/ L1 S/ L2

T/ L3

MC

U V W

88R

R/L1 S/L2 T/L3

88S

R1/L11 S1/L21

MC Bu1

MC1

MC2

MC3

ROH

SD

MC2 MC3 MC Small

MC Bu2 MC1

P/+P/+ N/-N/-

X11

RES

SD

IPF

RSO

SE

11

11

11

9 9 9

10

5

4

6

X10RDY 7

7

1

10

8

3

2

Inverter

High power factor converter

(FR-HC2) Limit resistor

Reactor 1 (FR-HCL21)

Power Supply

MCCB Reactor 2

(FR-HCL22)

Earth (Ground)

Limit MC

Buffer relay for driving MCs

MC power supply

stepdown transformer

Mini relay for filter capacitor alarm detector

Buffer relay for filter capacitor alarm detectors

Auxiliary contact for limit MCs (NO contact) 3

Filter capacitor alarm detector (NC contact) 2

Limit resistor (with thermostat) (NC contact) 3Filter capacitors 2

(FR-HCC2)

Fuse

64 INSTALLATION AND WIRING

Connection of stand-alone option units

2

NOTE The voltage phases of terminals R/L1, S/L2, and T/L3 and the voltage phases of terminals R4/L14, S4/L24, and T4/L34 must

be matched.

The control logic (sink logic/source logic) of the high power factor converter and the inverter must be matched. (Refer to page 41.)

When using a sine wave filter with FR-HC2, select MT-BSL-HC as a reactor for the sine wave filter.

For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

2.10.3 Connection of the power regeneration converter (MT-RC)

When connecting the power regeneration converter (MT-RC), perform wiring securely as follows. Incorrect connection will

damage the power regeneration converter and the inverter. After making sure that the wiring is correct and secure, set "1 or

101" in Pr.30 Regenerative function selection.

For the FR-A842-08660(355K) or lower, up to two cables can be connected to terminals P/+ and N/-. For the FR-A842-09620(400K) or higher,

up to four cables can be connected. To use more cables, use a bus bar.

NOTE When using the inverter with the MT-RC, install a magnetic contactor (MC) at the input side of the inverter so that power is

supplied to the inverter after one second or more has elapsed after powering ON the MT-RC. When power is supplied to the

inverter prior to the MT-RC, the inverter and the MT-RC may be damaged or the MCCB may be shut off or damaged.

When connecting the power coordination reactor and others, refer to Instruction Manual of the MT-RC for precautions.

R/L1 S/L2 T/L3 R1/L11 S1/L21

R R2 RES

U V W

Inverter / converter unit

MT-RCL

P/+ N/-

P N

RDY

SE

MT-RC

Reset signal

Ready signal

Three-phase AC power supply

MCCB MC2MC1

M

STF SD

S

T

S2

T2

R2

S2

T2

R

S

T

R1

S1

C

Alarm signalB A

1

MT-RC power supply (MC1)

Inverter input power supply (MC2)

1 s or more

ON

ON

INSTALLATION AND WIRING 65

MEMO

66

3

PRECAUTIONS FOR USE OF THE INVERTER 67

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 ..68 3.2 Power supply harmonics .........................................................75 3.3 Installation of a reactor ............................................................78 3.4 Power-OFF and magnetic contactor (MC) ..............................79 3.5 Countermeasures against deterioration of the 400 V class

motor insulation........................................................................80 3.6 Checklist before starting operation ........................................81 3.7 Failsafe system which uses the inverter ................................84

Electro-magnetic interference (EMI) and leakage currents

3.1 Electro-magnetic interference (EMI) and leakage currents

3.1.1 Leakage currents and countermeasures 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 countermeasures.

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.

Countermeasures

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.

Countermeasures

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.) As an earth

leakage current breaker, use the Mitsubishi earth leakage current breaker designed for harmonics and surge suppression.

Power supply

Thermal relay

Line-to-line static capacitances

MCCB MC Motor

InverterConverter unit

M

Line-to-line leakage currents path

68 PRECAUTIONS FOR USE OF THE INVERTER

Electro-magnetic interference (EMI) and leakage currents

3

Selecting the rated sensitivity current for the earth leakage circuit breaker

When using an earth leakage circuit breaker with the inverter circuit, select its rated sensitivity current as follows,

independently of the PWM carrier frequency.

Inverter/converter unit leakage current

400 V class (input power condition: 440 V/60 Hz, power supply unbalance within 3%)

Breaker designed for harmonic and surge suppression

Rated sensitivity current

In 10 (Ig1 + Ign + Igi + Ig2 + Igm)

Standard breaker

Rated sensitivity current

In 10 {Ig1 + Ign + Igi + 3 (Ig2 + Igm)}

Ig1, Ig2: Leakage currents in wire path during commercial

power supply operation

Ign: Leakage current of inverter input side noise filter

Igm: Leakage current of motor during commercial power

supply operation

Igi: Leakage current of inverter unit

(When the converter unit is connected, add the

leakage current of converter unit.)

Selection example for the connection of the 400 V class

Item Breaker designed for harmonic and

surge suppression Standard breaker

Leakage current Ig1 (mA) 1

66 5 m

= 0.11 3 1000 m

Leakage current Ign (mA) 0 (without noise filter)

Leakage current Igi (mA) 1 (without EMC filter) For the leakage current of the inverter, refer to the following table.

Leakage current Ig2 (mA) 1

66 60 m

= 1.32 3 1000 m

Motor leakage current Igm (mA) 0.36

Total leakage current (mA) 2.79 6.15

Rated sensitivity current (mA) ( Ig 10) 30 100

Inverter/ converter unit

FR-A800 (Standard model)

FR-A802 (Separated converter type)

Converter unit FR-CC2

EMC filter ON OFF - ON OFF

35 2 2 70 2

2 1 1 2 1

(mA)

Motor capacity (kW)

For " " connection, the amount of leakage current is appox.1/3 of the above value.

(Three-phase three-wire delta connection 400 V 60 Hz)

Example of leakage current per 1km during the commercial power supply operation when the CV cable is routed in metal conduit

Leakage current example of three- phase induction motor during the commercial power supply operation

(Totally-enclosed fan-cooled type motor 400 V 60 Hz)

0

20

40

60

80

100

120

le ak

ag e

cu rr

en ts

(m A

)

le ak

ag e

cu rr

en ts

(m A

)

2 3.5 5.5

8 1422 30 38

60 80 100

150

Cable size (mm2)

0. 1

0. 2 0. 3

0. 5 0. 7 1. 0

2. 0

1. 5 3. 7 2. 2

7. 5 1522 11

37 30

55 455.5 18. 5

Noise filter

Inverter

ELB

Ig1 Ign

Igi

Ig2 Igm

M 400 V 2.2 kW

3

5.5 mm2 5 m 5.5 mm2 60 m

Phase earthing (grounding)

Earthed-neutral system

PRECAUTIONS FOR USE OF THE INVERTER 69

Electro-magnetic interference (EMI) and leakage currents

NOTE Install the earth leakage circuit breaker (ELB) on the input side of the converter unit.

In the connection earthed-neutral system, the sensitivity current is blunt against a ground fault in the inverter output side.

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)

When the breaker is installed on the output side of the inverter, it may be unnecessarily operated by harmonics even if the

effective value is within the rating.

In this case, do not install the breaker since the eddy current and hysteresis loss will increase, leading to temperature rise.

The following models are standard breakers BV-C1, BC-V, NVB, NV-L, NV-G2N, NV-G3NA, NV-2F,

earth leakage relay (except NV-ZHA), and NV with AA neutral wire open-phase protection.

The other models are designed for harmonic and surge suppression: NV-C/NV-S/MN series, NV30-FA, NV50-FA, BV-C2,

earth leakage alarm breaker (NF-Z), NV-ZHA, and NV-H.

For the leakage current of a 75 kW or higher motor, contact the motor manufacturer.

70 PRECAUTIONS FOR USE OF THE INVERTER

Electro-magnetic interference (EMI) and leakage currents

3

3.1.2 Countermeasures 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. If these

electromagnetic noises cause peripheral devices to malfunction, EMI countermeasures should be taken to suppress noises.

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

countermeasures)

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 countermeasures must be taken:

- Provide surge suppressors for devices that generate many electromagnetic noises to suppress electromagnetic noises.

- Install data line filters (page 72) 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 to or converter unit cause the peripheral

devices to malfunction (EMI countermeasures)

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 71

Electro-magnetic interference (EMI) and leakage currents

Data line filter Data line filter is effective as an EMI countermeasure. Provide a data line filter for the detector cable, etc.

Data line filter: ZCAT3035-1330 (by TDK)

ESD-SR-250 (by NEC TOKIN)

Impedance (ZCAT3035-1330)

The impedance values above are reference values, and not guaranteed values.

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 countermeasures 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.

Set the EMC filter ON/OFF connector of the converter unit to the ON position. (Refer to page 74.) 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 countermeasures 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 countermeasures must be taken: Set the EMC filter ON/OFF connector of the converter unit to the ON position. (Refer to page 74.) 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.

Impedance () 10 to 100 MHz 100 to 500 MHz

80 150 34 1

TDK

39 1

Product name Lot number

30 1

Cable fixing band mount

13 1

OUTLINE DIMENSION DRAWINGS (ZCAT3035-1330)

[Unit: mm]

72 PRECAUTIONS FOR USE OF THE INVERTER

Electro-magnetic interference (EMI) and leakage currents

3

EMI countermeasure example

NOTE For compliance with the EU EMC Directive, refer to page 115.

Converter unit

Line noise filter

Install filter on inverter output 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.

EMC filter M

Power supply for

sensor

PRECAUTIONS FOR USE OF THE INVERTER 73

Electro-magnetic interference (EMI) and leakage currents

3.1.3 Converter unit (FR-CC2) built-in EMC filter The converter unit (FR-CC2) is equipped with a built-in EMC filter (capacitive filter).

These filters are effective in reducing air-propagated noise on the input side of the converter unit.

To enable the EMC filter, fit the EMC filter ON/OFF connector to the ON position.

Both of two EMC filter ON/OFF connectors are initially set to the OFF position (disabled).

To enable the EMC filter, fit both of the EMC filter ON/OFF connectors to the ON position.

Before removing a front cover, check to make sure that the indication of the inverter operation panel is OFF, wait for at least

10 minutes after the power supply has been switched OFF, and check that there is no residual voltage using a tester or the

like.

When disconnecting the connector, push the fixing tab and pull the connector straight without pulling the cable or forcibly

pulling the connector with the tab fixed.

When installing the connector, also engage the fixing tab securely.

(If it is difficult to disconnect the connector, use a pair of needle-nose pliers, etc.)

NOTE Fit the connector to either ON or OFF position.

Enabling (turning ON) the EMC filter increases leakage current. (Refer to page 69.)

WARNING While the inverter power is ON, do not open the front cover. Otherwise you may get an electric shock.

EMC filter OFF EMC filter ON

FILTER

O F

F O

N

FILTER

O F

F O

N

FILTER

OFF ON

FILTER

OFF ON

EMC filter ON/OFF connector

EMC filter ON/OFF connector

EMC filter OFF EMC filter ON

EMC filter ON/OFF connector

(Side view)

Disengage connector fixing tab With tab disengaged, pull up the connector straight.

74 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 countermeasure suppression techniques.

The differences between harmonics and noises

Countermeasures

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.

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.

Countermeasure 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/ converter

unit

R

S

T Z

Y

X U

V

W

R/L1

S/L2

T/L3

M

AC reactor (FR-HAL) Do not insert power

factor improving capacitor.

MCCB MC

P ow

er s

up pl

y

PRECAUTIONS FOR USE OF THE INVERTER 75

Power supply harmonics

3.2.2 Harmonic Suppression Guidelines in Japan Inverters have a converter section (rectifier circuit) and generate a harmonic current.

Harmonic currents flow from the inverter to a power receiving point via a power transformer. The Harmonic Suppression

Guidelines was established to protect other consumers from these outgoing harmonic currents.

The three-phase 200 V input specifications 3.7 kW or lower were previously covered by "the Harmonic Suppression Guidelines for

Household Appliances and General-purpose Products" and other models were covered by "the Harmonic Suppression Guidelines for

Consumers Who Receive High Voltage or Special High Voltage". However, the transistorized inverter has been excluded from the target

products covered by "the Harmonic Suppression Guidelines for Household Appliances and General-purpose Products" in January 2004

and "the Harmonic Suppression Guideline for Household Appliances and General-purpose Products" was repealed on September 6, 2004.

All capacity and all models of general-purpose inverter used by specific consumers are now covered by "the Harmonic

Suppression Guidelines for Consumers Who Receive High Voltage or Special High Voltage" (hereinafter referred to as "the

Specific Consumer Guidelines").

"Specific Consumer Guidelines"

This guideline sets forth the maximum harmonic currents outgoing from a high-voltage or especially high-voltage receiving

consumer who will install, add or renew harmonic generating equipment. If any of the maximum values is exceeded, this

guideline requires that consumer to take certain suppression measures.

Maximum Values of Outgoing Harmonic Currents per 1 kW Contract Power

Application of the specific consumer guidelines

Conversion factors

Equivalent Capacity Limits

Harmonic content (Values of the fundamental current is 100%)

Received power voltage 5th 7th 11th 13th 17th 19th 23rd Over

23rd 6.6 kV 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70 22 kV 1.8 1.3 0.82 0.69 0.53 0.47 0.39 0.36 33 kV 1.2 0.86 0.55 0.46 0.35 0.32 0.26 0.24

Classification Circuit type Conversion coefficient Ki

3 Three-phase bridge (Capacitor smoothing)

With reactor (DC side) K33 = 1.8 With reactors (AC, DC sides) K34 = 1.4

5 Self-excitation three-phase bridge When a high power factor converter is used K5 = 0

Received power voltage Reference capacity 6.6 kV 50 kVA 22/33 kV 300 kVA 66 kV or more 2000 kVA

reactor 5th 7th 11th 13th 17th 19th 23rd 25th Used (DC side) 30 13 8.4 5.0 4.7 3.2 3.0 2.2 Used (AC, DC sides) 28 9.1 7.2 4.1 3.2 2.4 1.6 1.4

Install, add or renew equipment

Calculation of equivalent capacity total

Equivalent capacity total

Calculation of outgoing harmonic current

Not more than harmonic current upper

limit?

Harmonic suppression measures unnecessary

Harmonic suppression measures necessaryEqual to or less

than upper limit

More than upper limit

Above reference capacity

Equal to or less than reference capacity

76 PRECAUTIONS FOR USE OF THE INVERTER

Power supply harmonics

3

Calculation of equivalent capacity P0 of harmonic generating equipment

"Equivalent capacity" is the capacity of a 6-pulse converter converted from the capacity of consumer's harmonic generating

equipment and is calculated by the following equation: If the sum of equivalent capacities is higher than the limit in (refer to

page 76), harmonics must be calculated with the following procedure:

Calculation of outgoing harmonic current

Outgoing harmonic current = fundamental wave current (value converted from received power voltage) operation ratio

harmonic content

Operation ratio: Operation ratio = actual load factor operation time ratio during 30 minutes

Harmonic content: Found in page 76.

Rated capacities and outgoing harmonic currents of inverter-driven motors

Determining if a countermeasure is required

A countermeasure for harmonics is required if the following condition is satisfied: outgoing harmonic current > maximum

value per 1 kW contract power contract power.

Harmonic suppression techniques

P0 = (Ki Pi) [kVA] Rated capacity: Determined by the capacity of the

applied motor and found in Table 5. The rated

capacity used here is used to calculate the generated

harmonic amount and is different from the power

supply capacity required for actual inverter drive.

Ki: Conversion coefficient (Refer to page 76)

Pi: Rated capacity of harmonic generating equipment [kVA]

i: Number indicating the conversion circuit type

Applicable motor (kW)

Fundamental wave current

(A)

Fundamental wave current

converted from 6.6 kV

(mA)

Rated capacity

(kVA)

Outgoing harmonic current converted from 6.6 kV (mA) (With a DC reactor, 100% operation ratio)

400 V 5th 7th 11th 13th 17th 19th 23rd 25th

75 123 7455 87.2 2237 969 626 373 350 239 224 164

90 147 8909 104 2673 1158 748 445 419 285 267 196

110 179 10848 127 3254 1410 911 542 510 347 325 239

132 216 13091 153 3927 1702 1100 655 615 419 393 288

160 258 15636 183 4691 2033 1313 782 735 500 469 344

220 355 21515 252 6455 2797 1807 1076 1011 688 645 473

250 403 24424 286 7327 3175 2052 1221 1148 782 733 537

280 450 27273 319 8182 3545 2291 1364 1282 873 818 600

315 506 30667 359 9200 3987 2576 1533 1441 981 920 675

355 571 34606 405 10382 4499 2907 1730 1627 1107 1038 761

400 643 38970 456 11691 5066 3274 1949 1832 1247 1169 857

450 723 43818 512 13146 5696 3681 2191 2060 1402 1315 964

500 804 48727 570 14618 6335 4093 2436 2290 1559 1462 1072

560 900 54545 638 16364 7091 4582 2727 2564 1746 1636 1200

630 1013 61394 718 18418 7981 5157 3070 2886 1965 1842 1351

No. Item Description

1 Reactor installation (FR-HAL)

The converter unit (FR-CC2) is equipped with the DC reactor on its DC side, and outgoing harmonic current can be suppressed. By installing an AC reactor (FR-HAL) on the AC side of the inverter, the outgoing harmonic current suppression performance can be improved.

2 high power factor converter (FR-HC2)

This converter trims the current waveform to be a sine waveform by switching the rectifier circuit (converter module) with transistors. Doing so suppresses the generated harmonic amount significantly. Connect it to the DC area of an inverter. Use the high power factor converter (FR-HC2) with the accessories that come as standard.

3 Installation of power factor improving capacitor

When used with a reactor connected in series, the power factor improving correction capacitor can absorb harmonic currents.

4 Transformer multi-phase operation

Use two transformers with a phase angle difference of 30 as in - and - combinations to provide an effect corresponding to 12 pulses, reducing low-degree harmonic currents.

5 Passive filter (AC filter)

A capacitor and a reactor are used together to reduce impedances at specific frequencies. Harmonic currents are expected to be absorbed greatly by using this technique.

6 Active filter

This filter detects the current in a circuit generating a harmonic current and generates a harmonic current equivalent to a difference between that current and a fundamental wave current to suppress the harmonic current at the detection point. Harmonic currents are expected to be absorbed greatly by using this technique.

PRECAUTIONS FOR USE OF THE INVERTER 77

Installation of a reactor

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 optional AC reactor (FR-HAL).

MCCB MC

Inverter/ 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 (FR-HAL)

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

)

78 PRECAUTIONS FOR USE OF THE INVERTER

Power-OFF and magnetic contactor (MC)

3

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.

When the power supply is 400 V class, 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 46 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 commercial

power supply-inverter switchover 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

PRECAUTIONS FOR USE OF THE INVERTER 79

Countermeasures against deterioration of the 400 V class motor insulation

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 Countermeasures against deterioration of the 400 V class motor insulation

In the PWM type inverter, a surge voltage attributable to wiring constants is generated at the motor terminals. Especially in a

400 V class motor, the surge voltage may deteriorate the insulation. When the 400 V class motor is driven by the inverter,

consider the following countermeasures:

Countermeasures

(With induction motor)

It is recommended to take one of the following countermeasures:

Rectifying the motor insulation and limiting the PWM carrier frequency according to the wiring length

For the 400 V class motor, use an insulation-enhanced motor.

Specifically,

- Order a "400 V class inverter-driven insulation-enhanced motor".

- For the dedicated motor such as the constant-torque motor and low-vibration motor, use an "inverter-driven dedicated

motor".

- Set Pr.72 PWM frequency selection as indicated below according to the wiring length.

Suppressing the surge voltage on the inverter side

- If the motor capacity is 280 kW or lower, connect the sine wave filter (MT-BSL/BSC) to the output side.

(With PM motor)

When the wiring length exceeds 50 m, set "9" (6 kHz) or less in Pr.72 PWM frequency selection.

NOTE When using the optional sine wave filter (MT-BSL/BSC), set Pr.72="25" (2.5 kHz).

For the details of the sine wave filter (MT-BSL/BSC), refer to the Instruction Manual of each option.

A sine wave filter (MT-BSL/BSC) can be used under V/F control. Do not use the filters under different control methods.

The carrier frequency is limited during PM sensorless vector control. (Refer to the FR-A800 Instruction Manual (Detailed))

Wiring length 100 m or shorter Longer than 100 m

Pr.72 PWM frequency selection 6 (6 kHz) or lower 4 (4 kHz) or lower

80 PRECAUTIONS FOR USE OF THE INVERTER

Checklist before starting operation

3

3.6 Checklist before starting operation The FR-A800 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

Crimping terminals are insulated. Use crimping 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.

31

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, a voltage drop in the main circuit will cause the motor torque to decrease especially during the output of a low frequency.

32

The total wiring length 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.

32

Countermeasures 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, activate the EMC filter (turn ON the EMC filter ON/OFF connector) to minimize interference.

74

On the inverter's output side, none of the power factor correction capacitor, surge suppressor, or radio noise filter is 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.

79

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 the terminals 10E and 5.

36

PRECAUTIONS FOR USE OF THE INVERTER 81

Checklist before starting operation

The converter unit and the inverter are correctly connected.

Make sure that the terminal P/+ of the converter unit and the terminal P/+ of the inverter, and the terminal N/- of the converter unit and the 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 the terminals P/+ and N/- (across terminals P and P/+ or across N and N/-).

Always connect the terminal RDA of the converter unit and the terminal MRS (X10) of the inverter, and the terminal SE of the converter unit and the terminal SD (terminal PC for source logic) of the inverter. Not connecting these terminals may damage the converter unit.

29

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.)

When switching to the commercial power supply operation while a failure such as an output short circuit is occurring between the magnetic contactor MC2 and the motor, the damage may further spread. When a failure occurs between the MC2 and motor, make sure to provide a protection circuit, such as using the OH signal input.

-

A countermeasure is provided 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.)

56

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.

79

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.

79

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.

79

An EMI countermeasure is provided 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 countermeasures 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 (Example: ZCAT3035-1330 TDK).

-

Checkpoint Countermeasure Refer to page

Check by user

Inverter/ converter unit

MC2

MC1

U V W

R/L1 S/L2 T/L3

IM Power supply

Undesirable current

Interlock

82 PRECAUTIONS FOR USE OF THE INVERTER

Checklist before starting operation

3

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 bearing, which may cause electrical corrosion of the bearing in rare cases depending on: condition of the grease used for the bearing, wiring, load, operating conditions of the motor, or specific inverter settings (high carrier frequency, EMC filter ON). Contact your sales representative to take appropriate countermeasures for the motor. The following shows examples of countermeasures for the inverter. Decrease the carrier frequency. Turn OFF the EMC filter. Provide a common mode choke on the output side of the inverter. (This is effective regardless of the EMC filter ON/OFF connector setting.)

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

PRECAUTIONS FOR USE OF THE INVERTER 83

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 activates and outputs 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 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 output signal (ALM signal)

b Inverter operating status Operation ready signal check. Operation ready signal (RY signal)

c Inverter running status Logic check of the start signal and running signal. Start signal (STF signal, STR signal) Inverter running signal (RUN signal)

d Inverter running status Logic check of the start signal and output current. Start signal (STF signal, STR signal) Output current detection signal (Y12 signal)

(a) Checking by the output of the inverter fault signal

When the inverter's protective function activates and the

inverter trips, the fault output signal (ALM signal) is

output. (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

Operation ready signal (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 signal (RUN signal) is output when

the inverter is running. (RUN signal is assigned to

terminal RUN in the initial setting.)

Check if Y12 signal is being output while inputting a start

signal to the inverter. (STF signal is a forward rotation

signal, and STR 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

84 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 FR-A800 Instruction Manual (Detailed).

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, start, 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 signal (Y12 signal) is output when the inverter operates and current flows into the motor.

Check if Y12 signal is being output while inputting a start signal to the inverter. (STF signal is a forward rotation signal,

and STR 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 signal (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 85

MEMO

86

4

PROTECTIVE FUNCTIONS 87

4 PROTECTIVE FUNCTIONS

This chapter explains the "PROTECTIVE FUNCTIONS" that operate in

this product.

Always read the instructions before using the equipment.

4.1 Inverter fault and alarm indications ........................................88 4.2 Reset method for the protective functions.............................88 4.3 Check and clear of the fault history ........................................89 4.4 List of fault displays .................................................................91

Inverter fault and alarm indications

4.1 Inverter fault and alarm indications When the inverter detects a fault, depending on the nature of the fault, the operation panel displays an error message or

warning, or a protective function activates to trip 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 activates, 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 FR-A800 Instruction Manual (Detailed).

The past eight faults can be displayed on the operation panel. (Fault history) (For operation, refer to page 89.)

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 activates, 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 (FR-DU08) and parameter unit (FR-PU07) is displayed. The inverter does not trip.

Warning The inverter does not trip even when a warning is displayed. However, failure to take appropriate measures will lead to a fault.

Alarm The inverter does not trip. An Alarm (LF) signal can also be output with a parameter setting.

Fault A protective function activates to trip the inverter and output a Fault (ALM) signal.

On the operation panel, press 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 reset signal (RES) for 0.1 s or more. (If the RES signal

is kept ON, "Err" appears (flickers) to indicate that the inverter is in

a reset status.)

ON

OFF

SD

Inverter

RES

88 PROTECTIVE FUNCTIONS

Check and clear of the fault history

4

4.3 Check and clear of the fault history The operation panel stores the fault indications which appears when a protective function is activated to display the fault

record for the past eight faults. (Fault history)

Check for the fault history

When an overcurrent trip occurs by an instantaneous overcurrent, the monitored current value saved in the fault history may be lower than the

actual current that has flowed.

The cumulative energization time and actual operation time are accumulated from 0 to 65535 hours, then cleared, and accumulated again from

0.

Fault history mode

Monitor mode Parameter setting mode Function mode

[Operation for displaying fault history] Eight past faults can be displayed with the setting dial. (The latest fault is ended by ".".)

When there is no fault history, "E0" is displayed.

Latest fault

First fault in past

Seventh fault in past

Fault history1

Output frequency

Flickering Flickering

FlickeringFlickering

Flickering Flickering

FlickeringFlickering

Cumulative energization time 2

Fault history number

Fault history number

Fault history number

Output current 1

Output voltage

Fault history2

Fault history8

Press the setting dial.

Press the setting dial.

Press the setting dial.

Time

Day

Month Year

PROTECTIVE FUNCTIONS 89

Check and clear of the fault history

Fault history clearing procedure

POINT Set Err.CL Fault history clear = "1" to clear the fault history.

Operation

1. Screen at power-ON

The monitor display appears.

2. Parameter setting mode

Press to choose the parameter setting mode. (The parameter number read previously appears.)

3. Selecting the parameter number

Turn until (fault history clear) appears. Press to read the present set value. " " (initial value) appears.

4.

Fault history clear

Turn to change the set value to " ". Press to start clear.

" " and " " flicker alternately after parameters are cleared.

Turn to read another parameter.

Press to show the setting again.

Press twice to show the next parameter.

90 PROTECTIVE FUNCTIONS

List of fault displays

4

4.4 List of fault displays For details, refer to the FR-A800 Instruction Manual (Detailed).

Operation panel indication Name

E rr

or m

es sa

ge

HOLD Operation panel lock

LOCD Password locked

to Er1 to Er4 Er8

Parameter write error

to rE1 to rE8 Copy operation error

Err. Error

W ar

n in

g

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 Safety stop

to 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

LDF Load fault warning

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

E.OLT Stall prevention stop

F au

lt

E. SOT Loss of synchronism detection

E.GF Output side earth (ground) fault overcurrent

E.LUP Upper limit fault detection

E.LDN Lower limit fault detection

E.LF Output phase loss

E.OHT External thermal relay operation

E.PTC PTC thermistor operation

E.OPT Option fault

to E.OP1 to E.OP3

Communication option fault

to E.16 to E.20

User definition error by the PLC function

E.PE Parameter storage device fault (control circuit board)

E.PUE PU disconnection

E.RET Retry count excess

E.PE2 Parameter storage device fault (main circuit board)

to

E.CPU E. 5 to E. 7

CPU fault

E.CTE

Operation panel power supply short circuit/RS-485 terminals power supply short circuit

E.P24 24 VDC power fault

E.CDO Abnormal output current detection

E.SER Communication fault (inverter)

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

to 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

Operation panel indication Name

PROTECTIVE FUNCTIONS 91

List of fault displays

If faults other than the above appear, contact your sales

representative.

F a

ul t

E.LCI 4 mA input fault

E.PCH Pre-charge fault

E.PID PID signal fault

to E. 1 to E. 3

Option fault

E.11 Opposite rotation deceleration fault

O th

er s

E---- Fault history

E. 0 No fault history

EV 24 V external power supply operation

RD Backup in progress

WR Restoration in progress

Operation panel indication Name

92 PROTECTIVE FUNCTIONS

5

PRECAUTIONS FOR MAINTENANCE AND INSPECTION 93

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..........................................................................94 5.2 Measurement of main circuit voltages, currents and

powers .......................................................................................101

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 32.)

Check the conductors and insulating materials for corrosion and damage.

Measure the insulation resistance.

Check and change the cooling fan and relay.

NOTE When using the safety stop function, periodic inspection is required to confirm that safety function of the safety system

operates correctly.

For more details, refer to the Safety Stop Function Instruction Manual.

94 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 FR-A800 Instruction Manual (Detailed)).

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 display is normal. Contact the manufacturer.

(2) Check for stain. Clean.

Meter Check that reading is normal. 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 95

Inspection item

5.1.4 Checking the inverter and converter semiconductor devices

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 tester. (For the resistance measurement, use the 100 range.)

Checking method Change the polarity of the tester alternately at the inverter terminals R/L1, S/L2, T/L3, U, V, W, P/+, and N/- and 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 . If all measured values are almost the same, although these values are not constant depending on the

module type and tester type, the modules are without fault.

Semiconductor device numbers and terminals to be checked

(Assumes the use of an analog meter.)

Tester polarity Result

Tester polarity Result

C on

ve rt

er

un it

D1 R/L1, P/+ Discontinuity

D4 R/L1, N/- Continuity

P/+ R/L1, Continuity N/- R/L1, Discontinuity

D2 S/L2, P/+ Discontinuity

D5 S/L2, N/- Continuity

P/+ S/L2, Continuity N/- S/L2, Discontinuity

D3 T/L3 P/+ Discontinuity

D6 T/L3 N/- Continuity

P/+ T/L3 Continuity N/- T/L3 Discontinuity

In ve

rt e

r

TR1 U P/+ Discontinuity

TR4 U N/- Continuity

P/+ U Continuity N/- U Discontinuity

TR3 V P/+ Discontinuity

TR6 V N/- Continuity

P/+ V Continuity N/- V Discontinuity

TR5 W P/+ Discontinuity

TR2 W N/- Continuity

P/+ W Continuity N/- W Discontinuity

Converter unit Inverter

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/-

96 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 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 FR-A800 Instruction Manual (Detailed) 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 97

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) After confirming the orientation of the fan, reinstall the fan so that the "AIR FLOW" faces up.

2) For reconnection of the fan, refer to the above figure. Tightening torque of the fan fixing screws is 0.73 Nm.

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

98 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-A800

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 number of switching operations (switching life).

The control terminal block must be replaced in case of failure of either relay between the relay output terminals C1 and B1

or A1, or terminals C2 and B2 or A2.

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.

5.1.7 Removal and reinstallation of the control circuit terminal block

This product 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 installation 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 inverter replacement, switch OFF the power, wait for at least 10 minutes, and then check the voltage with a

tester and such to ensure safety.

Loosen the screws

PRECAUTIONS FOR MAINTENANCE AND INSPECTION 99

Inspection item

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, a stress applied to the

control circuit terminal block or the control circuit connector may cause damage to them.)

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 41.)

Tighten the screws.

Slot the tongue into the groove.

Insert the terminal block parallel to the

inverter.

A Control circuit terminal blockInverter's control

circuit connector

View from side A

Control circuit terminal blockInverter's control circuit connector

100 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 equipment which has enough capacity for the current rating.

To measure and display the output voltage and output current of the inverter, it is recommended that the terminal AM and FM/

CA output functions of the inverter are used.

+ -

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 101

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 (designed for inverter)

Commercial power supply Within permissible AC voltage fluctuation (Refer to page 106.)

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/- Digital multimeter or other 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 (designed 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 (designed 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

Across AM(+) and 5 Approximately 10 VDC at maximum frequency (without frequency meter)

Across CA(+) and 5 Approximately 20 mADC at maximum frequency

Across FM(+) and SD

Approximately 5 VDC at maximum frequency (without frequency meter)

Pulse width T1: Adjust with C0 (Pr.900). Pulse cycle T2: Set with Pr.55. (frequency monitor only)

"SD" is common

Start signal Select signal Reset signal Output stop signal

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= %

8 VDC

T1

T2

102 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 digital power meters (for inverters) for the input side voltage.

Inverter output side When using a measuring instrument, use a digital power meter for inverters as the inverter outputs PWM-controlled square

wave voltage.

The value displayed on the operation panel is the inverter-controlled voltage itself. Hence, that value is accurate and it is

recommended to monitor values using the operation panel.

5.2.3 Measurement of currents Use a digital power meter (for inverter) for the input side of the converter unit (FR-CC2) and the output side of the inverter.

Since the converter unit input current 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 540 to 600 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 800

to 900 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 103

Measurement of main circuit voltages, currents and powers

5.2.6 Measurement of inverter output frequency In the initial setting of the FM-type inverter, 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 digital

multimeter 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-A800 Instruction Manual (Detailed).

In the initial setting of the CA-type inverter, a pulse train proportional to the output frequency is output across the analog

current output terminals CA and 5 of the inverter. Measure the current using a digital multimeter.

For detailed specifications of the analog current output terminal CA, refer to the FR-A800 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 Pressure test Do not conduct a pressure 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

104 PRECAUTIONS FOR MAINTENANCE AND INSPECTION

6

SPECIFICATIONS 105

6 SPECIFICATIONS

This chapter explains the "SPECIFICATIONS" of this product.

Always read the instructions before using the equipment.

6.1 Inverter rating............................................................................106 6.2 Common specifications ...........................................................107 6.3 Outline dimension drawings....................................................109

Inverter rating

6.1 Inverter rating 400 V class Inverter

The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric 4-pole standard motor.

The rated output capacity indicated assumes that the output voltage is 440 V.

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

FR-DU08: IP40 (except for the PU connector section)

For the power voltage exceeding 480 V, set Pr.977 Input voltage mode selection. (For details, refer to the FR-A800 Instruction Manual

(Detailed).)

Model FR-A842-[ ]-GF 07700 08660 09620 10940 12120 315K 355K 400K 450K 500K

Applicable motor capacity (kW)

SLD 400 450 500 560 630

LD 355 400 450 500 560

ND (initial setting) 315 355 400 450 500

HD 280 315 355 400 450

O ut

pu t

Rated capacity (kVA)

SLD 587 660 733 834 924

LD 521 587 660 733 834

ND (initial setting) 465 521 587 660 733

HD 417 465 521 587 660

Rated current (A)

SLD 770 866 962 1094 1212

LD 683 770 866 962 1094

ND (initial setting) 610 683 770 866 962

HD 547 610 683 770 866

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 (inverse-time characteristics) at surrounding air temperature of 50C

Rated voltage Three-phase 380 to 500 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 430 to 780 VDC

Control power supply auxiliary input Single phase 380 to 500 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) 163 163 243 243 243

106 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)

Communication specification Built-in CC-Link IE Field Network communication function

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, PID control, PID pre-charge function, easy dancer control, cooling fan operation selection, stop selection (deceleration stop/coasting), power failure time deceleration-to-stop function, 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, vibration 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 (FM type)

Max. 2.4 kHz: one terminal (output frequency) The monitored item can be changed using Pr.54 FM/CA terminal function selection.

Current output (CA type)

Max. 20 mADC: 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 frequency) The monitored item can be changed using Pr.158 AM terminal function selection.

Operation panel (FR-DU08)

Operating status

Output frequency, output current, output voltage, frequency setting value The monitored item can be changed using Pr.52 Operation panel main monitor selection.

Fault record Fault record is displayed when a fault occurs. Past 8 fault records and the conditions immediately before the fault (output voltage/current/frequency/cumulative energization time/year/month/date/time) are saved.

SPECIFICATIONS 107

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, Upper limit fault detection, Lower limit fault detection, Output side earth (ground) fault overcurrent, Output phase loss, External thermal relay operation, PTC thermistor operation, Option fault, Communication option fault, Parameter storage device fault (control circuit board), PU disconnection, Retry count excess, Parameter storage device fault (main circuit board), CPU fault, Operation panel power supply short circuit/RS-485 terminals power supply short circuit, 24 VDC power fault, Abnormal output current detection, Communication fault (inverter), Analog input fault, USB communication fault, Safety circuit 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, Option 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, Safety stop, 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, Load fault warning

En vi

ro nm

en t

Surrounding air temperature

0C to +50C (non-freezing) (LD, ND, HD ratings) 0C to +40C (non-freezing) (SLD rating)

Surrounding air humidity 95% RH or less (non-condensing) (With circuit board coating (conforming to IEC60721-3-3 3C2/3S2), IP55 compatible models) 90% RH or less (non-condensing) (Without circuit board coating)

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 in an altitude above 1000 m, derate the rated current 3% per 500 m.)

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.

108 SPECIFICATIONS

Outline dimension drawings

6

6.3 Outline dimension drawings FR-A842-07700(315K), FR-A842-08660(355K)

FR-A842-09620(400K), FR-A842-10940(450K), FR-A842-12120(500K)

(Unit: mm)

(Unit: mm)

3-12 hole 8- 25 hole

12 70 200

540 200 (70) 15

(1 5)

13 00

13 30

185 23

(1 7)

12 96

17185 442.5

4.5 4.5

3-12 hole 8-25 hole

(1 5)

15 50

15 80

12 100 240

680 240 (100) 15 185

442.5

4.5 4.5

17 15

46 23

(1 7)185

SPECIFICATIONS 109

Outline dimension drawings

Operation panel (FR-DU08, FR-LU08)

(Unit: mm)

27.8 FR-DU08

Operation panel connection connector (FR-ADP)(option)

66

72 .5

78 .5

3 3

3 3

72

16

17

3.2max

1 Denotes the space required to connect an optional parameter unit connection cable (FR-CB2[ ]). When using another cable, leave the space required for the cable specification.

Outline drawing Panel cutting dimension drawing

66

72 .5

21

5

22

20

Parameter unit connection cable (FR-CB2[ ] )(option)

2-M3 screw

Panel

Air-bleeding hole

120 or more1

110 SPECIFICATIONS

APPENDIX 111

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 ...........................................................112

Appendix 2 Comparison with FR-A840 ...........................................114 Appendix 3 Instructions for compliance with the EU Directives ..115 Appendix 4 Instructions for UL and cUL.........................................118 Appendix 5 Instructions for EAC .....................................................120 Appendix 6 Restricted Use of Hazardous Substances in

Electronic and Electrical Products..............................121 Appendix 7 Referenced Standard (Requirement of Chinese

standardized law) ..........................................................121

Appendix 1 For customers replacing the conventional model with this inverter

Appendix 1.1 Replacement of the FR-A740 series Difference and compatibility with FR-A740 series

Item FR-A740 FR-A842

Control method

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)

V/F control Advanced magnetic flux vector control Real sensorless vector control Vector control (with plug-in option / control terminal option) PM sensorless vector control (IPM motor/SPM motor)

Added functions - USB host function Safety stop function etc.

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

(MM-CF) 300 Hz 400 Hz

PID control Turn the X14 signal ON to enable PID control.

When the X14 signal is not assigned, just set a value 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 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 the terminal AU (The function of the terminal AU is switched by a switch.)

Input from the terminal 2. (The function of the 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 FR-DU07 (4-digit LED) FR-PU07

FR-DU08 (5-digit LED) FR-LU08 (LCD operation panel) FR-PU07 (Some functions are unavailable.) FR-DU07 is not supported.

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 (FR-HEL) is provided. Built in the converter unit (FR-CC2)

Brake unit FR-BU2, FR-BU5 FR-BU2

112 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.

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 The FR-A700 series' parameter setting can be easily copied to the FR-A800 series by using the setup software (FR

Configurator2). (Not supported by the 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 113

Appendix 2 Comparison with FR-A840

Item FR-A840 FR-A842

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 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

114 APPENDIX

Appendix 3 Instructions for compliance with the EU Directives

The EU Directives are issued to standardize different national regulations of the EU Member States and to facilitate free

movement of the equipment, whose safety is ensured, in the EU territory.

Since 1996, compliance with the EMC Directive that is one of the EU Directives has been legally required. Since 1997,

compliance with the Low Voltage Directive, another EU Directive, has been also legally required. When a manufacturer

confirms its equipment to be compliant with the EMC Directive and the Low Voltage Directive, the manufacturer must declare

the conformity and affix the CE marking.

The authorized representative in the EU

The authorized representative in the EU is shown below.

Company name: Mitsubishi Electric Europe B.V.

Address: Mitsubishi-Electric-Platz 1, 40882 Ratingen, Germany

EMC Directive We declare that this inverter conforms with the EMC Directive and affix the CE marking on the inverter.

EMC Directive: 2014/30/EU

Standard(s): EN 61800-3:2004+A1:2012 (Second environment / PDS Category "C3")

This inverter is not intended to be used on a low-voltage public network which supplies domestic premises. When using the

inverter in a residential area, take appropriate measures and ensure the conformity of the inverter used in the residential

area.

The installer shall provide a guide for installation and use, including recommended mitigation devices.

Note:

First environment

Environment including buildings/facilities which are directly connected to a low voltage main supply which also supplies

residential buildings. Directly connected means that there is no intermediate transformer between these buildings.

Second environment

Environment including all buildings/facilities which are not directly connected to a low voltage main supply which also supplies

residential buildings.

Note Ensure the EMC filter is enabled, install the product as stated below, and then carry out any wiring.

The converter unit is equipped with an EMC filter (Class C3). Enable the EMC filter. (For details, refer to page 74.)

Connect the inverter and the converter unit to an earthed (grounded) power supply.

Install the motor and controller cable found in the EMC Installation Manual (BCN-A21041-204) and Technical News

(MFS-113) according to the instructions.

To make full use of the built-in EMC filter, motor cable lengths should not exceed 20 m.

Confirm that the final application conforms with the required EMC standard.

APPENDIX 115

Low Voltage Directive We have self-confirmed our inverters as products compliant to the Low Voltage Directive and affix the CE marking on the

inverters.

Low Voltage Directive: 2014/35/EU

Conforming standard: EN 61800-5-1:2007

Outline of instructions Do not use an earth leakage current breaker as an electric shock protector without connecting the equipment to the

earth. Connect the equipment to the earth (ground) securely.

Wire the earth terminal independently. (Do not connect two or more cables to one terminal.)

Use the cable sizes on page 32 under the following conditions.

Surrounding air temperature 40C maximum

If conditions are different from above, select appropriate wire according to EN 60204-1 and IEC 60364-5-52.

Use a tinned (plating should not include zinc) crimping terminal to connect the earth (ground) cable. When tightening

the screw, be careful not to damage the threads.

For use as a product compliant with the Low Voltage Directive, use PVC cable whose size is indicated on page 32.

Use the molded case circuit breaker and magnetic contactor which conform to the EN or IEC Standard.

DC current may flow from the inverter to a protective earth (ground) conductor. When using a residual current device

(RDC) or residual current monitor (RDM), connect a type B RCD or RCM to the power supply side.

Use the inverter under the conditions of overvoltage category II (usable regardless of the earth (ground) condition of the

power supply), overvoltage category III (usable with the earthed-neutral system power supply, 400 V class only) and

pollution degree 2 or lower specified in IEC60664.

To use the inverter under the conditions of pollution degree 2, install it in the enclosure of IP2X or higher.

To use the inverter under the conditions of pollution degree 3, install it in the enclosure of IP54 or higher.

On the input and output of the inverter and the converter unit, use cables of the type and size set forth in EN 60204-1

and IEC 60364-5-52.

The operating capacity of the relay outputs (terminal symbols A1, B1, C1, A2, B2, C2) should be 30 VDC, 0.3 A. (Relay

output has basic isolation from the internal circuit of the inverter and the converter unit.)

Control circuit terminals on page 26 are safely isolated from the main circuit.

Environment (For the detail, refer to page 17.)

For installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude.

Wiring protection Class T, Class J, Class CC, or Class L fuses must be provided.

(Use a product which conforms to the EN or IEC Standard.)

Short circuit ratings Suitable For Use in A Circuit Capable of Delivering Not More Than 100 kA rms Symmetrical Amperes, 500 V Maximum.

During operation In storage During Transportation

Surrounding air temperature LD, ND (initial setting), HD: 0C to +50C SLD: 0C to +40C

-20 to +65C -20 to +65C

Ambient humidity 95%RH or less 95%RH or less 95%RH or less

Maximum altitude 2500 m 2500 m 10000 m

FR-CC2-[ ] H315K H355K H400K H450K H500K H560K H630K Rated fuse voltage (V) 500 V or more

Fuse allowable rating (A) 1100 1200 1350 1500 1800 1800 1800

116 APPENDIX

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 Instruction Manual (Detailed)) 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.

The electronic thermal memory retention function is not provided by the drive.

Operation characteristics of electronic thermal relay function

This function detects the overload 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 using the Mitsubishi Electric constant-

torque motor

(1) Set one of "1", "13" to "16" in Pr.71. (This

setting will enable the 100% constant-torque

characteristic in the low-speed range.)

(2) Set the rated current of the motor in Pr.9.

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.

When you set the electronic thermal relay

function dedicated to the Mitsubishi Electric

constant-torque motor, this characteristic curve

applies to operation at 6 Hz or higher.

Transistor protection is activated depending on

the temperature of the heatsink. 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 more330 Hz

or more3

20 Hz 10 Hz

0.5 Hz

Range for the transistor protection4

(s ) u

ni t d

is pl

ay in

th is

re gi

on (m

in ) u

ni t d

is pl

ay in

th

is re

gi on

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

APPENDIX 117

Appendix 4 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.)

Branch circuit 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 crimping terminals. Crimp the crimping terminals with the crimping

tool recommended by the terminal maker.

Short circuit ratings Suitable For Use in A Circuit Capable of Delivering Not More Than 100 kA rms Symmetrical Amperes, 500 V Maximum.

FR-CC2-[ ] H315K H355K H400K H450K H500K H560K H630K Rated fuse voltage (V) 500 V or more

Fuse allowable rating (A) 1100 1200 1350 1500 1800 1800 1800

118 APPENDIX

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 Instruction Manual (Detailed)) 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 using the Mitsubishi Electric constant-

torque motor

(1) Set one of "1", "13" to "16" in Pr.71. (This

setting will enable the 100% constant-torque

characteristic in the low-speed range.)

(2) Set the rated current of the motor in Pr.9.

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.

When you set the electronic thermal relay

function dedicated to the Mitsubishi Electric

constant-torque motor, this characteristic curve

applies to operation at 6 Hz or higher.

Transistor protection is activated depending on

the temperature of the heatsink. 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 more330 Hz

or more3

20 Hz 10 Hz

0.5 Hz

Range for the transistor protection4

(s ) u

ni t d

is pl

ay in

th is

re gi

on (m

in ) u

ni t d

is pl

ay in

th

is re

gi on

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

APPENDIX 119

Appendix 5 Instructions for EAC

The product certified in compliance with the Eurasian Conformity has the EAC marking.

Note: EAC marking

In 2010, three countries (Russia, Belarus, and Kazakhstan) established a Customs Union for the purposes of revitalizing the

economy by forming a large economic bloc by abolishing or reducing tariffs and unifying regulatory procedures for the

handling of articles.

Products to be distributed over these three countries of the Customs Union must comply with the Customs Union Technical

Regulations (CU-TR), and the EAC marking must be affixed to the products.

For information on the country of origin, manufacture year and month, and authorized sales representative (importer) in the

CU area of this product, refer to the following:

Country of origin indication

Check the rating plate of the product. (Refer to page 8.)

Example: MADE IN JAPAN

Manufactured year and month

Check the SERIAL number indicated on the rating plate of the product. (Refer to page 8.)

Authorized sales representative (importer) in the CU area

The authorized sales representative (importer) in the CU area is shown below.

Name: Mitsubishi Electric (Russia) LLC

Address: 52, bld 1 Kosmodamianskaya Nab 115054, Moscow, Russia

Phone: +7 (495) 721-2070

Fax: +7 (495) 721-2071

120 APPENDIX

Appendix 6 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

Appendix 7 Referenced Standard (Requirement of Chinese standardized law)

This Product is designed and manufactured accordance with following Chinese standards.

Machinery safety : GB/T 16855.1

GB/T 12668.502

GB 28526

GB/T 12668.3

Electrical safety : GB/T 12668.501

EMC : GB/T 12668.3

(Pb)

(Hg)

(Cd)

(Cr(VI))

(PBB)

(PBDE)

APPENDIX 121

122

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 responsibility for compensation against loss of opportunity, secondary loss, etc. 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.

123

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We do not provide a warranty against defects in the enclosed CD-ROM and related documents.

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Step 1. Start the personal computer and place the enclosed CD-ROM in the CD-ROM drive.

Step 2. Open the "index.html" file.

Step 3. The main window will open in the web browser. Follow the previous steps from Step 3 to Step 5.

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

124

REVISIONS

*The manual number is given on the bottom left of the back cover.

Revision date *Manual Number Revision Aug. 2015 IB(NA)-0600602ENG-A First edition

Jul. 2016 IB(NA)-0600602ENG-B Modification Safety stop function

Addition Instructions for EAC

Restricted Use of Hazardous Substances in Electronic and Electrical

Products

May 2019 IB(NA)-0600602ENG-C Addition Application of caution labels

Referenced Standard (Requirement of Chinese standardized law)

Removal and reinstallation precautions of the control circuit terminal block

IB(NA)-0600602ENG-C

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

1 BCN-C22005-982

FR-A800/A800 Plus Series Instruction Manual Supplement

1 Monitoring terminals S1 and S2 (FR Configurator2) Graph display using FR Configurator2 is supported for terminals S1 and S2 (data from the high speed sampling and the USB trace file). The state of terminals S1 and S2 can be displayed in graph form using FR Configurator2. The FR Configurator2 version 1.28E or later supports graph display for terminals S1 and S2. For details on FR Configurator2, refer to the FR Configurator2 Instruction Manual.

Digital source (monitor item) selection Terminals S1 and S2 can be selected as digital sources for the trace function. Select the digital sources (input/output signals) to be set to Pr.1038 to Pr.1045 from the following table. When a

value other than the ones in the following table is set, "0" (OFF) is applied for indication.

Setting value

Signal name

Setting value

Signal name

Setting value

Signal name

1 STF 21 X0 101 RUN 2 STR 22 X1 102 SU 3 AU 23 X2 103 IPF 4 RT 24 X3 104 OL 5 RL 25 X4 105 FU 6 RM 26 X5 106 ABC1 7 RH 27 X6 107 ABC2 8 JOG 28 X7 121 DO0 9 MRS 29 X8 122 DO1 10 STP(STOP) 30 X9 123 DO2 11 RES 31 X10 124 DO3 12 CS 32 X11 125 DO4 15 S2 33 X12 126 DO5 16 S1 34 X13 127 DO6

35 X14 128 RA1 36 X15 129 RA2 37 DY 130 RA3

BCN-C22005-982_ENG.fm 1

1 BCN-C22005-993

FR-A800/A800 Plus Series Instruction Manual Supplement

1 Earth (ground) fault detection at start / restricting reset method for an earth (ground) fault

The reset method for the output side earth (ground) fault overcurrent (E.GF) can be restricted. Select whether to enable or disable the earth (ground) fault detection at start. When enabled, the earth (ground)

fault detection is performed immediately after a start signal input to the inverter. Select whether to restrict the reset method for an earth (ground) fault.

Selecting whether to perform the earth (ground) fault detection at start

If an earth (ground) fault is detected at start while Pr.249 = "1 or 2", the output side earth (ground) fault overcurrent (E.GF) is detected and output is shut off.

Earth (ground) fault detection at start is enabled under V/F control and Advanced magnetic flux vector control. When the Pr.72 PWM frequency selection setting is high, enable the earth (ground) fault detection at start.

NOTE Because the detection is performed at start, output is delayed for approx. 20 ms every start. Use Pr.249 to enable/disable the earth (ground) fault detection at start. During operation, earth (ground) faults are

detected regardless of the Pr.249 setting.

Restricting reset method for an earth (ground) fault The reset method when the output is shut off due to the output side earth (ground) fault overcurrent (E.GF) can

be restricted. When E.GF occurs while Pr.249 = "2", E.GF can be reset only by turning OFF the control circuit power.

This restriction prevents the inverter from being damaged due to repeated reset operations by the other methods such as entering the RES signal.

When E.GF occurs while Pr.249 = "2", the output short-circuit detection (ALM4) signal can be output. For the terminal used to output the ALM4 signal, set "23" (positive logic) or "123" (negative logic) in any of Pr.190

to Pr.196 (Output terminal function selection). If Pr.249 is set to "2" while the retry function is enabled (Pr.67 is not set to "0"), no retry is performed even when

E.GF occurs. If Pr.249 is set to "2" while the automatic bypass switching after inverter fault is enabled (Pr.138 is not set to "1"),

the operation is not switched to the commercial power supply operation even when E.GF occurs.

NOTE Changing the terminal assignment using Pr.190 to Pr.196 (Output terminal function selection) may affect the

other functions. Set parameters after confirming the function of each terminal. E.GF is not cleared by turning ON the Fault clear (X51) signal when Pr.249 = "2". If E.GF occurs during emergency drive operation when Pr.249 = "2", the output is shut off.

Pr. Name Initial value Setting range Description

Earth (ground) fault Reset method

249 H101

Earth (ground) fault detection at start 0

0 Not detected at start Not restricted

1 Detected at start

2 Restricted

V/F Magnetic flux

2 BCN-C22005-993

2 Output short-circuit fault (E.SCF) Select the reset operation and fault indication for an output short-circuit.

The fault indication for an output short-circuit (E.OC1 to E.OC3, and E.SCF) can be changed by the Pr.521 setting.

When an output short-circuit is detected while Pr.521 = "1", E.SCF is displayed and the inverter output is shut off. When E.SCF occurs while Pr.521 = "1", E.SCF can be reset only by turning OFF the control circuit power. (E.OC1

to E.OC3 can be reset by any reset method.) This restriction prevents the inverter from being damaged due to repeated reset operations by the other methods

such as entering the RES signal. When E.SCF occurs, the output short-circuit detection (ALM4) signal can be output. For the terminal used to output the ALM4 signal, set "23" (positive logic) or "123" (negative logic) in any of Pr.190

to Pr.196 (Output terminal function selection). If the automatic bypass switching after inverter fault is enabled (Pr.138 is not set to "1"), the operation is not

switched to the commercial power supply operation even when E.SCF occurs.

NOTE When short-circuit resistance is large, the current does not reach the short-circuit detection level. In such a case,

an output short-circuit cannot be detected. Changing the terminal assignment using Pr.190 to Pr.196 (Output terminal function selection) may affect the

other functions. Set parameters after confirming the function of each terminal. E.SCF does not activate the retry function. E.SCF is not cleared by turning ON the Fault clear (X51) signal. If E.SCF occurs during emergency drive operation, the output is shut off. The communication data code for E.SCF is 20 (H14).

Pr. Name Initial value Setting range

Description Operation after detection Reset method

521 H194

Output short-circuit detection 0

0 E.OC1 to E.OC3 Not restricted 1 E.SCF Restricted

Operation panel indication E.SCF FR-LU08

indication Fault

Name Output short-circuit fault

Description The inverter output is shut off when an output short-circuit is detected while Pr.521 = "1". When Pr.521 = "0" (initial value), E.OC1, E.OC2, or E.OC3 appears when an output short-circuit is detected.

Check point Check for output short-circuit.

Corrective action Check the wiring to make sure that any output short circuit does not occur, then turn OFF the control circuit power to reset the inverter.

3 BCN-C22005-993

3 Extended detection time of the output current and zero current

The setting range of the Pr.151 Output current detection signal delay time and Pr.153 Zero current detection time is extended.

4 Selecting the command interface in the Network operation mode (Pr.338, Pr.339)

The proximity dog (X76) signal can be input via communication. The following table shows the command interface for the function in the Network operation mode, determined by

the parameter settings: an external terminal or a communication interface (RS-485 terminals or communication option).

[Explanation of Terms in Table] EXT: External terminal only Combined: Either external terminal or communication interface

Pr. Name Initial value Setting range Description

151 M461

Output current detection signal delay time 0 s 0 to 300 s

Set the output current detection time. Enter the time from when the output current reaches the set current or higher to when the Output current detection (Y12) signal is output.

153 M463

Zero current detection time 0.5 s 0 to 300 s

Set the time from when the output current drops to the Pr.152 setting or lower to when the Zero current detection (Y13) signal is output.

Pr.338 Communication operation command source 0: NET 1: EXT Pr.339 Communication speed command source 0: NET 1: EXT 2: EXT 0: NET 1: EXT 2: EXT

X76 Proximity dog Combined EXT

INVERTER

IN VER

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800 FR

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F IN STR

U C

TIO N

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A R

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A R

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INTRODUCTION 1

INSTALLATION AND WIRING 2

PRECAUTIONS FOR USE OF THE INVERTER 3

PROTECTIVE FUNCTIONS 4

PRECAUTIONS FOR MAINTENANCE AND

INSPECTION 5

SPECIFICATIONS 6

IB(NA)-0600602ENG-C(1905)MEE Printed in Japan Specifications subject to change without notice.

A800-GF FR-A802-GF (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE) FR-A842-07700(315K) to 12120(500K)-GF

HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

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