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Mitsubishi Electric FR-CC2-H355K Instruction Manual

F800 series, fr-f802 separated converter type.
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INVERTER
F800
FR-F802 (SEPARATED CONVERTER TYPE)
INSTRUCTION MANUAL (HARDWARE)
Inverter for fans and pumps
FR-F842-07700(355K) to 12120(560K)
INTRODUCTION
INSTALLATION AND WIRING
PRECAUTIONS FOR USE OF
THE INVERTER
PROTECTIVE FUNCTIONS
PRECAUTIONS FOR
MAINTENANCE AND
INSPECTION
SPECIFICATIONS
1
2
3
4
5
6

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Table of Contents

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   Summary of Contents for Mitsubishi Electric FR-CC2-H355K

  • Page 1 INVERTER F800 FR-F802 (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE) Inverter for fans and pumps FR-F842-07700(355K) to 12120(560K) INTRODUCTION INSTALLATION AND WIRING PRECAUTIONS FOR USE OF THE INVERTER PROTECTIVE FUNCTIONS PRECAUTIONS FOR MAINTENANCE AND INSPECTION SPECIFICATIONS...
  • Page 2: Safety Instructions

     Be sure to perform daily and periodic inspections as specified in engineering training. Such training may be available at your local Mitsubishi Electric office. Contact your local sales the Instruction Manual. If this product is used without any office for schedules and locations.
  • Page 3 CAUTION CAUTION Transportation and installation Usage  The temporary storage temperature (applicable to a short limited  The electronic thermal O/L relay function may not be enough for protection of a motor from overheating. It is recommended to time such as a transportation time) must be between -20 and install an external thermal relay or a PTC thermistor for overheat +65°C.
  • Page 4: Table Of Contents

    CONTENTS 1 INTRODUCTION Product checking Inverter component names About the related manuals 2 INSTALLATION AND WIRING Peripheral devices 2.1.1 Inverter and peripheral devices ........................12 2.1.2 Peripheral devices ............................14 Removal and reinstallation of the operation panel and the front covers Installation of the inverter and enclosure design 2.3.1 Inverter installation environment........................17 2.3.2...
  • Page 5 3 PRECAUTIONS FOR USE OF THE INVERTER 55 Electro-magnetic interference (EMI) and leakage currents 3.1.1 Leakage currents and precautions ......................... 56 3.1.2 Precautions against inverter-generated EMI ....................59 3.1.3 Converter unit (FR-CC2) built-in EMC filter....................62 Power supply harmonics 3.2.1 Power supply harmonics ..........................
  • Page 6 5.2.7 Measurement of inverter output frequency .....................93 5.2.8 Insulation resistance test using megger ......................93 5.2.9 Pressure test..............................93 6 SPECIFICATIONS Inverter rating Common specifications Outline dimension drawings APPENDIX Appendix1 For customers replacing the conventional model with this inverter........ 102 Appendix2 Comparison with FR-F840 ....................104 Appendix3 Instructions for compliance with the EU Directives............
  • Page 7 MEMO...
  • Page 8: Introduction

    Parameter unit ....Parameter unit (FR-PU07) PU ........Operation panel and parameter unit Inverter......Mitsubishi Electric inverter FR-F800 series (Separated converter type) Pr........Parameter number (Number assigned to function) PU operation ..... Operation using the PU (operation panel/parameter unit) External operation.....
  • Page 9: Product Checking

    Product checking Product checking Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model agrees with the order and the product is intact. Inverter model ∗1 Symbol Voltage class Symbol Structure, functionality Symbol Description Symbol Type...
  • Page 10: Inverter Component Names

    Inverter component names Inverter component names Component names are as follows. Refer to Symbol Name Description page RS-485 terminals Enables RS-485, MODBUS RTU, and BACnet communication. Plug-in option connector 1 Instruction Plug-in option connector 2 Connects a plug-in option or a communication option. Manual of the option Plug-in option connector 3...
  • Page 11: About The Related Manuals

    About the related manuals About the related manuals The manuals related to the FR-F800 are as follows. Manual name Manual number FR-F800 Instruction Manual (Detailed) IB-0600547ENG FR-CC2 (Converter unit) 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...
  • Page 12: Installation And Wiring

    INSTALLATION AND WIRING This chapter explains the installation and the wiring of this product. Always read the instructions before use. 2.1 Peripheral devices ..............12 2.2 Removal and reinstallation of the operation panel and the front covers ................15 2.3 Installation of the inverter and enclosure design ....17 2.4 Terminal connection diagrams ..........25...
  • Page 13: Peripheral Devices

    Peripheral devices Peripheral devices 2.1.1 Inverter and peripheral devices (c) Three-phase AC power supply (d) Molded case (b) Converter unit (a) Inverter (k) USB connector circuit breaker (FR-CC2) (FR-F802) USB host (MCCB) or earth (A connector) leakage current breaker (ELB), Communication fuse status indicator...
  • Page 14 Peripheral devices Refer Symbol Name Overview page The life of the inverter and the converter unit is influenced by the surrounding air temperature. Inverter (FR-F802) The surrounding air temperature should be as low as possible within the permissible range. This must be noted especially when the inverter and the converter unit installed in an enclosure.
  • Page 15: Peripheral Devices

    1212  The applicable 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.
  • Page 16: Removal And Reinstallation Of The Operation Panel And The Front Covers

    Removal and reinstallation of the operation panel and the front covers Removal and reinstallation of the operation panel and the front covers Removal and reinstallation of the operation panel • Loosen the two screws on the operation panel. • Press the upper edge of the operation panel while pulling (These screws cannot be removed.) out the operation panel.
  • Page 17 Removal and reinstallation of the operation panel and the front covers Removal of the front cover (upper side) Loosen Loosen Loosen With the front cover (lower side) removed, loosen the mounting screws on the front cover (upper side). These screws cannot be removed.
  • Page 18: Installation Of The Inverter And Enclosure Design

    Installation of the inverter and enclosure design Installation of the inverter and enclosure design When designing or manufacturing an inverter enclosure, determine the structure, size, and device layout of the enclosure by fully considering the conditions such as heat generation of the contained devices and the operating environment. An inverter uses many semiconductor devices.
  • Page 19 Installation of the inverter and enclosure design (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.
  • Page 20: Amount Of Heat Generated By The Inverter

    Installation of the inverter 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 the converter unit is shown in the following tables.
  • Page 21: Cooling System Types For Inverter Enclosure

    Installation of the inverter and enclosure design 2.3.3 Cooling system types for inverter enclosure From the enclosure that contains the inverter, the heat of the inverter and other equipment (transformers, lamps, resistors, etc.) and the incoming heat such as direct sunlight must be dissipated to keep the in-enclosure temperature lower than the permissible temperatures of the in-enclosure equipment including the inverter.
  • Page 22: Inverter Installation

    Installation of the inverter 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. •...
  • Page 23 Installation of the inverter and enclosure design Arrangement of multiple inverters and converter units When multiple inverters and converter units are placed in the same enclosure, generally arrange them horizontally as shown in the figure on the right. Converter Converter Inverter Inverter unit...
  • Page 24: Protruding The Heat Sink Through A Panel

    Installation of the inverter and enclosure design 2.3.5 Protruding the heat sink through a panel When encasing an inverter to an enclosure, the heat generated in the enclosure can be greatly reduced by protruding the heat sink of the inverter. When installing the inverter in a compact enclosure, etc., this installation method is recommended.
  • Page 25 Installation of the inverter and enclosure design  Removal of the rear installation frame 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 Upper installation and bottom of the inverter as shown on the right.
  • Page 26: Terminal Connection Diagrams

    Terminal connection diagrams Terminal connection diagrams FM type Sink logic Main circuit terminal Brake unit Control circuit terminal (Option) Converter unit R/L1 Motor S/L2 T/L3 Jumper Earth (Ground) R1/L11  S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output ...
  • Page 27 Terminal connection diagrams  &&A jumper is installed across terminal R1/L11 and terminal P/+, and across terminal S1/L21 and terminal N/-. When using separate power supply for the control circuit, remove the jumpers.  The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ...
  • Page 28: Main Circuit

    Terminal connection diagrams CA type Sourse logic Main circuit terminal Brake unit Control circuit terminal (Option) Converter unit R/L1 Motor S/L2 T/L3 Jumper Earth (Ground) R1/L11  S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output  (No voltage input allowed) ...
  • Page 29 Terminal connection diagrams  &&A jumper is installed across terminal R1/L11 and terminal P/+, and across terminal S1/L21 and terminal N/-. When using separate power supply for the control circuit, remove the jumpers.  The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ...
  • Page 30: Main Circuit Terminals

    Main circuit terminals Main circuit terminals 2.5.1 Details on the main circuit terminals of the inverter Terminal Refer Terminal name Terminal function description symbol to page U, V, W Inverter output Connect these terminals to a three-phase squirrel cage motor or a PM motor. - Connected to the terminals P/+ and N/-.
  • Page 31: Terminal Layout Of The Main Circuit Terminals, Wiring Of Power Supply And The Motor

    Main circuit terminals 2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor FR-CC2-H355K to FR-CC2-H630K FR-F842-07700(355K) to FR-F842-12120(560K) R1/L11 S1/L21 Charge lamp R1/L11 S1/L21 Charge lamp Jumper Jumper R/L1 T/L3 S/L2 To converter To inverter...
  • Page 32: Applicable Cables And Wiring Length

    Main circuit terminals 2.5.4 Applicable cables and wiring length Select a recommended cable size to ensure that the voltage drop ratio is within 2%. If the wiring distance is long between the inverter and motor, the voltage drop in the main circuit will cause the motor torque to decrease especially at a low speed.
  • Page 33 Main circuit terminals The line voltage drop can be calculated by the following formula: × wire resistance[mΩ/m] × wiring distance[m] × current[A] Line voltage drop [V]= 1000 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.
  • Page 34: Earthing (grounding) Precautions

    Main circuit terminals 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.
  • Page 35: Control Circuit

    Control circuit 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 Instruction Manual (Detailed) of the FR-F800. Input signal Terminal Terminal name...
  • Page 36 Control circuit Terminal Terminal name Terminal function description Rate Specification Symbol 10 0.4 VDC When connecting the frequency setting potentiometer at an initial Permissible load current: 10 mA Frequency setting status, connect it to terminal 10. power supply Change the input specifications of terminal 2 using Pr.73 when 50.5 VDC connecting it to terminal 10E.
  • Page 37 Control circuit Terminal Terminal name Terminal function description Rate Specification Symbol The output is in LOW state when the inverter output frequency is equal Inverter running to or higher than the starting frequency (initial value: 0.5 Hz). The output is in HIGH state during stop or DC injection brake operation. Permissible load: 24 The output is in LOW state when the output VDC (maximum 27...
  • Page 38 Control circuit Safety stop signal For the safety stop function, refer to page Terminal Terminal name Terminal function description Rate Specification Symbol Use terminals S1 and S2 to receive the safety stop signal input from the Safety stop input safety relay module. Terminals S1 and S2 can be used at a time (dual (Channel 1) channel).
  • Page 39: Details On The Control Circuit Terminals Of The Converter Unit (fr-cc2)

    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 Instruction Manual of the FR-CC2. Input signal Terminal Terminal name...
  • Page 40: Control Logic (sink/source) Change

    Control circuit Output signal Terminal Terminal name Terminal function description Rate Specification Symbol 1 changeover contact output that indicates that the protective function of Contact capacity: 230 Relay output 1 (fault the converter unit has been activated and the outputs are stopped. VAC 0.3 A (power output) Fault: discontinuity across B and C (continuity across A and C), Normal:...
  • Page 41 Control circuit Sink logic and source logic • In the sink logic, a signal turns ON when a current exits from the corresponding signal input terminal. Terminal SD is common to the contact input signals. Terminal SE is common to the open collector output signals. •...
  • Page 42: Wiring Of Inverter Control Circuit

    Control circuit 2.6.4 Wiring of inverter control circuit Control circuit terminal layout • Recommended cable gauge: 0.3 to 0.75 mm ∗1 1 F/C +24 SD So SOC S1 S2 PC 5 10E 10 SE SE IPF OL FU PC RL RM RH RT AU STP MRS SD SD STF STR JOG...
  • Page 43 Control circuit NICHIFU Co.,Ltd. Blade terminal Insulation cap Crimping tool Wire gauge (mm part No. part No. model No. 0.3 to 0.75 BT 0.75-11 VC 0.75 NH 69 (3) Insert each wire into the terminal. When using single wire or stranded wires without a crimp terminal, push the open/close button all the way down with a flathead screwdriver, and insert the wire.
  • Page 44: Wiring Precautions

    Control circuit 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. Inverter +24V +24V...
  • Page 45: When Using Separate Power Supplies For The Control Circuit And The Main Circuit

    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 mm to 2 mm •...
  • Page 46: When Supplying 24 V External Power To The Control Circuit

    Control circuit 2.6.7 When supplying 24 V external power to the control circuit Connect a 24 V external power supply across terminals +24 and SD. Connecting a 24 V external power supply enables I/O terminal ON/OFF operation, operation panel displays, control functions, and communication during communication operation even during power-OFF of inverter's main circuit power supply.
  • Page 47: Safety Stop Function

    Control circuit Operation while the 24 V external power is supplied • Faults 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. •...
  • Page 48: Connection Diagram

    Control circuit 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. Inverter/ Converter unit R/L1 S/L2 T/L3 So (SO) Logic IGBTs +24V Gate...
  • Page 49: Communication Connectors And Terminals

    Communication connectors and terminals 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.
  • Page 50: Usb Connector

    Communication connectors and terminals 2.7.2 USB connector USB host (A connector) Communication status Place a flathead screwdriver, indicator (LED) etc. in a slot and push up the USB device cover to open. (Mini B connector) Personal computer (FR Configurator2) USB host communication Interface Conforms to USB1.1 Transmission speed...
  • Page 51: Rs-485 Terminal Block

    Communication connectors and terminals USB device communication A USB (Ver. 1.1) cable connects the inverter with a personal computer. Parameter setting and monitoring can be performed by FR Configurator2. Interface Conforms to USB1.1 Transmission speed 12 Mbps Wiring length Maximum 5 m Connector USB mini B connector (receptacle) Power supply...
  • Page 52: Connection Of Stand-alone Option Units

    Connection of stand-alone option units 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. 2.8.1 Connection of the brake unit (FR-BU2) Connect the brake unit (FR-BU2) as shown below to improve the braking capability during deceleration.
  • Page 53: Connection Of The High Power Factor Converter (fr-hc2)

    Connection of stand-alone option units 2.8.2 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, set "rated motor voltage"...
  • Page 54: Connection Of The Power Regeneration Converter (mt-rc)

    Connection of stand-alone option units 2.8.3 Connection of the power regeneration converter (MT-RC) When connecting the power regeneration converter (MT-RC), perform wiring securely as shown below. Incorrect connection will damage the power regeneration converter and the inverter. After making sure that the wiring is correct, set "1" in Pr.30 Regenerative function selection.
  • Page 55 MEMO...
  • Page 56: Precautions For Use Of The Inverter

    PRECAUTIONS FOR USE OF THE INVERTER This chapter explains the precautions for use of this product. Always read the instructions before using the equipment. 3.1 Electro-magnetic interference (EMI) and leakage currents ..56 3.2 Power supply harmonics ............63 3.3 Installation of a reactor ............66 3.4 Power-OFF and magnetic contactor (MC) ......67...
  • Page 57: Electro-magnetic Interference (emi) And Leakage Currents

    Electro-magnetic interference (EMI) and leakage currents Electro-magnetic interference (EMI) and leakage currents 3.1.1 Leakage currents and precautions Capacitances exist between the inverter I/O cables, other cables and earth and in the motor, through which a leakage current flows. Since its value depends on the static capacitances, carrier frequency, etc., low acoustic noise operation at the increased carrier frequency of the inverter will increase the leakage current.
  • Page 58 Electro-magnetic interference (EMI) and leakage currents 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. •...
  • Page 59 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.
  • Page 60: Precautions Against Inverter-generated Emi

    Electro-magnetic interference (EMI) and leakage currents 3.1.2 Precautions against inverter-generated EMI Some electromagnetic noises enter the inverter or the converter unit to cause its malfunction, and others are radiated by the inverter or the converter unit to cause the peripheral devices to malfunction. Though the inverter or the converter unit is designed to have high immunity performance, it handles low-level signals, so it requires the following basic techniques.
  • Page 61 Electro-magnetic interference (EMI) and leakage currents Noise Precautions propagation path 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.
  • Page 62 Electro-magnetic interference (EMI) and leakage currents EMI precautions example Enclosure Decrease carrier frequency Install filter on inverter output side. Inverter Line noise Converter power Inverter Motor filter filter unit supply Use 4-core cable for motor Separate inverter, power cable and use one cable converter unit and as earth (ground) cable.
  • Page 63: Converter Unit (fr-cc2) Built-in Emc Filter

    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, connect two EMC filter ON/OFF female connectors to the ON male connectors.
  • Page 64: Power Supply Harmonics

    Power supply harmonics 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.
  • Page 65: Harmonic Suppression Guidelines

    Power supply harmonics 3.2.2 Harmonic Suppression Guidelines 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"...
  • Page 66 Power supply harmonics • 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 64), harmonics must be calculated with the following procedure: P0 = ∑...
  • Page 67: Installation Of A Reactor

    Installation of a reactor 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.
  • Page 68: Power-off And Magnetic Contactor (mc)

    Power-OFF and magnetic contactor (MC) 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.) •...
  • Page 69: Precautions Against Deterioration Of The 400 V Class Motor Insulation

    Precautions 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.
  • Page 70: Checklist Before Starting Operation

    Checklist before starting operation Checklist before starting operation The FR-F800 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. Refer Check Point to be checked...
  • Page 71 Checklist before starting operation Refer Check Point to be checked Action to page by user • 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.
  • Page 72 Checklist before starting operation Refer Check Point to be checked Action to page by user 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 Precautions are taken for an by reducing current at locked condition, starting current, etc.
  • Page 73: Failsafe System Which Uses The Inverter

    Failsafe system which uses the inverter Failsafe system which uses the inverter When a fault is detected by the protective function, the protective function is activated to 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.
  • Page 74 Failsafe system which uses the inverter (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.
  • Page 75 MEMO...
  • Page 76: Protective Functions

    PROTECTIVE FUNCTIONS This chapter explains the "PROTECTIVE FUNCTIONS" that operates in this product. Always read the instructions before using the equipment. 4.1 Inverter fault and alarm indications ........76 4.2 Reset method for the protective functions......76 4.3 Check and clear of the faults history ........77 4.4 List of fault displays ..............79...
  • Page 77: Inverter Fault And Alarm Indications

    Inverter fault and alarm indications 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 is activated to trip the inverter. •...
  • Page 78: Check And Clear Of The Faults History

    Check and clear of the faults history Check and clear of the faults 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. (Faults history) Check for the faults history Monitor mode Parameter setting mode...
  • Page 79 Check and clear of the faults history Faults history clearing procedure POINT POINT • Set Err.CL Fault history clear = "1" to clear the faults history. Operation Screen at power-ON The monitor display appears. Parameter setting mode Press to choose the parameter setting mode. (The parameter number read previously appears.) Selecting the parameter number Turn until "...
  • Page 80: List Of Fault Displays

    List of fault displays List of fault displays For details, refer to the Instruction Manual (Detailed) of the FR-F800. Operation panel (FR-DU08) Operation panel (FR-DU08) Name Name indication indication Output side earth (ground) E.GF HOLD Operation panel lock fault overcurrent E.LF Output phase loss LOCD...
  • Page 81 List of fault displays Operation panel (FR-DU08) Name indication E---- Faults history No fault records 24 V external power supply operation Backup in progress Restoration in progress If faults other than the above appear, contact your sales representative. PROTECTIVE FUNCTIONS...
  • Page 82: Precautions For Maintenance And Inspection

    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................82 5.2 Measurement of main circuit voltages, currents and powers ..................89 PRECAUTIONS FOR MAINTENANCE AND INSPECTION...
  • Page 83: Inspection Item

    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.
  • Page 84: Daily And Periodic Inspection

    Inspection item 5.1.3 Daily and periodic inspection Inspection Check Area of interval Corrective action at Inspection item Description by the inspection fault occurrence Periodic Daily user  Surrounding Check the surrounding air temperature, humidity,  Improve the environment. environment dirt, corrosive gas, oil mist, etc. Check fault location and Check for unusual vibration and noise.
  • Page 85: Checking The Inverter And Converter Modules

    Inspection item 5.1.4 Checking the inverter and converter modules Preparation • Disconnect the external power supply cables (R/L1, S/L2, T/L3) and motor cables (U, V, W). (The inverter and the converter unit (FR-CC2) can be measured with those cables connected.) •...
  • Page 86: Cleaning

    Inspection item 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. •...
  • Page 87 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.
  • Page 88: Removal And Reinstallation Of The Control Circuit Terminal Block

    Inspection item Smoothing capacitors A large-capacity aluminum electrolytic capacitor is used for smoothing in the main circuit DC section, and an aluminum electrolytic capacitor is used for stabilizing the control power in the control circuit. Their characteristics are deteriorated by the adverse effects of ripple currents, etc.
  • Page 89 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. •...
  • Page 90: Measurement Of Main Circuit Voltages, Currents And Powers

    Measurement of main circuit voltages, currents and powers 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.
  • Page 91 Measurement of main circuit voltages, currents and powers Measuring points and instruments Item Measuring point Measuring instrument Remarks (reference measured value) Power supply Across R/L1 and S/L2, Commercial power supply voltage S/L2 and T/L3, Moving-iron type AC voltmeter Within permissible AC voltage fluctuation (Refer ...
  • Page 92: Measurement Of Powers

    Measurement of main circuit voltages, currents and powers  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.
  • Page 93: Measurement Of Currents

    Measurement of main circuit voltages, currents and powers 5.2.3 Measurement of currents Use moving-iron type meter on the input side of the converter unit (FR-CC2) and the output side of the inverter. However, if the carrier frequency exceeds 5 kHz, do not use that meter since an overcurrent losses produced in the internal metal parts of the meter will increase and the meter may burn out.
  • Page 94: Measurement Of Inverter Output Frequency

    Measurement of main circuit voltages, currents and powers 5.2.7 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 meter (moving-coil type voltmeter) can be used to read the mean value of the pulse train output voltage.
  • Page 95 MEMO...
  • Page 96: Specifications

    SPECIFICATIONS This chapter explains the "SPECIFICATIONS" of this product. Always read the instructions before using the equipment. 6.1 Inverter rating................96 6.2 Common specifications ............97 6.3 Outline dimension drawings............99 SPECIFICATIONS...
  • Page 97: Inverter Rating

    Forced air cooling Approx. mass (kg)  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.
  • Page 98: Common Specifications

    Common specifications Common specifications Soft-PWM control / high carrier frequency PWM control (Selectable among V/F control (Optimum excitation control), Control method Advanced magnetic flux vector control (Advanced optimum excitation control) and PM motor control) Output frequency range 0.2 to 590 Hz (The upper-limit frequency is 400 Hz under Advanced magnetic flux vector control, and PM motor control.) 0.015 Hz/60 Hz (terminal 2, 4: 0 to 10 V/12 bits) Frequency Analog input...
  • Page 99 Common specifications Surrounding air -10°C to +50°C (non-freezing) (LD rating) -10°C to +40°C (non-freezing) (SLD rating) temperature With circuit board coating (conforming to IEC60721-3-3 3C2/3S2): 95% RH or less (non-condensing) Surrounding air humidity Without circuit board coating: 90% RH or less (non-condensing) Storage temperature ...
  • Page 100: Outline Dimension Drawings

    Outline dimension drawings Outline dimension drawings FR-F842-07700(355K), FR-F842-08660(400K) 3-φ12 hole 8-φ25 hole (70) (Unit: mm) FR-F842-09620(450K), FR-F842-10940(500K), FR-F842-12120(560K) 3-φ12 hole 8-φ25 hole (100) (Unit: mm) SPECIFICATIONS...
  • Page 101 Outline dimension drawings Operation panel (FR-DU08) Outline drawing Panel cutting dimension drawing 120 or more ∗1 Panel 3.2max 27.8 Parameter unit FR-DU08 connection cable (FR-CB2[ ] )(option) Air-bleeding hole Operation panel connection connector 2-M3 screw (FR-ADP)(option) ∗1 Denotes the space required to connect an optional parameter unit connection cable (FR-CB2[ ]).
  • Page 102: Appendix

    APPENDIX APPENDIX provides the reference information for use of this product. Refer to APPENDIX as required. Appendix1 For customers replacing the conventional model with this inverter ............102 Appendix2 Comparison with FR-F840 ..........104 Appendix3 Instructions for compliance with the EU Directives ..105 Appendix4 Instructions for UL and cUL .........108...
  • Page 103: Appendix1 For Customers Replacing The Conventional Model With This Inverter

    Appendix1 For customers replacing the conventional model with this inverter Appendix1.1 Replacement of the FR-F740(P) series Difference and compatibility with FR-F740(P) series Item FR-F740(P) FR-F842 V/F control V/F control Control method Simple magnetic flux vector control Advanced magnetic flux vector control IPM motor control PM motor control (IPM motor/SPM motor) USB host function...
  • Page 104 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-F800 series, many functions (parameters) have been added. When setting these parameters, the parameter names and setting ranges are not displayed.
  • Page 105: Appendix2 Comparison With Fr-f840

    Appendix2 Comparison with FR-F840 Item FR-F842 Remarks (FR-F840) Setting ranges "0 to 2, 10, 11, 20, 21, 100, 101, 110, Pr.30 Regenerative Setting ranges "2, 10, 11, 102, 110, 111" 111, 120, 121" Initial value "10" function selection Initial value "0" Monitor function (Pr.52, Pr.54, Pr.158, Emergency drive status...
  • Page 106: Appendix3 Instructions For Compliance With The Eu Directives

    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.
  • Page 107: Low Voltage Directive

    Low Voltage Directive We have self-confirmed our inverters as products compliant to the Low Voltage Directive (Conforming standard EN 61800-5- 1) and affix the CE marking on the inverters.  Outline of instructions • Do not use an earth leakage current breaker as an electric shock protector without connecting the equipment to the earth.
  • Page 108 Range for  When you set the electronic thermal relay function the transistor protection ∗4 dedicated to the Mitsubishi Electric constant-torque motor, this characteristic curve applies to operation at 6 Hz or higher. 105% 52.5%  Transistor protection is activated depending on the...
  • Page 109: Appendix4 Instructions For Ul And Cul

    Appendix4 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.
  • Page 110 It is not the percentage to the rated motor current. Range for the transistor  When you set the electronic thermal relay function protection ∗4 dedicated to the Mitsubishi Electric constant-torque motor, this characteristic curve applies to operation at 6 Hz or 105% 52.5% higher. 100 120 ...
  • Page 111: Appendix5 Instructions For Eac

    • 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...
  • Page 112: Appendix 6 Restricted Use Of Hazardous Substances In Electronic And Electrical Products

    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”...
  • Page 113 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.
  • Page 114 • The copyright and other rights of the enclosed CD-ROM all belong to Mitsubishi Electric Corporation. • No part of the enclosed CD-ROM may be copied or reproduced without the permission of Mitsubishi Electric Corporation. • Specifications of the enclosed CD-ROM are subject to change for modification without notice.
  • Page 115 REVISIONS *The manual number is given on the bottom left of the back cover. Print Date *Manual Number Revision Jul. 2014 IB(NA)-0600550ENG-A First edition Jun. 2018 IB(NA)-0600550ENG-B Modification • Short circuit ratings for UL Addition • Instructions for EAC • Restricted Use of Hazardous Substances in Electronic and Electrical Products •...
  • Page 116 HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN FR-F802 INSTRUCTION Model MANUAL (HARDWARE) Model code 1A2-P54 IB(NA)-0600550ENG-B(1806)MEE Printed in Japan Specifications subject to change without notice.

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