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Mitsubishi Electric A800 Plus Instruction Manual

Separated converter type, roll to roll function.
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INVERTER
FR-A802-R2R (SEPARATED CONVERTER TYPE)
INSTRUCTION MANUAL (HARDWARE)
Roll to Roll Function
FR-A842-07700(315K) to 12120(500K)-R2R
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

   Also See for Mitsubishi Electric A800 Plus

   Summary of Contents for Mitsubishi Electric A800 Plus

  • Page 1 INVERTER FR-A802-R2R (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE) Roll to Roll Function FR-A842-07700(315K) to 12120(500K)-R2R INTRODUCTION INSTALLATION AND WIRING PRECAUTIONS FOR USE OF THE INVERTER PROTECTIVE FUNCTIONS PRECAUTIONS FOR MAINTENANCE AND INSPECTION SPECIFICATIONS...
  • Page 2  Be sure to perform daily and periodic inspections as specified in • A person who took a proper engineering training. Such training may be available at your local Mitsubishi Electric the Instruction Manual. If a product is used without any office.
  • 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 time such as a transportation time) must be between -20 and protection of the motor from overheating. It is recommended to +65°C.
  • Page 4: The Inverter

    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...
  • Page 5: Table Of Contents

    CONTENTS 1 INTRODUCTION Product checking and accessories Inverter component names About the related manuals 2 INSTALLATION AND WIRING Peripheral devices 2.1.1 Inverter and peripheral devices ........................14 2.1.2 Peripheral devices............................16 Removal and reinstallation of the front cover Installation of the inverter and enclosure design 2.3.1 Inverter installation environment ........................
  • Page 6 2.11 Installing a communication option 3 PRECAUTIONS FOR USE OF THE INVERTER 71 Electro-magnetic interference (EMI) and leakage currents 3.1.1 Leakage currents and countermeasures ......................72 3.1.2 Precautions against inverter-generated EMI ....................75 3.1.3 Converter unit (FR-CC2) built-in EMC filter ....................78 Power supply harmonics 3.2.1 Power supply harmonics..........................79 3.2.2...
  • Page 7 5.2.6 Measurement of inverter output frequency....................108 5.2.7 Insulation resistance test using megger ....................... 108 5.2.8 Pressure test ..............................108 6 SPECIFICATIONS Inverter rating Common specifications Outline dimension drawings 6.3.1 Inverter outline dimension drawings......................113 APPENDIX Appendix 1 Comparison with FR-A840-R2R.................... 116 Appendix 2 Instructions for compliance with the EU Directives............
  • Page 8: Introduction

    Operation panel ......Operation panel and LCD operation panel Parameter unit ........ Parameter unit (FR-PU07) PU ........... Operation panel and parameter unit Inverter..........Mitsubishi Electric inverter FR-A800 series (Separated converter type) FR-A800-E ........Mitsubishi Electric inverter FR-A800 series (Ethernet model) Ethernet board ........ Ethernet communication board (FR-A8ETH) Vector control compatible option..
  • Page 9: Product Checking And Accessories

    Product checking and accessories 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 ∗1 Symbol Voltage class Symbol...
  • Page 10 Product checking and accessories How to read the SERIAL number Rating plate example The SERIAL consists of one symbol, two characters indicating the production     year and month, and six characters indicating the control number. Symbol Year Month Control number The last digit of the production year is indicated as the Year, and the Month is...
  • Page 11: Inverter Component Names

    Inverter component names Inverter component names Component names are shown below. RS-485 model Refer to Symbol Name Description page RS-485 terminals Enables RS-485 and MODBUS RTU 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 12 Inverter component names Ethernet model Refer to Symbol Name Description page Instruction Plug-in option connector 1 Connects a plug-in option or a communication option. Manual of Plug-in option connector 3 the option The connector 2 cannot be used because the Ethernet board is installed in the initial Plug-in option connector 2 status.
  • Page 13: About The Related Manuals

    About the related manuals About the related manuals The manuals related to FR-A800 are shown below. Manual name Manual number FR-A800 Instruction Manual (Detailed) IB-0600503ENG Roll to Roll Function Manual IB-0600622ENG FR-A800-E-R2R Ethernet Function Manual IB-0600813ENG FR-CC2 Instruction Manual IB-0600543ENG FR Configurator2 Instruction Manual IB-0600516ENG FR-A800 PLC Function Programming Manual...
  • Page 14: Installation And Wiring

    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 ..............14 2.2 Removal and reinstallation of the front cover......18 2.3 Installation of the inverter and enclosure design ....20 2.4 Terminal connection diagrams ..........27...
  • Page 15: Peripheral Devices

    Peripheral devices Peripheral devices 2.1.1 Inverter and peripheral devices (c) Three-phase AC power supply (d) Moulded case (b) Converter unit (a) Inverter (k) USB connector circuit breaker (FR-CC2) (FR-A802) USB host (MCCB) or earth (A connector) leakage current breaker (ELB), Communication fuse status indicator...
  • Page 16 Peripheral devices Refer Symbol Name Overview to page The life of the inverter and the converter unit is influenced by the surrounding air temperature. Inverter (FR-A802) 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.
  • Page 17: Peripheral Devices

    400K 09620 H400K 400K 09620 450K 10940 H450K 450K 10940 500K 12120 H500K 500K 12120 H560K H630K ∗1 The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric 4-pole standard motor. INSTALLATION AND WIRING...
  • Page 18 FR-CC2-H630K 2000 A 1400 A rated product ∗1 Assumes the use of a Mitsubishi Electric 4-pole standard motor with the power supply voltage of 400 VAC 50 Hz. ∗2 Select an MCCB according to the power supply capacity. Install one MCCB per converter.
  • Page 19: Removal And Reinstallation Of The Front

    Removal and reinstallation of the front cover Removal and reinstallation of the front cover 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 20 Removal and reinstallation of the front cover Removal of the front cover Loosen Loosen Loosen With the terminal block cover removed, loosen the screws on the front cover. These screws cannot be removed. While holding the areas around the installation hooks on the sides of the front cover, pull out the front cover using its upper side as a support.
  • Page 21: 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 22 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 23: Cooling System Types For Inverter Enclosure

    Installation of the inverter and enclosure design 2.3.2 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 24: Inverter Installation

    Installation of the inverter and enclosure design 2.3.3 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 25 Installation of the inverter and enclosure design Encasing multiple inverters and converter units When multiple inverters and converter units are placed in the same enclosure, arrange them horizontally as shown in the figure on the right. Converter Converter Inverter Inverter unit unit Do not place multiple products vertically.
  • Page 26: Protruding The Heat Sink Through A Panel

    Installation of the inverter and enclosure design 2.3.4 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 27 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 28: Terminal Connection Diagrams

    Terminal connection diagrams Terminal connection diagrams FM type (RS-485 model) 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 ∗1 S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output ∗7 (No voltage input allowed) ∗2 Forward rotation start...
  • Page 29 Terminal connection diagrams ∗1 Terminals R1/L11 and S1/L21 are connected to 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. ∗2 The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ∗3 Terminal JOG is also used as the pulse train input terminal.
  • Page 30 Terminal connection diagrams CA type (RS-485 model) Source logic Main circuit terminal Brake unit Control circuit terminal (Option) Converter unit R/L1 Motor S/L2 T/L3 Jumper Earth (Ground) R1/L11 ∗1 S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output ∗7 (No voltage input allowed) ∗2 Forward rotation start Relay output 1...
  • Page 31 Terminal connection diagrams ∗1 Terminals R1/L11 and S1/L21 are connected to 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. ∗2 The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ∗3 Terminal JOG is also used as the pulse train input terminal.
  • Page 32 Terminal connection diagrams FM type (Ethernet model) 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 ∗1 S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output ∗7 (No voltage input allowed) ∗2 Forward rotation start Relay output 1...
  • Page 33 Terminal connection diagrams ∗1 Terminals R1/L11 and S1/L21 are connected to 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. ∗2 The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ∗3 Terminal JOG is also used as the pulse train input terminal.
  • Page 34 Terminal connection diagrams CA type (Ethernet model) Source logic Main circuit terminal Brake unit Control circuit terminal (Option) Converter unit R/L1 Motor S/L2 T/L3 Jumper Earth (Ground) R1/L11 ∗1 S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output ∗7 (No voltage input allowed) ∗2 Forward rotation start Relay output 1...
  • Page 35 Terminal connection diagrams ∗1 Terminals R1/L11 and S1/L21 are connected to 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. ∗2 The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ∗3 Terminal JOG is also used as the pulse train input terminal.
  • Page 36 Terminal connection diagrams 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. Across terminals P and P and 50 m or lower Total wiring...
  • Page 37: 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. Connected to terminals P/+ and N/-.
  • Page 38: 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-H315K to FR-CC2-H500K FR-A842-07700(315K) to FR-A842-12120(500K) R1/L11 S1/L21 Charge lamp R1/L11 S1/L21 Charge lamp Jumper Jumper R/L1 T/L3 S/L2 To converter To inverter unit Power supply Motor...
  • Page 39: 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 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.
  • Page 40 Main circuit terminals Total wiring length 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.) Total wiring length 300 m 300 m 500 m or less 300 m + 300 m = 600 m 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.
  • Page 41: 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 42: 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 FR-A800 Instruction Manual (Detailed). Input signal Terminal Rated...
  • Page 43 Control circuit Terminal Rated Terminal name Terminal function description Symbol specification 10 VDC ±0.4 V 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 in Pr.73 when connecting 5 VDC ±0.5 V it to terminal 10E.
  • Page 44 Control circuit Terminal Rated Terminal name Terminal function description Symbol specification Switched to LOW when the inverter output frequency is equal to or Inverter running higher than the starting frequency (initial value 0.5 Hz). Switched to Permissible load 24 HIGH during stop or DC injection brake operation. VDC (maximum 27 Switched to LOW when the output frequency VDC) 0.1 A...
  • Page 45 Control circuit Communication Terminal Terminal Terminal function description symbol name Communication can be made via Ethernet. Category: 100BASE-TX/10BASE-T Data transmission speed: 100 Mbps (100BASE-TX) / 10 Mbps (10BASE-T) Transmission method: Baseband Ethernet — Maximum segment length: 100 m between the hub and the inverter connector Number of cascade connection stages: Up to 2 (100BASE-TX) / up to 4 (10BASE-T) Interface: RJ-45...
  • Page 46: 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 FR-CC2 Instruction Manual. Input signal Terminal Rated...
  • Page 47: Control Logic (sink/source) Change

    Control circuit Output signal Terminal Rated Terminal name Terminal function description Symbol specification 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 48 Control circuit 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. •...
  • Page 49: Wiring Of Inverter Control Circuit

    Control circuit 2.6.4 Wiring of inverter control circuit Control circuit terminal layout ∗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 ∗4 ∗2...
  • Page 50 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 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.
  • Page 51: Wiring Precautions

    Control circuit Signal inputs by contactless switches The contact input terminals of the inverter (STF, STR, STOP, RH, RM, RL, JOG, RT, MRS, RES, AU, CS) can be controlled using a transistor instead of a contact switch as shown below. Inverter +24 V +24 V...
  • Page 52: 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 53: 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 54 Control circuit Operation while the 24 V external power is supplied • Fault records and parameters can be read and parameters can be written (when the parameter write from the operation panel is enabled) using the operation panel keys. • The safety stop function is disabled during the 24 V external power supply operation. •...
  • Page 55: Safety Stop Function

    Control circuit 2.6.8 Safety stop function Function description The terminals related to the safety stop function are shown below. Terminal Terminal function description symbol Between S1 and SIC, S2 and SIC For input of the safety stop channel 1. ∗1 Open: In safety stop mode For input of the safety stop channel 2.
  • Page 56 Control circuit Safety stop function operation Output Input terminal Output Operation panel Input Internal safety Inverter running signal terminal indication ∗1 ∗2 power circuit status status ∗8 ∗9 ∗10 So (SO) SAFE E.SAF ∗6 ∗7 ― ― ― Output shutoff (Safe state) Not displayed Not displayed Normal Drive enabled Not displayed Not displayed...
  • Page 57: Communication Connectors And Terminals

    Communication connectors and terminals Communication connectors and terminals 2.7.1 PU connector Mounting the operation panel (FR-DU08) or parameter unit (FR-PU07) on the enclosure surface • Having an operation panel (FR-DU08) or a parameter unit (FR-PU07) on the enclosure surface is convenient. With a connection cable, the operation panel (FR-DU08) or the parameter unit (FR-PU07) can be mounted to the enclosure surface and connected to the inverter.
  • Page 58: Usb Connector

    Communication connectors and terminals 2.7.2 USB connector USB host (A connector) Communication status indicator (LED) Place a flathead screwdriver, etc. in a slot and push up the USB device cover to open. (Mini B connector) USB host communication Interface Conforms to USB 1.1 Transmission speed 12 Mbps Wiring length...
  • Page 59: Rs-485 Terminal Block (rs-485 Model)

    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 Configurator 2. Interface Conforms to USB 1.1 Transmission speed 12 Mbps Wiring length Maximum 5 m Connector USB mini B connector (receptacle)
  • Page 60: Ethernet Port (ethernet Model)

    Communication connectors and terminals 2.7.4 Ethernet port (Ethernet model) Ethernet communication specifications Item Description Category 100BASE-TX/10BASE-T Data transmission speed 100 Mbps (100BASE-TX) / 10 Mbps (10BASE-T) Transmission method Baseband Maximum segment length 100 m between the hub and the inverter Number of cascade connection stages Up to 2 (100BASE-TX) / up to 4 (10BASE-T) Interface...
  • Page 61: Connection Of Motor With Encoder (vector Control)

    Connection of motor with encoder (vector control) Connection of motor with encoder (vector control) Using encoder-equipped motors together with a vector control compatible option enables speed and torque control operations under orientation control, encoder feedback control, and full-scale vector control. This section explains wiring for use of the FR-A8AP.
  • Page 62 Connection of motor with encoder (vector control) Switches of the FR-A8AP • Encoder type selection switch (SW3) Differential line Selects either the differential line driver or complementary setting. driver (initial status) It is initially set to the differential line driver. Switch its position according to the output circuit.
  • Page 63 Connection of motor with encoder (vector control) Encoder cable FR-JCBL FR-V7CBL F-DPEVSB 12P 0.2 mm D/MS3057-12A F-DPEVSB 12P 0.2 mm D/MS3057-12A Approx. 140 mm Approx. 140 mm Earth cable Earth cable ∗1 60 mm 60 mm D/MS3106B20-29S D/MS3106B20-29S • Shield earthing P-clip is Model Length L (m) Model...
  • Page 64 Connection of motor with encoder (vector control) • Connection terminal compatibility table Encoder cable FR-V7CBL FR-JCBL Do not connect anything to this. Do not connect anything to this. FR-A8AP terminal Do not connect anything to this. Wiring example • Speed control Vector control dedicated motor, Standard motor with encoder, 5 V differential line driver 12 V complementary...
  • Page 65 Connection of motor with encoder (vector control) ∗1 The pin number differs according to the encoder used. The control works properly with or without the Z-phase being connected. ∗2 Connect the encoder so that there is no looseness between the motor and motor shaft. Speed ratio must be 1:1. ∗3 Earth (ground) the shield of the encoder cable to the enclosure using a tool such as a P-clip.
  • Page 66: Parameter Settings For A Motor With Encoder

    Parameter settings for a motor with encoder Parameter settings for a motor with encoder Parameter for the encoder (Pr.359, Pr.369, Pr.851, Pr.852) • Set the encoder specifications. Initial Setting Name Description value range Set when using a motor for which forward Set for the operation at 120 Hz or rotation (encoder) is clockwise (CW) viewed less.
  • Page 67: Connection Of Stand-alone Option Units

    Connection of stand-alone option units 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.
  • Page 68: Connection Of The High Power Factor Converter (fr-hc2)

    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, set "rated motor voltage"...
  • Page 69: Connection Of The Power Regeneration Converter (mt-rc)

    Connection of stand-alone option units 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 46.) •...
  • Page 70: Installing A Communication Option

    Installing a communication option 2.11 Installing a communication option • To use a communication option, the enclosed earthing (grounding) cable needs to be installed. Install the cable according to the following procedure. Installation procedure Insert spacers into the mounting holes that will not be tightened with the option mounting screws. Fit the connector of the communication option to the guide of the connector of the inverter, and insert the option as far as it goes.
  • Page 71 MEMO...
  • Page 72: 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 ..72 3.2 Power supply harmonics ............79 3.3 Installation of a reactor ............82 3.4 Power-OFF and magnetic contactor (MC) ......83...
  • Page 73: 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 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.
  • Page 74 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 75 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 76: 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 77 Electro-magnetic interference (EMI) and leakage currents Noise Countermeasure 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 78 Electro-magnetic interference (EMI) and leakage currents EMI countermeasure 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 79: 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, fit the EMC filter ON/OFF connector to the ON position.
  • Page 80: 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 81: Harmonic Suppression Guidelines In Japan

    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"...
  • Page 82 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 80), harmonics must be calculated with the following procedure: P0 = ∑...
  • Page 83: 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 84: 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 16 for selection.) •...
  • Page 85: Countermeasures Against Deterioration Of The 400 V Class Motor Insulation

    Countermeasures against deterioration of the 400 V class motor insulation 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.
  • Page 86: Checklist Before Starting Operation

    Checklist before starting operation 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. Refer Check Checkpoint...
  • Page 87 Checklist before starting operation Refer Check Checkpoint Countermeasure to page by user • Make sure that terminal P/+ of the converter unit and terminal P/+ of the inverter, and terminal N/- of the converter unit and terminal N- of the inverter are correctly connected.
  • Page 88 Checklist before starting operation Refer Check Checkpoint Countermeasure 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 A countermeasure is provided for an by reducing current at locked condition, starting current, etc.
  • Page 89: 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 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.
  • Page 90 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 (Y12) signal is output when the inverter operates and current flows into the motor. Check if the Y12 signal is being output while inputting a start signal to the inverter.
  • Page 91 MEMO...
  • Page 92: 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 indications...........92 4.2 Reset method for the protective functions......92 4.3 Check and clear of the fault history ........93 4.4 List of fault displays ..............95...
  • Page 93: Inverter Fault And Indications

    Inverter fault and indications Inverter fault and indications • When a fault occurs in the inverter, a protective function is automatically activated to shut off the inverter output and show an indication on the operation panel of the inverter. • When any fault occurs, take an appropriate corrective action, then reset the inverter, and resume the operation. Restarting the operation without a reset may break or damage the inverter.
  • Page 94: Check And Clear Of The Fault History

    Check and clear of the fault history 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 Monitor mode Parameter setting mode...
  • Page 95 Check and clear of the fault history Clearing the fault history POINT POINT • Set Err.CL Fault history clear = "1" to clear the fault history. Operation Turning ON the power of the inverter The monitor display appears. Selecting the parameter setting mode Press to choose the parameter setting mode.
  • Page 96: List Of Fault Displays

    List of fault displays List of fault displays For details, refer to the FR-A800 Instruction Manual (Detailed). Operation panel indication Name Operation panel indication Name E.LF Output phase loss HOLD Operation panel lock External thermal relay E.OHT LOCD Password locked operation E.PTC PTC thermistor operation...
  • Page 97 List of fault displays Operation panel indication Name E---- Fault 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 98: 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................98 5.2 Measurement of main circuit voltages, currents and powers ..................105 PRECAUTIONS FOR MAINTENANCE AND INSPECTION...
  • Page 99: 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 100: 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 ∗3 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 101: Checking The Inverter And Converter Semiconductor Devices

    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.) •...
  • Page 102: 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 103 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 104 Inspection item 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.
  • Page 105: Removal And Reinstallation Of The Control Circuit Terminal Block

    Inspection item 5.1.7 Removal and reinstallation of the control circuit terminal block The FR-A800 series inverter has a removable control circuit terminal block, which can be replaced with a new one or a control terminal option. Removal and reinstallation 1) Loosen the two mounting screws at the both side of the control circuit terminal block. (These screws cannot be removed.) Slide down the control circuit terminal block to remove it.
  • Page 106: 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 107 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, Within permissible AC voltage fluctuation (Refer T/L3 and R/L1 page 110.)
  • Page 108: Measurement Of Powers

    Measurement of main circuit voltages, currents and powers ∗1 Use an FFT to measure the output voltage accurately. A tester or general measuring instrument cannot measure accurately. ∗2 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 109: Measurement Of Inverter Output Frequency

    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.
  • Page 110: Specifications

    SPECIFICATIONS This chapter explains the "SPECIFICATIONS" of this product. Always read the instructions before using the equipment. 6.1 Inverter rating................110 6.2 Common specifications ............111 6.3 Outline dimension drawings............113 SPECIFICATIONS...
  • Page 111: Inverter Rating

    Cooling system Forced air cooling Approx. mass (kg) ∗1 The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric 4-pole standard motor. ∗2 For the SND rating, the carrier frequency is always 2 kHz. ∗3 The rated output capacity indicated assumes that the output voltage is 440 V.
  • Page 112: Common Specifications

    Common specifications Common specifications Soft-PWM control, high carrier frequency PWM control (selectable among V/F control, Advanced magnetic flux vector Control method control, Real sensorless vector control), Optimum excitation control, and vector control ∗1 0.2 to 590 Hz (The upper frequency limit is 400 Hz (200 Hz for the SND rating) under Advanced magnetic flux vector Output frequency range control, Real sensorless vector control, and vector control ∗1...
  • Page 113 Common specifications 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, Upper limit fault detection , Lower limit fault ∗5...
  • Page 114: Outline Dimension Drawings

    Outline dimension drawings Outline dimension drawings 6.3.1 Inverter outline dimension drawings FR-A842-07700(315K), FR-A842-08660(355K)-R2R 3-φ12 hole 8-φ25 hole (70) (Unit: mm) FR-A842-09620(400K), FR-A842-10940(450K), FR-A842-12120(500K)-R2R 3-φ12 hole 8-φ25 hole (100) (Unit: mm) SPECIFICATIONS...
  • Page 115 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 116: Appendix

    APPENDIX APPENDIX provides the reference information for use of this product. Refer to APPENDIX as required. Appendix 1 Comparison with FR-A840-R2R ........116 Appendix 2 Instructions for compliance with the EU Directives ..117 Appendix 3 Instructions for UL and cUL .........120 Appendix 4 Instructions for EAC .............122 Appendix 5 Restricted Use of Hazardous Substances in...
  • Page 117: Appendix 1 Comparison With Fr-a840-r2r

    Appendix 1 Comparison with FR-A840-R2R Item FR-A840-R2R FR-A842-R2R Setting ranges "0 to 2, 10, 11, 20, 21, 100 to 102, Pr.30 Regenerative Setting ranges "2, 10, 11, 102, 110, 111" 110, 111, 120, 121" function selection Initial value "10" Initial value "0" Pr.70 Special With the parameter Without the parameter...
  • Page 118: Appendix 2 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 119 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.
  • Page 120 It is not the percentage to the rated motor current. protection ∗4 ∗3 When you set the electronic thermal relay function dedicated to the Mitsubishi Electric constant-torque motor, 105% 52.5% this characteristic curve applies to operation at 6 Hz or higher.
  • Page 121: Appendix 3 Instructions For Ul And Cul

    Appendix 3 Instructions for UL and cUL (Standard to comply with: UL 508C, CSA C22.2 No.274-13) General Precaution CAUTION - Risk of Electric Shock - The bus capacitor discharge time is 10 minutes. Before starting wiring or inspection, switch power off, wait for more than 10 minutes, and check for residual voltage between terminal P/+ and N/- with a meter etc., to avoid a hazard of electrical shock.
  • Page 122 It is not the percentage to the rated motor current. protection ∗4 ∗3 When you set the electronic thermal relay function dedicated to the Mitsubishi Electric constant-torque motor, this characteristic 52.5% 105% curve applies to operation at 6 Hz or higher. ∗4...
  • Page 123: Appendix 4 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 124: Appendix 5 Restricted Use Of Hazardous Substances In Electronic And Electrical Products

    Appendix 5 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 125 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 126 • 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 127 REVISIONS *The manual number is given on the bottom left of the back cover. Revision Date *Manual Number Revision Jan. 2016 IB(NA)-0600607ENG-A First edition Aug. 2018 IB(NA)-0600607ENG-B Addition • Ethernet model • Restricted Use of Hazardous Substances in Electronic and Electrical Products •...
  • Page 128 HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN IB(NA)-0600607ENG-C(1905)MEE Printed in Japan Specifications subject to change without notice.

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