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Chapter 3 Precautions for Use of the Inverter....56 Electro-magnetic interference (EMI) and leakage currents ......56 3.1.1 Leakage currents and countermeasures.
Safety Instructions Thank you for choosing Mitsubishi Electric inverter. This Instruction Manual provides detailed instructions for advanced settings of the FR-E800 series inverters. Incorrect handling might cause an unexpected fault. Before using this product, read this Instruction Manual and the document enclosed with the product carefully to ensure proper use.
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Electric shock prevention WARNING Do not remove the front cover or the wiring cover while the power of this product is ON, and do not run this product with the front cover or the wiring cover removed as the exposed high voltage terminals or the charging part of the circuitry can be touched.
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Additional instructions The following instructions must be also followed. If the product is handled incorrectly, it may cause unexpected fault, an injury, or an electric shock. CAUTION Transportation and installation To prevent injury, wear cut-resistant gloves when opening packaging with sharp tools. ...
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WARNING Usage Stay away from the equipment after using the retry function in this product as the equipment will restart suddenly after the output shutoff of this product. Access to the motor is allowed only after it is fully confirmed that the motor does not start running. ...
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CAUTION Usage When installing the MC on the output side of the inverter, turn it ON/OFF while both the inverter and motor are at a stop. The electronic thermal O/L relay function may not be enough for protection of a motor from overheating. It is recommended to install an external thermal relay for overheat protection.
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General instruction For clarity, illustrations in this Instruction Manual may be drawn with covers or safety guards removed. Ensure all covers and safety guards are properly installed prior to starting operation. For details on the PM motor, refer to the Instruction Manual of the PM motor.
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CHAPTER 1 Introduction Product checking and accessories .........................11 Component names ..............................13 Operation steps ..............................16 About the related manuals............................18...
Introduction The contents described in this chapter must be read before using this product. Always read the instructions before use. Abbreviations Item Description Operation panel Inverter Mitsubishi Electric inverter FR-E800 series Parameter number (Number assigned to function) PU operation Operation using the PU External operation Operation using the control circuit signals...
Product checking and accessories Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model agrees with the order and the product is intact. Inverter model Rating plate Inverter model MODEL :FR-E860-0017-1 Input rating INPUT :XXXXX...
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• E: Availability of circuit board coating / plated conductors is shown. Symbol Circuit board coating Plated conductor None Without coating Without plated conductors With coating Without plated conductors With coating With plated conductors Conforming to IEC 60721-3-3 3C2 NOTE •...
Component names Standard model Component names are as follows. 1. Introduction 1.2 Component names...
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Refer to Symbol Name Description page Instruction Plug-in option connection connector Connects a plug-in option or a communication option. Manual of the option Control logic switch Select the sink logic (SINK) or the source logic (SOURCE). Voltage/current input switch Select voltage or current for the input via terminals 2 and 4. PU connector Used for the RS-485 communication.
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Ethernet model Component names are as follows. Refer to Symbol Name Description page Instruction Plug-in option connection connector Connector for a plug-in option or a communication option. Manual of the option Control logic switch Select the sink logic (SINK) or the source logic (SOURCE). Voltage/current input switch Select voltage or current for the input via terminals 2 and 4.
Operation steps : Initial setting Step of operation Frequency command Installation/mounting Inverter output Wiring of the power frequency supply and motor Time (Hz) Start command Control mode selection Start command via the PU/Ethernet connector of the inverter and plug-in to give a start to give a start to give a start option (Communication)
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Symbol Overview Refer to page Install the inverter. Perform wiring for the power supply and the motor. Select the control method (V/F control, Advanced magnetic flux vector control, Real sensorless vector control, Instruction Manual and PM sensorless vector control). (Function) Instruction Manual Give the start command via communication.
About the related manuals The manuals related to FR-E800 are as follows. Manual name Manual number FR-E800 Inverter Safety Guideline IB-0600857ENG FR-E800-E Inverter Safety Guideline IB-0600860ENG FR-E860 Inverter Safety Guideline IB-0600862ENG FR-E860-E Inverter Safety Guideline IB-0600863ENG FR-E800 Instruction Manual (Function) IB-0600868ENG FR-E800 Instruction Manual (Communication) IB-0600871ENG...
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CHAPTER 2 Installation and Wiring Peripheral devices ..............................20 Removal and reinstallation of the front cover ......................23 Installation of the inverter and enclosure design ....................25 Terminal connection diagrams..........................30 Main circuit terminals ..............................34 Control circuit................................38 Communication connectors and terminals......................49 Connection of stand-alone option units ........................53...
Installation and Wiring This chapter explains the installation and the wiring of this product. Always read the instructions before use. Peripheral devices 2.1.1 Inverter and peripheral devices (b) Three-phase AC power supply (c) Molded case circuit breaker (h) USB power supply (MCCB) or earth leakage USB device current breaker (ELB), fuse...
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Refer to Symbol Name Overview page The life of the inverter is influenced by the surrounding air temperature. The surrounding air temperature should be as low as possible within the permissible range. This must be noted especially when the inverter is Inverter (FR-E800) installed in an enclosure.
2.1.2 Peripheral devices Check the model of the inverter you purchased. Appropriate peripheral devices must be selected according to the capacity. Refer to the following table for right selection. Molded case circuit breaker / earth leakage circuit breaker • The following shows the rated current of the molded case circuit breaker (MCCB) or earth leakage circuit breaker (ELB). Without AC/DC With AC/DC power Inverter model...
Removal and reinstallation of the front cover Removal of the front cover Loosen Loosen Loosen Loosen the screw on the front cover. (This screw cannot be removed.) Pull out the cover using its lower side as a support. With the cover removed, the control circuit terminals can be wired and the plug-in option can be installed. ...
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Removal of the wiring cover (FR-E860-0040(2.2K) or lower) Guides Guides Guides Screwdriver Screwdriver Screwdriver Insert a tool such as a flathead screwdriver into the half-hole above the "PUSH" mark on the wiring cover to push the cover behind the wiring cover approx.
Installation of the inverter and enclosure design 2.3.1 Inverter installation environment The following table lists the standard specifications of the inverter installation environment. Using the inverter in an environment that does not satisfy the conditions deteriorates the performance, shortens the life, and causes a failure. Refer to the following points, and take adequate measures.
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Humidity Operate the inverter within the ambient air humidity of usually 45 to 90% (up to 95% with circuit board coating). Too high humidity will pose problems of reduced insulation and metal corrosion. On the other hand, too low humidity may cause a spatial electrical breakdown.
Countermeasure • Provide the enclosure with rubber vibration isolators. • Strengthen the structure to prevent the enclosure from resonance. • Install the enclosure away from the sources of the vibration. 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.
2.3.3 Inverter installation Inverter placement Front cover Comb-shaped wiring cover • Remove the front cover and wiring cover to fix the inverter. • Install the inverter on a strong surface securely with screws. • Leave enough clearances and take cooling measures. •...
When installing multiple inverters, fully take measures to prevent the surrounding air temperature of the inverter from being higher than the permissible value by providing ventilation or increasing the enclosure size. Inverter Inverter Inverter Inverter Guide Guide Guide Inverter Inverter Enclosure Enclosure (b) Vertical arrangement...
Terminal connection diagrams Standard model Sink logic Main circuit terminal Control circuit terminal DC reactor Earth (Ground) PR N/- Jumper MCCB Motor R/L1 Three-phase S/L2 AC power T/L3 supply Earth (Ground) Main circuit Earth (Ground) Control circuit Relay output
Control input signals (No voltage input allowed) Forward rotation start...
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The initial setting varies depending on the specification. Terminal input specifications can be changed by analog input specification switchover (Pr.73, Pr.267). To input voltage, set the voltage/current input selection switch to "V". To input current, set the switch to "I". The initial setting varies depending on the specification. (Refer to the FR-E800 Instruction Manual (Function).) It is recommended to use 2 W 1 kΩ...
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Ethernet model Sink logic Main circuit terminal Control circuit terminal DC reactor Earth (Ground) PR N/- Jumper MCCB Motor R/L1 Three-phase S/L2 AC power T/L3 supply Earth (Ground) Earth Main circuit (Ground) Control circuit Relay output
Control input signals (No voltage input allowed)
Forward rotation start Relay output...
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NOTE • To prevent a malfunction due to noise, keep the signal cables 10 cm or more away from the power cables. Also, keep the cables of the main circuit for input and output separated. • After wiring, wire offcuts must not be left in the inverter. Wire offcuts can cause a fault, failure or malfunction.
Main circuit terminals 2.5.1 Details on the main circuit terminals Refer to Terminal symbol Terminal name Terminal function description page R/L1, S/L2, T/L3 AC power input Connect these terminals to the commercial power supply. — Connect these terminals to a three-phase squirrel cage motor or a PM U, V, W Inverter output —...
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The cable size is that of the HIV cable (600 V grade heat-resistant PVC insulated wire) etc. with continuous maximum permissible temperature of 75°C. It assumes a surrounding air temperature of 50°C or lower and the wiring distance of 20 m or shorter. The cable size is that of the THHW cable with continuous maximum permissible temperature of 75°C.
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NOTE • Especially for long-distance wiring, the inverter may be affected by a charging current caused by stray capacitances of the wiring, leading to an activation of the overcurrent protection, malfunction of the fast-response current limit operation, or even to an inverter failure. It may also cause a malfunction or fault of the equipment connected ON the inverter output side. If the fast-response current limit function malfunctions, disable the function.
2.5.4 Earthing (grounding) precautions Always earth (ground) the motor and inverter. Purpose of earthing (grounding) Generally, an electrical apparatus has an earth (ground) terminal, which must be connected to the ground before use. An electrical circuit is usually insulated by an insulating material and encased. However, it is impossible to manufacture an insulating material that can shut off a leakage current completely, and actually, a slight current flows into the case.
Control circuit 2.6.1 Details on the control circuit terminals (standard model) Input signal Refer Terminal Type Terminal name Terminal function description Rated specification symbol page Turn ON the STF signal to start When the STF and Forward rotation start forward rotation and turn it OFF to STR signals are turned stop.
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Refer Terminal Type Terminal name Terminal function description Rated specification symbol page 5 ±0.5 VDC, Frequency setting Used as the power supply for an external frequency setting permissible load current: power supply (speed setting) potentiometer. 10 mA Inputting 0 to 5 VDC (or 0 to 10 VDC) provides the maximum output frequency at 5 V (or 10 V) and makes input and output proportional.
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Safety stop signal Terminal Refer to Terminal name Terminal function description Rated specification symbol page Use terminals S1 and S2 to receive the safety stop signal input from the safety relay module. Terminals S1 and S2 can be used Input resistance: 4.7 kΩ, Safety stop input at a time (dual channel).
2.6.2 Details on the control circuit terminals (Ethernet model) Input signal Refer Terminal Type Terminal name Terminal function description Rated specification symbol page Turn ON the STF signal to start Input resistance: 4.7 kΩ, When the STF and Forward rotation start forward rotation and turn it OFF to voltage when contacts STR signals are turned...
Output signal Terminal Refer Type Terminal name Terminal function description Rated specification symbol to page 1 changeover contact output that indicates that an inverter's protective function has been activated and the outputs are Contact capacity: 240 Relay output (fault stopped.
(The output signals may be used in either the sink or source logic independently of the switch setting.) For sink logic SINK SOURCE NOTE • Never change the control logic while power is ON. 2.6.4 Wiring of control circuit Control circuit terminal layout ...
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Ethernet model • Recommended cable gauge: 0.3 to 0.75 mm S1 S2 PC D10 DI1 SD SO SOC Wiring method Power supply connection Use crimp terminals and stripped wire for the control circuit wiring. For single wire, the stripped wire can be used without crimp terminal.
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• Phoenix Contact Co., Ltd. Ferrule part No. Wire gauge Crimping tool Without insulation model No. With insulation sleeve sleeve AI 0,34-10TQ — AI 0,5-10WH — 0.75 AI 0,75-10GY A 0,75-10 CRIMPFOX 6 AI 1-10RD A 1-10 1.25, 1.5 AI 1, 5-10BK A 1, 5-10 0.75 (two-wire AI-TWIN 2×0,75-10GY...
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NOTE • Pulling out the wire forcefully without pushing the open/close button all the way down may damage the terminal block. • Use a small flathead screwdriver (tip thickness: 0.4 mm / tip width: 2.5 mm). If a flathead screwdriver with a narrow tip is used, terminal block may be damaged. Commercially available products (as of April 2019) Product Model...
2.6.5 Safety stop function Function description The terminals related to the safety stop function are as follows. Terminal Terminal function description symbol Status of both the circuit between terminals S1 and PC and the Input terminal as the safety stop channel 1. circuit between terminals S2 and PC Open: Safety stop is activated.
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Safety stop function operation Internal Output Operation panel *1*2 *8*9*10 Input terminal Output signal Inverter Input safety terminal indication operating power circuit status SAFE SAFE2 E.SAF status Output shutoff — — — (Safe state) displayed displayed Operation Normal enabled displayed displayed Output shutoff...
Communication connectors and terminals 2.7.1 PU connector (standard model) Mounting the operation panel on the enclosure surface • Having an enclosure surface operation panel (FR-PA07) is convenient. With a connection cable, the operation panel can be mounted to the enclosure surface and connected to the inverter. To connect the operation panel to the inverter, use an option FR-CB2[], or a connector (RJ-45 connector) and cable (communication cable) available on the market.
2.7.2 Ethernet connector (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 Up to 2 (100BASE-TX) / up to 4 (10BASE-T) stages Topology...
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Wiring method Connection Turn OFF the power of the programmable controller and the inverter. Remove the inverter front cover. Check the orientation of the connectors. Insert the connector part of the Ethernet cable to the communication connector until it clicks. ...
2.7.3 USB connector USB device communication The inverter can be connected to a computer with a USB (ver. 1.1) cable. Parameter setting and monitoring can be performed by using FR Configurator2. Interface Conforms to USB 1.1 (USB 2.0 full speed) Transmission speed 12 Mbps Wiring length...
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 Instruction Manual of the corresponding option unit. 2.8.1 Connection of the brake resistor •...
2.8.2 Connection of the DC reactor • When using the DC reactor, connect it to terminals P/+ and P1. In this case, the jumper connected across terminals P/+ and P1 must be removed. Otherwise, the reactor will not be effective. DC reactor Remove the jumper...
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CHAPTER 3 Precautions for Use of the Inverter Electro-magnetic interference (EMI) and leakage currents ..................56 Power supply harmonics............................60 Installation of a reactor ............................61 Power shutdown and magnetic contactor (MC)......................62 Countermeasures against deterioration of the 600 V class motor insulation............64 Checklist before starting operation .........................65 Failsafe system which uses the inverter .........................68...
Precautions for Use of the Inverter This chapter explains the precautions for use of this product. Always read the instructions before use. 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.
Countermeasures • Use Pr.9 Electronic thermal O/L relay. • If the carrier frequency setting is high, decrease the Pr.72 PWM frequency selection setting. Note that motor noise increases. Selecting Pr.240 Soft-PWM operation selection makes the sound inoffensive. To ensure that the motor is protected against line-to-line leakage currents, it is recommended to use a temperature sensor to directly detect motor temperature.
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EMI measures to reduce electromagnetic noises that are radiated by the inverter to cause the peripheral devices to malfunction Inverter-generated noises are largely classified into those radiated by the inverter itself and by the I/O cables connected to its main circuit, those electromagnetically and electrostatically induced to the signal cables of the peripheral devices close to the power cable connected to the inverter main circuit, and those transmitted through the power cables.
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• Specification example (ZCAT3035-1330 by TDK) Item Description 10 to 100 MHz Impedance (Ω) 100 to 500 MHz 39 1 Cable fixing band mount 34 1 Outline dimension drawings (mm) Product name Lot number The impedance values above are reference values, and not guaranteed values. ...
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.
Installation of a reactor When the inverter is connected near a large-capacity power transformer (500 kVA or more) or when a power factor correction capacitor is to be switched over, an excessive peak current may flow in the power input circuit, damaging the converter circuit. To prevent this, always install an AC reactor, which is available as an option.
Power shutdown and magnetic contactor (MC) Inverter input side magnetic contactor (MC) On the inverter input side, it is recommended to provide an MC for the following purposes. (Refer to page 22 for selection.) • To disconnect the inverter from the power supply at activation of a protective function or at malfunctioning of the driving system (emergency stop, etc.).
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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.
Countermeasures against deterioration of the 600 V class motor insulation In the PWM type inverter, a surge voltage attributable to wiring constants is generated at the motor terminals. Especially in a 600 V class motor, the surge voltage may deteriorate the insulation. When the 600 V class motor is driven by the inverter, consider the following countermeasures: 100% 20 30...
Checklist before starting operation The FR-E800 series inverter is a highly reliable product, but incorrect peripheral circuit making or operation/handling method may shorten the product life or damage the product. Before starting operation, always recheck the following points. Refer to Check by Checkpoint Countermeasure...
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Refer to Check by Checkpoint Countermeasure page user When using a switching circuit as shown below, chattering due to misconfigured sequence or arc generated at switching may allow undesirable current to flow in and damage the inverter. Miswiring may also damage the inverter. (Note that a PM motor cannot be driven by the commercial power supply.) When using the electronic bypass Interlock...
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Refer to Check by Checkpoint Countermeasure page user When a motor is driven by the inverter, axial voltage is generated on the motor shaft, which may cause electrical corrosion of the bearing in rare cases depending on the wiring, load, operating conditions of the motor or specific Countermeasures are taken inverter settings (high carrier frequency).
Failsafe system which uses the inverter When a fault is detected by the protective function, the protective function activates and outputs the Fault signal. However, the 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.
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Checking the inverter operating status by using the start signal input to the inverter and the Inverter running signal output from the inverter ... (c) The Inverter running (RUN2) signal is output when the inverter is running. Check if the RUN2 signal is output while a start signal (the STF/STR signal for forward/reverse rotation command) is input to the inverter.
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Command speed and actual operation check Check for a gap between the actual speed and commanded speed by comparing the inverter's speed command and the speed detected by the speed detector. Controller System failure Sensor Inverter (speed, temperature, air volume, etc.) To the alarm detection sensor 3.
Specifications This chapter explains the specifications of this product. Always read the instructions before use. Inverter rating Three-phase 575 V power supply 0017 0027 0040 0061 0090 0120 Model FR-E860-[] 0.75K 1.5K 2.2K 3.7K 5.5K 7.5K Applicable motor 11.0 capacity (kW) ND (initial setting) 0.75...
Common specifications Control method Soft-PWM control / High carrier frequency PWM control Induction Selectable among V/F control, Advanced magnetic flux vector control, and Real sensorless vector motor control PM motor (PM sensorless vector control) Induction 0.2 to 590 Hz (The upper-limit frequency is 400 Hz under Advanced magnetic flux vector control and Output motor Real sensorless vector control.)
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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, Undervoltage, Input phase loss, Stall prevention stop, Loss of synchronism detection Upper limit fault detection, Lower limit fault detection, Brake transistor fault, Output side earth (ground) Fault...
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Revisions *The manual number is given on the bottom left of the back cover. Revision date Manual number Revision Dec. 2019 IB(NA)-0600906ENG First edition IB(NA)-0600906ENG-A...
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HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN IB(NA)-0600906ENG-A(1912)MEE Printed in Japan Specifications subject to change without notice.
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