Mitsubishi Electric FR-A802-GN Instruction Manual
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Mitsubishi Electric FR-A802-GN Instruction Manual

Mitsubishi Electric FR-A802-GN Instruction Manual

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INVERTER
A800-GN
FR-A802-GN (SEPARATED CONVERTER TYPE)
INSTRUCTION MANUAL (HARDWARE)
High functionality and high performance
FR-A842-07700(315K) to 12120(500K)-GN
Class B/A
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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Summary of Contents for Mitsubishi Electric FR-A802-GN

  • Page 1 INVERTER A800-GN Class B/A FR-A802-GN (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE) High functionality and high performance FR-A842-07700(315K) to 12120(500K)-GN INTRODUCTION INSTALLATION AND WIRING PRECAUTIONS FOR USE OF THE INVERTER PROTECTIVE FUNCTIONS PRECAUTIONS FOR MAINTENANCE AND INSPECTION SPECIFICATIONS...

  • Page 2: Safety Instructions

    Manual. In addition to this manual, read these instruction manuals carefully to ensure proper use. Do not use this product until you have a full knowledge of this product mechanism, safety information and instructions. The manuals can be downloaded in PDF form from the Mitsubishi Electric FA Global Website. Please forward this Instruction Manual to the end user.

  • Page 3: Additional Instructions

     Additional Instructions The following instructions must be also followed. If the product WARNING is handled incorrectly, it may cause unexpected fault, an injury, Usage or an electric shock.  Stay away from the equipment when the retry function is set as it will restart suddenly after a trip.
  • Page 4 Application of caution labels CAUTION Caution labels are used to ensure safety during use of Mitsubishi Electric inverters. Usage Apply the following labels to the inverter if the "retry function" and/  The electronic thermal relay function does not guarantee or "automatic restart after instantaneous power failure"...
  • Page 5 CONTENTS 1 INTRODUCTION Product checking Inverter component names 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 or the front covers Installation and enclosure design 2.3.1 Inverter installation environment ........................
  • Page 6 2.10.2 Connection of the high power factor converter (FR-HC2) ................65 2.10.3 Connection of the power regeneration converter (MT-RC)................67 3 PRECAUTIONS FOR USE OF THE INVERTER 69 Electro-magnetic interference (EMI) and leakage currents 3.1.1 Leakage currents and countermeasures ......................70 3.1.2 Countermeasures against inverter-generated EMI..................73 3.1.3 Converter unit (FR-CC2) built-in EMC filter ....................76 Power supply harmonics...

  • Page 7: Table Of Contents

    5.2.4 Example of measuring converter unit (FR-CC2) input power factor............. 105 5.2.5 Measurement of converter output voltage (across terminals P and N) ............105 5.2.6 Measurement of inverter output frequency....................106 5.2.7 Insulation resistance test using megger ....................... 106 5.2.8 Pressure test ..............................
  • Page 8 Operation panel ......Operation panel (FR-DU08) and LCD operation panel (FR-LU08) Parameter unit ........ Parameter unit (FR-PU07) PU ........... Operation panel and parameter unit Inverter..........Mitsubishi Electric inverter FR-A800 series (Separated converter type) Vector control compatible option..FR-A8AP/FR-A8AL/FR-A8APA/FR-A8APR/FR-A8APS (plug-in option), FR- A8TP (control terminal option) Pr.

  • 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.  Applicable inverter model ∗1 Symbol Voltage class Symbol Structure, functionality Symbol Description...

  • Page 10: Inverter Component Names

    Inverter component names Inverter component names Component names are shown below. Refer to Symbol Name Description page RS-485 terminals Enables RS-485 and MODBUS RTU communication. Plug-in option connector 2 Instruction Connects a plug-in option or a communication option. Manual of Plug-in option connector 3 the option Voltage/current input switch...

  • Page 11: Operation Status Leds

    Related manuals  Operation status LEDs LINK1 LINK2 L.ERR NOTE • For details, refer to the CC-Link IE TSN Function Manual. Related manuals Manuals related to the FR-A800 inverter are shown in the following table. Name Manual number FR-A800 Instruction Manual (Detailed) IB-0600503ENG CC-Link IE TSN Function Manual IB-0600843ENG...

  • Page 12: 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 ..............12 2.2 Removal and reinstallation of the operation panel or the front covers ................15 2.3 Installation and enclosure design ...........17 2.4 Terminal connection diagrams ..........25...

  • Page 13: Peripheral Devices

    Peripheral devices Peripheral devices 2.1.1 Inverter and peripheral devices (c) Three-phase AC power supply (P) Programmable controller (RJ71GN11-T2) Ethernet cable (d) Molded case (b) Converter unit (k) USB connector (a) Inverter circuit breaker (FR-CC2) (FR-A802) USB host (MCCB) or earth (A connector) leakage current breaker (ELB),...
  • 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-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 15 FR-CC2-H630K 2000 A 1400 A rated product  Assumes the use of a Mitsubishi Electric 4-pole standard motor with the power supply voltage of 400 VAC 50 Hz.  Select an MCCB according to the power supply capacity. Install one MCCB per converter.

  • Page 16: Removal And Reinstallation Of The Operation Panel Or The Front Covers

    Removal and reinstallation of the operation panel or the front covers Removal and reinstallation of the operation panel or the front covers Removal and reinstallation of the operation panel • Loosen the two screws on the operation panel. • Push the upper part of the operation panel and pull the (These screws cannot be removed.) operation panel to remove.
  • Page 17 Removal and reinstallation of the operation panel or the front covers Removal of the upper front cover Loosen Loosen Loosen With the lower front cover removed, loosen the screws on the upper front cover. (These screws cannot be removed.) While holding the areas around the installation hooks on the sides of the upper front cover, pull out the cover using its upper side as a support.

  • Page 18: Installation And Enclosure Design

    Installation and enclosure design Installation and enclosure design When designing or manufacturing an inverter enclosure, determine the structure, size, and device layout of the enclosure by fully considering the conditions such as heat generation of the contained devices and the operating environment. An inverter uses many semiconductor devices.

  • Page 19: High Altitude

    Installation 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 and enclosure design 2.3.2 Amount of heat generated by the inverter Installing the heat sink inside the enclosure When the heat sink is installed inside the enclosure, the amount of heat generated by the inverter unit and converter unit is shown in the following tables.

  • Page 21: Cooling System Types For Inverter Enclosure

    Installation 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 Placement

    Installation and enclosure design 2.3.4 Inverter installation Inverter placement • Install the inverter on a strong surface securely with screws. • Leave enough clearances and take cooling measures. • Avoid places where the inverter is subjected to direct sunlight, high temperature and high humidity. •...
  • Page 23 Installation 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. The exhaust air temperature of the inverter and the converter unit may be increased.

  • Page 24: Panel Cutting

    Installation and enclosure design 2.3.5 Protruding the heat sink through the panel When encasing an inverter to an enclosure, the heat generated in the enclosure can be greatly reduced by protruding the heat sink of the inverter through the panel. When installing the inverter in a compact enclosure, etc., this installation method is recommended.

  • Page 25: Installation Of The Inverter

    Installation 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. frame (rear side) Lower installation frame (rear side)

  • 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 Fuse 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 27 Terminal connection diagrams  The terminals R1/L11 and S1/L21 are connected to the terminals P/+ and N/- with a jumper respectively. When using separate power supply for the control circuit, remove the jumpers from R1/L11 and S1/L21.  The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ...
  • Page 28 Terminal connection diagrams CA type Source logic Main circuit terminal Brake unit Control circuit terminal (Option) Converter unit Fuse 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  The terminals R1/L11 and S1/L21 are connected to the terminals P/+ and N/- with a jumper respectively. When using separate power supply for the control circuit, remove the jumpers from R1/L11 and S1/L21.  The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ...

  • 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-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 32 Main circuit terminals 2.5.4 Recommended 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 33 Main circuit terminals • Inverter (LD rating) Cable gauge Crimp PVC cables, etc. terminal Inverter Terminal Tightening AWG/MCM HIV cables, etc. (mm    model screw Torque Earthing Earthing FR-A842-[ ] size (N·m)  U, V, W U, V, W P/+, N/- (grounding) U, V, W...
  • Page 34 Main circuit terminals Total wiring length  With induction motor Connect one or more general-purpose motors within the total wiring length 500 m. (The wiring length should be 100 m or less under vector control.) Total wiring length 300 m 300 m 500 m or less 300 m+300 m=600 m...

  • Page 35: 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 36: 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 Common...
  • Page 37 Control circuit Terminal Common Terminal name Terminal function description Rated specification symbol 10 VDC 0.4 V Permissible load When connecting the frequency setting potentiometer Frequency setting at an initial status, connect it to the terminal 10. current 10 mA power supply Change the input specifications of the terminal 2 in 5 VDC0.5 V Pr.73 when connecting it to the terminal 10E.

  • Page 38: Output Signal

    Control circuit Output signal Terminal Terminal Common Terminal function description Rated specification symbol name 1 changeover contact output that indicates that an inverter's protective function has been activated and the Relay output 1 outputs are stopped. — Contact capacity 230 (fault output) Fault: discontinuity across B and C (continuity across A VAC 0.3 A (power...

  • Page 39: Common Terminal

    Control circuit Safety stop signal For the safety stop function, refer to page Terminal Rated Terminal name Common Terminal function description symbol specification The terminals S1 and S2 are used for the safety stop input Safety stop input signal for the safety relay module. The terminals S1 and S2 (Channel 1) are used at the same time (dual channel).
  • Page 40 Control circuit Communication Terminal Terminal Terminal function description symbol name PORT 1 — Communication can be made via the CC-Link IE TSN. PORT 2 With the PU connector, communication can be made through RS-485. (For connection on a 1:1 basis only) Conforming standard: EIA-485 (RS-485) —...

  • Page 41: 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 42 Control circuit Output signal Terminal Rated Common Terminal name Terminal function description symbol specification 1 changeover contact output that indicates that the protective function of the converter unit has been activated Contact capacity 230 Relay output 1 (fault and the outputs are stopped. VAC 0.3 A (power output) Fault: discontinuity across B and C (continuity across A...

  • Page 43: Control Logic (Sink/Source) Change

    Control circuit 2.6.3 Control logic (sink/source) change Change the control logic of input signals as necessary. To change the control logic, change the jumper connector position on the control circuit board. Remove the control circuit terminal block and change the control logic. (Refer to page 101 for details on how to remove the control circuit terminal block.) Connect the jumper connector to the connector pin of the desired control logic.
  • Page 44 Control circuit • When using an external power supply for transistor output Sink logic Source logic Use the terminal PC as a common terminal, and perform Use the terminal SD as a common terminal, and perform wiring as shown below. (Do not connect terminal SD of the wiring as shown below.

  • Page 45: Control Circuit Terminal Layout

    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 46 Control circuit NICHIFU Co.,Ltd. Cable gauge Blade terminal Insulation cap Crimping tool product number product number product number 0.3 to 0.75 BT 0.75-11 VC 0.75 NH 69 (3) Insert the wires into a socket. When using a single wire or stranded wires without crimp terminal, push the open/close button all the way down with a flathead screwdriver, and insert the wire.

  • Page 47: Signal Inputs By Contactless Switches

    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 48: 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 49 Control circuit NOTE • When using separate power supplies, always remove the jumpers from terminals R1/L11 and S1/L21. The inverter may be damaged if the jumpers are not removed. • The voltage should be the same as that of the main control circuit when the control circuit power is supplied from other than the input side of the MC.

  • Page 50: 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 the 24 V external power supply across terminals +24 and SD. The 24 V external power supply enables I/O terminal ON/OFF operation, operation panel displays, control functions, and communication during communication operation even during power-OFF of inverter's main circuit power supply.

  • Page 51: Safety Stop Function

    Control circuit Operation while the 24 V external power is supplied • Fault history and parameters can be read and parameters can be written (when the parameter write from the operation panel is enabled) using the operation panel keys. • The safety stop function is disabled during the 24 V external power supply operation. •...

  • Page 52: 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. FR-A800 R/L1 S/L2 T/L3 So (SO) Logic IGBTs +24V Gate Gate ASIC...

  • Page 53: 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 (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 54 Communication connectors and terminals 2.7.2 CC-Link IE TSN function CC-Link IE TSN communication specifications The communication specification varies depending on the specification of the master. Item Description 1 Gbps Communication speed 100 Mbps  B (Compatible with protocol version 2.0 or 1.0) ...

  • Page 55: Ethernet Cable Connection

     ANSI/TIA/EIA-568-B (Category 5e) Recommended products (as of April 2023) Model Manufacturer SC-E5EW series Mitsubishi Electric System & Service Co., Ltd.   SC-E5EW cable is for in-enclosure and indoor uses. SC-E5EW-L cable is for outdoor use. NOTE • For CC-Link IE TSN wiring, use the recommended wiring components by CC-Link Partner Association.

  • Page 56: Usb Connector

    Communication connectors and terminals 2.7.3 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 USB1.1 Transmission speed 12 Mbps Wiring length...
  • Page 57 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 USB1.1 Transmission speed 12 Mbps Wiring length Maximum 5 m Connector USB mini B connector (receptacle)

  • Page 58: 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 orientation control, encoder feedback control, and speed, torque, and positioning control operations under full-scale vector control. This section explains wiring for use of the FR-A8AP.

  • Page 59: Encoder Specification

    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 60: Encoder Cable

    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  60 mm 60 mm D/MS3106B20-29S D/MS3106B20-29S • Shield earthing P-clip is Model Length L (m) Model...

  • Page 61: Wiring Example

    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 62 Connection of motor with encoder (vector control) • Position control Vector control dedicated motor, 12 V complementary Positioning unit Vector control MELSEC-Q QD75P[]N/QD75P[] dedicated motor MELSEC-L LD75P[] Inverter To converter unit Earth (ground) STOP Forward stroke end FR-A8AP Reverse stroke end Pre-excitation/servo on Clear signal CLEAR...
  • Page 63 Connection of motor with encoder (vector control) Instructions for encoder cable wiring • Use shielded twisted pair cables (0.2 mm or larger) to connect the FR-A8AP. For the wiring to the terminals PG and SD, use several cables in parallel or use a thick cable, according to the wiring length. To protect the cables from noise, run them away from any source of noise (such as the main circuit and power supply voltage).

  • Page 64: 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 rotation (encoder) is clockwise (CW) viewed 120 Hz or less.

  • Page 65: 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 66: 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 and secure, set the rated motor voltage in Pr.19 Base frequency voltage (under V/F control) or Pr.83 Rated motor voltage (under other than V/F control) and "2 or 102"...
  • Page 67 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 42.) •...

  • Page 68: Connection Of The Power Regeneration Converter (Mt-Rc)

    Connection of stand-alone option units 2.10.3 Connection of the power regeneration converter (MT-RC) When connecting the power regeneration converter (MT-RC), perform wiring securely as follows. Incorrect connection will damage the power regeneration converter and the inverter. After making sure that the wiring is correct and secure, set "10 or 110"...
  • Page 69 MEMO...

  • Page 70: 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 ..70 3.2 Power supply harmonics ............77 3.3 Installation of a reactor ............80 3.4 Power-OFF and magnetic contactor (MC) ......81...

  • Page 71: 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 Capacitance 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 capacitance, carrier frequency, etc., low acoustic noise operation at the increased carrier frequency of the inverter will increase the leakage current.

  • Page 72: Selecting The Rated Sensitivity Current For The Earth Leakage Circuit Breaker

    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 73 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 74 Electro-magnetic interference (EMI) and leakage currents 3.1.2 Countermeasures against inverter-generated 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 75 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 76 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 77: 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 78: 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 79: 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 80 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 78), harmonics must be calculated with the following procedure: P0 = ∑...

  • Page 81: 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 82: 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 83: Countermeasures Against Deterioration Of The 400 V Class Motor Insulation

    Countermeasures against deterioration of the 400 V class motor insulation NOTE • Before wiring or inspection for a PM motor, confirm that the PM motor is stopped. In an application, such as fan and blower, where the motor is driven by the load, a low-voltage manual contactor must be connected at the inverter's output side, and wiring and inspection must be performed while the contactor is open.

  • Page 84: 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 85 Checklist before starting operation Refer Check Checkpoint Countermeasure 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 86 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 87: 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 activates and outputs a fault signal. However, a fault signal may not be output at an inverter's fault occurrence when the detection circuit or output circuit fails, etc. Although Mitsubishi assures the best quality products, provide an interlock which uses inverter status output signals to prevent accidents such as damage to the machine when the inverter fails for some reason.
  • Page 88 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 89 MEMO...

  • Page 90: Protective Functions

    PROTECTIVE FUNCTIONS This chapter explains the "PROTECTIVE FUNCTIONS" that operate in this product. Always read the instructions before using the equipment. 4.1 Inverter fault and alarm indications ........90 4.2 Reset method for the protective functions......90 4.3 Check and clear of the fault history ........91 4.4 List of fault displays ..............93...

  • Page 91: 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 activates to trip the inverter. •...

  • Page 92: 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 93: Operation

    Check and clear of the fault history Fault history clearing procedure POINT POINT • Set Err.CL Fault history clear = "1" to clear the fault 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 94: 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.FIN Heat sink overheat HOLD Operation panel lock E.OLT Stall prevention stop LOCD Password locked Loss of synchronism E.SOT detection...

  • Page 95: Operation Panel Indication

    List of fault displays Operation panel indication Name Magnetic pole position E.MP unknown External fault during output E.EF operation E.LCI 4 mA input fault E.PCH Pre-charge fault E.PID PID signal fault E.1 to E.3 Option fault Opposite rotation E.11 deceleration fault E---- Fault history No fault history...

  • Page 96: 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................96 5.2 Measurement of main circuit voltages, currents and powers ..................103 PRECAUTIONS FOR MAINTENANCE AND INSPECTION...

  • Page 97: 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 98: 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 99: Checking Method

    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 100: Replacement Of Parts

    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 101 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 102: Smoothing Capacitors

    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 103 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 104: 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 105: Measuring Point

    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 108.)

  • Page 106: 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 107: 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 108: Specifications

    SPECIFICATIONS This chapter explains the "SPECIFICATIONS" of this product. Always read the instructions before using the equipment. 6.1 Inverter rating................108 6.2 Common specifications ............109 6.3 Outline dimension drawings............111 SPECIFICATIONS...

  • Page 109: 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 110: 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, vector control , and PM sensorless vector control  0.2 to 590 Hz (The upper-limit frequency is 400 Hz under Advanced magnetic flux vector control, Real sensorless vector Output frequency range control, vector control , and PM sensorless vector control.)
  • Page 111 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, Loss of synchronism detection , Upper limit ...

  • Page 112: Outline Dimension Drawings

    Outline dimension drawings Outline dimension drawings FR-A842-07700(315K), FR-A842-08660(355K) 8 x I 25 hole 3 x I12 hole (70) 442.5 (Unit: mm) FR-A842-09620(400K), FR-A842-10940(450K), FR-A842-12120(500K) 8 x I25 hole 3 x I12 hole (100) 442.5 (Unit: mm) SPECIFICATIONS...
  • Page 113 Outline dimension drawings Operation panel (FR-DU08, FR-LU08) Outline drawing Panel cutting dimension drawing 120 or more Panel 3.2max 27.8 Parameter unit FR-DU08 connection cable (FR-CB2[ ] )(option) Air-bleeding hole Operation panel connection connector 2 x M3 screw (FR-ADP)(option) Denotes the space required to connect an optional parameter unit connection cable (FR-CB2[ ]).

  • Page 114: Appendix

    APPENDIX APPENDIX provides the reference information for use of this product. Refer to APPENDIX as required. Appendix 1 For customers replacing the conventional model with this inverter ............114 Appendix 2 Comparison with FR-A840 ...........116 Appendix 3 Instructions for compliance with the EU Directives ..117 Appendix 4 Instructions for UL and cUL .........120...

  • Page 115: Appendix 1 For Customers Replacing The Conventional Model With This Inverter

    Appendix 1 For customers replacing the conventional model with this inverter Appendix 1.1 Replacement of the FR-A740 series Difference and compatibility with FR-A740 series Item FR-A740 FR-A842 V/F control V/F control Advanced magnetic flux vector control Advanced magnetic flux vector control Control method Real sensorless vector control Real sensorless vector control...

  • Page 116: Installation Precautions

    Installation precautions • Removal procedure of the front cover is different. (Refer to page 15.) • Plug-in options of the FR-A700 series are not compatible. • Operation panel (FR-DU07) cannot be used. Wiring precautions • The spring clamp type terminal block has changed to the screw type. Use of blade terminals is recommended. Instructions for continuous use of the FR-PU07 (parameter unit) manufactured in September 2015 or earlier •...

  • Page 117: Appendix 2 Comparison With Fr-A840

    Appendix 2 Comparison with FR-A840 Item FR-A840 FR-A842 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 3 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

    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  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: Motor Overload Protection

    Region on the right of 30 Hz characteristic curve 20 Hz or more Non-operation region • When using the Mitsubishi Electric constant torque motor 10 Hz 20 Hz Region on the left of 10 Hz 6 Hz characteristic curve (1) Set one of "1", "13"...

  • Page 121: Appendix 4 Instructions For Ul And Cul

    Appendix 4 Instructions for UL and cUL (Standard to comply with: UL 508C, CSA C22.2 No.274-13) General Precaution CAUTION - Risk of Electric Shock - The bus capacitor discharge time is 10 minutes. Before starting wiring or inspection, switch power off, wait for more than 10 minutes, and check for residual voltage between terminal P/+ and N/- with a meter etc., to avoid a hazard of electrical shock.
  • Page 122 Region on the right of 30 Hz characteristic curve 20 Hz or more Non-operation region • When using the Mitsubishi Electric constant torque motor 10 Hz 20 Hz Region on the left of 10 Hz 6 Hz characteristic curve (1) Set one of "1", "13"...

  • Page 123: Branch Circuit Protection

    Manual (HARDWARE) and the Instruction Manual (Detailed) intended for use with this product. Please forward relevant manuals to the end user. The manuals can also be downloaded in PDF form from the Mitsubishi Electric FA Global Website. To order manuals, please contact your sales representative.
  • Page 124 • 12-phase rectification Converter model Cat. No. Manufacturer Rating (A) FR-CC2-H315K PC33UD69V900TF Mersen FR-CC2-H355K PC33UD69V900TF Mersen FR-CC2-H400K PC33UD69V1100TF Mersen 1100 FR-CC2-H450K PC33UD69V1100TF Mersen 1100 FR-CC2-H500K PC33UD69V1100TF Mersen 1100 FR-CC2-H560K PC33UD69V1100TF Mersen 1100 FR-CC2-H630K PC33UD69V1100TF Mersen 1100 Capacitor discharge time / Temps de décharge du condensateur CAUTION -Risk of Electric Shock- Before wiring or inspection, check that the LED indicator turns OFF.
  • Page 125 Region on the right of 30 Hz characteristic curve 20 Hz or more • When using the Mitsubishi Electric constant-torque motor Non-operation region 10 Hz 20 Hz Region on the left of 10 Hz 6 Hz characteristic curve (1) Set one of "1, 13 to 16"...

  • Page 126: Appendix 5 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 Turkey A.S. Head Office Address: Serifali Mahallesi Kale Sokak. No:41 34775 Umraniye, Istanbul, Turkey Phone: +90-216-969-25-00...

  • Page 127: 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 128: Appendix 7 Referenced Standard (Requirement Of Chinese Standardized Law)

    Appendix 7 Referenced Standard (Requirement of Chinese standardized law) This Product is designed and manufactured accordance with following Chinese standards. Machinery safety : GB/T 16855.1 GB/T 12668.502 GB 28526 GB/T 12668.3 Electrical safety : GB/T 12668.501 : GB/T 12668.3 Appendix 8 Compliance with the UK certification scheme We declare that this product conforms with the related technical requirements under UK legislation, and...
  • Page 129 MEMO...
  • Page 130 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 131 REVISIONS *The manual number is given on the bottom left of the back cover. Revision date *Manual Number Revision Apr. 2019 IB(NA)-0600840ENG-A First edition Aug. 2020 IB(NA)-0600840ENG-B Added • Ring topology • Transmission speed of 100 Mbps Sep. 2022 IB(NA)-0600840ENG-C Added •...
  • Page 132 HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN IB(NA)-0600840ENG-D(2410)MEE Printed in Japan Specifications subject to change without notice.

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