Mitsubishi Electric 800 Series Instruction Manual
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Mitsubishi Electric 800 Series Instruction Manual

Mitsubishi Electric 800 Series Instruction Manual

Inverter connection, standard model
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INVERTER
FR-D800
Instruction Manual (Connection)
(Standard model)
Compact & easy-to-use inverter
FR-D820-0.1K-008 to 7.5K-318
FR-D840-0.4K-012 to 7.5K-163
FR-D820S-0.1K-008 to 2.2K-100
FR-D810W-0.1K-008 to 0.75K-042

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  • Page 1 INVERTER FR-D800 Instruction Manual (Connection) (Standard model) Compact & easy-to-use inverter FR-D820-0.1K-008 to 7.5K-318 FR-D840-0.4K-012 to 7.5K-163 FR-D820S-0.1K-008 to 2.2K-100 FR-D810W-0.1K-008 to 0.75K-042...

  • Page 2: Table Of Contents

    Safety Instructions ..............4 Chapter 1 Introduction .
  • Page 3 Connection of stand-alone option units ......... . 71 2.8.1 Connection of the brake resistor (FR-D820-0.4K-025 or higher, FR-D840-0.4K-012 or higher, FR-D820S-0.4K-025 or higher, and FR-D810W-0.4K-025 or higher) .
  • Page 4 Chapter 5 Appendix ........117 Instructions for EAC............117 Compliance with the UK certification scheme .

  • Page 5: Safety Instructions

    • A person who possesses a certification in regard with electric appliance handling, or a person who took a proper engineering training. Such training may be available at your local Mitsubishi Electric office. • A person who can access operating manuals for the protective devices (for example, light curtain) connected to the safety control system, or a person who has read these manuals thoroughly and familiarized themselves with the protective devices.

  • Page 6: Fire Prevention

    WARNING  Before wiring or inspection for a PM motor, confirm that the PM motor is stopped as a PM motor is a synchronous motor with high-performance magnets embedded inside and high-voltage is generated at the motor terminals while the motor is running even after the power of this product is turned OFF.

  • Page 7: Additional Instructions

    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. ...
  • Page 8 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. ...
  • Page 9 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 or a PTC thermistor for overheat protection.

  • Page 10: General Instruction

    CAUTION Emergency stop  A safety backup such as an emergency brake must be provided for devices or equipment in a system to prevent hazardous conditions in case of failure of this product or an external device controlling this product. ...
  • Page 11 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 12: Chapter 1 Introduction

    (FR-PA07) Parameter unit Parameter unit (FR-PU07) Operation panel and parameter unit Inverter Mitsubishi Electric FR-D800 series inverter D800 Standard model (RS-485 communication) Parameter number (Number assigned to function) PU operation Operation using the PU (operation panel / parameter unit)

  • Page 13: Product Checking

    Product checking Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model agrees with the order and the product is intact.  Inverter model FR-D8 0.1K-008 Rating plate Inverter model MODEL FR-D820-0.1K-008 Input rating INPUT :XXXXX...

  • Page 14: How To Read The Serial Number

     How to read the SERIAL number The SERIAL consists of two symbols, three characters indicating the production year and month, and six characters indicating the control number. Rating plate example The last two digits of the production year are indicated as the Year, and the Month is indicated □□...

  • Page 15: Component Names

    Component names Component names are as follows. (h) (i) Symbol Name Description Refer to page Control logic switch Select the sink logic (SINK) or the source logic (SOURCE). Voltage/current input switches (SW1, Select voltage or current for the input via terminals 2 and 4. SW2) PU connector Used for the RS-485 communication.

  • Page 16: Operation Steps

    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 to give a start to give a start to give a start command? command? Connect a switch, relay, etc.

  • Page 17: Related Manuals

    When using this inverter for the first time, prepare the following manuals as required and use the inverter safely. The latest version of e-Manual Viewer and the latest PDF manuals can be downloaded from the Mitsubishi Electric FA Global Website.

  • Page 18: Chapter 2 Installation And Wiring

    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 (a) Inverter (c) Molded case circuit breaker (m) USB power supply (MCCB) or earth leakage USB device current breaker (ELB), fuse...
  • Page 19 Symbol Name Overview Refer page Inverter (FR-D800) 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 installed in an enclosure.

  • Page 20: Peripheral Devices

    • Electromagnetic wave interference: The input/output (main circuit) of the inverter includes high frequency components, which may interfere with the communication devices (such as AM radios) used near the inverter. Connect the optional radio noise filter FR-BIF (for use in the input side only), line noise filter FR-BSF01/FR-BLF, Filterpack, or EMC filter to minimize interference. A Filterpack (FR-BFP2), which contains a DC reactor and a noise filter, is also available.
  • Page 21 • When the inverter capacity is larger than the motor capacity, select the MCCB and the MC according to the inverter model, and select cables and the reactor according to the motor output. Incorrect selection may cause an inrush current at power ON, resulting in output shutoff by the breaker.
  • Page 22 • When the inverter capacity is larger than the motor capacity, select the MCCB and the MC according to the inverter model, and select cables and the reactor according to the motor output. Incorrect selection may cause an inrush current at power ON, resulting in output shutoff by the breaker.

  • Page 23: Opening/Closing Of The Front Cover And Removal/Reinstallation Of The Combed-Shaped Wiring Cover

    Opening/closing of the front cover and removal/ reinstallation of the combed-shaped wiring cover  How to open the front cover (FR-D820-0.75K-042 or lower, FR-D840-1.5K- 037 or lower, FR-D820S-0.75K-042 or lower, FR-D810W-0.4K-025 or lower) • Example of FR-D820-0.1K-008 Lightly hold the both sides. (a) While lightly holding the lower parts of the both sides of the inverter, pull open the front cover using its upper end as a support.
  • Page 24  How to close the front cover (FR-D820-0.75K-042 or lower, FR-D840-1.5K- 037 or lower, FR-D820S-0.75K-042 or lower, FR-D810W-0.4K-025 or lower) • Example of FR-D820-0.1K-008 (a) Push the front cover downward using its upper end as a support to close the cover. ...
  • Page 25  Removal of the front cover (FR-D820-0.75K-042 or lower, FR-D840-1.5K- 037 or lower, FR-D820S-0.75K-042 or lower, FR-D810W-0.4K-025 or lower) • Example of FR-D820-0.1K-008 Hinge shaft of the inverter case (a) Pull open the front cover 90° or more to remove it from the hinge shaft of the inverter case. ...
  • Page 26  Reinstallation of the front cover (FR-D820-0.75K-042 or lower, FR-D840- 1.5K-037 or lower, FR-D820S-0.75K-042 or lower, FR-D810W-0.4K-025 or lower) • Example of FR-D820-0.1K-008 Hinge shaft of the inverter case Front cover notch Push the upper corners of the front cover, and snap the notches onto the hinge shaft of the inverter case.
  • Page 27  Reinstallation of the front cover (FR-D820-1.5K-070 or higher, FR-D840- 2.2K-050 or higher, FR-D820S-1.5K-070 or higher, FR-D810W-0.75K-042) • Example of FR-D820-1.5K-070 Front cover Hook Sockets of the wiring cover Hook Hinge shaft of the inverter case Front cover notch Push the upper corners of the front cover, and snap the notches onto the hinge shaft of the inverter case.
  • Page 28  How to open/close the front cover for side-by-side installation (FR-D820- 0.75K-042 or lower, FR-D840-1.5K-037 or lower, FR-D820S-0.75K-042 or lower, FR-D810W-0.4K-025 or lower) • How to open Pull the lower corners of the front cover one by one. (a) Slowly pull the lower corners of the front cover one by one. •...
  • Page 29  Removal of the comb-shaped wiring cover • FR-D820-1.5K-070 to 3.7K-165, FR-D840-2.2K-050, FR-D840-3.7K-081, FR-D820S-1.5K-070, FR-D820S-2.2K-100, FR- D810W-0.75K-042 Loosen Guide Comb-shaped wiring cover (a) Loosen the mounting screw of the comb-shaped wiring cover. (b) Pull out the cover along the guides in the direction shown by the arrow in the figure above. •...
  • Page 30  Reinstallation of the comb-shaped wiring cover • FR-D820-1.5K-070 to 3.7K-165, FR-D840-2.2K-050, FR-D840-3.7K-081, FR-D820S-1.5K-070, FR-D820S-2.2K-100, FR- D810W-0.75K-042 Tighten Guide Comb-shaped wiring cover (a) Fit the comb-shaped wiring cover to the inverter along the guides. (b) Tighten the mounting screw of the cover. (Tightening torque: 0.6 to 0.8 N·m) •...

  • Page 31: Installation Of The Inverter And Enclosure Design

    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.

  • Page 32: High Altitude

     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.

  • Page 33: Amount Of Heat Generated By The Inverter

     Vibration, impact The vibration resistance of the inverter is up to 5.9 m/s at 10 to 55 Hz frequency and 1 mm amplitude for the directions of X, Y, Z axes. Subjecting the product to vibration and impacts over a long period of time may loosen the structure and cause poor contacts of connectors, even if those vibration and impacts are within the specified values.
  • Page 34  Installing the heat sink outside the enclosure When the heat sink is installed outside the enclosure, the amount of heat generated by the inverter unit is shown in the following table. Voltage Inverter model Amount of heat generated (W) Heat sink section Control section (outside of...

  • Page 35: Output Current Reduction When The Surrounding Air Temperature Is Between 50°C And 60°C For Nd Rating And Between 40°C And 60°C For Sld Rating

    2.3.3 Output current reduction when the surrounding air temperature is between 50°C and 60°C for ND rating and between 40°C and 60°C for SLD rating When the surrounding air temperature is between 50°C and 60°C, reduce the rated output current as shown in the following table.
  • Page 36 • FR-D840-0.4K-012 to FR-D840-3.7K-081 Output current [A] 3.7K 2.2K 1.5K 0.75K 0.4K 12.0 10.0 1.08 0.84 Surrounding air temperature [°C] <PWM carrier frequency> SLD: 2 kHz or lower SLD: 3 kHz or higher ND: 2 kHz or lower ND, SLD: 3 kHz or higher •...

  • Page 37: Standby Power Consumption By The Inverter

    2.3.4 Standby power consumption by the inverter The following table shows the standby power consumption during a stop. Voltage Inverter model Standby power consumption (W) Light duty Heavy duty Three-phase FR-D820-0.1K-008 200 V class FR-D820-0.2K-014 FR-D820-0.4K-025 FR-D820-0.75K-042 FR-D820-1.5K-070 10.5 FR-D820-2.2K-100 FR-D820-3.7K-165 FR-D820-5.5K-238 FR-D820-7.5K-318...

  • Page 38: Cooling System Types For Inverter Enclosure

    2.3.5 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 39: Inverter Installation

    2.3.6 Inverter installation  Inverter placement FR-D820-0.1K-008 to 0.75K-042 FR-D820-1.5K-070 to 7.5K-318 FR-D820S-0.1K-008 to 0.4K-025 FR-D840-0.4K-012 to 7.5K-163 FR-D810W-0.1K-008 to 0.4K-025 FR-D820S-0.75K-042 to 2.2K-100 FR-D810W-0.75K-042 Front cover Comb-shaped wiring cover • For the FR-D820-1.5K-070 to 7.5K-318, FR-D840-0.4K-012 to 7.5K-163, FR-D820S-0.75K-042 to 2.2K-100, and FR- D810W-0.75K-042, remove the comb-shaped wiring cover before installing the inverter to the enclosure surface with the mounting screws.
  • Page 40  Above the inverter Heat is blown up from inside the inverter by the small fan built in the unit. Any equipment placed above the inverter should be heat resistant.  Arrangement of multiple inverters When multiple inverters are placed in the same enclosure, arrange them horizontally as shown in the figure (a). When it is inevitable to arrange them vertically to minimize space, take such measures as to provide guides between the inverters since heat generated in the inverters in bottom row can increase the temperatures in the inverters in top row, causing inverter failures.

  • Page 41: Terminal Connection Diagrams

    Terminal connection diagrams  Sink logic Main circuit terminal Control circuit terminal Single-phase power input DC reactor Brake unit (Option) MCCB (FR-HEL) R/L1 Single-phase Earth AC power S/L2 (Ground) supply PR N/- Jumper MCCB Motor R/L1 Three-phase S/L2 AC power T/L3 supply Earth (Ground)
  • Page 42 Remove the jumper between P1 and P/+ to connect the DC reactor. (Single-phase 100 V power input model is not compatible with the DC reactor.) The function of these terminals can be changed using the Input terminal function selection (Pr.178 to Pr.182). (Refer to the Instruction Manual (Function).) The initial setting varies depending on the specification.
  • Page 43  Source logic Main circuit terminal Control circuit terminal Single-phase power input DC reactor Brake unit (Option) MCCB (FR-HEL) R/L1 Single-phase Earth AC power S/L2 (Ground) supply PR N/- Jumper MCCB Motor R/L1 Three-phase S/L2 AC power T/L3 supply Earth (Ground) Main circuit Earth (Ground)
  • Page 44 Remove the jumper between P1 and P/+ to connect the DC reactor. (Single-phase 100 V power input model is not compatible with the DC reactor.) The function of these terminals can be changed using the Input terminal function selection (Pr.178 to Pr.182). (Refer to the Instruction Manual (Function).) The initial setting varies depending on the specification.

  • Page 45: Main Circuit Terminals

    Main circuit terminals 2.5.1 Details on the main circuit terminals Terminal Terminal name Terminal function description Refer to symbol page R/L1, S/L2, T/ AC power input Connect these terminals to the commercial power supply. — U, V, W Inverter output Connect these terminals to a three-phase squirrel cage motor or a PM —...
  • Page 46  Single-phase 200 V class FR-D820S-0.1K-008 to 0.75K-042 FR-D820S-1.5K-070, FR-D820S-2.2K-100 Jumper Jumper R/L1 S/L2 T/L3 R/L1 S/L2 T/L3 Earthing (grounding) terminal Earthing (grounding) Power supply Motor terminal Power supply Motor  Single-phase 100 V class FR-D810W-0.1K-008 to 0.4K-025 FR-D810W-0.75K-042 R/L1 S/L2 T/L3 R/L1...

  • Page 47: Applicable Cables And Wiring Length

    2.5.3 Applicable cables and wiring length  For the ND rating • Three-phase 200 V class (220 V input power supply, without a power factor improving AC or DC reactor) Applicable Terminal Tightening Crimp Cable gauge inverter screw torque terminal HIV cables, etc.
  • Page 48 • Single-phase 200 V class (220 V input power supply, without a power factor improving AC or DC reactor) Applicable Terminal Tightening Crimp Cable gauge inverter screw torque terminal HIV cables, etc. (mm AWG/MCM PVC cables, etc. (mm model size N·m R/L1, R/L1,...
  • Page 49  For the SLD rating • Three-phase 200 V class (220 V input power supply, without a power factor improving AC or DC reactor) Applicable Terminal Tightening Crimp Cable gauge inverter screw torque terminal HIV cables, etc. (mm AWG/MCM PVC cables, etc. (mm model size N·m...
  • Page 50 THHW cable with a continuous maximum permissible temperature of 75°C. It assumes a surrounding air temperature of 40°C or lower and the wiring distance of 20 m or shorter. (For the use in the United States or Canada, refer to "Instructions for UL and cUL" in the document enclosed with the product.) PVC cable with a continuous maximum permissible temperature of 70°C.
  • Page 51  Total wiring length  With induction motor Connect one or more general-purpose motors within the total wiring length shown in the following table. Cable type Pr.72 setting Voltage 0.1K 0.2K 0.4K 0.75K 1.5K 2.2K 3.7K or (carrier frequency) class higher Unshielded 1 (1 kHz) or lower...

  • Page 52: Earthing (Grounding) Precautions

    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.

  • Page 53: Control Circuit

    Control circuit 2.6.1 Details on the control circuit terminals  Input signal Terminal Common Terminal name Terminal function description Rated Refer symbol specification page Forward rotation start Turn ON the STF signal to When the STF Input resistance: (sink start forward rotation and and STR signals 4.7 kΩ, (negative...

  • Page 54: Output Signal

     Output signal Type Terminal Common Terminal Terminal function description Rated specification Refer symbol name page Relay — Relay output 1 changeover contact output that indicates that an Contact capacity: A, B, C (fault output) inverter's protective function has been activated and 240 VAC 2 A (power the outputs are stopped.

  • Page 55: Common Terminal

     Common terminal Terminal Common Terminal name Terminal function description Rated Refer symbol specification page — Contact input common Common terminal for the contact input terminal (sink logic). — — (sink (negative common)) External transistor Connect this terminal to the power supply common common (source terminal of a transistor output (open collector output) (positive common))

  • Page 56: Control Logic (Sink/Source) Change

    Terminal R+/FU functions as the open collector output terminal FU in the initial setting. To use the terminal as the RS-485 terminal R+, set the switch to R+. Terminal R-/SD functions as the common terminal SD for contact input terminals in the initial setting. To use the terminal as the RS-485 terminal R-, set the switch to R-.
  • Page 57 Current flow concerning the input/output signal Current flow concerning the input/output signal when sink logic is selected when source logic is selected Source logic Sink logic Current STF/ Sink Current STF/ connector Source connector STR/ STR/ Inverter Inverter DC input (sink type) DC input (source type) <Example: QX40>...

  • Page 58: Wiring Of Control Circuit

    2.6.3 Wiring of control circuit  Control circuit terminal layout • Recommended cable gauge: 0.3 to 0.75 mm S2 PC So SoC PC STF STR RL RM RH R+/FU R-/SD SE RUN 2. Installation and Wiring 2.6 Control circuit...

  • Page 59: Wiring Method

     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. Connect the end of wires (crimp terminal or stranded wire) to the terminal block. Strip the signal wires as follows.

  • Page 60: Wire Removal

    Insert the wire into the terminal block. When using single wire or stranded wire without crimp terminal, push the open/close button all the way down with a flathead screw driver, and insert the wire. Open/close button Flathead screwdriver NOTE • When using stranded wires without a blade terminal, twist enough to avoid short circuit with a nearby terminals or wires. •...

  • Page 61: Signal Inputs By Contactless Switches

     Common terminals of the control circuit (SD, PC, 5, SE) • Terminals SD (sink logic), PC (source logic), 5, and SE are common terminals (0 V) for I/O signals. (All common terminals are isolated from each other.) Do not earth (ground) these terminals. Avoid connecting terminal SD (sink logic) with terminal 5, terminal PC (source logic) with terminal 5, and terminal SE with terminal 5.

  • Page 62: Safety Stop Function

    2.6.4 Safety stop function  Function description The terminals related to the safety stop function are as follows. Terminal Terminal function description symbol Input terminal as the safety stop channel 1. Status of both the circuit between terminals S1 and PC and the circuit between terminals S2 and PC Input terminal as the safety stop channel 2.
  • Page 63  Safety stop function operation *1*2 *8*9*10 Input Internal Input terminal Output Output signal Inverter Operation panel power safety terminal operating indication circuit status SAFE SAFE2 E.SAF status — — — Output shutoff (Safe state) displayed displayed Normal Operation enabled displayed displayed Normal...

  • Page 64: Communication Connectors And Terminals

    Communication connectors and terminals 2.7.1 PU connector  Mounting the operation panel on the enclosure surface • Having an enclosure surface operation panel (FR-PA07) or a parameter unit on the enclosure surface is convenient. With a connection cable, the operation panel or the parameter unit can be mounted to the enclosure surface and connected to the inverter.
  • Page 65  Before communication SW5 SW6 OPEN 100Ω R+/FU R-/SD SE PU connector RS-485 terminals If any cable is connected to the RS-485 terminals, remove the wiring. When terminals R+/FU and R-/SD are used as terminals FU and SD, the wiring does not need to be removed. Set the R+/FU switch (SW5) to the upper position (FU) (initial status) and the R-/SD switch (SW6) to the upper position (SD) (initial status).

  • Page 66: Connection Cable

     Connection cable Use Ethernet cables compliant with the following standards. Ethernet cable Connector Standard Category 5e or higher straight cable (double RJ-45 connector The cables compliant with the following standards: shielded / STP) • IEEE 802.3 (1000BASE-T) • ANSI/TIA/EIA-568-B (Category 5e) NOTE Refer to the following for the cable (USB to RS-485 converter) to connect a computer with a USB Type-A port to an inverter.
  • Page 67 • Connecting multiple inverters (four-wire type) Computer Distributor Distributor Built-in RS-485 Communication port cable 1 6 3 4 5 1 6 3 4 5 Inverter Inverter Inverter PU connector PU connector PU connector On the inverter most remotely connected with the computer, set the terminating resistor switch (SW4) to the 100 Ω side. •...

  • Page 68: Wiring And Configuration Of Rs-485 Terminals

    2.7.2 Wiring and configuration of RS-485 terminals  Before communication SW5 SW6 OPEN 100Ω R+/FU R-/SD SE PU connector RS-485 terminals If any cable is connected to the PU connector, remove the wiring. Set the R+/FU switch (SW5) to the lower position (R+) and the R-/SD switch (SW6) to the lower position (R-). FU (initial status) SD (initial status) ...
  • Page 69  Wiring the RS-485 terminals • The size of RS-485 terminals is the same as that of other control circuit terminals. Refer to page 57 for the wiring method.  System configuration of RS-485 terminals • Computer and inverter connection (1:1) Computer Computer Inverter...
  • Page 70  RS-485 terminal wiring method • Wiring between a computer and an inverter for RS-485 communication Computer *2*3 • Wiring between a computer and multiple inverters for RS-485 communication Computer *2*3 Station 0 Station 1 Station ｎ Make connection in accordance with the Instruction Manual of the computer to be used with. Fully check the terminal numbers of the computer since they vary with the model.

  • Page 71: Usb Connector

    2.7.3 USB connector  USB device communication The inverter can be connected to a computer with a USB cable (connector: USB Type-C). Parameter setting and monitoring can be performed by using FR Configurator2. Interface Conforms to USB 2.0 Wiring length Maximum 5 m Connector USB Type-C connector (receptacle)

  • Page 72: Connection Of Stand-Alone Option Units

    Connection of stand-alone option units The inverter accepts a variety of stand-alone option units as required. Incorrect connection will cause inverter damage or accident. Connect and operate the option unit carefully in accordance with the Instruction Manual of the corresponding option unit. 2.8.1 Connection of the brake resistor (FR-D820-0.4K-025 or higher, FR-D840-0.4K-012 or higher, FR-D820S-0.4K-025...
  • Page 73 High-duty Thermal relay Rated operating current supply brake resistor model voltage (Mitsubishi Electric product) 100 V/ FR-ABR-0.4K TH-T25-0.7A 120 VAC: 2 A (NO contact) / 3 A (NC contact), 200 V 240 VAC: 1 A (NO contact) / 2 A (NC contact) FR-ABR-0.75K...
  • Page 74  Connection of a brake resistor other than the FR-ABR Use a brake resistor that has resistance and power consumption values higher than the following. Also, the brake resistor must have a sufficient capacity to consume the regenerative power. Voltage class Inverter Minimum resistance Power consumption...

  • Page 75: Connection Of The Brake Unit (Fr-Bu2(-H))

    CAUTION • If the resistor selection is incorrect, overcurrent may damage the inverter built-in brake transistor. Besides, the resistor may be burned due to overheat. • If the selection of the thermal relay is incorrect, the resistor may be burned due to overheat. 2.8.2 Connection of the brake unit (FR-BU2(-H)) Connect the brake unit (FR-BU2(-H)) as follows to improve the braking capability during deceleration.

  • Page 76: Connection Of The High Power Factor Converter (Fr-Hc2)

     Connection example with the FR-BR-(H) resistor unit ∗2 FR-BR MCCB Motor R/L1 ∗4 Three phase AC S/L2 power supply T/L3 ∗3 FR-BU2 Inverter ∗1 ∗3 10 m or less When wiring, make sure to match the terminal symbols (P/+, N/-) on the inverter and on the brake unit (FR-BU2). (Incorrect connection will damage the inverter and brake unit.) When the power supply is 400 V class, install a stepdown transformer.

  • Page 77: Connection Of The Multifunction Regeneration Converter (Fr-Xc)

    Do not install an MCCB or MC across terminals (R/L1, S/L2, T/L3) on the reactor 1 and terminals (R4/L14, S4/L24, T4/L34) on the FR-HC2. Doing so disrupts proper operation. Securely perform grounding (earthing) by using the earth (ground) terminal. Installation of a fuse is recommended. (Refer to the FR-HC2 Instruction Manual.) NOTE •...

  • Page 78: Connection Of The Ac Reactor (Fr-Hal)

    Install UL listed fuses on the input side of the reactor to meet the UL/cUL standards (refer to the FR-XC Instruction Manual for information about the fuse). *10 Do not install an MCCB or MC between the reactor and the converter. Doing so disrupts proper operation. CAUTION •...

  • Page 79: Connection Of The Dc Reactor (Fr-Hel)

    NOTE • As a reference, the cable gauge for the connection must be equal to or larger than that of the power cables (R/L1, S/L2, T/L3) and the earthing (grounding) cable. (Refer to page 46.) 2.8.6 Connection of the DC reactor (FR-HEL) •...

  • Page 80: Chapter 3 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 use. Electro-magnetic interference (EMI) and leakage currents 3.1.1 Leakage currents and countermeasures Capacitance exists between the inverter I/O cables, other cables and earth and in the motor, through which a leakage current flows.

  • Page 81: Selecting The Rated Sensitivity Current For The Earth Leakage Circuit Breaker

    MCCB Thermal relay Motor Power Inverter supply Line-to-line static capacitance Line-to-line leakage currents path  Precautions • 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.

  • Page 82: Techniques And Measures For Electromagnetic Compatibility (Emc)

    NOTE • Install the earth leakage circuit breaker (ELB) on the input side of the inverter. • In the connection earthed-neutral system, the sensitivity current is blunt against a ground fault in the inverter output side. Earthing (Grounding) must conform to the requirements of national and local safety regulations and electrical codes. (NEC section 250, IEC 61140 class 1 and other applicable standards) •...
  • Page 83  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.
  • Page 84  Data line filter Data line filter is effective as an EMI countermeasure. Provide a data line filter for the detector cable, etc. • Commercially available data line filter: ZCAT3035-1330 (by TDK), ESD-SR-250 (by TOKIN) • Specification example (ZCAT3035-1330 by TDK) Item Description Impedance (Ω)

  • Page 85: 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 86: Conversion Factor

    purpose Products in January 2004 and the Harmonic Suppression Guideline for Household Appliances and General-purpose Products was repealed on September 6, 2004. All capacity and all models of general-purpose inverter used by specific consumers are now covered by "the Harmonic Suppression Guidelines for Consumers Who Receive High Voltage or Special High Voltage"...
  • Page 87  Harmonic content (when the fundamental current is considered as 100%) Reactor 11th 13th 17th 19th 23rd 25th Three-phase bridge Not used (capacitor smoothing) Used (AC side) 14.5 Used (DC side) Used (AC, DC sides) Single-phase bridge Not used — —...
  • Page 88 Item Description Transformer multi-phase Use two transformers with a phase angle difference of 30° in combinations of to Δ and Δ to Δ, to operation provide an effect corresponding to 12 pulses, reducing low-degree harmonic currents. Passive filter A capacitor and a reactor are used together to reduce impedances at specific frequencies. Harmonic (AC filter) currents are expected to be absorbed greatly by using this technique.

  • Page 89: Installation Of A Reactor

    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 (FR-HAL), which is available as an option.

  • Page 90: Power Shutdown And Magnetic Contactor (Mc)

    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 19 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.).
  • Page 91 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 92: 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. When the 400 V class motor is driven by the inverter, consider the following countermeasures: ...

  • Page 93: Checklist Before Starting Operation

    Checklist before starting operation The FR-D800 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. Checkpoint Countermeasure Refer to Check page...
  • Page 94 Checkpoint Countermeasure Refer to Check page by user When using the electronic bypass When using a switching circuit as shown below, chattering due to misconfigured — operation, electrical and sequence or arc generated at switching may allow undesirable current to flow in mechanical interlocks are and damage the inverter.
  • Page 95 Checkpoint Countermeasure Refer to Check page by user Countermeasures are taken When a motor is driven by the inverter, axial voltage is generated on the motor — against electrical corrosion on the shaft, which may cause electrical corrosion of the bearing in rare cases motor bearing.

  • Page 96: 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 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.
  • Page 97  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 (RUN) signal is output when the inverter is running. Check if the RUN signal is output while a start signal (the STF/STR signal for forward/reverse rotation command) is input to the inverter.
  • Page 98  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.

  • Page 99: Chapter 4 Specifications

    Forced air Approx. mass (kg) The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric standard 4-pole motor. The rated output capacity is the value with respect to 230 V output voltage. The percentage of the overload current rating is the ratio of the overload current to the inverter's rated output current. For repeated duty, allow time for the inverter and motor to return to or below the temperatures under 100% load.
  • Page 100 Forced air Approx. mass (kg) The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric standard 4-pole motor. The rated output capacity is the value with respect to 440 V output voltage. The percentage of the overload current rating is the ratio of the overload current to the inverter's rated output current. For repeated duty, allow time for the inverter and motor to return to or below the temperatures under 100% load.
  • Page 101 Forced air Approx. mass (kg) The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric standard 4-pole motor. The rated output capacity is the value with respect to 230 V output voltage. The percentage of the overload current rating is the ratio of the overload current to the inverter's rated output current. For repeated duty, allow time for the inverter and motor to return to or below the temperatures under 100% load.
  • Page 102 Natural Approx. mass (kg) The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric standard 4-pole motor. The rated output capacity is the value with respect to 230 V output voltage. The percentage of the overload current rating is the ratio of the overload current to the inverter's rated output current. For repeated duty, allow time for the inverter and motor to return to or below the temperatures under 100% load.

  • Page 103: Motor Rating

    Motor rating 4.2.1 PM motor EM-A  Motor specifications EM-AMF 0.1kW 3000r/min 200V • A: Electromagnetic brake Symbol Electromagnetic brake None Without With • B: Shaft end Symbol Shaft end None Standard Key shaft • C: Protective structure Symbol Protective structure None IP44 IP65...
  • Page 104  Specifications of the dedicated PM motor (EM-A motor) (200 V class)  Motor specifications (standard) Motor model: EM-AMF[] 0.1kW 0.2kW 0.4kW 0.75kW 1.5kW 2.2kW 3.7kW 5.5kW 7.5kW Applicable inverter model 0.1K-008 0.2K-014 0.4K-025 0.75K- 1.5K-070 2.2K-100 3.7K-165 5.5K-238 7.5K-318 FR-D820-[] Rated speed (r/min) 3000...
  • Page 105  Specifications of the dedicated PM motor (EM-A motor) (400 V class)  Motor specifications (standard) Motor model: EM-AMF[] 0.4kW 0.75kW 1.5kW 2.2kW 3.7kW 5.5kW 7.5kW Applicable inverter model 0.4K-012 0.75K-022 1.5K-037 2.2K-050 3.7K-081 5.5K-120 7.5K-163 FR-D840-[] Rated speed (r/min) 3000 Maximum speed (r/min) 4000...

  • Page 106: Motor Torque

     Motor torque Torque Short time operation range(3s) 200% 150% Continuous operation range 100% 3000 4000 Motor rotation speed(r/min) • When the input voltage is low, the torque may be reduced. • In the low-speed range, torque ripples or uneven rotation occur. Adjust the setting of Pr.820 Speed control P gain 1 as required.

  • Page 107: Common Specifications

    Common specifications Control method Soft-PWM control / High carrier frequency PWM control Induction Selectable among V/F control and Advanced magnetic flux vector control motor PM motor PM sensorless vector control Output Induction 0.2 to 590 Hz (The upper-limit frequency is 400 Hz under Advanced magnetic flux vector control.) frequency motor range...
  • Page 108 Protective Overcurrent trip during acceleration, overcurrent trip during constant speed, overcurrent trip during Protective functions deceleration/stop, regenerative overvoltage trip during acceleration, regenerative overvoltage trip /warning during constant speed, regenerative overvoltage trip during deceleration or stop, inverter overload trip function (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...

  • Page 109: Outline Dimension Drawings

    Outline dimension drawings 4.4.1 Inverter outline dimension drawings FR-D820-0.1K-008, FR-D820-0.2K-014, FR-D820-0.4K-025, FR-D820-0.75K-042 FR-D840-0.4K-012, FR-D840-0.75K-022, FR-D840-1.5K-037 FR-D820S-0.1K-008, FR-D820S-0.2K-014, FR-D820S-0.4K-025, FR-D820S-0.75K-042 FR-D810W-0.1K-008, FR-D810W-0.2K-014, FR-D810W-0.4K-025 φC （6） Inverter model FR-D820-0.1K-008 80.5 FR-D820-0.2K-014 FR-D820-0.4K-025 102.5 FR-D820-0.75K-042 132.5 FR-D840-0.4K-012 129.5 FR-D840-0.75K-022 FR-D840-1.5K-037 167.5 FR-D820S-0.1K-008 80.5 FR-D820S-0.2K-014 FR-D820S-0.4K-025 132.5...
  • Page 110 FR-D820-1.5K-070, FR-D820-2.2K-100, FR-D820-3.7K-165 FR-D840-2.2K-050, FR-D840-3.7K-081 FR-D820S-1.5K-070, FR-D820S-2.2K-100 FR-D810W-0.75K-042 2×φC Inverter model FR-D820-1.5K-070 132.5 FR-D820-2.2K-100 FR-D820-3.7K-165 142.5 FR-D840-2.2K-050 155.5 FR-D840-3.7K-081 FR-D820S-1.5K-070 FR-D820S-2.2K-100 FR-D810W-0.75K-042 (Unit: mm) 4. Specifications 4.4 Outline dimension drawings...
  • Page 111 FR-D820-5.5K-238, FR-D820-7.5K-318 FR-D840-5.5K-120, FR-D840-7.5K-163 2×φC （6） Inverter model FR-D820-5.5K-238 FR-D820-7.5K-318 FR-D840-5.5K-120 FR-D840-7.5K-163 (Unit: mm) 4. Specifications 4.4 Outline dimension drawings...

  • Page 112: Dedicated Motor Outline Dimension Drawings

    4.4.2 Dedicated motor outline dimension drawings  Dedicated PM motor (EM-A) outline dimension drawings  EM-AMF 0.1kW, 0.2kW 4×φ6.6 0.4 kW 194.5 154.5 4 × φ6.6 0.75kW (Unit: mm) 4. Specifications 4.4 Outline dimension drawings...
  • Page 113 1.5 kW 45° 4×φ9 2.2kW 45° φ9 × 3.7kW 116.5 104.5 45° 2×M8 screw, depth: 16 4×φ13.5 Screw holes for suspension bolts (upper/lower) (Unit: mm) 4. Specifications 4.4 Outline dimension drawings...
  • Page 114 5.5 kW 116.5 149.5 2×M8 screw, depth: 16 4×φ13.5 Screw holes for suspension bolts (upper/lower) 7.5kW 116.5 194.5 2×M8 screw, depth: 16 4×φ13.5 Screw holes for suspension bolts (upper/lower) (Unit: mm) 4. Specifications 4.4 Outline dimension drawings...
  • Page 115  EM-AMFB 0.1kW, 0.2kW φ6.6 × 0.4 kW 245.5 205.5 φ6.6 × 0.75kW 275.5 235.5 45° 4×φ6.6 (Unit: mm) 4. Specifications 4.4 Outline dimension drawings...
  • Page 116 1.5 kW 111.5 45° φ9 × 2.2kW 141.5 45° φ9 × 3.7kW 116.5 104.5 45° 2×M8 screw, depth: 16 4×φ13.5 Screw holes for suspension bolts (upper/lower) (Unit: mm) 4. Specifications 4.4 Outline dimension drawings...
  • Page 117 5.5 kW □176 116.5 149.5 2×M8 screw, depth: 16 4×φ13.5 Screw holes for suspension bolts (upper/lower) 7.5kW □176 116.5 194.5 2×M8 screw, depth: 16 4×φ13.5 Screw holes for suspension bolts (upper/lower) (Unit: mm) 4. Specifications 4.4 Outline dimension drawings...

  • Page 118: Chapter 5 Appendix

    • 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 119: Restricted Use Of Hazardous Substances In Electronic And Electrical Products

    Restricted Use of Hazardous Substances in Electronic and Electrical Products The mark of restricted use of hazardous substances in electronic and electrical products is described as follows based on the "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products" of the People's Republic of China.

  • Page 120: Warranty

    (1) Damages caused by any cause found not to be the responsibility of Mitsubishi Electric. (2) Loss in opportunity, lost profits incurred to the user by Failures of Mitsubishi Electric products. (3) Special damages and secondary damages whether foreseeable or not, compensation for accidents, and compensation for damages to products other than Mitsubishi Electric products.

  • Page 121: Revisions

    Revisions *The manual number is given on the bottom left of the back cover. Revision date Manual number Revision Dec. 2024 First edition IB(NA)-0601029ENG-A IB(NA)-0601029ENG-A...
  • Page 122 FR-D800 TORISETSU Model SETSUZOKU EIBUN Model code 1AJ080 HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN IB(NA)-0601029ENG-A(2412)MEE Printed in Japan Specifications subject to change without notice.

This manual is also suitable for:

Fr-d800Fr-d820-0.1k-008Fr-d820-7.5k-318Fr-d840-0.4k-012Fr-d840-7.5k-163Fr-d820s-0.1k-008 ... Show all

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