Mitsubishi Electronics A800 User Manual

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INVERTER A800

FR-A802 (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE)

FR-A842-07700(315K) to 12120(500K)

INTRODUCTION

INSTALLATION AND WIRING

PRECAUTIONS FOR USE OF

THE INVERTER

PROTECTIVE FUNCTIONS

PRECAUTIONS FOR

MAINTENANCE AND

INSPECTION

SPECIFICATIONS

Thank you for choosing this Mitsubishi inverter.

Warning

Caution

This Instruction Manual describes handling and cautions about the hardware, such as installation and wiring, for the FR-A802 (separated converter type) that are different from the FR-800. Information about the software, such as basic operations and parameters, is described in the FR-A800 Instruction Manual (Detailed) in the CD-ROM enclosed with the product. In addition to this manual, please read the manuals in the enclosed CD-ROM carefully. Do not use this product until you have a full knowledge of the equipment, safety information and instructions. Please forward this Instruction Manual to the end user.

Safety Instructions

Do not attempt to install, operate, maintain or inspect the product until you have read through this Instruction Manual (Detailed) and appended documents carefully and can use the equipment correctly. Do not use this product until you have a full knowledge of the equipment, safety information and instructions. Installation, operation, maintenance and inspection must be performed by qualified personnel. Here, an expert means a person who meets all the conditions below.

• A person who took a proper engineering training. Such training may be available at your local Mitsubishi Electric office. Contact your local sales office for schedules and locations.

• A person who can access operating manuals for the protective devices (e.g. light curtain) connected to the safety control system. A person who has read and familiarized himself/herself with the manuals.

In this Instruction Manual (Detailed), the safety instruction levels are classified into "Warning" and "Caution"

Incorrect handling may cause hazardous conditions, resulting in death or severe injury.

Incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause only material damage.

The level may even lead to a serious

consequence according to conditions. Both instruction levels must be followed because these are important to personal safety.

 Electric Shock Prevention

Warning

 While the inverter power is ON, do not open the front cover or

the wiring cover. Do not run the inverter with the front cover or the wiring cover removed. Otherwise you may access the exposed high voltage terminals or the charging part of the circuitry and get an electric shock.

 Even if power is OFF, do not remove the front cover except for

wiring or periodic inspection. You may accidentally touch the charged inverter circuits and get an electric shock.

 Before wiring or inspection, LED indication of the operation

panel must be switched OFF. Any person who is involved in wiring or inspection shall wait for at least 10 minutes after the power supply has been switched OFF and check that there are no residual voltage using a tester or the like. The capacitor is charged with high voltage for some time after power OFF, and it is dangerous.

 This inverter must be earthed (grounded). Earthing (grounding)

must conform to the requirements of national and local safety regulations and electrical code (NEC section 250, IEC 536 class 1 and other applicable standards). A neutral-point earthed (grounded) power supply inverter in compliance with EN standard must be used.

 Any person who is involved in wiring or inspection of this

equipment shall be fully competent to do the work.

 The inverter must be installed before wiring. Otherwise you may

get an electric shock or be injured.

 Setting dial and key operations must be performed with dry

hands to prevent an electric shock. Otherwise you may get an electric shock.

 Do not subject the cables to scratches, excessive stress,heavy

loads or pinching. Otherwise you may get an electric shock.

 Do not change the cooling fan while power is ON. It is dangerous

to change the cooling fan while power is ON.

 Do not touch the printed circuit board or handle the cables with

wet hands. Otherwise you may get an electric shock.

 An PM motor is a synchronous motor with high-performance

magnets embedded in the rotor. Motor terminals holds highvoltage while the motor is running even after the inverter power is turned OFF. Before wiring or inspection, the motor must be confirmed to be stopped. In an application, such as fan and blower, where the motor is driven by the load, a low-voltage manual motor starter must be connected at the inverter's output side, and wiring and inspection must be performed while the motor starter is open. Otherwise you may get an electric shock.

 Fire Prevention

Caution

 Inverter must be installed on a nonflammable wall without holes

(so that nobody touches the inverter heatsink on the rear side, etc.). Mounting it to or near flammable material may cause a fire.

 If the inverter has become faulty, the inverter power must be

switched OFF. A continuous flow of large current may cause a fire.

 Be sure to perform daily and periodic inspections as specified in

the Instruction Manual. If a product is used without any inspection, a burst, breakage, or a fire may occur.

 Injury Prevention

Caution

 The voltage applied to each terminal must be the ones specified

in the Instruction Manual. Otherwise burst, damage, etc. may occur.

 The cables must be connected to the correct terminals.

Otherwise burst, damage, etc. may occur.

 The polarity (+ and -) must be correct. Otherwise burst, damage,

etc. may occur.

 While power is ON or for some time after power-OFF, do not

touch the inverter as it will be extremely hot. Touching these devices may cause a burn.

 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 Mounting

 Any person who is opening a package using a sharp object,

such as a knife and cutter, must wear gloves to prevent injuries caused by the edge of the sharp object.

 The product must be transported in correct method that

corresponds to the weight. Failure to do so may lead to injuries.

 Do not stand or rest heavy objects on the product.  Do not stack the boxes containing inverters higher than the

number recommended.

 When carrying the inverter, do not hold it by the front cover; it

may fall off or fail.

 During installation, caution must be taken not to drop the inverter

as doing so may cause injuries.

 The product must be installed on the surface that withstands the

weight of the inverter.

 Do not install the product on a hot surface.  The mounting orientation of the inverter must be correct.  The inverter must be installed on a strong surface securely with

screws so that it will not drop.

 Do not install or operate the inverter if it is damaged or has parts

missing.

 Foreign conductive objects must be prevented from entering the

inverter. That includes screws and metal fragments or other flammable substance such as oil.

 As the inverter is a precision instrument, do not drop or subject it

to impact.

 The surrounding air temperature for LD, ND (initial setting), and

HD models must be between -10 and +50°C (non-freezing). The surrounding air temperature for SLD must be between -10 and +40°C (non-freezing). Otherwise the inverter may be damaged.

 The ambient humidity must be 95%RH or less (non-

condensing). Otherwise the inverter may be damaged. (Refer to

page 17 for details.)

Safety Instructions

Caution

Transportation and Mounting

 The storage temperature (applicable for a short time, e.g. during

transit) must be between -20 and +65°C. Otherwise the inverter may be damaged.

 The inverter must be used indoors (without corrosive gas,

flammable gas, oil mist, dust and dirt etc.) Otherwise the inverter may be damaged.

 The inverter must be used at an altitude of 2500 m or less above

sea level, with 2.9 m/s (directions of X, Y, Z axes). Otherwise the inverter may be damaged. (Refer to page 17 for details.)

 If halogen-based materials (fluorine, chlorine, bromine, iodine,

etc.) infiltrate into a Mitsubishi product, the product will be damaged. Halogen-based materials are often included in fumigant, which is used to sterilize or disinfest wooden packages. When packaging, prevent residual fumigant components from being infiltrated into Mitsubishi products, or use an alternative sterilization or disinfection method (heat disinfection, etc.) for packaging. Sterilization of disinfection of wooden package should also be performed before packaging the product.

Wiring

 Do not install a power factor correction capacitor or surge

suppressor/capacitor type filter on the inverter output side. These devices on the inverter output side may be overheated or burn out.

 The output side terminals (terminals U, V, and W) must be

connected correctly. Otherwise the motor will rotate inversely.

 PM motor terminals (U, V, W) hold high-voltage while the PM

motor is running even after the power is turned OFF. Before wiring, the PM motor must be confirmed to be stopped. Otherwise you may get an electric shock.

 Never connect an PM motor to the commercial power supply.

Applying the commercial power supply to input terminals (U,V, W) of an PM motor will burn the PM motor. The PM motor must be connected with the output terminals (U, V, W) of the inverter.

Trial run

 Before starting operation, each parameter must be confirmed

and adjusted. A failure to do so may cause some machines to make unexpected motions.

or less vibration at 10 to 55 Hz

Warning

Usage

 Everyone must stay away from the equipment when the retry

function is set as it will restart suddenly after a trip.

 Since pressing a key may not stop output depending on

the function setting status, separate circuit and switch that make an emergency stop (power OFF, mechanical brake operation for emergency stop, etc.) must be provided.

 OFF status of the start signal must be confirmed before resetting

the inverter fault. Resetting inverter fault with the start signal ON restarts the motor suddenly.

 Do not use an PM motor for an application where the PM motor

is driven by its load and runs at a speed higher than the maximum motor speed.

 Use this inverter only with three-phase induction motors or with

an PM motor. Connection of any other electrical equipment to the inverter output may damage the equipment.

 Performing pre-excitation (LX signal and X13 signal) under

torque control (Real sensorless vector control) may start the motor running at a low speed even when the start command (STF or STR) is not input The motor may run also at a low speed when the speed limit value = 0 with a start command input. It must be confirmed that the motor running will not cause any safety problem before performing pre-excitation.

 Do not modify the equipment.  Do not perform parts removal which is not instructed in this

manual. Doing so may lead to fault or damage of the product.

Caution

Usage

 The electronic thermal relay function does not guarantee

protection of the motor from overheating. It is recommended to install both an external thermal and PTC thermistor for overheat protection.

 Do not use a magnetic contactor on the inverter input for

frequent starting/stopping of the inverter. Otherwise the life of the inverter decreases.

 The effect of electromagnetic interference must be reduced by

using a noise filter or by other means. Otherwise nearby electronic equipment may be affected.

 Appropriate measures must be taken to suppress harmonics.

Otherwise power supply harmonics from the inverter may heat/ damage the power factor correction capacitor and generator.

 When driving a 400V class motor by the inverter, the motor must

be an insulation-enhanced motor or measures must be taken to suppress surge voltage. Surge voltage attributable to the wiring constants may occur at the motor terminals, deteriorating the insulation of the motor.

 When parameter clear or all parameter clear is performed, the

required parameters must be set again before starting operations. because all parameters return to their initial values.

 The inverter can be easily set for high-speed operation. Before

changing its setting, the performances of the motor and machine must be fully examined.

 Stop status cannot be hold by the inverter's brake function. In

addition to the inverter’s brake function, a holding device must be installed to ensure safety.

 Before running an inverter which had been stored for a long

period, inspection and test operation must be performed.

 Static electricity in your body must be discharged beforeyou

touch the product.

 Only one PM motor can be connected to an inverter.  An PM motor must be used under PM sensorless vector control.

Do not use a synchronous motor, induction motor, or synchronous induction motor.

 Do not connect an PM motor in the induction motor control

settings (initial settings). Do not use an induction motor in the PM sensorless vector control settings. It will cause a failure.

 In the system with an PM motor, the inverter power must be

turned ON before closing the contacts of the contactor at the output side.

Emergency stop

 A safety backup such as an emergency brake must be provided

to prevent hazardous conditions to the machine and equipment in case of inverter failure.

 When the breaker on the inverter input side trips, thewiring must

be checked for fault (short circuit), and internalparts of the drive unit for a damage, etc. The cause of the trip must be identified and removed before turning ON the power of the breaker.

 When a protective function activates, take an appropriate

corrective action, then reset the inverter, and resume the operation.

Maintenance, inspection and parts replacement

 Do not carry out a megger (insulation resistance) test on the

control circuit of the inverter. It will cause a failure.

Disposal

 The inverter must be treated as industrial waste.

General instruction

 Many of the diagrams and drawings in the Instruction Manual

show the product without a cover or partially open for explanation. Never operate the product in this manner. The cover must be always reinstalled and the instruction in the Instruction Manual must be followed when operating the product. For more details on the PM motor, refer to the Instruction Manual of the PM motor.

Safety Instructions

1 INTRODUCTION 7

1.1 Product checking and accessories 8

1.2 Inverter component names 9

1.3 About the related manuals 10

2 INSTALLATION AND WIRING 11

2.1 Peripheral devices 12

2.1.1 Inverter and peripheral devices ......................................................................................................................12

2.1.2 Peripheral devices ..........................................................................................................................................14

2.2 Removal and reinstallation of the front cover 15

2.3 Installation of the inverter and enclosure design 17

2.3.1 Inverter installation environment.....................................................................................................................17

2.3.2 Cooling system types for inverter enclosure...................................................................................................19

2.3.3 Inverter installation..........................................................................................................................................20

2.3.4 Protruding the heatsink...................................................................................................................................22

2.4 Terminal connection diagrams 24

2.5 Main circuit terminals 28

2.5.1 Details on the main circuit terminals of the inverter........................................................................................28

2.5.2 Details on the main circuit terminals of the converter unit (FR-CC2)..............................................................28

2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor......................................29

2.5.4 Applicable cables and wiring length................................................................................................................30

2.5.5 Earthing (grounding) precautions ...................................................................................................................32

2.6 Control circuit 33

2.6.1 Details on the control circuit terminals of the inverter.....................................................................................33

2.6.2 Details on the control circuit terminals of the converter unit (FR-CC2)...........................................................37

2.6.3 Control logic (sink/source) change .................................................................................................................38

2.6.4 Wiring of inverter control circuit ......................................................................................................................40

2.6.5 Wiring precautions..........................................................................................................................................42

2.6.6 When using separate power supplies for the control circuit and the main circuit...........................................43

2.6.7 When supplying 24 V external power to the control circuit.............................................................................44

2.6.8 Safety stop function ........................................................................................................................................45

2.7 Communication connectors and terminals 47

2.7.1 PU connector ..................................................................................................................................................47

2.7.2 USB connector................................................................................................................................................48

2.7.3 RS-485 terminal block ....................................................................................................................................49

2.8 Connection of motor with encoder (vector control) 50

2.9 Connection of stand-alone option units 57

2.9.1 Connection of the brake unit (FR-BU2) ..........................................................................................................57

2.9.2 Connection of the high power factor converter (FR-HC2) ..............................................................................58

CONTENTS

3 PRECAUTIONS FOR USE OF THE INVERTER 59

3.1 Electro-magnetic interference (EMI) and leakage currents 60

3.1.1 Leakage currents and countermeasures........................................................................................................ 60

3.1.2 Countermeasures against inverter-generated EMI ........................................................................................ 63

3.1.3 Converter unit (FR-CC2) built-in EMC filter....................................................................................................66

3.2 Power supply harmonics 67

3.2.1 Power supply harmonics ................................................................................................................................ 67

3.2.2 Harmonic Suppression Guidelines in Japan .................................................................................................. 68

3.3 Installation of a reactor 70

3.4 Power-OFF and magnetic contactor (MC) 71

3.5 Countermeasures against deterioration of the 400 V class motor insulation 72

3.6 Checklist before starting operation 73

3.7 Failsafe system which uses the inverter 76

4 PROTECTIVE FUNCTIONS 79

4.1 Inverter fault and alarm indications 80

4.2 Reset method for the protective functions 80

4.3 Check and clear of the faults history 81

4.4 List of fault displays 83

5 PRECAUTIONS FOR

MAINTENANCE AND INSPECTION 85

5.1 Inspection item 86

5.1.1 Daily inspection .............................................................................................................................................. 86

5.1.2 Periodic inspection ......................................................................................................................................... 86

5.1.3 Daily and periodic inspection.......................................................................................................................... 87

5.1.4 Checking the inverter and converter modules................................................................................................88

5.1.5 Cleaning ......................................................................................................................................................... 89

5.1.6 Replacement of parts ..................................................................................................................................... 89

5.1.7 Inverter replacement ...................................................................................................................................... 91

5.2 Measurement of main circuit voltages, currents and powers 92

5.2.1 Measurement of powers................................................................................................................................. 94

5.2.2 Measurement of voltages and use of PT........................................................................................................94

5.2.3 Measurement of currents ............................................................................................................................... 95

5.2.4 Use of CT and transducer .............................................................................................................................. 95

5.2.5 Example of measuring converter unit (FR-CC2) input power factor............................................................... 95

5.2.6 Measurement of converter output voltage (across terminals P and N) .......................................................... 95

5.2.7 Measurement of inverter output frequency.....................................................................................................96

CONTENTS

5.2.8 Insulation resistance test using megger .........................................................................................................96

5.2.9 Pressure test...................................................................................................................................................96

6 SPECIFICATIONS 97

6.1 Inverter rating 98

6.2 Common specifications 100

6.3 Outline dimension drawings 102

6.3.1 Inverter outline dimension drawings .............................................................................................................102

6.3.2 Converter unit (FR-CC2) outline dimension drawings ..................................................................................104

APPENDIX 105

Appendix1 For customers replacing the conventional model with this inverter................................ 106

Appendix2 Comparison with FR-A840 .................................................................................................... 108

Appendix3 Instructions for compliance with the EU Directives........................................................... 109

Appendix4 Instructions for UL and cUL ................................................................................................. 111

CONTENTS

MEMO

1 INTRODUCTION

This chapter contains the descriptions that must be read before using this product. Always read the instructions before using the equipment.

1.1 Product checking and accessories.........................................8

1.2 Inverter component names ......................................................9

DU..................................... Operation panel (FR-DU08)

PU..................................... Operation panel (FR-DU08) and parameter unit (FR-PU07)

Inverter.............................. Mitsubishi inverter FR-A800 series (Separated converter type)

Pr. ..................................... Parameter number (Number assigned to function)

PU operation..................... Operation using the PU (FR-DU08/FR-PU07)

External operation............. Operation using the control circuit signals

Combined operation ......... Combined operation using the PU (FR-DU08/FR-PU

07) and External operation

• Connection diagrams in this Instruction Manual suppose that the control logic of the input terminal is the sink

logic, unless otherwise specified. (For the control logic, refer to page 38.)

Harmonic Suppression Guidelines

All the models of the inverters used by specific consumers are covered by "the Harmonic Suppression Guidelines for Consumers Who Receive High Voltage or Special High Voltage". For the details, refer to page 68.

INTRODUCTION

Product checking and accessories

1.1 Product checking and accessories

Unpack the product and check the capacity plate on the front cover and the rating plate on the side to ensure that the model

agrees with the order and the product is intact.

 Applicable inverter model

Symbol Voltage class

400V class

Symbol Structure, functionality

F R - A 8 4 2 -

Symbol

Circuit board coating (3C2)

Not usedNot used

-60

-06

With With

Rating plate

Inverter model

Input rating

Output rating

SERIAL

Separated converter type

315K

Plated conductor

Not used Not used

With

Symbol Description

315K to 500K

07700 to 12120

ND rated inverter capacity (kW)

SLD rated inverter current (A)

- 1

Symbol Type∗1

-1

-2

Manufactured

year and month

 Specification differs by the type as follows.

Type Monitor output

FM (terminal FM equipped model)

CA (terminal CA equipped model)

Terminal FM (pulse train output) Terminal AM (analog voltage output (0 to 10 VDC))

Terminal CA (analog current output (0 to 20 mA DC)) Terminal AM (analog voltage output (0 to 10 VDC))

NOTE

• Hereinafter, the inverter model name consists of the rated current and the applicable motor capacity.

(Example) FR-A842-07700(315K)

 How to read the SERIAL number

Rating plate example

   

Symbol Year Month Control number

SERIAL

Initial setting

Built-in

EMC filter

OFF Sink logic 60 Hz

ON Source logic 50 Hz

The SERIAL consists of one symbol, two characters indicating the production

year and month, and six characters indicating the control number.

The last digit of the production year is indicated as the Year, and the Month is

indicated by 1 to 9, X (October), Y (November), or Z (December).

Control logic

Rated

frequency

Pr.19 Base frequency

voltage

9999 (same as the power supply voltage)

8888 (95% of the power supply voltage)

INTRODUCTION

1.2 Inverter component names

Component names are shown below.

Inverter component names

(a)

(d)

(b)

(c)

(e)

(f)

(o)

(n)

(j)

(k)

(l)

(m)

(g)

(h)

(i)

(q)

(p)

Symbol Name Description

(a) RS-485 terminals Enables RS-485 and Modbus-RTU communication. 49

(b) Plug-in option connector 1

(d) Plug-in option connector 3

(e) Voltage/current input switch Selects between voltage and current for the terminal 2 and 4 inputs.

(f) Control circuit terminal block Connects cables for the control circuit. 33

(g) PU connector

(h) USB A connector Connects a USB memory device. 48

(i) USB mini B connector

(j) Front cover

(k) Power lamp Stays ON while the power is supplied to the control circuit (R1/L11, S1/L21). 29

(l) Alarm lamp Turns ON when the protective function of the inverter is activated. 79

(m) Charge lamp Stays ON while the power is supplied to the main circuit. 29

(n) Operation panel (FR-DU08) Operates and monitors the inverter.

(o) Terminal block cover Remove this cover for wiring. 15

(p) Main circuit terminal block Connects cables for the main circuit. 28

(q) Cooling fan Cools the inverter. 90

 Refer to the FR-A800 Instruction Manual (Detailed)

Connects a plug-in option or a communication option.

Connects the operation panel (FR-DU08) or the parameter unit (FR-PU07). This connector also enables the RS-485 communication.

Connects a personal computer and enables communication with FR Configurator2.

Remove this cover for the installation of the product, installation of a plug-in (communication) option, RS-485 terminal wiring, switching of the voltage/ current input switch, etc.

Instruction Manual of the option

Refer to

page



INTRODUCTION

About the related manuals

1.3 About the related manuals

The manuals related to FR-A800 are shown below.

Manual name Manual number

FR-A800 Instruction Manual (Detailed) IB-0600503ENG

FR-CC2 Instruction Manual IB-0600543ENG

FR Configurator2 Instruction Manual IB-0600516ENG

FR-A800 PLC Function Programming Manual IB-0600492ENG

FR-A800Safety stop function instruction manual BNC-A23228-001

INTRODUCTION

2 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 front cover........................15

2.3 Installation of the inverter and enclosure design ..................17

2.4 Terminal connection diagrams ................................................24

2.5 Main circuit terminals ...............................................................28

2.6 Control circuit ...........................................................................33

2.7 Communication connectors and terminals ............................47

2.8 Connection of motor with encoder (vector control) ..............50

2.9 Connection of stand-alone option units .................................57

INSTALLATION AND WIRING

Peripheral devices

2.1 Peripheral devices

2.1.1 Inverter and peripheral devices

(d) Moulded case

circuit breaker (MCCB) or earth leakage current breaker (ELB), fuse

(e) Magnetic

contactor (MC)

(f) AC reactor

(FR-HAL)

(g) Noise filter

(b) Converter unit

(FR-CC2)

R/L1 S/L2T/L3 N/-N/- P/+P/+ N/-P/+

Earth

(Ground)

(i) Brake unit

(FR-BU2)

(a) Inverter

(FR-A802)

Earth

(Ground)

IM connection

UVW

(k) USB connector

USB host (A connector)

Communication status indicator (LED)(USB host)

USB device (Mini B connector)

PM connection

USB

Personal computer (FR Configurator 2)

(l) Noise filter

(FR-BSF01, FR-BLF)

(n) Contactor

Example) No-fuse switch (DSN type)

(h) High power factor converter

(FR-HC2)

P/+

(j) Resistor unit

(MT-BR5)

: Install these options as required.

(m) Induction

motor

Earth

(Ground)

Earth (Ground)

(o) PM motor

NOTE

• To prevent an electric shock, always earth (ground) the motor, the inverter, and the converter unit.

• Do not install a power factor correction capacitor or surge suppressor or capacitor type filter on the inverter's output side. Doing so will cause the inverter to trip or the capacitor and surge suppressor to be damaged. If any of the above devices is connected, immediately remove it. When installing a molded case circuit breaker on the output side of the inverter, contact the manufacturer of the molded case circuit breaker.

• Electromagnetic wave interference The input/output (main circuit) of the inverter or the converter unit includes high frequency components, which may interfere with the communication devices (such as AM radios) used near the inverter or the converter unit. In this case, activating the EMC filter of the converter unit may minimize interference. (Refer to page 66.)

• For details of options and peripheral devices, refer to the respective Instruction Manual.

• A PM motor cannot be driven by the commercial power supply.

• A PM motor is a motor with permanent magnets embedded inside. High voltage is generated at the motor terminals while the motor is running. Before closing the contactor at the output side, make sure that the inverter power is ON and the motor is stopped.

INSTALLATION AND WIRING

Peripheral devices

Symbol Name Overview

The life of the inverter and the converter unit is influenced by the

(a) Inverter (FR-A802)

(b) Converter unit (FR-CC2)

(d)

(e) Magnetic contactor (MC)

(f) AC reactor (FR-HAL)

(g) Noise filter

(h) High power factor converter (FR-HC2)

(i) Brake unit (FR-BU2)

(j) Resistor unit (MT-BR5)

(k) USB connection

(l) Noise filter

(m) Induction motor Connect a squirrel-cage induction motor. —

(n)

(o) PM motor

Molded case circuit breaker (MCCB), earth leakage circuit breaker (ELB), or fuse

Contactor Example) No-fuse switch (DSN type)

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. Incorrect wiring may lead to damage of the inverter and the converter unit. The control signal lines must be kept fully away from the main circuit lines to protect them from noise. The converter unit built-in EMC filter can reduce the noise.

Must be within the permissible power supply specifications of the converter unit.

Must be selected carefully since an inrush current flows in the converter unit at power ON.

Install this to ensure safety. Do not use this to start and stop the inverter. Doing so will shorten the life of the inverter and the converter unit.

Install this to suppress harmonics and to improve the power factor. An AC reactor (FR-HAL) (option) is required when installing the inverter near a large power supply system (1000 kVA or more). Under such condition, the inverter and the converter unit may be damaged if you do not use a reactor. Select a reactor according to the applied motor capacity.

Suppresses the noise radiated from the power supply side of the converter unit.

Suppresses the power supply harmonics significantly. Install these options as required. When FR-HC2 is used, FR-CC2 is not required.

Allows the inverter to provide the optimal regenerative braking capability. Install these options as required.

A USB (Ver. 1.1) cable connects the inverter with a personal computer. A USB memory device enables parameter copies and the trace function.

Install this to reduce the electromagnetic noise generated from the inverter and the converter unit. The noise filter is effective in the range from about

0.5 MHz to 5 MHz.

Connect this for an application where a PM motor is driven by the load even while the inverter power is OFF. Do not open or close the contactor while the inverter is running (outputting).

A PM motor can be used. A PM motor cannot be driven by the commercial power supply.

Refer

page

17 24 66

—

INSTALLATION AND WIRING

Peripheral devices

MCCB Converter unit

INV

2.1.2 Peripheral devices

Selecting the converter unit (FR-CC2)

Select the capacity of the FR-CC2 converter unit according to the connected motor capacity.

Inverter

Motor

capacity

(kW)

280 H315 - - - - - - - - - 315K 07700 547

315 H315K - - - - - - 315K 07700 610 355K 08660 610

355 H355K - - - 315K 07700 683 355K 08660 683 400K 09620 683

400 H400K 315K 07700 770 355K 08660 770 400K 09620 770 450K 10940 770

450 H450K 355K 08660 866 400K 09620 866 450K 10940 866 500K 12120 866

500 H500K 400K 09620 962 450K 10940 962 500K 12120 962 - - -

Converter

unit

FR-CC2-[ ]



 The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi 4-pole standard motor.

SLD (superlight duty) LD (light duty)

Model

FR-A842-[ ]

Rated

current

(A)

Model

FR-A842-[ ]

Rated

current

(A)

Selecting the breaker/magnetic contactor

Check the model of the inverter and the converter unit you purchased. Appropriate peripheral devices must be selected

according to the capacity.

Refer to the table below to prepare appropriate peripheral devices.

• 400 V class

Motor output (kW)

315 FR-CC2-H315K 700A S-N600

355 FR-CC2-H355K 800A S-N600

400 FR-CC2-H400K 900A S-N800

450 FR-CC2-H450K 1000A 1000A rated product

500 FR-CC2-H500K 1200A 1000A rated product

Applicable converter



model

Molded case circuit breaker (MCCB)

earth leakage circuit breaker (ELB)

(NF, NV type)

ND (normal duty,

initial value)

Model

FR-A842-[ ]

Input-side magnetic contactor

Rated

current

(A)

HD (heavy duty)

Model

FR-A842-[ ]

Rated

current

(A)

 Assumes the use of a Mitsubishi 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. For the use in the United States or Canada, provide the appropriate UL and cUL listed fuse or UL489 molded case circuit breaker (MCCB) that is suitable for branch circuit protection. (Refer to page 111.)

 The magnetic contactor is selected based on the AC-1 class. The electrical durability of magnetic contactor is 500,000 times. When the

magnetic contactor is used for emergency stops during motor driving, the electrical durability is 25 times. If using an MC for emergency stop during driving the motor, select an MC regarding the converter unit input side current as JEM1038-AC-3 class rated current. When using an MC on the inverter output side for commercial-power supply operation switching using a general-purpose motor, select an MC regarding the rated motor current as JEM1038-AC-3 class rated current.

NOTE

• When the converter unit capacity is larger than the motor capacity, select an MCCB and a magnetic contactor according to

the converter unit model, and select cables and reactors according to the motor output.

• When the breaker on the converter unit's input side trips, check for the wiring fault (short circuit), damage to internal parts of

the inverter and the converter unit, etc. The cause of the trip must be identified and removed before turning ON the power of

the breaker.

INSTALLATION AND WIRING

Removal and reinstallation of the front cover

2.2 Removal and reinstallation of the front cover

Removal and reinstallation of the operation panel

• Loosen the two screws on the operation panel.

(These screws cannot be removed.)

To reinstall the operation panel, align its connector on the back with the PU connector of the inverter, and insert the operation

panel. After confirming that the operation panel is fit securely, tighten the screws. (Tightening torque: 0.40 to 0.45 N·m)

• Push the upper part of the operation panel and pull the

operation panel to remove.

Removal of the terminal block cover

(a) (b)

(a) Remove the mounting screws to remove the terminal block cover. (The number of the mounting screws differs by the capacity.) (b) With the terminal block cover removed, wiring of the main circuit terminals can be performed.

INSTALLATION AND WIRING

Removal and reinstallation of the front cover

Loosen

Fasten

Removal of the front cover

(a) (b)

Loosen

(a) With the terminal block cover removed, loosen the mounting screws on the front cover. These screws cannot be removed. (b) While holding the areas around the installation hooks on the sides of the front cover, pull out the front cover using its upper side

as a support.

(c) With the front cover removed, wiring of the control circuit and the RS-485 terminals, and installation of the plug-in option can be

performed.

(c)

Reinstallation of the front cover and the terminal block cover

(a)

(a) Insert the upper hooks of the front cover into the sockets of the inverter.

(b) Tighten the mounting screw at the lower part of the front cover. (c) Fasten the terminal block cover with the mounting screws. (The number of the mounting screws differs by the capacity.)

Securely install the front cover to the inverter by fixing the hooks on the sides of the cover into place.

(b) (c)

Fasten

NOTE

• Fully make sure that the front cover and the terminal block cover are installed securely. Always tighten the mounting screws

of the front cover and the terminal block cover.

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

2.3 Installation of the inverter and enclosure design

When designing or manufacturing an inverter enclosure, determine the structure, size, and device layout of the enclosure by

fully considering the conditions such as heat generation of the contained devices and the operating environment. An inverter

uses many semiconductor devices. To ensure higher reliability and long period of operation, operate the inverter in the

ambient environment that completely satisfies the equipment specifications.

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.

Standard environmental specifications of the inverter

Item Description

Surrounding air temperature

Surrounding air humidity

Storage temperature -20 to + 65°C

Atmosphere Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)

Altitude Maximum 1,000 m above sea level

Vibration

LD, ND (initial setting), HD -10 to +50°C (non-freezing)

5cm

SLD -10 to +40°C (non-freezing)

With circuit board coating 95% RH or less (non-condensing) Without circuit board coating 90% RH or less (non-condensing)





or less at 10 to 55 Hz (directions of X, Y, Z axes)

2.9 m/s

 Temperature applicable for a short time, e.g. in transit.  For the installation at an altitude above 1,000 m (up to 2,500 m), derate the rated current 3% per 500 m.

(1.97 inches)

Measurement position

Inverter

Measurement position

5cm

(1.97 inches) 5cm (1.97 inches)

Temperature

The permissible surrounding air temperature of the inverter is between -10°C and +50°C (-10°C and +40°C at the SLD rating).

Always operate the inverter within this temperature range. Operation outside this range will considerably shorten the service

lives of the semiconductors, parts, capacitors and others. Take the following measures to keep the surrounding air

temperature of the inverter within the specified range.

(a) Measures against high temperature

• Use a forced ventilation system or similar cooling system. (Refer to page 19.)

• Install the enclosure in an air-conditioned electric chamber.

• Block direct sunlight.

• Provide a shield or similar plate to avoid direct exposure to the radiated heat and wind of a heat source.

• Ventilate the area around the enclosure well.

(b) Measures against low temperature

• Provide a space heater in the enclosure.

• Do not power OFF the inverter. (Keep the start signal of the inverter OFF.)

• Select an installation place where temperature does not change suddenly.

• Avoid installing the inverter near the air outlet of an air conditioner.

• If temperature changes are caused by opening/closing of a door, install the inverter away from the door.

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. The insulation distance defined in JEM1103 "Control Equipment Insulator" is humidity of 45 to

85%.

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

(a) Measures against high humidity

• Make the enclosure enclosed, and provide it with a hygroscopic agent.

• Provide dry air into the enclosure from outside.

• Provide a space heater in the enclosure.

(b) Measures against low humidity

Air with proper humidity can be blown into the enclosure from outside. Also when installing or inspecting the unit, discharge

your body (static electricity) beforehand, and keep your body away from the parts and patterns.

Condensation may occur if frequent operation stops change the in-enclosure temperature suddenly or if the outside air

temperature changes suddenly.

Condensation causes such faults as reduced insulation and corrosion.

• Take the measures against high humidity in (a).

• Do not power OFF the inverter. (Keep the start signal of the inverter OFF.)

Dust, dirt, oil mist

Dust and dirt will cause such faults as poor contacts, reduced insulation and cooling effect due to the moisture-absorbed

accumulated dust and dirt, and in-enclosure temperature rise due to a clogged filter. In an atmosphere where conductive

powder floats, dust and dirt will cause such faults as malfunction, deteriorated insulation and short circuit in a short time.

Since oil mist will cause similar conditions, it is necessary to take adequate measures.

Countermeasure

• Place the inverter in a totally enclosed enclosure.

Take measures if the in-enclosure temperature rises. (Refer to page 19.)

• Purge air.

Pump clean air from outside to make the in-enclosure air pressure higher than the outside air pressure.

Corrosive gas, salt damage

If the inverter is exposed to corrosive gas or to salt near a beach, the printed board patterns and parts will corrode or the

relays and switches will result in poor contact.

In such places, take the measures given above.

Explosive, flammable gases

As the inverter is non-explosion proof, it must be contained in an explosion-proof enclosure. In places where explosion may

be caused by explosive gas, dust or dirt, an enclosure cannot be used unless it structurally complies with the guidelines and

has passed the specified tests. This makes the enclosure itself expensive (including the test charges). The best way is to

avoid installation in such places and install the inverter in a non-hazardous place.

High altitude

Use the inverter at an altitude of within 1000 m. For use at an altitude above 1,000 m (up to 2,500 m), derate the rated current

3% per 500 m.

If it is used at a higher place, it is likely that thin air will reduce the cooling effect and low air pressure will deteriorate dielectric

strength.

Vibration, impact

The vibration resistance of the inverter is up to 2.9 m/s2 at 10 to 55 Hz frequency and 1 mm amplitude for the directions of X,

Y, Z axes. Applying vibration and impacts for a long time may loosen the structures and cause poor contacts of connectors,

even if those vibration and impacts are within the specified values.

Especially when impacts are applied repeatedly, caution must be taken because such impacts may break the installation feet.

Countermeasure

• Provide the enclosure with rubber vibration isolators.

• Strengthen the structure to prevent the enclosure from resonance.

• Install the enclosure away from the sources of the vibration.

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

INV

Heat pipe

2.3.2 Cooling system types for inverter enclosure

From the enclosure that contains the inverter, the heat of the inverter and other equipment (transformers, lamps, resistors,

etc.) and the incoming heat such as direct sunlight must be dissipated to keep the in-enclosure temperature lower than the

permissible temperatures of the in-enclosure equipment including the inverter.

The cooling systems are classified as follows in terms of the cooling calculation method.

(a) Cooling by natural heat dissipation from the enclosure surface (totally enclosed type)

(b) Cooling by heatsink (aluminum fin, etc.)

(d) Cooling by heat exchanger or cooler (heat pipe, cooler, etc.)

Cooling system Enclosure structure Comment

Natural cooling

Forced cooling

Natural ventilation (enclosed, open type)

Natural ventilation (totally enclosed type)

Heatsink cooling

Forced ventilation

Heat pipe This is a totally enclosed for enclosure downsizing.

Heatsink

INV

This system is low in cost and generally used, but the enclosure size increases as the inverter capacity increases. This system is for relatively small capacities.

Being a totally enclosed type, this system is the most appropriate for hostile environment having dust, dirt, oil mist, etc. The enclosure size increases depending on the inverter capacity.

This system has restrictions on the heatsink mounting position and area. This system is for relatively small capacities.

This system is for general indoor installation. This is appropriate for enclosure downsizing and cost reduction, and often used.

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

Vertical

2.3.3 Inverter installation

Inverter placement

• Install the inverter on a strong surface securely with screws.

• Leave enough clearances and take cooling measures.

• Avoid places where the inverter is subjected to direct sunlight, high temperature and high humidity.

• Install the inverter on a nonflammable wall surface.

• When encasing multiple inverters in an enclosure, install them in parallel as a cooling measure.

• For heat dissipation and maintenance, keep clearance between the inverter and the other devices or enclosure surface.

The clearance below the inverter is required as a wiring space, and the clearance above the inverter is required as a heat

dissipation space.

Clearances (side)Clearances (front)

20cm (7.87inches) or more

5cm (1.97 inches) or more

∗1

Inverter

Allow clearance.

Vertical

10cm

(3.94inches)

or more

10cm (3.94inches) or more

20cm (7.87inches) or more

 For replacing the cooling fan, 30 cm (11.81 inches) or more of space is necessary in front of the inverter. Refer to pag e 90 for fan replacement.

Installation orientation of the inverter

Install the inverter on a wall as specified. Do not mount it horizontally or in any other way.

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.

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

Inverter Inverter

Encasing multiple inverters and converter units

When multiple inverters and converter units are placed in the

same enclosure, generally arrange them horizontally as shown

in the figure on the right.

Do not place multiple products vertically. The exhaust air

temperature of the inverter and the converter unit may be

increased.

When mounting multiple inverters and converter units, fully take

caution not to make the surrounding air temperature of the

inverter and the converter unit higher than the permissible value

by providing ventilation and increasing the enclosure size.

Converter

unit

Converter

unit

Arrangement of multiple inverters and converter units

Arrangement of the ventilation fan and inverter

Heat generated in the inverter is blown up from the bottom of

the unit as warm air by the cooling fan. When installing a

ventilation fan for that heat, determine the place of ventilation

fan installation after fully considering an air flow. (Air passes

through areas of low resistance. Make an airway and airflow

plates to expose the inverter to cool air.)

Inverter

Enclosure

Converter

unit

Inverter

Arrangement of the ventilation fan and inverter

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

2.3.4 Protruding the heatsink

When encasing an inverter to an enclosure, the heat generated in the enclosure can be greatly reduced by protruding the

heatsink of the inverter.

When installing the inverter in a compact enclosure, etc., this installation method is recommended.

 Panel cutting

Cut the panel of the enclosure according to the inverter capacity.

FR-A842-07700(315K)

FR-A842-08660(355K)

1515 1270

1300

200

520

Hole

200

6-M10 screw

FR-A842-09620(400K)

FR-A842-10940(450K)

FR-A842-12120(500K)

15152015

1550

660

240 240

Hole

6-M10 screw

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

NOTE

Upper installation frame (rear side)

Lower installation frame (rear side)

 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

and bottom of the inverter as shown on the right.

 Installation of the inverter

Push the inverter heatsink portion outside the enclosure and fix the enclosure and inverter with upper and lower

installation frame.

Enclosure

Inside the enclosure

Inverter

Exhausted air

Installation frame

There are finger guards behind the enclosure. Therefore, the thickness of the panel should be less than 10 mm (∗1) and also do not place anything around finger guards to avoid contact with the finger guards.

Enclosure

10mm

∗1

140mm

Finger guard

• Having a cooling fan, the cooling section which comes out of the enclosure cannot be used in the environment of water drops,

• Be careful not to drop screws, dust etc. into the inverter and cooling fan section.

oil, mist, dust, etc.

Cooling

wind

185mm

6mm

Dimension of the outside of the enclosure

INSTALLATION AND WIRING

Terminal connection diagrams

2.4 Terminal connection diagrams

FM type

Sink logic

Converter unit

R/L1

P/+

S/L2

N/-

T/L3

RDI

RES

+24

RDB

RDA

RSO

IPF

FAN

Main circuit terminal

Control circuit terminal

Control input signals (No voltage input allowed) 

Forward rotation start

Reverse rotation start

Start self-holding selection

Multi-speed selection

Second function selection

Terminal 4 input selection

Selection of automatic restart

after instantaneous power failure

Contact input common

(Common for external power supply transistor)

Frequency setting signals (Analog)

Frequency setting potentiometer 1/2W1kΩ

Connector for plug-in option connection

Safety stop signal

Safety stop input (Channel 1)

Safety stop input (Channel 2)

High speed

Middle speed

Low speed

Jog operation

Output stop

24V external power

supply input

Common terminal



Auxiliary input

Terminal 4 input (Current input)

Safety stop input common

Brake unit (Option)

Jumper



Earth

(Ground)

Reset

24VDC power supply

(+) (-)

Shorting wire

P/+

N/-

R1/L11 S1/L21

Main circuit

Control circuit

STF

STR

STP(STOP)

JOG



MRS

X10



RES

+24

10E(+10V)

10(+5V)

0 to 5VDC

0 to 10VDC 0 to 20mADC

(Analog common)

0 to ±10VDC

0 to ±5VDC selectable

4 to 20mADC

0 to 5VDC 0 to 10VDC

connector 1 connector 2

connector 3

24V

SIC

SINK

SOURCE

24V

Voltage/current



input switch

OFF

Initial value

selectable

Initial value

selectable

Output shutoff circuit



PU connector

USB A connector

USB mini B connector

RXD+

Terminating

resistor

U V

RUN

Running

Up to frequency

IPF



Overload

Frequency detection

Open collector output common

Sink/source common

F/C

(FM)



TXD+

TXD-

RXD-

VCC

Safety monitor output

SOC

Safety monitor output common

Relay output 1 (Fault output)

Relay output 2

Open collector output 

Calibration resistor

(+)

(-)

Data transmission

Data reception

GND

Motor

Earth (Ground)

Relay output 



Analog signal output (0 to ±10VDC)

RS-485 terminals

(Permissible load current 100mA)

Indicator (Frequency meter, etc.)

Moving-coil type 1mA full-scale

INSTALLATION AND WIRING

Terminal connection diagrams

NOTE

 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).  Terminal JOG is also used as the pulse train input terminal. Use Pr.291 to choose JOG or pulse.  The X10 signal (NC contact input specification) is assigned to the terminal MRS in the initial setting. Set Pr.599 = "0" to change the input

specification of the X10 signal to NO contact.

 Terminal input specifications can be changed by analog input specification switchover (Pr.73, Pr.267). To input a voltage (0 to 5 V/0 to 10 V), set

the voltage/current input switch OFF. To input a current (4 to 20 mA), set the voltage/current input switch ON. Terminals 10 and 2 are also used as a PTC input terminal. (Pr.561)

 It is recommended to use 2 W 1 k when the frequency setting signal is changed frequently.  The function of these terminals can be changed with the output terminal assignment (Pr.195, Pr.196).  The function of these terminals can be changed with the output terminal assignment (Pr.190 to Pr.194).  No function is assigned in the initial setting. Use Pr.192 for function assignment.  The terminal FM can be used to output pulse trains as open collector output by setting Pr.291.  Not required when calibrating the scale with the operation panel.

• To prevent a malfunction due to noise, keep the signal cables 10 cm or more away from the power cables. Also, separate the

main circuit cables at the input side from the main circuit cables at the output side.

• After wiring, wire offcuts must not be left in the inverter.

Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter clean.

When drilling mounting holes in an enclosure etc., take caution not to allow chips and other foreign matter to enter the

inverter.

• Set the voltage/current input switch correctly. Incorrect setting may cause a fault, failure or malfunction.

INSTALLATION AND WIRING

Terminal connection diagrams

CA type

Sourse logic

Main circuit terminal

Control circuit terminal

Converter unit

R/L1

P/+

S/L2

N/-

T/L3

RDI

RES

+24

RDB

RDA

RSO

IPF

FAN

Control input signals (No voltage input allowed) 

Forward rotation start

Reverse rotation start

Start self-holding selection

Multi-speed selection

Second function selection

Terminal 4 input selection

Selection of automatic restart

after instantaneous power failure

power supply transistor

Frequency setting signals (Analog)

Frequency setting potentiometer 1/2W1kΩ

Connector for plug-in option connection

Safety stop signal

Safety stop input (Channel 1)

Safety stop input (Channel 2)

Middle speed

Jog operation

Common for external

24V external power

supply input

Common terminal



Auxiliary input

Terminal 4 input (Current input)

Safety stop input common

Jumper

(Ground)

High speed

Low speed

Output stop

Reset

Contact input common

24VDC power supply

(+) (-)

Brake unit (Option)



Earth

Shorting wire

P/+

N/-

R1/L11 S1/L21

Main circuit

Control circuit

STF

STR

STP(STOP)

JOG



MRS

X10



RES

+24

10E(+10V)

10(+5V)

0 to 5VDC

0 to 10VDC 0 to 20mADC

(Analog common)

0 to ±10VDC

0 to ±5VDC selectable

4 to 20mADC

0 to 5VDC 0 to 10VDC

connector 1 connector 2

connector 3

24V

SIC

SINK

SOURCE

24V

Voltage/current



input switch

OFF

Initial value

selectable

Initial value

selectable

Output shutoff circuit



PU connector

USB A connector

USB mini B connector

RXD+

Terminating

resistor

Relay output 1 (Fault output)

Relay output 2

RUN

Running

Up to frequency

IPF



Overload

Frequency detection

Open collector output common

Sink/source common

F/C

(CA)

TXD+

TXD-

RXD-

VCC

Safety monitor output

SOC

Safety monitor output common

Open collector output 

Relay output 

(+)

Analog current output (0 to 20mADC)

(-)

(+)

Analog signal output (0 to ±10VDC)

(-)

RS-485 terminals

Data transmission

Data reception

GND

(Permissible load

current 100mA)

Motor

Earth (Ground)

INSTALLATION AND WIRING

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.

specification of the X10 signal to NO contact.

 Terminal input specifications can be changed by analog input specification switchover (Pr.73, Pr.267). To input a voltage (0 to 5 V/0 to 10 V), set

the voltage/current input switch OFF. To input a current (4 to 20 mA), set the voltage/current input switch ON. Terminals 10 and 2 are also used as a PTC input terminal. (Pr.561)

NOTE

• To prevent a malfunction due to noise, keep the signal cables 10 cm or more away from the power cables. Also, separate the

main circuit cables at the input side from the main circuit cables at the output side.

• After wiring, wire offcuts must not be left in the inverter.

Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter clean.

When drilling mounting holes in an enclosure etc., take caution not to allow chips and other foreign matter to enter the

inverter.

• Set the voltage/current input switch correctly. Incorrect setting may cause a fault, failure or malfunction.

Connection between the converter unit and the inverter

Perform wiring so that the commands sent from the converter unit are transmitted to the inverter without fail. Incorrect

connection may damage the converter unit and the inverter.

For the wiring length, refer to the table below.

Total wiring

length

Across the terminals P and P and

the terminals N and N

Other control signal cables 30 m or lower

50 m or lower

For the cable gauge of the cable across the main circuit terminals P/+ and N/- (P and P, N and N), refer to page 30.

Converter unit

(FR-CC2)

MCCB

Power supply

 Do not install an MCCB across the terminals P/+ and N/- (across terminals P and P/+ or across N and N/-). Connecting the opposite polarity of

terminals N/- and P/+ will damage the inverter.

 For the terminal used for the X10 signal input, set "10" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function.

(The X10 signal is assigned to the terminal MRS in the initial setting.) For the X10 signal, NC contact input specification is selected in the initial setting. Set Pr.599 = "0" to change the input specification to NO contact.

 For the terminal used for the X11 signal input, set "11" in any of Pr.178 to Pr.189 (input terminal function selection) to assign the function. For

RS-485 or any other communication where the start command is only transmitted once, use the X11 signal to save the operation mode at the time of an instantaneous power failure.

 Always connect the terminal RDA of the converter unit and the terminal MRS (X10) of the inverter, and the terminal SE of the converter unit and

the terminal SD (sink logic) of the inverter. Not connecting these terminals may damage the converter unit.

R/L1

N/-

S/L2

T/L3

R1/L11 S1/L21

RDA

RDB

IPF

RSO





Inverter

P/+P/+ N/-

R1/L11 S1/L21

MRS(X10)





X11

RES

U V

INSTALLATION AND WIRING

Main circuit terminals

2.5 Main circuit terminals

2.5.1 Details on the main circuit terminals of the

inverter

Terminal

symbol

U, V, W Inverter output

R1/L11, S1/L21

P/+, N/- Converter unit connection

Terminal name Terminal function description

Connect these terminals to a three-phase squirrel cage motor or an PM motor.

Connected to the terminals P/+ and N/-. To retain the fault display and fault

Power supply for the control circuit

Earth (ground)

output, or to use the converter unit (FR-CC2), remove the jumpers installed in terminals R1/L11 and S1/L21, and apply external power supply to these terminals. The power capacity necessary when separate power is supplied from R1/L11 and S1/L21 is 80 VA.

Connect the converter unit (FR-CC2), brake unit (FR-BU2), or high power factor converter (FR-HC2).

For earthing (grounding) the inverter chassis. This must be earthed (grounded).

2.5.2 Details on the main circuit terminals of the

converter unit (FR-CC2)

Terminal

symbol

R/L1, S/L2, T/L3

R1/L11, S1/L21

P/+, N/- Inverter connection Connect to terminals P/+ and N/- of the inverter. 24

Terminal name Terminal function description

AC power input Connect these terminals to the commercial power supply. -

Connected to the AC power supply terminals R/L1 and S/L2. To retain the

fault display and fault output, remove the jumpers across terminals R/L1 and Power supply for the control circuit

Earth (ground)

R1/L11 and across S/L2 and S1/L21, and supply external power to these

terminals.

The power capacity necessary when separate power is supplied from R1/L11

and S1/L21 is 80 VA.

For earthing (grounding) the converter unit chassis. This must be earthed

(grounded).

Refer

to page

24, 57

Refer

to page

INSTALLATION AND WIRING

Main circuit terminals

2.5.3 Terminal layout of the main circuit terminals,

wiring of power supply and the motor

FR-CC2-315K to FR-CC2-500K FR-A842-07700(315K) to FR-A842-12120(500K)

R1/L11 S1/L21

Charge lamp

Jumper

N/-

Charge lamp

Jumper

R/L1

S/L2

Power supply

T/L3

N/-

P/+

To inverter

To converter

unit

P/+

Motor

NOTE

• Make sure the power cables are connected to the R/L1, S/L2, and T/L3 of the converter unit. (Phase need not be matched.)

Never connect the power cable to the U, V, and W of the inverter. Doing so will damage the inverter.

• Connect the motor to the U, V, and W of the inverter. (The phases must be matched.)

• When wiring the main circuit conductor, tighten a nut from the right side of the conductor.

When wiring two wires, place wires on both sides of the conductor. (Refer to the diagram below.)

For wiring, use bolts (nuts) provided with the inverter.

• When wiring the main circuit conductor (R/L1, S/L2, T/L3) of the converter unit (FR-CC2), use the bolts (nuts) for main circuit

wiring, which are provided on the front side of the conductor.

FR-CC2-H315K, H355K FR-CC2-H400K to H500K

Connect the cables here.

INSTALLATION AND WIRING

Main circuit terminals

2.5.4 Applicable cables and wiring length

Select a recommended cable size to ensure that the voltage drop will be 2% or less.

If the wiring distance is long between the inverter and motor, the voltage drop in the main circuit will cause the motor torque to

decrease especially at a low speed.

The following table indicates a selection example for the wiring length of 20 m (440 V input power supply, 150% overload

current rating for 1 minute).

• Converter unit (FR-CC2)

Crimping

Converter

model

FR-CC2-[ ]

315K M12 (M10) 46 150-12 2150 2150 100 2300 2150 150

355K M12 (M10) 46 C2-200 2200 2200 100 2350 2185 295

400K M12 (M10) 46 C2-200 2200 2200 100 2400 2185 295

450K M12 (M10) 46 C2-250 2250 2250 100 2500 2240 2120

500K M12 (M10) 46 C2-200 3200 3200 2100 2500 2240 2120

Terminal

screw Size



Tightening

Torque

N·m

terminal

R/L1, S/L2,

T/L3

HIV cables, etc. (mm2)

R/L1,

S/L2,

P/+, N/-

(grounding)

T/L3

• Inverter

Crimping

Inverter

model

FR-A840-[ ]

Terminal

screw

size



Tightening

Torque

N·m

terminal

HIV cables, etc. (mm2)

U, V, W U, V, W P/+, N/-

Earthing

(grounding)

cable

07700(315K) M12 (M10) 46 150-12 2150 2150 100 2300 2150 150

08660(355K) M12 (M10) 46 C2-200 2200 2200 100 2350 2185 295

09620(400K) M12 (M10) 46 C2-200 2200 2200 100 2400 2185 295

10940(450K) M12 (M10) 46 C2-250 2250 2250 100 2500 2240 2120

12120(500K) M12 (M10) 46 C2-250 2250 3200 2100 2500 2240 2120

 The gauge of the cable with the continuous maximum permissible temperature of 90°C or higher. (LMFC (heat resistant flexible cross-linked

polyethylene insulated cable), etc.). It assumes a surrounding air temperature of 40°C or lower and in-enclosure wiring.

 The recommended cable size is that of the cable (THHN cable) with continuous maximum permissible temperature of 90°C. It assumes a

surrounding air temperature of 40°C or lower and in-enclosure wiring. (Selection example for use mainly in the United States.)

 The cable size is that of the cable (XLPE cable) with continuous maximum permissible temperature of 90°C. It assumes a surrounding air

temperature of 40°C or lower and in-enclosure wiring. (Selection example for use mainly in Europe.

 The terminal screw size indicates the size of a terminal screw for R/L1, S/L2, T/L3, U, V, W, P/+, N/-, and a screw for earthing (grounding).

Screw size for earthing (grounding) is indicated in parentheses.

The line voltage drop can be calculated by the following formula:

Cable gauge

Earthing

cable

Cable gauge

AWG/MCM



R/L1, S/L2,

T/L3

AWG/MC M

U, V, W U, V, W

PVC cables, etc.

)

(mm R/L1, S/L2,

T/L3

Earthing

(grounding)

cable

PVC cables, etc.

(mm2)

Earthing

(grounding)

cable

Line voltage drop [V]=

× wire resistance[mΩ/m] × wiring distance[m] × current[A]

1000

Use a larger diameter cable when the wiring distance is long or when it is desired to decrease the voltage drop (torque

reduction) in the low speed range.

NOTE

• Tighten the terminal screw to the specified torque.

A screw that has been tightened too loosely can cause a short circuit or malfunction.

A screw that has been tightened too tightly can cause a short circuit or malfunction due to the unit breakage.

• Use crimping terminals with insulation sleeves to wire the power supply and motor.

INSTALLATION AND WIRING

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

500 m or less

When driving a 400 V class motor by the inverter, surge voltages attributable to the wiring constants may occur at the

motor terminals, deteriorating the insulation of the motor. In this case, take one of the following measure.

• Use a "400 V class inverter-driven insulation-enhanced motor" and set Pr.72 PWM frequency selection according to

the wiring length.

Wiring length 100 m or shorter Wiring length longer than 100 m

6 (6 kHz) or lower 4 (4 kHz) or lower

• If the motor capacity is 280 kW or lower, connect the sine wave filter (MT-BSL/BSC) to the output side.

300 m

300 m+300 m=600 m

 With PM motor

Use the wiring length of 100 m or shorter when connecting a PM motor.

Use one PM motor for one inverter. Multiple PM motors cannot be connected to an inverter.

When the wiring length exceeds 50 m for a 400 V class motor driven by an inverter under PM sensorless vector control,

set "9" (6 kHz) or less in Pr.72 PWM frequency selection.

NOTE

• Especially for long-distance wiring, the inverter may be affected by a charging current caused by the stray capacitances of the

wiring, leading to a malfunction of the overcurrent protective function or fast response current limit function or a malfunction or

fault of the equipment connected on the inverter output side. If the fast-response current limit function malfunctions, disable

this function. (For the details of Pr.156 Stall prevention operation selection, refer to the FR-A800 Instruction Manual

(Detailed))

• A sine wave filter (MT-BSL/BSC) can be used under V/F control. Do not use the filters under different control methods.

• For the details of Pr.72 PWM frequency selection, refer to the FR-A800 Instruction Manual (Detailed).

• Refer to page 72 to drive a 400 V class motor by an inverter.

• The carrier frequency is limited during PM sensorless vector control. (Refer to the FR-A800 Instruction Manual (Detailed))

INSTALLATION AND WIRING

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. 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. The

purpose of earthing (grounding) the case of an electrical apparatus is to prevent operators from getting an electric shock from

this leakage current when touching it.

To avoid the influence of external noises, this earthing (grounding) is important to audio equipment, sensors, computers and

other apparatuses that handle low-level signals or operate very fast.

Earthing (grounding) methods and earthing (grounding) work

As described previously, earthing (grounding) is roughly classified into an electrical shock prevention type and a noise-

influenced malfunction prevention type. Therefore, these two types should be clearly distinguished, and the following work

must be done to prevent the leakage current having the inverter's high frequency components from entering the malfunction

prevention type earthing (grounding):

• Whenever possible, use the independent earthing (grounding) for the inverter.

If independent earthing (grounding) (I) is not available, use (II) common earthing (grounding) in the figure below where the

inverter is connected with the other equipment at an earthing (grounding) point. Do not use the other equipment's earthing

(grounding) cable to earth (ground) the inverter as shown in (III).

A leakage current containing many high frequency components flows into the earthing (grounding) cables of the inverter

and peripheral devices. Because of this, the inverter must be earthed (grounded) separately from EMI-sensitive devices.

In a high building, it may be effective to use the EMI prevention type earthing (grounding) connecting to an iron structure

frame, and electric shock prevention type earthing (grounding) with the independent earthing (grounding) together.

• Earthing (Grounding) must conform to the requirements of national and local safety regulations and electrical codes.

(NEC section 250, IEC 536 class 1 and other applicable standards).

A neutral-point earthed (grounded) power supply in compliance with EN standard must be used.

• use the thickest possible earthing (grounding) cable. The earthing (grounding) cable should be the size indicated in the

table on page 30.

• The earthing (grounding) point should be as close as possible to the inverter, and the earth (ground) wire length should

be as short as possible.

• Run the earthing (grounding) cable as far away as possible from the I/O wiring of equipment sensitive to noises and run

them in parallel in the minimum distance.

Inverter/

converter

unit

(I) Independent earthing (grounding).......Good

To be compliant with the EU Directive (Low Voltage Directive), refer to page 109.

INSTALLATION AND WIRING

Other

equipment

Inverter/

converter

unit

(II) Common earthing (grounding).......Good

Other

equipment

Inverter/

converter

unit

(III) Common earthing (grounding) cable.......Not allowed

Other

equipment

Control circuit

2.6 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

Symbol

Type

STF Forward rotation start

STR Reverse rotation start

STOP

RH RM RL

JOG

MRS (X10)

RES Reset

Contact input

Terminal name Terminal function description Rate Specification

Start self-holding selection

Multi-speed selection

Jog mode selection

Pulse train input

Second function selection

Output stop (Inverter operation enable)

Terminal 4 input selection Selection of automatic restart after instantaneous power failure Contact input common (sink)

External transistor common (source)

24 VDC power supply common

External transistor common (sink)

Contact input common (source) 24 VDC power supply common

Turn ON the STF signal to start forward rotation and turn it OFF to stop. Turn ON the STR signal to start reverse rotation and turn it OFF to stop.

Turn ON the STOP signal to self-hold the start signal.

Multi-speed can be selected according to the combination of RH, RM and RL signals.

Turn ON the JOG signal to enable JOG operation (initial setting) and turn ON the start signal (STF or STR) to start JOG operation.

Terminal JOG is also used as the pulse train input terminal. To use as a pulse train input terminal, change the Pr.291 setting. (maximum input pulse: 100k pulses/s)

Turn ON the RT signal to enable the second function. When the second function such as "second torque boost" and "second V/F (base frequency)" is set, turning ON the RT signal enables the selected function. Connect to the terminal RDA of the converter unit (FR-CC2). When the RDA signal is turned OFF, the inverter output is shut off. The X10 signal (NC contact) is assigned to the terminal MRS in the initial setting. Use Pr.599 to change the specification to NO contact. Use this signal to reset a fault output provided when a protective function is activated. Turn ON the RES signal for 0.1s or longer, then turn it OFF. In the initial setting, reset is always enabled. By setting Pr.75, reset can be enabled only at an inverter fault occurrence. The inverter recovers about 1s after the reset is released. The terminal 4 function is available only when the AU signal is ON Turning ON the AU signal disables the terminal 2 function.

When the CS signal is left ON, the inverter restarts automatically at power restoration. Note that restart setting is necessary for this operation. In the initial setting, a restart is disabled.



Common terminal for contact input terminal (sink logic) and terminal FM Connect this terminal to the power supply common terminal of a transistor output (open collector output) device, such as a programmable controller, in the source logic to avoid malfunction by



undesirable current. Common terminal for the 24 VDC power supply (terminal PC, terminal +24) Isolated from terminals 5 and SE. Connect this terminal to the power supply common terminal of a transistor output (open collector output) device, such as a programmable controller, in the source logic to avoid malfunction by undesirable current.

Common terminal for contact input terminal (source logic).



Can be used as a 24 VDC 0.1 A power supply.

When the STF and STR signals are turned ON simultaneously, the stop command is given.

Input resistance

4.7 k Voltage when contacts are open: 21 to 27 VDC When contacts are short-circuited: 4 to 6 mADC

Input resistance 2 k When contacts are short-circuited: 8 to 13 mADC

Input resistance

4.7 k Voltage when contacts are open: 21 to 27 VDC When contacts are short-circuited: 4 to 6 mADC

———

Power supply voltage range 19.2 to 28.8 VDC Permissible load current 100 mA

INSTALLATION AND WIRING

Control circuit

Terminal

Typ e

10E

Frequency setting

10 2

Thermistor

Symbol

Terminal name Terminal function description Rate Specification

10 VDC 0.4 V Permissible load current 10 mA 5 VDC0.5 V Permissible load current 10 mA When voltage is input: Input resistance 10 k 1 k Maximum permissible voltage 20 VDC When current is input: Input resistance 245  5  Permissible maximum current 30 mA

Voltage/current input switch



switch2

switch1

Input resistance 10 k 1 k Permissible maximum voltage 20 VDC

———

Applicable PTC thermistor specification Overheat detection resistance:

0.5 to 30 k (Set by Pr.561)

2 4

Frequency setting power supply

Frequency setting (voltage)

Frequency setting (current)

Frequency setting auxiliary

Frequency setting common

PTC thermistor input

When connecting the frequency setting potentiometer at an initial status, connect it to the terminal 10. Change the input specifications of the terminal 2 in Pr.73 when connecting it to the terminal 10E.

Inputting 0 to 5 VDC (or 0 to 10 V, 0 to 20 mA) provides the maximum output frequency at 5 V (10 V, 20 mA) and makes input and output proportional. Use Pr.73 to switch among input 0 to 5 VDC (initial setting), 0 to 10 VDC, and 0 to 20 mA. Set the voltage/current input switch in the ON position to select current input (0 to 20 mA).

Inputting 4 to 20 mADC (or 0 to 5 V, 0 to 10 V) provides the maximum output frequency at 20 mA and makes input and output proportional. This input signal is valid only when the AU signal is ON (terminal 2 input is invalid). Use Pr.267 to switch among input 4 to 20 mA (initial setting), 0 to 5 VDC, and 0 to 10 VDC. Set the voltage/current input switch in the OFF position to select voltage input (0 to 5 V/0 to 10 V). Use Pr.858 to switch terminal functions.

Inputting 0 to 5 VDC or 0 to 10 VDC adds this signal to terminal 2 or 4 frequency setting signal. Use Pr.73 to switch between input 0 to 5 VDC and 0 to 10 VDC (initial setting). Use Pr.868 to switch terminal functions. Common terminal for frequency setting signal (terminal 2, 1 or 4) and analog output terminal AM. Do not earth (ground).

For receiving PTC thermistor outputs. When PTC thermistor is valid (Pr.561  "9999"), the terminal 2 is not available for frequency setting.



+24

Power supply input

 Set Pr.73, Pr.267, and the voltage/current input switch correctly, then input an analog signal in accordance with the setting.

 The sink logic is initially set for the FM-type inverter.  The source logic is initially set for the CA-type inverter.

24 V external power supply input

Applying a voltage with the voltage/current input switch ON (current input is selected) or a current with the switch OFF (voltage input is selected) could cause component damage of the inverter or analog circuits of output devices. (For the details, refer to the FR-A800 Instruction Manual (Detailed).)

Output signal

Terminal

Symbol

Type

A1, B1, C1

Relay

A2, B2, C2

Terminal name Terminal function description Rate Specification

Relay output 1 (fault output)

Relay output 2 1 changeover contact output

For connecting a 24 V external power supply. If a 24 V external power supply is connected, power is supplied to the control circuit while the main power circuit is OFF.

1 changeover contact output that indicates that an inverter's protective function has been activated and the outputs are stopped. Fault: discontinuity across B and C (continuity across A and C), Normal: continuity across Band C (discontinuity across A and C)

Input voltage 23 to

25.5 VDC Input current 1.4 A or less

Contact capacity 230 VAC 0.3 A (power factor = 0.4) 30 VDC 0.3 A

INSTALLATION AND WIRING

Control circuit

Terminal

Symbol

Typ e

RUN Inverter running

SU Up to frequency

OL Overload alarm

Open collector

IPF Open collector output

FU Frequency detection



Pulse

AM Analog voltage output

Analog



 Terminal FM is provided in the FM-type inverter.  Terminal CA is provided in the CA-type inverter.

Terminal name Terminal function description Rate Specification

Open collector output common

For meter

NPN open collector output

Analog current output

Switched to LOW when the inverter output frequency is equal to or higher than the starting frequency (initial value 0.5 Hz). Switched to HIGH during stop or DC injection brake operation.

Switched to LOW when the output frequency is within the set frequency range 10% (initial value). Switched to HIGH during acceleration/ deceleration and at a stop.

Switched to LOW when stall prevention is activated by the stall prevention function. Switched to HIGH when stall prevention is canceled.

No function is assigned in the initial setting. The function can be assigned setting Pr.192.

Switched to LOW when the inverter output frequency is equal to or higher than the preset detection frequency, and to HIGH when it is less than the preset detection frequency.

Common terminal for terminals RUN, SU, OL, IPF, FU ———

Outputs a selected monitored item (such as output frequency) among several monitored items. The signal is not output during an inverter reset. The output signal is proportional to the magnitude of the corresponding monitoring item. Use Pr.55, Pr.56, and Pr.866 to set full scales for the monitored output frequency, output current, and torque.

Fault code (4 bits) output.

Output item: Output frequency (initial setting)

This terminal can be used for open collector outputs by setting Pr.291.

Output item: Output frequency (initial setting)

Permissible load 24 VDC (maximum 27 VDC) 0.1 A (The voltage drop is

2.8 V at maximum while the signal is ON.) LOW is when the open collector output transistor is ON (conducted). HIGH is when the transistor is OFF (not conducted).

Permissible load current 2 mA For full scale 1440 pulses/s

Maximum output pulse: 50k pulses/s Permissible load current: 80 mA

Output signal 0 to 10 VDC, Permissible load current 1 mA (load impedance 10 k or more) resolution 8 bits

Load impedance 200  to 450  Output signal 0 to 20 mADC

Communication

Terminal

symbol

Type

— PU connector

TXD+

TXD-

RS-485

RXD+

RXD-

RS-485 terminals

—

USB

Terminal

name

Inverter transmission terminal

Inverter reception terminal

Earthing (grounding)

USB A connector

USB B connector

Terminal function description

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) Transmission format: Multidrop link Communication speed: 4800 to 115200 bps Wiring length: 500 m

The RS-485 terminals enable the communication by RS-485. Conforming standard: EIA-485 (RS-485) Transmission format: Multidrop link Communication speed: 300 to 115200 bps Overall length: 500 m

A connector (receptacle) A USB memory device enables parameter copies and the trace function.

Mini B connector (receptacle) Connected to a personal computer via USB to enable setting, monitoring, test operations of the inverter by FR Configurator2.

Interface: Conforms to USB1.1 (USB2.0 fullspeed compatible) Transmission speed: 12 Mbps

INSTALLATION AND WIRING

Control circuit

Safety stop signal

For the safety stop function, refer to page 45.

Terminal

Symbol

SIC

SOC

Terminal name Terminal function description Rate Specification

Safety stop input (Channel 1)

Safety stop input (Channel 2)

Safety stop input terminal common

Safety monitor output Open collector output

Safety monitor output terminal common

The terminals S1 and S2 are used for the safety stop input signal for the safety relay module. The terminals S1 and S2 are used at the same time (dual channel). Inverter output is shutoff by shortening/opening between terminals S1 and SIC, or between S2 and SIC. In the initial status, terminal S1 and S2 are shorted with the terminal PC by shorting wires. The terminal SIC is shorted with the terminal SD. Remove the shorting wires and connect the safety relay module when using the safety stop function.

Common terminal for terminals S1 and S2. ———

Indicates the safety stop input signal status. Switched to LOW when the status is other than the internal safety circuit failure. Switched to HIGH during the internal safety circuit failure status. LOW is when the open collector output transistor is ON (conducted). HIGH is when the transistor is OFF (not conducted). Refer to the Safety stop function instruction manual (BCNA23228-001) when the signal is switched to HIGH while both terminals S1 and S2 are open. (Please contact your sales representative for the manual.)

Common terminal for terminal SO. ———

Input resistance

4.7 k Input current 4 to 6 mADC (with 24 VDC input)S2

permissible load 24 VDC (27 VDC at maximum), 0.1 A (The voltage drop is

3.4 V at maximum while the signal is ON.)

INSTALLATION AND WIRING

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

Symbol

Typ e

RES Reset

RDI Contact input The function can be assigned by setting Pr.178.

Contact input

Terminal name Terminal function description Rate Specification

Use this signal to reset a fault output provided when a protective function is activated. Turn ON the RES signal for 0.1 s or longer, then turn it OFF. In the initial setting, reset is always enabled. By setting Pr.75, reset can be set enabled only at fault occurrence of the converter unit. The inverter recovers about 1s after the reset is released.

The external thermal relay input (OH) signal is used when using an

External thermal relay input

Contact input common (sink)

External transistor common (source)

24 VDC power supply common

External transistor common (sink)

Contact input common (source)

24 VDC power supply common

external thermal relay or a thermal protector built into the motor to protect the motor from overheating. When the thermal relay is activated, the inverter trips by the external thermal relay operation (E.OHT).

Common terminal for contact input terminal (sink logic) and terminal FM

Connect this terminal to the power supply common terminal of a transistor output (open collector output) device, such as a programmable controller, in the source logic to avoid malfunction by undesirable current.

Common terminal for the 24 VDC power supply (terminal PC, terminal +24) Isolated from terminals 5 and SE.

Common terminal for contact input terminal (source logic).

Can be used as a 24 VDC 0.1 A power supply.

Input resistance

4.7 k Voltage when contacts are open: 21 to 27 VDC When contacts are short-circuited: 4 to 6 mADC

———

Power supply voltage range 19.2 to 28.8 VDC Permissible load current 100 mA

+24

Power supply input

24 V external power supply input

For connecting a 24 V external power supply. If a 24 V external power supply is connected, power is supplied to the control circuit while the main power circuit is OFF.

INSTALLATION AND WIRING

Input voltage 23 to

25.5 VDC Input current 1.4 A or less

Control circuit

NOTE

Jumper connector

Output signal

Terminal

Symbol

Type

A1, B1, C1

Relay

88R, 88S

RDA

RDB

RSO Inverter reset

IPF

Open collector

FAN Cooling fan fault Switched to LOW when a cooling fan fault occurs.

Terminal name Terminal function description Rate Specification

Relay output 1 (fault output)

For manufacturer setting. Do not use.

Inverter operation enable (NO contact)

Inverter operation enable (NC contact)

Instantaneous power failure

Open collector output common

1 changeover contact output that indicates that the protective function of the converter unit has been activated and the outputs are stopped. Fault: discontinuity across B and C (continuity across A and C), Normal: continuity across Band C (discontinuity across A and C)

Switched to LOW when the converter unit operation is ready. Assign the signal to the terminal MRS (X10) of the inverter. The inverter can be started when the RDA status is LOW.

Switched to LOW when a converter unit fault occurs or the converter is reset. The inverter can be started when the RDB status is HIGH.

Switched to LOW when the converter is reset (RES-ON). Assign the signal to the terminal RES of the inverter. The inverter is reset when it is connected with the RSO status LOW.

Switched to LOW when an instantaneous power failure is detected.

Common terminal for terminals RDA, RDB, RSO, IPF, FAN Connect this terminal to the terminal SD (sink logic) or PC (source logic) of the inverter.

Contact capacity 230 VAC 0.3 A (power factor = 0.4) 30 VDC 0.3 A

Permissible load 24 VDC (maximum 27 VDC) 0.1 A (The voltage drop is

2.8 V at maximum while the signal is ON.) LOW is when the open collector output transistor is ON (conducted). HIGH is when the transistor is OFF (not conducted).

———

Caution

 Do not use the empty terminals (NC) of the control circuit. Doing so may lead to damage of the converter unit

and the inverter.

 Always connect the terminal RDA of the converter unit and the terminal MRS (X10) of the inverter, and the

terminal SE of the converter unit and the terminal SD (terminal PC in the source logic) of the inverter. Not doing so may lead to damage of the converter unit.

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.

Connect the jumper connector to the connector pin of the desired control logic.

The control logic of input signals is initially set to the sink logic (SINK) for the FM type inverter.

The control logic of input signals is initially set to the source logic (SOURCE) for the CA type inverter.

(The output signals may be used in either the sink or source logic independently of the jumper connector position.)

SOURCE

SINK

Jumper connector

• Make sure that the jumper connector is installed correctly.

• Never change the control logic while power is ON.

INSTALLATION AND WIRING

For sink logic

Control circuit

Sink logic and source logic

• In the sink logic, a signal switches ON when a current flows from the corresponding signal input terminal.

Terminal SD is common to the contact input signals. Terminal SE is common to the open collector output signals.

• In the source logic, a signal switches ON when a current flows into the corresponding signal input terminal.

Terminal PC is common to the contact input signals. Terminal SE is common to the open collector output signals.

Current flow concerning the input/output signal when sink logic is selected

Sink logic

Current

STF

STR

Inverter

RUN

TB1

TB17

24VDC

Current flow

DC input (sink type) <Example: QX40>

Sink connector

Current flow concerning the input/output signal when source logic is selected

Source logic

Current

STF

STR

Inverter

RUN

24VDC

Current flow

DC input (source type) <Example: QX80>

TB1

TB18

Source connector

• When using an external power supply for transistor output

Sink logic

Use the terminal PC as a common terminal, and perform

wiring as shown below. (Do not connect terminal SD of the

inverter with the terminal 0V of the external power supply.

When using terminals PC-SD as a 24 VDC power supply,

do not install an external power supply in parallel with the

inverter. Doing so may cause a malfunction in the inverter

due to undesirable currents.)

QY40P type transistor

output unit

Constant

voltage

circuit

TB1

TB2

TB17

TB18

24VDC

STF

STR

Inverter

24VDC (SD)

Current flow

Source logic

Use the terminal SD as a common terminal, and perform

wiring as shown below. (Do not connect terminal PC of the

inverter with the terminal +24 V of the external power

supply. When using terminals PC-SD as a 24 VDC power

supply, do not install an external power supply in parallel

with the inverter. Doing so may cause a malfunction in the

inverter due to undesirable currents.)

STF

STR

24VDC

Inverter

24VDC (SD)

QY80 type transistor

output unit

Constant

voltage

circuit

Fuse

TB1

TB2

TB17

TB18

Current flow

INSTALLATION AND WIRING

Control circuit

Wire

Sleeve

0 to 0.5mm (0.02 inch)

2.6.4 Wiring of inverter control circuit

Control circuit terminal layout

2 5 4 1 F/C

5 10E 10 SE SE SU

 This terminal operates as the terminal FM for the FM type, and as the terminal CA for the CA type.  Represents the terminal STOP.  The X10 signal is assigned in the initial setting.  No signal is assigned in the initial setting.

∗1

+24

SD SD S1 S2 PC A1 B1 C1 A2 B2 C2SICSo

SOC

RUN

IPF OL FU PC RL RM RH RT AU SD SD CSSTP

MRS

RES

∗2∗4

∗3

(X10)

STF STR

JOG

Wiring method

• Power supply connection

For the control circuit wiring, strip off the sheath of a cable, and use it with a blade terminal. For a single wire, strip off the

sheath of the wire and apply directly.

Insert the blade terminal or the single wire into a socket of the terminal.

(1) Strip off the sheath for the below length. If the length of the sheath peeled is too long, a short circuit may occur with

neighboring wires. If the length is too short, wires might come off.

Wire the stripped cable after twisting it to prevent it from becoming loose. In addition, do not solder it.

Cable sheath stripping length

10 mm

(2) Crimp the blade terminal.

Insert wires to a blade terminal, and check that the wires come out for about 0 to 0.5 mm from a sleeve.

Check the condition of the blade terminal after crimping. Do not use a blade terminal of which the crimping is inappropriate,

or the face is damaged.

Unstranded wires

Wire

Sleeve

Wires are not inserted into the sleeve

0 to 0.5mm (0.02 inch)

Damaged

Crumpled tip

• Blade terminals commercially available (as of February 2012)

Phoenix Contact Co., Ltd.

Cable gauge

(mm2)

0.3 AI 0, 5-10WH - -

0.5 AI 0, 5-10WH - AI 0, 5-10WH-GB

0.75 AI 0, 75-10GY A 0, 75-10 AI 0, 75-10GY-GB

1 AI 1-10RD A 1-10 AI 1-10RD/1000GB

1.25, 1.5 AI 1, 5-10BK A 1, 5-10 AI 1, 5-10BK/1000GB

0.75 (for two wires) AI-TWIN 2  0, 75-10GY - -

 A blade terminal with an insulation sleeve compatible with the MTW wire which has a thick wire insulation.  Applicable for the terminals A1, B1, C1, A2, B2, and C2 only.

INSTALLATION AND WIRING

With insulation sleeve Without insulation sleeve For UL wire 

Blade terminal model

Crimping tool

name

CRIMPFOX 6



NICHIFU Co.,Ltd.

• Pulling out the wire forcefully without pushing the open/close

button all the way down may damage the terminal block.

• Use a small flathead screwdriver (tip thickness: 0.4 mm/tip

width: 2.5 mm).

If a flathead screwdriver with a narrow tip is used, terminal

block may be damaged.

Commercially available products (as of February 2012)

• Place the flathead screwdriver vertical to the open/close

button. In case the blade tip slips, it may cause an inverter

damage or injury.

Name Model Manufacturer

Driver

SZF 0- 0,4  2,5

Phoenix Contact Co., Ltd. Contact Co., Ltd.

Cable gauge

(mm2)

0.3 to 0.75 BT 0.75-11 VC 0.75 NH 69

Blade terminal

product number

Insulation

product number

(3) Insert the wires into a socket.

When using a single wire or stranded wires without a blade terminal, push the

open/close button all the way down with a flathead screwdriver, and insert the

wire.

NOTE

• When using stranded wires without a blade terminal, twist enough to avoid short circuit with a nearby terminals or wires.

• Never change the control logic while power is ON.

•Wire removal Pull the wire while pushing the open/close button all

the way down firmly with a flathead screwdriver.

Open/close button

NOTE

Control circuit

Crimping tool

Open/close button

Flathead screwdriver

Common terminals of the control circuit (SD, PC, 5, SE)

• Terminals SD (sink logic), PC (source logic), 5, and SE are common terminals (0V) for I/O signals. (All common terminals

are isolated from each other.) Do not earth (ground) these terminals. Avoid connecting the terminal SD (sink logic) with 5,

the terminal PC (source logic) with 5, and the terminal SE with 5.

• In the sink logic, terminal SD is a common terminal for the contact input terminals (STF, STR, STOP, RH, RM, RL, JOG, RT,

MRS, RES, AU, CS) and the pulse train output terminal (FM

control circuit by photocoupler.

• In the source logic, terminal PC is a common terminal for the contact input terminals (STF, STR, STOP, RH, RM, RL, JOG,

RT, MRS, RES, AU, CS). The open collector circuit is isolated from the internal control circuit by photocoupler.

• Terminal 5 is a common terminal for the frequency setting terminals (2, 1 or 4) and the analog output terminals (AM, CA

It should be protected from external noise using a shielded or twisted cable.

• Terminal SE is a common terminal for the open collector output terminals (RUN, SU, OL, IPF, FU). The contact input circuit

is isolated from the internal control circuit by photocoupler.

 Terminal FM is provided in the FM-type inverter.  Terminal CA is provided in the CA-type inverter.

). The open collector circuit is isolated from the internal

).

INSTALLATION AND WIRING

Control circuit

Micro signal contacts Twin contacts

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.

+24V

STF, etc

Inverter

External signal input using transistor

(sink logic)

STF, etc

External signal input using transistor

(source logic)

Inverter

+24V

2.6.5 Wiring precautions

• It is recommended to use a cable of 0.75 mm2 for the connection to the control circuit terminals.

• The wiring length should be 30 m (200 m for the terminal FM) at the

maximum.

• Use two or more parallel micro-signal contacts or twin contacts to prevent

contact faults when using contact inputs since the control circuit input signals

are micro-currents.

• To suppress EMI, use shielded or twisted cables for the control circuit

terminals and run them away from the main and power circuits (including the 200V relay sequence circuit). For the cables

connected to the control circuit terminals, connect their shields to the common terminal of the connected control circuit

terminal. When connecting an external power supply to the terminal PC, however, connect the shield of the power supply

cable to the negative side of the external power supply. Do not directly earth (ground) the shield to the enclosure, etc.

• Do not apply a voltage to the contact input terminals (STF, etc.) of the control circuit.

• Always apply a voltage to the fault output terminals (A1, B1, C1, A2, B2, C2) via a relay coil, lamp, etc.

• Separate the wiring of the control circuit away from the wiring of the main circuit.

Make cuts in rubber bush of the inverter side and lead the wires through.

Rubber bush

(viewed from inside)

Make cuts along the lines on the inside with a cutter knife

INSTALLATION AND WIRING

Control circuit

InverterConverter unit

R/L1

S/L2

P/+

N/-

T/L3

R1/L11

S1/L21

P/+

N/-

Remove the jumper

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

• Tightening torque: 1.5 N·m

to 2 mm

Connected to

When a fault occurs, opening of the electromagnetic contactor (MC) on the inverter power supply side results in power loss in

the control circuit, disabling the fault output signal retention. Terminals R1/L11 and S1/L21 are provided to hold a fault signal.

In this case, connect the power supply terminals R1/L11 and S1/L21 of the control circuit to the input side of the MC.

The terminals R1/L11 and S1/L21 are connected to the terminals P/+ and N/- with a jumper respectively. Do not connect the

power cable to incorrect terminals. Doing so may damage the inverter.

(c)

Power supply terminal block for the control circuit

R1/L11

(a) (b) (d)

(a) Remove the upper screws. (b) Remove the lower screws. (c) Pull the jumper toward you to remove. (d) Connect the separate power supply cable for the control circuit to the upper terminals (R1/L11, S1/L21)

Power supply terminal block for the control circuit

S1/L21

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.

• The power capacity necessary when separate power is supplied from R1/L11 and S1/L21 is 80 VA.

• If the main circuit power is switched OFF (for 0.1 s or more) then ON again, the inverter is reset and a fault output will not be

held.

INSTALLATION AND WIRING

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. When the main circuit power supply is turned ON, the power supply changes from the 24 V external power supply to the main circuit power supply.

Specification of the applied 24 V external power supply

Item Rate Specification

Input voltage DC23 to 25.5 V

Input current 1.4 A or lower

Commercially available products (as of October 2013)

Model Manufacturer

S8JX-N05024C  Specifications: Capacity 50 W, output voltage 24 VDC, output current 2.1 A Installation method: Front installation with cover

S8VS-06024 Specifications: Capacity 60 W, output voltage 24 VDC, output current 2.5 A Installation method: DIN rail installation

 For the latest information about OMRON power supply, contact OMRON corporation.



OMRON Corporation

Starting and stopping the 24 V external power supply operation

• Supplying 24 V external power while the main circuit power is OFF starts the 24 V external power supply operation.

Likewise, turning OFF the main circuit power while supplying 24 V external power starts the 24 V external power supply

operation.

• Turning ON the main circuit power stops the 24 V external power supply operation and enables the normal operation.

NOTE

• When the 24 V external power is supplied while the main circuit power supply is OFF, the inverter operation is disabled.

• In the initial setting, when the main power supply is turned ON during the 24 V external power supply operation, a reset is

performed in the inverter, then the power supply changes to the main circuit power supply. (The reset can be disabled using

Pr.30.)

Confirming the 24 V external power supply input

• During the 24 V external power supply operation, "EV" flickers on the operation panel. The alarm lamp also flickers. Thus,

the 24 V external power supply operation can be confirmed even when the operation panel is removed.

Flickering

POWER ALARM

• During the 24 V external power supply operation, the 24 V external power supply operation signal (EV) is output. To use the

EV signal, set "68 (positive logic) or 168 (negative logic)" in one of Pr.190 to Pr.196 (output terminal function selection)

to assign function to an output terminal.

INSTALLATION AND WIRING

Control circuit

NOTE

Operation while the 24 V external power is supplied

• Faults history and parameters can be read and parameters can be written (when the parameter write from the operation

panel is enabled) using the operation panel keys.

• The safety stop function is disabled during the 24 V external power supply operation.

• During the 24 V external power supply operation, monitored items and signals related to inputs to main circuit power supply,

such as output current, converter output voltage, and IPF signal, are invalid.

• The alarms, which have occured when the main circuit power supply is ON, continue to be output after the power supply is

changed to the 24 V external power supply. Perform the inverter reset or turn OFF then ON the power to reset the faults.

• The retry function is invalid for all alarms during the 24 V external power supply.

• The output data is retained when "1 or 11" is set in Pr.495 Remote output selection.

NOTE

• Inrush current equal to or higher than the 24 V external power supply specification may flow at power-ON. Confirm that the

power supply and other devices are not affected by the inrush current and the voltage drop caused by it. Depending on the

power supply, the inrush current protection may be activated to disable the power supply. Select the power supply and

capacity carefully.

• When the wiring length between the external power supply and the inverter is long, the voltage often drops. Select the

appropriate wiring size and length to keep the voltage in the rated input voltage range.

• In a serial connection of several inverters, the current increases when it flows through the inverter wiring near the power

supply. The increase of the current causes voltage to drop further. Use the inverter after confirming that the input voltage of

each converter unit is within the rated input voltage range. Depending on the power supply, the inrush current protection may

be activated to disable the power supply. Select the power supply and capacity carefully.

• "E.SAF" or "E.P24" may appear when the start-up time of the 24 V power supply is too long (less than 1.5 V/s) in the 24 V

external power supply operation.

• "E.P24" may appear when the 24 V external power supply input voltage is low. Check the external power supply input.

• Do not touch the control circuit terminal block (circuit board) during the 24 V power supply operation (when conducted).

Otherwise you may get an electric shock or burn.

2.6.8 Safety stop function

Function description

The terminals related to the safety stop function are shown below.

Terminal

symbol

S1  For input of the safety stop channel 1.

 For input of the safety stop channel 2.

SIC

 Common terminal for terminals S1 and S2.

SOC Open collector output (terminal SO) common

Outputs when an alarm or failure is detected. The signal is output when no internal safety circuit failure

 In the initial status, terminals S1 and PC, S2 and PC, and SIC and SD are respectively shorted with shorting wires. To use the safety stop

function, remove all the shorting wires, and then connect to the safety relay module as shown in the connection diagram.

 At an internal safety circuit failure, the operation panel displays one of the faults shown on the next page.

• Use the terminal SO to output a fault and to prevent restarting of the inverter. The signal cannot be used as safety stop input

terminal to other devices.

Terminal function description

 exists.

Between S1 and SIC, S2 and SIC Open: In safety stop mode Short: Other than the safety stop mode.

OFF: Internal safety circuit failure ON: No internal safety circuit failure



INSTALLATION AND WIRING

Control circuit

Fault record

Operation panel

indication

Option fault E.OPT Communication option fault E.OP1 Parameter storage device fault E.PE Retry count excess E.RET Parameter storage device fault E.PE2 Operation panel power supply short circuit RS-485 terminals power supply short circuit

E.CTE

24 VDC power fault E.P24 Safety circuit fault E.SAF

Overspeed occurrence E.OS Speed deviation excess detection E.OSD Signal loss detection E.ECT Excessive position fault E.OD Brake sequence fault E.MB1 to E.MB7 Encoder phase fault E.EP

CPU fault

E.CPU E.5 to E.7

Internal circuit fault E.13

Fault record

Operation panel

indication

Connection diagram

To prevent restart at fault occurrence, connect terminals SO and SOC to the reset button, which are the feedback input

terminals of the safety relay module.

RESET

Emergency stop button

SOC

SIC

Safety relay module

/ Safety programmable controller

FR-A800

Logic

+24V

Fuse

CPU

ASIC

Gate

Driver

G G

Gate

Driver

R/L1 S/L2 T/L3

Safety stop function operation

Input

power

OFF - - - OFF Output shutoff (Safe state)

Input signal Internal safety

S1-SIC S2-SIC SO 

Shorted Shorted

Open Open

circuit failure



Without ON Drive enabled With OFF Output shutoff (Safe state)

 ON Output shutoff (Safe state)

Without With OFF Output shutoff (Safe state)

Output signal

Inverter running status

Shorted Open N/A OFF Output shutoff (Safe state) Open Shorted N/A OFF Output shutoff (Safe state)

N/A denotes a condition where circuit fault does not apply.

 At an internal safety circuit failure, the operation panel displays one of the fault shown in the following table.  SA is displayed when both of the S1 and S2 signals are in open status and no internal safety circuit failure exists.  ON: Transistor used for an open collector output is conducted.

OFF: Transistor used for an open collector output is not conducted.

IGBTs

Internal safety circuit failure

At an internal safety circuit failure, the terminal SO turns OFF.

The following faults can cause the internal safety circuit failure (terminal SO-OFF).

For more details, refer to the Safety Stop Function Instruction Manual (BCN-A23228-001).

Find a PDF copy of this manual in the CD-ROM enclosed with the product.

It is also can be downloaded from the Mitsubishi Electric FA Global Website.

http://www.mitsubishielectric.co.jp/fa/

INSTALLATION AND WIRING

Communication connectors and terminals

2.7 Communication connectors and terminals

2.7.1 PU connector

Mounting the operation panel (FR-DU08) or parameter unit (FR-PU07) on

the enclosure surface

• Having an operation panel (FR-DU08) or a parameter unit (FR-PU07) on the enclosure surface is convenient. With a

connection cable, the operation panel (FR-DU08) or the parameter unit (FR-PU07) can be mounted to the enclosure

surface and connected to the inverter.

Use the option FR-CB2[ ], or connectors and cables available on the market.

(To install the operation panel (FR-DU08), the optional connector (FR-ADP) is required.) )

Securely insert one end of the connection cable until the stoppers are fixed.

Parameter unit connection cable (FR-CB2[ ])(option)

Parameter unit (FR-PU07) (option)

Operation panel (FR-DU08)

STF FWD PU

Operation panel connection connector (FR-ADP)(option)

NOTE

• Refer to the following table when fabricating the cable on the user side. Keep the total cable length within 20 m.

• Commercially available products (as of February 2012)

Name Model Manufacturer

Communication cable

RJ-45 connector 5-554720-3 Tyco Electronics

SGLPEV-T (Cat5e/300 m) 24AWG  4P

Mitsubishi Cable Industries, Ltd.

Communication operation

• Using the PU connector enables communication operation from a personal computer, etc. When the PU connector is

connected with a personal, FA or other computer by a communication cable, a user program can run to monitor the inverter

or read and write parameters.

Communication can be performed with the Mitsubishi inverter protocol (computer link operation).

(For details, refer to the FR-A800 Instruction Manual (Detailed).)

INSTALLATION AND WIRING

Communication connectors and terminals

2.7.2 USB connector

Place a flathead screwdriver, etc. in a slot and push up the cover to open.

USB host communication

USB host (A connector)

Communication status indicator (LED)

USB device (Mini B connector)

Conforms to USB1.1

12 Mbps

Maximum 5 m

USB A connector (receptacle)

FAT32

1 GB or more (used in the recorder mode of the trace function)

Not available

Transmission speed

Compatible

USB memory

Interface

Wiring length

Connector

(Format) Capacity

Encryption function

• Different inverter data can be saved in a USB memory device.

The USB host communication enables the following functions.

Function Description

• Copies the parameter setting from the inverter to the USB memory device. A maximum of 99 parameter setting files can be saved in a USB memory device.

Parameter copy

Trace

PLC function data copy

• The parameter setting data copied in the USB memory device can be copied to other inverters. This function is useful in backing up the parameter setting or for sharing the parameter setting among multiple inverters.

• The parameter setting data copied in the USB memory device can be saved in a personal computer and edited in FR Configurator 2.

• The monitored data and output status of the signals can be saved in a USB memory device.

• The saved data can be imported to FR Configurator2 to diagnose the operating status of the inverter.

• This function copies the PLC function project data to a USB memory device when the PLC function is used.

• The PLC function project data copied in the USB memory device can be copied to other inverters.

• This function is useful in backing up the parameter setting and for allowing multiple inverters to operate by the same sequence programs.

• When the inverter recognizes the USB memory device without any problem, is briefly displayed on the

operation panel.

• When the USB memory device is removed, is briefly displayed on the operation panel.

• The operating status of the USB host can be checked on the LED display of the inverter.

LED display

status

OFF No USB connection.

ON The communication is established between the inverter and the USB device.

Flickering rapidly The USB memory device is being accessed. (Do not remove the USB memory device.)

Flickering slowly Error in the USB connection.

Operating status

• When a device such as a USB battery charger is connected to the USB connector and an excessive current (500 mA or

more) flows, USB host error (UF warning) is displayed on the operation panel.

• If a UF warning occurs, disconnect the USB device and set Pr.1049 = "1" to cancel the USB error. (The UF warning can

also be canceled by resetting the inverter power or resetting with the RES signal.)

NOTE

• Do not connect devices other than a USB memory device to the inverter.

• If a USB device is connected to the inverter via a USB hub, the inverter cannot recognize the USB memory device properly.

• For the details of usage, refer to the FR-A800 Instruction Manual (Detailed).

INSTALLATION AND WIRING

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

Transmission speed

Wiring length

Connector

Power supply

Conforms to USB1.1

12 Mbps

Maximum 5 m

USB mini B connector (receptacle)

Self-powered

NOTE

• For the details of FR Configurator2, refer to the Instruction Manual of FR Configurator2.

2.7.3 RS-485 terminal block

Communication operation

Conforming standard

Transmission format

Communication speed

Overall length

Connection cable

The RS-485 terminals enables communication operation from a personal computer, etc. When the PU connector is connected

with a personal, FA or other computer by a communication cable, a user program can run to monitor the inverter or read and

write parameters.

Communication can be performed with the Mitsubishi inverter protocol (computer link operation) and Modbus-RTU protocol.

(For details, refer to the FR-A800 Instruction Manual (Detailed).)

EIA-485 (RS-485)

Multidrop link

115200 bps maximum

500 m

Twisted pair cable (4 pairs)

OPEN

100Ω

NOTE

Terminating resistor switch

Initially-set to "OPEN". Set only the terminating resistor switch of the remotest inverter to the "100Ω" position.

RDA1

SDA1

P5S

(VCC)SG(GND)

VCC GND

P5S

(VCC)SG(GND)

• To avoid malfunction, keep the RS-485 terminal wires away from the control circuit board.

• For wiring of the RS-485 terminals used with a plug-in option, lead the wires on the left side of the plug-in option.

SDB1

(TXD1+)

(TXD1-)

TXD RXD

SDA2

SDB2

(TXD2+)

(TXD2-)

(RXD1+)

+-+

RDA2

(RXD2+)

RDB1

(RXD1-)

RDB2

(RXD2-)

INSTALLATION AND WIRING

Connection of motor with encoder (vector control)

2.8 Connection of motor with encoder (vector

control)

Using an encoder-equipped motor together with the plug-in option FR-A8AP enables speed, torque, and positioning control

operations under orientation control, encoder feedback control, and full-scale vector control.

Appearance and parts name of FR-A8AP

Front view

Terminal layout

PZ1

PZ2

PIN and PO are not used.

PA1

PB1

PA2

PB2

Symbol Name Description

(a)

(d)

(f)

(a)

123

(h)

SW2

SW1

SW3

(b)

(a)

Rear view

(a)

to page

a Mounting hole Used for installation to the inverter. —

b Terminal block Connected with the encoder. 53

c Encoder type selection switch (SW3) Switches the encoder type (differential line driver/complementary). 51

d CON2 connector Not used. —

Terminating resistor selection switch (SW1)

Switch for manufacturer setting (SW2)

Switches ON or OFF the internal terminating resistor. 51

—

Do not change from the initially-set status. (Switches 1 and 2 are OFF .)

g Connector Connected to the option connector of the inverter. 9

h LED for manufacturer check Not used. —

Refer

Terminals of the FR-A8AP

Terminal

symbol

PA1 Encoder A-phase signal input terminal

PA2 Encoder A-phase inverse signal input terminal

PB1 Encoder B-phase signal input terminal

PB2 Encoder B-phase inverse signal input terminal

PZ1 Encoder Z-phase signal input terminal

PZ2 Encoder Z-phase inverse signal input terminal

PG Encoder power supply (positive side) input terminal

SD Encoder power supply ground terminal

Not used.

NOTE

• When the encoder's output voltage differs from its input power supply voltage, the signal loss detection (E.ECT) may occur.

• Incorrect wiring or faulty setting to the encoder will cause a fault such as an overcurrent (E.OC[ ]) and an inverter

overload (E.THT).

Correctly perform the encoder wiring and setting.

Terminal name Description

A-, B- and Z-phase signals are input from the encoder.

Input terminal for the encoder power supply. Connect the external power supply (5 V, 12 V, 15 V, 24 V) and the encoder power cable. When the encoder output is the differential line driver type, only 5 V can be input. Make the voltage of the external power supply same as the encoder output voltage. (Check the encoder specification.)

INSTALLATION AND WIRING

Connection of motor with encoder (vector control)

Switches of the FR-A8AP

• Encoder type selection switch (SW3)

Selects either the differential line driver or complementary setting.

It is initially set to the differential line driver. Switch its position according to the

output circuit.

Differential line driver (initial status)

SW2

123

SW1

SW3

Complementary

• Terminating resistor selection switch (SW1)

Selects ON/OFF of the internal terminating resistor.

Set the switch to ON (initial status) when an encoder output type is

differential line driver, and set to OFF when complementary.

ON: with internal terminating resistor (initial status)

without internal terminating resistor

OFF:

NOTE

• Set all switches to the same setting (ON/OFF).

• Set the switch "OFF" when sharing an encoder with another unit (NC

(computerized numerical controller), etc.) having a terminating resistor

under the differential line driver setting.

• Prepare an encoder's power supply (5 V/12 V/15 V/24 V) according to the encoder's output voltage. When the encoder output

is the differential line driver type, only 5 V can be input.

• The SW2 switch is for manufacturer setting. Do not change the setting.

Internal terminating resistor-ON (initial status)

Internal terminating resistor-OFF

SW2

123

SW1

SW3

INSTALLATION AND WIRING

Connection of motor with encoder (vector control)

Model Length L (m)

FR-JCBL5 5

FR-JCBL15 15

FR-JCBL30 30



Earth cable

F-DPEVSB 12P 0.2 mm

D/MS3106B20-29S

D/MS3057-12A

11mm

60mm

Approx. 140 mm

Model Length L (m)

FR-V7CBL5 5

FR-V7CBL15 15

FR-V7CBL30 30

• Shield earthing P-clip is

included.

Encoder cable

FR-JCBL FR-V7CBL

C R A N B P

H K

PLG

D/MS3057-12A

D/MS3106B20-29S

Positioning keyway

D/MS3106B20-29S (As viewed from wiring side)

C P

FR-A800

(FR-A8AP)

PA1 PA2 PB1 PB2 PZ1 PZ2

PG SD

2 mm

A B C D F G

S R

PLG

Positioning keyway

D/MS3106B20-29S (As viewed from wiring side)

Earth cable

60mm

FR-A800

(FR-A8AP)

PA1

PA2 PB1 PB2 PZ1 PZ2

PG SD

F-DPEVSB 12P 0.2 mm

 As the terminal block of the FR-A8AP is an insertion type, cables need to be treated. (Refer to the following description.)

11 m m

2 mm

Approx. 140 mm

• As the terminal block of the FR-A8AP is an insertion type, cables need to be treated when the encoder cables of the

inverter are crimping terminals. Cut the crimping terminal of the encoder cable and strip its sheath to make its cable wires

loose.

Also, treat the shielding wires of the shielded twisted pair cable to ensure that they will not contact conductive areas.

Wire the stripped cable after twisting it to prevent it from becoming loose. In addition, do not solder it.

NOTE

• Information on blade terminals

Terminal screw

size

M2 0.3, 0.5 AI 0,5-6WH A 0,5-6 CRIMPFOX 6

Terminal screw

size

M2 0.3 to 0.75 BT 0.75-7 VC 0.75 NH 69

• When using a blade terminal (without insulation sleeve),

INSTALLATION AND WIRING

Cable stripping size

(0.2 inches)5mm

Commercially available products (as of February 2012)

Phoenix Contact Co., Ltd.

Cable gauge

(mm2)

(With insulation sleeve)

Blade terminal model

NICHIFU Co.,Ltd.

Cable gauge

(mm2)

Blade terminal product

number

take caution that the twisted wires do not come out.

(Without insulation sleeve)

Insulation product

number

Crimping tool

name

Crimping tool

product number

Connection of motor with encoder (vector control)

∗4 ∗6

∗3

PA1

FR-A8AP

PA2

PB1

PB2

PZ1

PZ2

∗1

OFF

Vector control

dedicated motor U V

U V

∗2

PLG

(+)

(-)

∗5

Earth (Ground)

Inverter

12VDC power supply

Differential

Terminating

resistor

Complementary

• Connection terminal compatibility table

Encoder cable FR-V7CBL FR-JCBL

PA1 PA PA

PA2 Do not connect anything to this. PAR

PB1 PB PB

FR-A8AP terminal

PB2 Do not connect anything to this. PBR

PZ1 PZ PZ

PZ2 Do not connect anything to this. PZR

PG PG 5E

SD SD AG2

Wiring example

• Speed control

Standard motor with encoder, 5 V differential line driver

Vector control dedicated motor,

12 V complementary

Frequency command

• Torque control

Speed limit command

To converter unit

Forward rotation start Reverse rotation start

Contact input common

Inverter

P/+ N/-

STF

STR

FR-A8AP

PA1

PA2

U V

Earth (Ground)

PB1

PB2

Frequency setting

potentiometer

1/2W1kΩ

Torque limit

command

(±10V)

(+) (-)

Differential

PZ1

PZ2

Complementary

Terminating resistor ON

OFF

∗4

∗3

(-)

∗6

(+)

Standard motor with encoder (SF-JR), 5 V differential line driver

Forward rotation start Reverse rotation start

Contact input common

Frequency setting

potentiometer

1/2W1kΩ

Torque

command

(±10V)

To converter unit

(+) (-)

Inverter

P/+ N/-

STF

STR

FR-A8AP

Differential

Complementary

Terminating

resistor ON

OFF

∗4

PA1

PA2

PB1

PB2

PZ1

PZ2

U V

Earth (Ground)

∗3

∗6

(+)

Motor with

encoder

∗1

PLG

∗2

5VDC power supply

∗5

Motor with

encoder U V

∗1

PLG

∗2

5VDC power supply

(-)

∗5

Vector control

Earth (Ground)

∗3

(-)

dedicated motor U V

∗1

12VDC power supply

Inverter

FR-A8AP

Differential

Complementary

Terminating

resistor

∗4 ∗6

OFF

PA1

PA2

PB1

PB2

PZ1

PZ2

(+)

Vector control dedicated motor,

12 V complementary

INSTALLATION AND WIRING

PLG

∗2

∗5

Connection of motor with encoder (vector control)

• Position control

Vector control dedicated motor, 12 V complementary

Positioning unit

MELSEC-Q QD75P[]N/QD75P[]

MELSEC-L LD75P[]

FLS

RLS

DOG

STOP

CLEAR

PULSE F

PULSE R

CLRCOM

PULSE COM

RDYCOM

COM

READY

Torque limit command

(±10V)

Vector control

dedicated motor

To converter unit

P/+ N/-

Inverter

U V

Earth (ground)

Forward stroke end

Reverse stroke end

Pre-excitation/servo on

Clear signal

Pulse train

Sign signal

24VDC power supply

Preparation ready signal

(+) (-)

 The pin number differs according to the encoder used.

Speed, control, torque control, and position control by pulse train input are available with or without the Z-phase being connected.

 Connect the encoder so that there is no looseness between the motor and motor shaft. Speed ratio must be 1:1.  Earth (ground) the shield of the encoder cable to the enclosure using a tool such as a P-clip. (Refer to pag e 55.)  For the complementary, set the terminating resistor selection switch to OFF position. (Refer to page 51.)  A separate power supply of 5 V / 12 V / 15 V / 24 V is necessary according to the encoder power specification.

When the encoder output is the differential line driver type, only 5 V can be input. Make the voltage of the external power supply the same as the encoder output voltage, and connect the external power supply between PG and SD.

 For terminal compatibility of the FR-JCBL, FR-V7CBL, and FR-A8AP, refer to page 53.  Assign the function using Pr.178 to Pr.184, Pr.187 to Pr.189 (input terminal function selection).  When position control is selected, terminal JOG function is invalid and simple position pulse train input terminal

becomes valid.

 Assign the function using Pr.190 to Pr.194 (output terminal function selection).

STF

STR

∗7

CLR ∗7

JOG

NP ∗7

RDY ∗9

FR-A8AP

∗8

Differential

line driver

Complementary

Terminating

resistor

OFF

PA1

PA2

PB1

PB2

PZ1

PZ2

∗4 ∗6

∗1

PLG

∗2

∗3

(+)

12VDC

(-)

power supply

∗5

INSTALLATION AND WIRING

Connection of motor with encoder (vector control)

Encoder cable

Shield

P-clip

Earthing (grounding) example using a P-clip

Instructions for encoder cable wiring

• Use shielded twisted pair cables (0.2 mm2 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).

Example of parallel connection

PA1 PA2 FB1 FB2 PZ1 PZ2

with two cables

Encoder

A B C D F G

(with complementary encoder output)

FR-A800

(FR-A8AP)

2 mm

S R

Wiring length Parallel connection Larger-size cable

Within 10 m At least two cables in parallel

Within 20 m At least four cables in parallel

Within 100 m

 At least six cables in parallel

 When differential line driver is set and a wiring length is 30 m or more.

The wiring length can be extended to 100 m by increasing the 5 V power supply (approximately to 5.5 V) while using six or more 0.2 mm

cables in parallel or a 1.25 mm

or larger gauge cable. The voltage applied must be within power supply specifications of encoder.

Cable gauge 0.2 mm

0.4 mm2 or larger

0.75 mm

1.25 mm

or larger

gauge

• To reduce noise of the encoder cable, earth (ground) the encoder's shielded cable to the enclosure

(as close as possible to the inverter) with a P-clip or U-clip made of metal.

• When one encoder is shared between FR-A8AP and CNC (computerized numerical controller), its output signal should be

connected as shown below. In this case, the wiring length between FR-A8AP and CNC should be as short as possible,

within 5 m.

Inverter

(FR-A8AP)

Encoder

NOTE

• For the details of the optional encoder dedicated cable (FR-JCBL/FR-V7CBL), refer to pa ge 52.

• The FR-V7CBL is provided with a P-clip for earthing (grounding) shielded cables.

Maximum 5 m

(two parallel cables)

INSTALLATION AND WIRING

Connection of motor with encoder (vector control)

CCW

Parameter for the encoder (Pr.359, Pr.369)

Pr. Name

359 C141

369 C140

The above parameters can be set when the FR-A8AP (option) is mounted.

Encoder rotation direction

Number of encoder pulses

Initial value

1024 0 to 4096

Setting

range

100

101

Description

Set when using a motor for which forward rotation (encoder) is clockwise (CW) viewed from the shaft.

Set when using a motor for which forward rotation (encoder) is counterclockwise (CCW) viewed from the shaft.

Set the number of encoder pulses output. Set the number of pulses before it is multiplied by 4.

Parameter settings for the motor under vector control

Pr.9

Motor name

Electronic

thermal O/L relay

Standard motor Rated motor current 0 (3)  Motor capacity

Constant-torque motor Rated motor current 1 (13)  Motor capacity

 Offline auto tuning is required (Refer to the FR-A800 Instruction Manual (Detailed))  Set this parameter according to the motor.

Pr.71

Applied

motor

Pr.80

Motor

capacity

Pr.81

Number of

motor poles

Number of motor poles

Set for the operation at 120 Hz or less.

Set for the operation at a frequency higher than 120 Hz.

Set for the operation at 120 Hz or less.

Set for the operation at a frequency higher than 120 Hz.

Pr.359

Encoder

rotation

direction

 

Pr.369

Number of

encoder

pulses

INSTALLATION AND WIRING

Connection of stand-alone option units

2.9 Connection of stand-alone option units

The inverter accepts a variety of stand-alone option units as required.

Incorrect connection will cause inverter damage or accident. Connect and operate the option unit carefully in accordance with

the corresponding option unit manual.

2.9.1 Connection of the brake unit (FR-BU2)

Connect the brake unit (FR-BU2) as shown below to improve the braking capability during deceleration.

After wiring securely, set Pr.30 Regenerative function selection = "11" .

Set Pr.0 Brake mode selection = "2" in the brake unit FR-BU2.

∗2

OFFON

CR1

CR2

CR3 CR4

TH1

P PR

TH2

Resistor unit

MT-BR5

TH1

P PR

TH2

CR1

∗4

CR2

∗4

Three phase

C power

supply

MCCB

R/L1 S/L2 T/L3

Inverter/

converter

∗5

P/+

N/-

Motor

U V

∗1

P N

BUE SD

Brake unit

FR-BU2

10 m or less

∗3

A B

Resistor unit

MT-BR5

P PR

Resistor unit

MT-BR5

P PR

Resistor unit

MT-BR5

 When wiring, make sure to match the terminal symbol (P/+, N/-) at the inverter side and at the brake unit

(FR-BU2) side. (Incorrect connection will damage the inverter and brake unit.)

 When the power supply is 400 V class, install a stepdown transformer.  The wiring distance between the inverter, brake unit (FR-BU2) and resistor unit (MT-BR5) must be within

5 m each. Even when the cable is twisted, the wiring length must be within 10 m.

 The contact between TH1 and TH2 is open in the normal status and is closed at a fault.  The CN8 connector used with the MT-BU5 type brake unit is not used.

TH1

TH2

TH1

TH2

CR3

∗4

CR4

∗4

NOTE

• The stall prevention (overvoltage), oL, does not occur while Pr.30 Regenerative function selection = "11" .

• For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

INSTALLATION AND WIRING

Connection of stand-alone option units

2.9.2 Connection of the high power factor converter

(FR-HC2)

When connecting the high power factor converter (FR-HC2) to suppress power harmonics, perform wiring securely as shown

below. Incorrect connection will damage the high power factor converter and the inverter.

After making sure that the wiring is correct, set "rated motor voltage" in Pr.19 Rated motor voltage (under V/F control) or

Pr.83 Regenerative function selection (under other that V/F control) and "2" in Pr.30 Regenerative function selection.

Power Supply

High power

factor converter

(FR-HC2)

R4/L14

∗2

S4/L24

T4/L34

N/-

RDY

∗6

IPF

ROH

RSO

Inverter

R1/L11

∗1

∗3

∗7

S1/L21

P/+P/+ N/-

X10

X11

∗4

∗5

RES

∗7

MCCB

Limit resistor

∗11

Reactor 1

(FR-HCL21)

∗9 ∗9 ∗9

R2/

R/ L1

L12 S2/

S/ L2

L22

T2/

T/ L3

L32

Filter capacitors 2

(FR-HCC2)

Filter capacitor

alarm detector

(NC contact) 2

Bu2

Buffer relay for

filter capacitor

alarm detectors

MC1

MC2

MC3

∗11

MC1

Auxiliary contact for limit MCs (NO contact) 3

Limit MC

Limit resistor (with thermostat)

MC2

MC1

MC2

MC3

Reactor 2

(FR-HCL22)

R3/ L13

S3/ L23

T3/ L33

(NC contact) 3

Mini relay for filter capacitor alarm detector

MC3

Small

R4/

L14

S4/

L24

T4/

L34

MC power

supply

stepdown

transformer

Bu1

Buffer relay for driving MCs

88R

88S

R/L1 S/L2 T/L3

R1/L11

∗8

∗10

S1/L21

 Remove jumpers installed in terminals R1/L11 and S1/L21 of the inverter, and connect the power supply for the control circuit to terminals

R1/L11 and S1/L21.

 The voltage phases of terminals R4/L14, S4/L24, and T4/L34 and the voltage phases of terminals R/L1, S/L2, and T/L3 must be matched.  Do not install an MCCB across the terminals P/+ and N/- (across terminals P and P/+ or across N and N/-). Connecting the opposite polarity

of terminals N/- and P/+ will damage the inverter. For the A802 series, installation of a fuse is not required.

 Change the FR-HC2 parameter setting to Pr.10 RDY signal logic selection = "0" (positive logic).  Use Pr.178 to Pr.189 (input terminal function selection) to assign the terminals used for the X10 signal.

For RS-485 or any other communication where the start command is only transmitted once, use the X11 signal to save the operation mode at the time of an instantaneous power failure.

 Assign the IPF signal to an FR-HC2 terminal. (Refer to the Instruction Manual of FR-HC2.)  Always connect the FR-HC2 terminal RDY to the inverter terminal MRS(X10), and the FR-HC2 terminal SE to the inverter terminal SD. Not

connecting these terminals may damage the FR-HC2.

 Always connect the R/L1, S/L2, and T/L3 terminals of FR-HC2 to the power supply. Operating the inverter without connecting them will

damage the FR-HC2.

 Do not install an MCCB or MC between the reactor 1 terminals (R/L1, S/L2, T/L3) and the FR-HC2 terminals (R4/L14, S4/L24, T4/L34). It

will not operate properly.

 Securely perform grounding (earthing) by using the grounding (earthing) terminal.  The number of connected peripheral devices differs according to the capacity. For the detail, refer to the FR-HC2 Instruction Manual.

U V

∗10

Earth (Ground)

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

38.)

• When using a sine wave filter with FR-HC2, select MT-BSL-HC as a reactor for the sine wave filter.

• For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

INSTALLATION AND WIRING

3 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 ..60

3.2 Power supply harmonics .........................................................67

3.3 Installation of a reactor ............................................................70

3.4 Power-OFF and magnetic contactor (MC) ..............................71

3.5 Countermeasures against deterioration of the 400 V class

motor insulation........................................................................72

3.6 Checklist before starting operation ........................................73

3.7 Failsafe system which uses the inverter ................................76

PRECAUTIONS FOR USE OF THE INVERTER

Electro-magnetic interference (EMI) and leakage currents

3.1 Electro-magnetic interference (EMI) and

leakage currents

3.1.1 Leakage currents and countermeasures

Capacitances exist between the inverter I/O cables, other cables and earth and in the motor, through which a leakage current

flows. Since its value depends on the static capacitances, carrier frequency, etc., low acoustic noise operation at the

increased carrier frequency of the inverter will increase the leakage current. Therefore, take the following countermeasures.

Select the earth leakage current breaker according to its rated sensitivity current, independently of the carrier frequency

setting.

To-earth (ground) leakage currents

Leakage currents may flow not only into the inverter's own line but also into the other lines through the earthing (grounding)

cable, etc. These leakage currents may operate earth leakage circuit breakers and earth leakage relays unnecessarily.

Countermeasures

• If the carrier frequency setting is high, decrease the Pr.72 PWM frequency selection setting.

Note that motor noise increases. Selecting Pr.240 Soft-PWM operation selection makes the sound inoffensive.

• By using earth leakage circuit breakers designed for harmonic and surge suppression in the inverter's own line and other

line, operation can be performed with the carrier frequency kept high (with low noise).

To-earth (ground) leakage currents

• Take caution as long wiring will increase the leakage current. Decreasing the carrier frequency of the inverter reduces the

leakage current.

• Increasing the motor capacity increases the leakage current.

Line-to-line leakage currents

Harmonics of leakage currents flowing in static capacitances between the inverter output cables may operate the external

thermal relay unnecessarily.

MCCB MC

Power supply

Line-to-line leakage currents path

Countermeasures

•Use Pr.9 Electronic thermal O/L relay.

• If the carrier frequency setting is high, decrease the Pr.72 PWM frequency selection setting.

Note that motor noise increases. Selecting Pr.240 Soft-PWM operation selection makes the sound inoffensive.

To ensure that the motor is protected against line-to-line leakage currents, it is recommended to use a temperature sensor

to directly detect motor temperature.

Installation and selection of the molded case circuit breaker

Install a molded case circuit breaker (MCCB) on the power receiving side to protect the wiring at the inverter input side.

Select an MCCB according to the inverter input side power factor, which depends on the power supply voltage, output

frequency and load. Especially for a completely electromagnetic MCCB, a slightly large capacity must be selected since its

operation characteristic varies with harmonic currents. (Check it in the data of the corresponding breaker.) As an earth

leakage current breaker, use the Mitsubishi earth leakage current breaker designed for harmonics and surge suppression.

Inverter

Thermal relay

Line-to-line static capacitances

Motor

PRECAUTIONS FOR USE OF THE INVERTER

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.

• Breaker designed for harmonic and surge suppression

Rated sensitivity current

In  10  (Ig1 + Ign + Igi + Ig2 + Igm)

• Standard breaker

Rated sensitivity current

In  10  {Ig1 + Ign + Igi + 3  (Ig2 + Igm)}

Ig1, Ig2: Leakage currents in wire path during commercial

power supply operation

Ign: Leakage current of inverter input side noise filter

Igm: Leakage current of motor during commercial power

supply operation

Igi: Leakage current of inverter unit

(When the converter unit is connected, add the

leakage current of converter unit.)

Example of leakage current per 1km during the commercial power supply operation when the CV cable is routed in metal conduit

(Three-phase three-wire delta connection 400V60Hz)

120

100

23.5

8142230386080

size (mm2)

100

150

leakage currents (mA)

For " " connection, the amount of leakage current is appox.1/3 of the above value.

5.5

Cable

• Selection example for the connection of the 400 V class

Leakage current example of threephase induction motor during the commercial power supply operation

(Totally-enclosed fan-cooled type motor 400V60Hz)

2. 0

1. 0

0. 7

0. 5

0. 3

0. 2

0. 1

1. 5 3. 7

leakage currents (mA)

2. 2

Motor capacity (kW)

Breaker designed

Item

for harmonic and

Standard breaker

surge suppression

5.5mm

ELB

Ig1 Ign

5m 5.5mm

Noise

filter

Inverter

Leakage current Ig1 (mA)

60m

3φ

400V

2.2kW

Ig2 Igm

Igi

Leakage current Ign (mA) 0 (without noise filter)

Leakage current Igi (mA)

Leakage current Ig2 (mA)

66 

3 1000 m

1 (without EMC filter) For the leakage current of the inverter, refer to the following table.

66 

3 1000 m

Motor leakage current Igm (mA) 0.36

Total leakage current (mA) 2.79 6.15

Rated sensitivity current (mA) ( Ig  10) 30 100

5 m

60 m

• Inverter/converter unit leakage current

400 V class (input power condition: 440 V/60 Hz, power supply unbalance within 3%)

Inverter/

converter unit

FR-A800

(Standard model)

FR-A802

(Separated converter type)

Converter unit FR-CC2

H315K, H355K H400K to H500K

EMC filter ON OFF - ON OFF ON OFF

Phase earthing (grounding)

3522 352702

7. 5 152211373055

455.5 18. 5

= 0.11

= 1.32

Earthed-neutral system

211 2121

(mA)

PRECAUTIONS FOR USE OF THE INVERTER

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. (NEC

section 250, IEC 536 class 1 and other applicable standards)

• When the breaker is installed on the output side of the inverter, it may be unnecessarily operated by harmonics even if the

effective value is within the rating.

In this case, do not install the breaker since the eddy current and hysteresis loss will increase, leading to temperature rise.

• The following models are standard breakers BV-C1, BC-V, NVB, NV-L, NV-G2N, NV-G3NA, NV-2F,

earth leakage relay (except NV-ZHA), and NV with AA neutral wire open-phase protection.

The other models are designed for harmonic and surge suppression: NV-C/NV-S/MN series, NV30-FA, NV50-FA, BV-C2,

earth leakage alarm breaker (NF-Z), NV-ZHA, and NV-H.

• For the leakage current of a 75 kW or higher motor, contact the motor manufacturer.

PRECAUTIONS FOR USE OF THE INVERTER

Electro-magnetic interference (EMI) and leakage currents

3.1.2 Countermeasures against inverter-generated

EMI

Some electromagnetic noises enter the inverter or the converter unit to cause its malfunction, and others are radiated by the

inverter or the converter unit to cause the peripheral devices to malfunction. Though the inverter or the converter unit is

designed to have high immunity performance, it handles low-level signals, so it requires the following basic techniques. Also,

since the inverter chops outputs at high carrier frequency, that could generate electromagnetic noises. If these

electromagnetic noises cause peripheral devices to malfunction, EMI countermeasures should be taken to suppress noises.

These techniques differ slightly depending on EMI paths.

• Basic techniques

- Do not run the power cables (I/O cables) and signal cables of the inverter or the converter unit in parallel with each other

and do not bundle them.

- Use shielded twisted pair cables for the detector connecting and control signal cables and connect the sheathes of the

shielded cables to terminal SD.

- Ground (Earth) the inverter or the converter unit, motor, etc. at one point.

• Techniques to reduce electromagnetic noises that enter and cause a malfunction of the inverter or the converter unit (EMI

countermeasures)

When devices that generate many electromagnetic noises (which use magnetic contactors, electromagnetic brakes, many

relays, for example) are installed near the inverter or the converter unit and it may malfunction due to electromagnetic

noises, the following countermeasures must be taken:

- Provide surge suppressors for devices that generate many electromagnetic noises to suppress electromagnetic noises.

- Install data line filters (page 64) to signal cables.

- Ground (Earth) the shields of the detector connection and control signal cables with cable clamp metal.

• Techniques to reduce electromagnetic noises that are radiated by the inverter to or converter unit cause the peripheral

devices to malfunction (EMI countermeasures)

Noises generated from the inverter or the converter unit are largely classified into those radiated by the cables connected to

the inverter or the converter unit and its main circuits (I/O), those electromagnetically and electrostatically induced to the

signal cables of the peripheral devices close to the main circuit power supply, and those transmitted through the power

supply cables.

Inverter generated electromagnetic noise

Air propagated

noise

Electromagnetic

induction noise

Electrostatic

induction noise

Electrical path

propagated noise

Noise directly radiated from the inverter or the converter unit

Noise radiated from power supply cable

Noise radiated from motor connection cable

Path (d), (e)

Path (f)

Noise propagated through power supply cable

Noise from earthing (grounding) cable due to leakage current

Path (a)

Path (b)

Path (c)

Path (g)

Path (h)

(g)

Instrument Receiver

(b)

(a)

(c)

Motor

(e)

(g)

Converter

unit

Inverter

(d)

power supply

(a)

(f)

(c)

Telephone

Sensor

(h)

PRECAUTIONS FOR USE OF THE INVERTER

Electro-magnetic interference (EMI) and leakage currents

Noise

propagation path

(a)(b)(c)

(d)(e)(f)

(g)

(h)

Data line filter

Countermeasure

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. The following countermeasures must be taken:

• Install easily affected devices as far away as possible from the inverter or the converter unit.

• Run easily affected signal cables as far away as possible from the inverter or the converter unit, and its I/O cables.

• Do not run the signal cables and power cables (inverter or converter unit I/O cables) in parallel with each other and do not bundle them.

• Set the EMC filter ON/OFF connector of the converter unit to the ON position. (Refer to pag e 6 6.)

• Inserting a line noise filter into the output suppresses the radiated noise from the cables.

• Use shielded cables as signal cables and power cables and run them in individual metal conduits to produce further effects.

When the signal cables are run in parallel with or bundled with the power cables, magnetic and static induction noises may be propagated to the signal cables to cause malfunction of the devices and the following countermeasures must be taken:

• Install easily affected devices as far away as possible from the inverter or the converter unit.

• Run easily affected signal cables as far away as possible from the inverter or the converter unit, and its I/O cables.

• Do not run the signal cables and power cables (inverter or converter unit I/O cables) in parallel with each other and do not bundle them.

• Use shielded cables as signal cables and power cables and run them in individual metal conduits to produce further effects.

When the power supplies of the peripheral devices are connected to the power supply of the inverter or the converter unit in the same line, its generated noises may flow back through the power supply cables to cause malfunction of the devices and the following countermeasures must be taken:

• Set the EMC filter ON/OFF connector of the converter unit to the ON position. (Refer to pag e 6 6.)

• Install the line noise filter to the power cables (output cables) of the inverter.

When a closed loop circuit is formed by connecting the peripheral device wiring to the inverter or the converter unit, leakage currents may flow through the earthing (grounding) cable of the inverter or the converter unit to cause the device to malfunction. In that case, disconnecting the earthing (grounding) cable from the device may stop the malfunction of the device.

Data line filter is effective as an EMI countermeasure. Provide a data line filter for the detector cable, etc.

<Example> Data line filter: ZCAT3035-1330 (by TDK)

ESD-SR-250 (by NEC TOKIN)

Impedance (ZCAT3035-1330)

Impedance ()

10 to 100 MHz 100 to 500 MHz

80 150

39 1

34 1

Cable fixing band mount

The impedance values above are reference values, and not guaranteed values.

TDK

Product name Lot number

OUTLINE DIMENSION DRAWINGS (ZCAT3035-1330)

[Unit: mm]

13 1

30 1

PRECAUTIONS FOR USE OF THE INVERTER

EMI countermeasure example

Electro-magnetic interference (EMI) and leakage currents

Inverter power supply

Separate inverter, converter unit and power line by more than 30cm (at least 10cm) from sensor circuit.

Control power supply

NOTE

• For compliance with the EU EMC Directive, refer to page 10 9.

Enclosure Decrease carrier frequency

Converter

EMC

filter

Do not earth (ground) enclosure directly. Do not earth (ground) control cable.

unit

Inverter

Power

supply for

sensor

Install filter on inverter output side.

Line noise

filter

Use 4-core cable for motor power cable and use one cable as earth (ground) cable.

Use a twisted pair shielded cable

Sensor

Do not earth (ground) shield but connect it to signal common cable.

Motor

PRECAUTIONS FOR USE OF THE INVERTER

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. The EMC filter is initially set to the "disabled"

(OFF) position.

(For the FR-CC2-H400K or higher, two EMC filter ON/OFF connectors are provided. The both connectors are initially set to

the "disabled" (OFF) position. To enable the EMC filter, fit the both EMC filter ON/OFF connectors to the ON position.)

EMC filter ON/OFF connector

FILTER

OFF ON

EMC filter OFF EMC filter ON

EMC filter ON/OFF connector (Provided for the FR-CC2-H400K or higher)

FILTER

OFF ON

EMC filter OFF EMC filter ON

• Before removing a front cover, check to make sure that the indication of the inverter operation panel is OFF, wait for at least

10 minutes after the power supply has been switched OFF, and check that there is no residual voltage using a tester or the

like.

• When disconnecting the connector, push the fixing tab and pull the connector straight without pulling the cable or forcibly

pulling the connector with the tab fixed.

When installing the connector, also engage the fixing tab securely.

(If it is difficult to disconnect the connector, use a pair of needle-nose pliers, etc.)

OFF ON

FILTER

EMC filter

ON/OFF connector

(Side view)

Disengage connector fixing tab With tab disengaged,

pull up the connector straight.

NOTE

• Fit the connector to either ON or OFF position.

• Enabling (turning ON) the EMC filter increases leakage current. (Refer to page 61.)

Warning

 While the inverter power is ON, do not open the front cover. Otherwise you may get an electric shock.

PRECAUTIONS FOR USE OF THE INVERTER

Power supply harmonics

NOTE

3.2 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. Take the following countermeasure suppression techniques.

• The differences between harmonics and noises

Item Harmonics Noise

Frequency

Environment To-electric channel, power impedance. To-space, distance, wiring path,

Quantitative understanding Theoretical calculation possible. Random occurrence, quantitative grasping difficult.

Generated amount Nearly proportional to the load capacity.

Affected equipment immunity Specified by standards per equipment. Different depending on maker's equipment specifications.

Countermeasure Provide a reactor. Increase distance.

• Countermeasures The harmonic current generated from the inverter

to the input side differs according to various

conditions such as the wiring impedance, whether

a reactor is used or not, and output frequency and

output current on the load side.

For the output frequency and output current, we

understand that this should be calculated in the

conditions under the rated load at the maximum

operating frequency.

Normally 40th to 50th degrees or less (3 kHz or less).

MCCB MC

Power supply

 The converter unit (FR-CC2) is equipped with the DC reactor.

High frequency (several 10 kHz to 1 GHz order).

Changes with the current variation ratio. (Gets larger as switching speed increases.)

DC reactor

AC reactor

(FR-HAL)

R/L1

S/L2

T/L3

converter

Inverter/

∗1

Do not insert power factor improving capacitor.

• The power factor improving capacitor and surge suppressor on the inverter output side may be overheated or damaged by

the harmonic components of the inverter output. Also, since an excessive current flows in the inverter to activate overcurrent

protection, do not provide a capacitor and surge suppressor on the inverter output side when the motor is driven by the

inverter. For power factor improvement, install a reactor on the inverter input side or in the DC circuit.

PRECAUTIONS FOR USE OF THE INVERTER

Power supply harmonics

Install, add or renew

equipment

Calculation of equivalent

capacity total

Equivalent

capacity total

Calculation of outgoing

harmonic current

Not more than

harmonic current upper

limit?

Harmonic suppression measures unnecessary

Harmonic suppression

measures necessary

Equal to or less than upper limit

More than upper limit

Above reference capacity

Equal to or less than reference capacity

3.2.2 Harmonic Suppression Guidelines in Japan

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" and other models were covered by "the Harmonic Suppression Guidelines for

Consumers Who Receive High Voltage or Special High Voltage". However, the transistorized inverter has been excluded from the target

products covered by "the Harmonic Suppression Guidelines for Household Appliances and General-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" (hereinafter referred to as "the

Specific Consumer Guidelines").

• "Specific Consumer Guidelines"

This guideline sets forth the maximum harmonic currents outgoing from a high-voltage or especially high-voltage receiving

consumer who will install, add or renew harmonic generating equipment. If any of the maximum values is exceeded, this

guideline requires that consumer to take certain suppression measures.

• Maximum Values of Outgoing Harmonic Currents per 1 kW Contract Power

Received p ower

voltage

6.6 kV 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70 22 kV 1.8 1.3 0.82 0.69 0.53 0.47 0.39 0.36 33 kV 1.2 0.860.550.460.350.320.260.24

5th 7th 11th 13th 17th 19th 23rd

Over 23rd

Application of the specific consumer guidelines

• Conversion factors for FR-A800 series

Classification Circuit type Conversion coefficient Ki

Three-phase bridge (Capacitor smoothing)

Self-excitation three-phase bridge When a high power factor converter is used K5 = 0

With reactor (DC side) With reactors (AC, DC sides)

• Equivalent Capacity Limits

Received power voltage Reference capacity

6.6 kV 50 kVA 22/33 kV 300 kVA 66 kV or more 2000 kVA

• Harmonic content (Values of the fundamental current is 100%)

reactor 5th 7th 11 th 13th 17th 19th 23rd 25th

Used (DC side)  30 13 8.4 5.0 4.7 3.2 3.0 2.2 Used (AC, DC sides)

 The converter unit (FR-CC2) is equipped with the DC reactor on its DC side.

PRECAUTIONS FOR USE OF THE INVERTER

 28 9.1 7.2 4.1 3.2 2.4 1.6 1.4

 K33 = 1.8

 K34 = 1.4

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 68), harmonics must be calculated with the following procedure:

∑ (Ki  Pi) [kVA]

P0 =

Ki: Conversion coefficient (Refer to page 68) Pi: Rated capacity of harmonic generating equipment [kVA] i: Number indicating the conversion circuit type

 Rated capacity: Determined by the capacity of the

applied motor and found in Table 5. The rated capacity used here is used to calculate the generated harmonic amount and is different from the power supply capacity required for actual inverter drive.

• Calculation of outgoing harmonic current

Outgoing harmonic current = fundamental wave current (value converted from received power voltage)

 operation ratio 

harmonic content

• Operation ratio: Operation ratio = actual load factor  operation time ratio during 30 minutes

• Harmonic content: Found in page 68.

• Rated capacities and outgoing harmonic currents of inverter-driven motors

Outgoing harmonic current converted from 6.6 kV (mA)

(With a DC reactor, 100% operation ratio)

Applicable

motor

(kW)

Rated

current (A)

400 V 5th 7th 11th 13th 17th 19th 23rd 25th

Fundamental wave current

converted

from 6.6 kV

Rated

capacity

(kVA)

(mA)

75 123 7455 87.2 2237 969 626 373 350 239 224 164

90 147 8909 104 2673 1158 748 445 419 285 267 196

110 179 10848 127 3254 1410 911 542 510 347 325 239

132 216 13091 153 3927 1702 1100 655 615 419 393 288

160 258 15636 183 4691 2033 1313 782 735 500 469 344

220 355 21515 252 6455 2797 1807 1076 1011 688 645 473

250 403 24424 286 7327 3175 2052 1221 1148 782 733 537

280 450 27273 319 8182 3545 2291 1364 1282 873 818 600

315 506 30667 359 9200 3987 2576 1533 1441 981 920 675

355 571 34606 405 10382 4499 2907 1730 1627 1107 1038 761

400 643 38970 456 11691 5066 3274 1949 1832 1247 1169 857

450 723 43818 512 13146 5696 3681 2191 2060 1402 1315 964

500 804 48727 570 14618 6335 4093 2436 2290 1559 1462 1072

560 900 54545 638 16364 7091 4582 2727 2564 1746 1636 1200

• Determining if a countermeasure is required

A countermeasure for harmonics is required if the following condition is satisfied: outgoing harmonic current > maximum

value per 1 kW contract power  contract power.

• Harmonic suppression techniques

No. Item Description

Reactor installation

(FR-HAL)

high power factor

converter (FR-HC2)

Installation of power

factor improving capacitor

Transformer multi-phase

operation

Passive filter

(AC filter)

Active filter

(Active filter)

The converter unit (FR-CC2) is equipped with the DC reactor on its DC side, and outgoing harmonic current can be suppressed. By installing an AC reactor (FR-HAL) on the AC side of the inverter, the outgoing harmonic current suppression performance can be improved.

This converter trims the current waveform to be a sine waveform by switching the rectifier circuit (converter module) with transistors. Doing so suppresses the generated harmonic amount significantly. Connect it to the DC area of an inverter. Use the high power factor converter (FR-HC2) with the accessories that come as standard.

When used with a reactor connected in series, the power factor improving correction capacitor can absorb harmonic currents.

Use two transformers with a phase angle difference of 30° as in - and - combinations to provide an effect corresponding to 12 pulses, reducing low-degree harmonic currents.

A capacitor and a reactor are used together to reduce impedances at specific frequencies. Harmonic currents are expected to be absorbed greatly by using this technique.

This filter detects the current in a circuit generating a harmonic current and generates a harmonic current equivalent to a difference between that current and a fundamental wave current to suppress the harmonic current at the detection point. Harmonic currents are expected to be absorbed greatly by using this technique.

PRECAUTIONS FOR USE OF THE INVERTER

Installation of a reactor

3.3 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. To prevent this, always install an optional AC reactor (FR-HAL).

Power supply

MCCB MC

AC reactor

(FR-HAL)

converter unit

R/L1

S/L2

T/L3

Inverter/

5300 5000

Capacities requiring installation of

4000

AC reactor

3000

2000

capacity (kVA)

1000

Power supply system

110 165 247 330 420 550 kV

Inverter capacity

PRECAUTIONS FOR USE OF THE INVERTER

Power-OFF and magnetic contactor (MC)

3.4 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.)

• To disconnect the inverter from the power supply at activation of a protective function or at malfunctioning of the driving

system (emergency stop, etc.).

• To prevent any accident due to an automatic restart at power restoration after an inverter stop made by a power failure.

• To separate the inverter from the power supply to ensure safe maintenance and inspection work.

If using an MC for emergency stop during operation, select an MC regarding the converter unit input side current as

JEM1038-AC-3 class rated current.

NOTE

• Since repeated inrush currents at power ON will shorten the life of the converter circuit (switching life is about 1,000,000

times), frequent starts and stops of the magnetic contactor must be avoided. Turn ON/OFF the inverter start controlling

terminals (STF, STR) to run/stop the inverter.

• Inverter start/stop circuit example

As shown below, always use the start signal (ON or OFF of STF(STR) signal) to make a start or stop.

MCCB

Power supply

Operation preparation

OFF

Stop

 When the power supply is 400 V class, install a stepdown transformer.  Connect the power supply terminals R1/L11, S1/L21 of the control circuit to the input side of the MC to hold an alarm signal when the inverter's

protective circuit is activated. At this time, remove jumpers across terminals R1/L11 and S1/L21. (Refer to page 43 for removal of the jumper.)

Start/Stop

Start

∗1

R/L1

S/L2

T/L3

R1/L11

S1/L21

Converter

unit

P/+

N/-

∗2 ∗2

RDA

P/+

N/-

R1/L11

S1/L21

X10

Inverter

STF/STR SD

To the motor

Handling of the magnetic contactor on the inverter's output side

Switch the magnetic contactor between the inverter and motor only when both the inverter and motor are at a stop. When the

magnetic contactor is turned ON while the inverter is operating, overcurrent protection of the inverter and such will activate.

When an MC is provided to switch to a commercial power supply, for example, it is recommended to use the commercial

power supply-inverter switchover function Pr.135 to Pr.139. (The commercial power supply operation is not available with

vector control dedicated motors nor with PM motors.)

Handling of the manual contactor on the inverter's output side

A PM motor is a synchronous motor with high-performance magnets embedded inside. High-voltage is generated at the motor

terminals while the motor is running even after the inverter power is turned OFF. In an application where the PM motor is

driven by the load even after the inverter is powered OFF, a low-voltage manual contactor must be connected at the inverter's

output side.

PRECAUTIONS FOR USE OF THE INVERTER

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. Otherwise you may get an electric shock.

• Do not open or close the contactor while the inverter is running (outputting).

3.5 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:

• Countermeasures

(With induction motor)

It is recommended to take one of the following countermeasures:

• Rectifying the motor insulation and limiting the PWM carrier frequency according to the wiring length

For the 400 V class motor, use an insulation-enhanced motor

Specifically,

- Order a "400 V class inverter-driven insulation-enhanced motor".

- For the dedicated motor such as the constant-torque motor and low-vibration motor, use an "inverter-driven dedicated

motor".

-Set Pr.72 PWM frequency selection as indicated below according to the wiring length.

Wiring length

100 m or shorter Longer than 100 m

Pr.72 PWM frequency selection 6 (6 kHz) or lower 4 (4 kHz) or lower

• Suppressing the surge voltage on the inverter side

- If the motor capacity is 280 kW or lower, connect the sine wave filter (MT-BSL/BSC) to the output side.

(With PM motor)

• When the wiring length exceeds 50 m, set "9" (6 kHz) or less in Pr.72 PWM frequency selection.

• When using the optional sine wave filter (MT-BSL/BSC), set Pr.72="25" (2.5 kHz).

• For the details of the sine wave filter (MT-BSL/BSC), refer to the Instruction Manual of each option.

• A sine wave filter (MT-BSL/BSC) can be used under V/F control. Do not use the filters under different control methods.

• The carrier frequency is limited during PM sensorless vector control. (Refer to the FR-A800 Instruction Manual (Detailed))

PRECAUTIONS FOR USE OF THE INVERTER

Checklist before starting operation

3.6 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.

Checkpoint Countermeasure

Crimping terminals are insulated.

The wiring between the power supply (R/L1, S/L2, T/L3) and the motor (U, V, W) is correct.

No wire offcuts are left from the time of wiring.

The main circuit cable gauge is correctly selected.

The total wiring length within the specified length.

Countermeasures are taken against EMI.

On the inverter's output side, none of the power factor correction capacitor, surge suppressor, or radio noise filter is installed.

When performing an inspection or rewiring on the product that has been energized, the operator has waited long enough after shutting off the power supply.

The inverter's output side has no short circuit or ground fault occurring.

The circuit is not configured to use the converter unit's input-side magnetic contactor to start/stop the inverter frequently.

The voltage applied to the I/O signal circuits of the inverter and the converter unit is within the specifications.

Use crimping terminals with insulation sleeves to wire the power supply and the motor.

Application of power to the output terminals (U, V, W) of the inverter will damage the inverter. Never perform such wiring.

Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter and the converter unit clean. When drilling mounting holes in an enclosure etc., take caution not to allow chips and other foreign matter to enter the inverter and the converter unit.

Use an appropriate cable gauge to suppress the voltage drop to 2% or less. If the wiring distance is long between the inverter and motor, a voltage drop in the main circuit will cause the motor torque to decrease especially during the output of a low frequency.

Keep the total wiring length is within the specified length. In long distance wiring, charging currents due to stray capacitance in the wiring may degrade the fast-response current limit operation or cause the equipment on the inverter's output side to malfunction. Pay attention to the total wiring length.

The input/output (main circuit) of the inverter and the converter unit includes high frequency components, which may interfere with the communication devices (such as AM radios) used near the inverter and the converter unit. In such case, activate the EMC filter (turn ON the EMC filter ON/OFF connector) to minimize interference.

Doing so will cause the inverter to trip or the capacitor and surge suppressor to be damaged. If any of the above devices is connected, immediately remove it.

For a short time after the power-OFF, a high voltage remains in the smoothing capacitor, and it is dangerous. Before performing an inspection or rewiring, wait 10 minutes or longer after the power supply turns OFF, then confirm that the voltage across the main circuit terminals P/+ and N/- of the inverter is low enough using a tester, etc.

• A short circuit or earth (ground) fault on the inverter's output side may damage the inverter module.

• Fully check the insulation resistance of the circuit prior to inverter operation since repeated short circuits caused by peripheral circuit inadequacy or an earth (ground) fault caused by wiring inadequacy or reduced motor insulation resistance may damage the inverter module.

• Fully check the to-earth (ground) insulation and phase-to-phase insulation of the inverter's output side before power-ON. Especially for an old motor or use in hostile atmosphere, securely check the motor insulation resistance, etc.

Since repeated inrush currents at power ON will shorten the life of the inverter and the converter unit, frequent starts and stops of the magnetic contactor must be avoided. Turn ON/OFF the inverter's start signals (STF, STR) to run/stop the inverter.

Application of a voltage higher than the permissible voltage to the I/O signal circuits of the inverter and the converter unit or opposite polarity may damage the I/O devices. Especially check the wiring to prevent the speed setting potentiometer from being connected incorrectly to short circuit the terminals 10E and 5.

Refer

to page

Check

by user

PRECAUTIONS FOR USE OF THE INVERTER

Checklist before starting operation

Checkpoint Countermeasure

The converter unit and the inverter are correctly connected.

When using the electronic bypass operation, electrical and mechanical interlocks are provided between the electronic bypass contactors MC1 and MC2.

A countermeasure is provided for power restoration after a power failure.

Wheng using the vector control, the encoder is properly installed.

A magnetic contactor (MC) is installed on the converter unit's input side.

The magnetic contactor on the inverter's output side is properly handled.

When using a PM motor, a lowvoltage manual contactor is installed on the inverter's output side.

An EMI countermeasure is provided for the frequency setting signals.

• 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. Connecting the opposite polarity of terminals N/- and P/+ will damage the inverter. Also, do not install an MCCB across the terminals P/+ and N/- (across terminals P and P/+ or across N and N/-).

• Always connect the terminal RDA of the converter unit and the terminal MRS (X10) of the inverter, and the terminal SE of the converter unit and the terminal SD (terminal PC for source logic) of the inverter. Not connecting these terminals may damage the converter unit.

When using a switching circuit as shown below, chattering due to misconfigured sequence or arc generated at switching may allow undesirable current to flow in and damage the inverter. Mis-wiring may also damage the inverter. (The commercial power supply operation is not available with vector control dedicated motors nor with PM motors.)

MC1

Interlock

Power supply

converter unit

When switching to the commercial power supply operation while a failure such as an output short circuit is occurring between the magnetic contactor MC2 and the motor, the damage may further spread. When a failure occurs between the MC2 and motor, make sure to provide a protection circuit, such as using the OH signal input.

If the machine must not be restarted when power is restored after a power failure, provide an MC in the converter unit's input side and also make up a sequence which will not switch ON the start signal. If the start signal (start switch) remains ON after a power failure, the inverter will automatically restart as soon as the power is restored.

The encoder must be directly connected to a motor shaft without any backlash. (Real sensorless vector control, PM sensorless vector control do not require an encoder.)

On the converter unit's input side, connect an MC for the following purposes:

• To disconnect the inverter and the converter unit from the power supply at activation of a protective function or at malfunctioning of the driving system (emergency stop, etc.).

• To prevent any accident due to an automatic restart at power restoration after an inverter stop made by a power failure.

• To separate the inverter and the converter unit from the power supply to ensure safe maintenance and inspection work.

If using an MC for emergency stop during operation, select an MC regarding the converter unit input side current as JEM1038-AC-3 class rated current.

Switch the magnetic contactor between the inverter and motor only when both the inverter and motor are at a stop.

A PM motor is a synchronous motor with high-performance magnets embedded inside. High-voltage is generated at the motor terminals while the motor is running even after the inverter power is turned OFF. 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. Otherwise you may get an electric shock.

If electromagnetic noise generated from the inverter and the converter unit causes frequency setting signal to fluctuate and the motor rotation speed to be unstable when changing the motor speed with analog signals, the following countermeasures are effective:

• Do not run the signal cables and power cables (inverter and converter unit I/ O cables) in parallel with each other and do not bundle them.

• Run signal cables as far away as possible from power cables (inverter and converter I/O cables).

• Use shielded cables.

• Install a ferrite core on the signal cable (Example: ZCAT3035-1330 TDK).

R/L1

S/L2

T/L3

Inverter/

Undesirable current

MC2

Refer

to page

Check

by user

PRECAUTIONS FOR USE OF THE INVERTER

Checklist before starting operation

Checkpoint Countermeasure

A countermeasure is provided for an overload operation.

The specifications and rating match the system requirements.

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 by reducing current at locked condition, starting current, etc. Reducing current may extend the service life but may also cause torque shortage, which leads to a start failure. Adding a margin to the current can eliminate such a condition. For an induction motor, use the inverter and the converter unit of a higher capacity (up to two ranks). For a PM motor, use the inverter and the converter unit, and PM motor of higher capacities.

Make sure that the specifications and rating match the system requirements. -

Refer

to page

Check

by user

PRECAUTIONS FOR USE OF THE INVERTER

Failsafe system which uses the inverter

3.7 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. Also at the same time consider the system

configuration where a failsafe from outside the inverter, without using the inverter, is enabled even if the inverter fails.

Interlock method which uses the inverter status output signals

By combining the inverter output signals to provide an interlock as shown below, an inverter failure can be detected.

No. Interlock method Check method Used signals

b Inverter operating status Operation ready signal check. Operation ready signal (RY signal)

c Inverter running status Logic check of the start signal and running signal.

d Inverter running status Logic check of the start signal and output current.

Inverter protective function operation

(a) Checking by the output of the inverter fault signal

When the inverter's protective function activates and the

inverter trips, the fault output signal (ALM signal) is

output. (ALM signal is assigned to terminal A1B1C1 in

the initial setting).

With this signal, check that the inverter operates

properly.

In addition, negative logic can be set. (ON when the

inverter is normal, OFF when the fault occurs.)

(b) Checking the inverter operating status by the inverter

operation ready completion signal

Operation ready signal (RY signal) is output when the

inverter power is ON and the inverter becomes

operative.

Check if the RY signal is output after powering ON the

inverter.

input to the inverter and inverter running signal

The inverter running signal (RUN signal) is output when

the inverter is running. (RUN signal is assigned to

terminal RUN in the initial setting.)

Check if Y12 signal is being output while inputting a start

signal to the inverter. (STF signal is a forward rotation

signal, and STR is a reverse rotation signal.) Even after

the start signal is turned OFF, the RUN signal is kept

output until the inverter makes the motor to decelerate

and to stop. For the logic check, configure a sequence

considering the inverter's deceleration time.

Operation check of an alarm contact. Circuit error detection by negative logic.

ALM

(when output

at NC contact)

RES

Power supply

STF

Output frequency

RUN

Fault output signal (ALM signal)

Start signal (STF signal, STR signal) Running signal (RUN signal)

Start signal (STF signal, STR signal) Output current detection signal (Y12 signal)

Inverter fault occurrence (trip)

Output frequency

OFF

Reset processing

(about 1s)

Reset ON

ON OFF

Pr. 13 Starting

frequency

Reset processing

ON OFF

Time

DC injection brake operation point

DC injection brake operation

Time

PRECAUTIONS FOR USE OF THE INVERTER

Failsafe system which uses the inverter

Output

signal

Pr.190 to Pr.196 setting

Positive logic Negative logic

ALM 99 199

RY 11 111

RUN 0 100

Y12 12 112

(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. (STF signal is a forward rotation signal,

and STR is a reverse rotation signal.) The Y12 signal is initially set to be output at 150% rated inverter current. Adjust

the level to around 20% using no load current of the motor as reference with Pr.150 Output current detection level.

Like the inverter running signal (RUN signal), even after the start signal is turned OFF, the Y12 signal is kept output until

the inverter stops the output to a decelerating motor. For the logic check, configure a sequence considering the

inverter's deceleration time.

• When using various signals, assign the functions to Pr.190 and

Pr.196 (output terminal function selection) referring to the

table on the left.

NOTE

• Changing the terminal assignment using Pr.190 and Pr.196 (output terminal function selection) may affect the other

functions. Set parameters after confirming the function of each terminal.

• For the details of the parameters and signals, refer to the FR-A800 Instruction Manual (Detailed).

Backup method outside the inverter

Even if the interlock is provided by the inverter status signal, enough failsafe is not ensured depending on the failure status of

the inverter itself. For example, if an inverter CPU fails in a system interlocked with the inverter's fault, start, and RUN signals,

no fault signal will be output and the RUN signal will be kept ON because the inverter CPU is down.

Provide a speed detector to detect the motor speed and current detector to detect the motor current and consider the backup

system such as performing a check as below according to the level of importance of the system.

(a) Start signal and actual operation check

Check the motor running and motor current while the start signal is input to the inverter by comparing the start signal to

the inverter and detected speed of the speed detector or detected current of the current detector. Note that the current

is flowing through the motor while the motor coasts to stop, even after the inverter's start signal is turned OFF. For the

logic check, configure a sequence considering the inverter's deceleration time. In addition, it is recommended to check

the three-phase current when using the current detector.

(b) 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

Inverter

Sensor

(speed, temperature,

air volume, etc.)

To the alarm detection sensor

PRECAUTIONS FOR USE OF THE INVERTER

MEMO

4 PROTECTIVE

FUNCTIONS

This chapter explains the "PROTECTIVE FUNCTIONS" that operates in

this product.

Always read the instructions before using the equipment.

4.1 Inverter fault and alarm indications ........................................80

4.2 Reset method for the protective functions.............................80

4.3 Check and clear of the faults history......................................81

4.4 List of fault displays .................................................................83

PROTECTIVE FUNCTIONS

Inverter fault and alarm indications

4.1 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.

• When any fault occurs, take an appropriate corrective action, then reset the inverter, and resume the operation. Restarting

the operation without a reset may break or damage the inverter.

• When a protective function activates, note the following points.

Item Description

Fault output signal

Fault or alarm indication When a protective function activates, the operation panel displays a fault indication.

Operation restart method

• Inverter fault or alarm indications are categorized as below.

Displayed item Description

Error message

Warning

Alarm The inverter does not trip. An Alarm (LF) signal can also be output with a parameter setting.

Fault A protective function activates to trip the inverter and output a Fault (ALM) signal.

Opening the magnetic contactor (MC) provided on the input side of the inverter at a fault occurrence shuts off the control power to the inverter, therefore, the fault output will not be retained.

While a protective function is activated, the inverter output is kept shutoff. Reset the inverter to restart the operation.

A message regarding an operational fault and setting fault by the operation panel (FR-DU08) and parameter unit (FR-PU07) is displayed. The inverter does not trip.

The inverter does not trip even when a warning is displayed. However, failure to take appropriate measures will lead to a fault.

NOTE

• For the details of fault displays and other malfunctions, refer to the FR-A800 Instruction Manual (Detailed).

• The past eight faults can be displayed on the operation panel. (Faults history) (For the operation, refer to page 81.)

4.2 Reset method for the protective functions

Reset the inverter by performing any of the following operations. Note that the accumulated heat value of the electronic

thermal relay function and the number of retries are cleared (erased) by resetting the inverter.

The inverter recovers about 1 s after the reset is released.

• On the operation panel, press to reset the inverter.

(This may only be performed when a fault occurs.)

• Switch power OFF once, then switch it ON again.

• Turn ON the reset signal (RES) for 0.1 s or more. (If the RES signal

is kept ON, "Err" appears (flickers) to indicate that the inverter is in

a reset status.)

OFF

Inverter

RES

NOTE

• OFF status of the start signal must be confirmed before resetting the inverter fault. Resetting an inverter fault with the start

signal ON restarts the motor suddenly.

PROTECTIVE FUNCTIONS

Check and clear of the faults history

4.3 Check and clear of the faults history

The operation panel stores the fault indications which appears when a protective function is activated to display the fault

record for the past eight faults. (Faults history)

Check for the faults history

Monitor mode Parameter setting mode Function mode

Faults history mode

[Operation for displaying faults history]

Eight past faults can be displayed with the setting dial. (The latest fault is ended by ".".)

Faults history1

Faults history2

Press the setting dial.

Faults history number

Latest fault

Faults history number

First fault in past

Output frequency

Flickering Flickering

Time

Day

Flickering Flickering

Month

Output current ∗1

Output voltage

Cumulative energization time ∗2

Year

FlickeringFlickering

Faults history8

When there is no faults history, "E0" is displayed.

 When an overcurrent trip occurs by an instantaneous overcurrent, the monitored current value saved in the faults history may be lower than the

actual current that has flowed.

 The cumulative energization time and actual operation time are accumulated from 0 to 65535 hours, then cleared, and accumulated again from

Press the setting dial.

Faults history number

FlickeringFlickering

Seventh fault in past

PROTECTIVE FUNCTIONS

Check and clear of the faults history

Faults history clearing procedure

POINTPOINT

•Set Err.CL Fault history clear = "1" to clear the faults history.

Operation

Screen at power-ON

The monitor display appears.

Parameter setting mode

Press to choose the parameter setting mode. (The parameter number read previously appears.)

Selecting the parameter number

Turn until (faults history clear) appears. Press to read the present set value. " " (initial value)

appears.

Faults history clear

Turn to change the set value to " ". Press to start clear.

" " and " " flicker alternately after parameters are cleared.

•Turn to read another parameter.

•Press to show the setting again.

•Press twice to show the next parameter.

PROTECTIVE FUNCTIONS

4.4 List of fault displays

For details, refer to the FR-A800 Instruction Manual (Detailed).

Operation panel indication Name

E---- Faults history

HOLD Operation panel lock

LOCD Password locked

Er1 to Er4 Er8

Error message

rE1 to rE4 rE6 to rE8

Err. Error

Parameter write error

Copy operation error

List of fault displays

Operation panel indication Name

E.OLT Stall prevention stop

E. SOT Loss of synchronism detection

E.GF

E.LF Output phase loss

E.OHT

E.PTC PTC thermistor operation

E.OPT Option fault

E.OP1 Communication option fault

to E.16 to E.20

Output side earth (ground) fault overcurrent

External thermal relay operation

User definition error by the PLC function

OL Stall prevention (overcurrent)

oL Stall prevention (overvoltage)

PS PU stop

CP Parameter copy

SA Safety stop

Warning

Alarm

Fault

MT1 to MT3 Maintenance timer 1 to 3

UF USB host error

HP1

HP2

HP3

FN Fan alarm

E.OC1

E.OC2

E.OC3

E.OV1

E.OV2

E.OV3

E.THT

E.THM

E.FIN Heatsink overheat

Electronic thermal relay function pre-alarm

Speed limit indication (output during speed limit)

Home position return setting error Home position return uncompleted Home position return parameter setting error 24 V external power supply operation

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)

Fault

E.PE Parameter storage device fault

E.PUE PU disconnection

E.RET Retry count excess

E.PE2 Parameter storage device fault

E.CPU E. 5 to E. 7/

E.CTE

E.P24 24 VDC power fault

E.CDO

E.SER Communication fault (inverter)

E.AIE Analog input fault

E.USB USB communication fault

E.SAF Safety circuit fault

E.PBT E.13

E.OS Overspeed occurrence

E.OSD

E.ECT Signal loss detection

E.OD Excessive position fault

E.MB1 to E.MB7

E.EP Encoder phase fault

E.LCI 4 mA input fault

CPU fault

Operation panel power supply short circuit RS-485 terminals power supply short circuit

Abnormal output current detection

Internal circuit fault

Speed deviation excess detection

Brake sequence fault

PROTECTIVE FUNCTIONS

List of fault displays

Operation panel indication Name

E.PCH Pre-charge fault

E.PID PID signal fault

Fault

to E. 1 to E. 3 Option fault

E.11

If faults other than the above appear, contact your sales

representative.

Opposite rotation deceleration fault

PROTECTIVE FUNCTIONS

5 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..........................................................................86

5.2 Measurement of main circuit voltages, currents and

powers .......................................................................................92

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

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.

Precautions for maintenance and inspection

When accessing the inverter for inspection, wait for at least 10 minutes after the power supply has been switched OFF, and

then make sure that the voltage across the main circuit terminals P/+ and N/- of the inverter is not more than 30 VDC using a

tester, etc.

5.1 Inspection item

5.1.1 Daily inspection

Basically, check for the following faults during operation.

• Motor operation fault

• Improper installation environment

• Cooling system fault

• Abnormal vibration, abnormal noise

• Abnormal overheat, discoloration

5.1.2 Periodic inspection

Check the areas inaccessible during operation and requiring periodic inspection.

Consult us for periodic inspection.

• Check and clean the cooling system........... Clean the air filter, etc.

• Check the tightening and retighten.............. The screws and bolts may become loose due to vibration, temperature

changes, etc. Check and tighten them.

Tighten them according to the specified tightening torque. (Refer to page 30.)

• Check the conductors and insulating materials for corrosion and damage.

• Measure the insulation resistance.

• Check and change the cooling fan and relay.

NOTE

• When using the safety stop function, periodic inspection is required to confirm that safety function of the safety system

operates correctly.

For more details, refer to the Safety Stop Function Instruction Manual (BCN-A23228-001).

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

5.1.3 Daily and periodic inspection

Inspection item

Area of

inspection

General

Main circuit

Control circuit, protective circuit

Cooling system

Display

Load motor

Inspection

Inspection item Description

Surrounding environment

Overall unit

Power supply voltage

General

Conductors, cables

Transformer/ reactor

Terminal block Check for a damage. 

Smoothing aluminum electrolytic capacitor

Relay/contactor

Operation check

Overall

Aluminum electrolytic capacitor

Components check

Cooling fan

Heatsink

Indication

Meter Check that reading is normal. 

Operation check

 Oil component of the heat dissipation grease used inside the inverter may leak out. The oil component, however, is not flammable, corrosive, nor

conductive and is not harmful to humans. Wipe off such oil component.

 It is recommended to install a voltage monitoring device for checking the voltage of the power supplied to the inverter.  One to two years of periodic inspection cycle is recommended. However, it differs according to the installation environment.

Consult us for periodic inspection.

Check the surrounding air temperature, humidity, dirt, corrosive gas, oil mist, etc.

Check for unusual vibration and noise. 

Check for dirt, oil, and other foreign material. Check that the main circuit voltages and control

voltages are normal. (1) Check with megger (across main circuit

terminals and earth (ground) terminal). (2) Check for loose screws and bolts.  Retighten. (3) Check for overheat traces on the parts.  Contact the manufacturer. (4) Check for stain.  Clean. (1) Check conductors for distortion.

(2) Check cable sheaths for breakage and

deterioration (crack, discoloration, etc.). Check for unusual odor and abnormal increase of

whining sound.

(1) Check for liquid leakage.  Contact the manufacturer. (2) Check for safety valve projection and bulge.  Contact the manufacturer.

(3) Judge by visual check 

Check that the operation is normal and no chattering sound is heard.

(1) Check that the output voltages across phases

are balanced while operating the inverter alone. (2) Check that no fault is found in protective and

display circuits in a sequence protective

operation test.

(1) Check for unusual odor and discoloration. 

(2) Check for serious rust development.  Contact the manufacturer. (1) Check for liquid leakage in a capacitor and

deformation trace. (2) Visual check and judge by the life check of the

control circuit capacitor. (Refer to the FR-A800

Instruction Manual (Detailed)). (1) Check for unusual vibration and noise.  Replace the fan.

(2) Check for loose screws and bolts. 

(3) Check for stain.  Clean. (1) Check for clogging.  Clean. (2) Check for stain.  Clean. (1) Check that display is normal.  Contact the manufacturer. (2) Check for stain.  Clean.

Check for vibration and abnormal increase in operation noise.



  Clean.

interval

Periodic

Daily

 Improve the environment.

 Inspect the power supply.

 Contact the manufacturer.



 Contact the manufacturer.



Corrective action at

fault occurrence



Check fault location and retighten.

Stop the equipment and contact the manufacturer.

Fix with the fan cover fixing screws

Stop the equipment and contact the manufacturer.

Check by the

user

NOTE

• Continuous use of a leaked, deformed, or degraded smoothing aluminum electrolytic capacitor (as shown in the table above)

may lead to a burst, breakage or fire. Replace such capacitor without delay.

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

Inspection item

NOTE

5.1.4 Checking the inverter and converter modules

Preparation

• Disconnect the external power supply cables (R/L1, S/L2, T/L3) and motor cables (U, V, W). (The inverter and the converter

unit (FR-CC2) can be measured with those cables connected.)

• Prepare a tester. (For the resistance measurement, use the 100  range.)

Checking method

Change the polarity of the tester alternately at the inverter terminals R/L1, S/L2, T/L3, U, V, W, P/+, and N/- and check the

electric continuity.

• Before measurement, check that the smoothing capacitor is discharged.

• At the time of electric discontinuity, the measured value is almost ∞. When there is an instantaneous electric continuity, due to

the smoothing capacitor, the tester may not indicate ∞. At the time of electric continuity, the measured value is several  to

several tens of . If all measured values are almost the same, although these values are not constant depending on the

module type and tester type, the modules are without fault.

Module device numbers and terminals to be checked

Converter module Inverter module

P/+

D1 D2 D3

TR1 TR3 TR5

R/L1

S/L2

T/L3

Converter

Inverter

D4 D5 D6

module

TR1

TR3

module

TR5

N/-

TR4 TR6 TR2

Tester

polarity

R/L1, N/- Continuity

S/L2, N/- Continuity

T/L3 N/- Continuity

U N/- Continuity

TR4

V N/- Continuity

TR6

W N/- Continuity

TR2

Result

N/-

Tester

polarity

R/L1, P/+ Discontinuity

P/+ R/L1, Continuity N/- R/L1, Discontinuity

S/L2, P/+ Discontinuity

P/+ S/L2, Continuity N/- S/L2, Discontinuity

T/L3 P/+ Discontinuity

P/+ T/L3 Continuity N/- T/L3 Discontinuity

U P/+ Discontinuity

P/+ U Continuity N/- U Discontinuity

V P/+ Discontinuity

P/+ V Continuity N/- V Discontinuity

W P/+ Discontinuity

P/+ W Continuity N/- W Discontinuity

Result

(Assumes the use of an analog meter.)

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

Inspection item

NOTE

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.

• Do not use solvent, such as acetone, benzene, toluene and alcohol, as these will cause the inverter surface paint to peel off.

• The display, etc. of the operation panel (FR-DU08) and parameter unit (FR-PU07) are vulnerable to detergent and alcohol.

Therefore, avoid using them for cleaning.

5.1.6 Replacement of parts

The inverter consists of many electronic parts such as semiconductor devices.

The following parts may deteriorate with age because of their structures or physical characteristics, leading to reduced

performance or fault of the inverter. For preventive maintenance, the parts must be replaced periodically.

Use the life check function as a guidance of parts replacement.

Part name Estimated lifespan Description

Cooling fan 10 years Replace (as required)

Main circuit smoothing capacitor 10 years

On-board smoothing capacitor 10 years

Relays — As required

Main circuit fuse 10 years Replace (as required)

 Estimated lifespan for when the yearly average surrounding air temperature is 40°C.

(without corrosive gas, flammable gas, oil mist, dust and dirt etc.)

 Output current (80% of the inverter rating)

 Replace (as required)

 Replace the board (as required)

NOTE

• For parts replacement, contact the nearest Mitsubishi FA center.

Inverter parts life display

The inverter diagnoses the control circuit capacitor and the cooling fan by itself, and estimates their lives.

The self-diagnostic warning is output when the life span of each part is near its end. It gives an indication of replacement time.

The life warning output can be used as a guideline for life judgment.

Parts Judgment level

Control circuit capacitor Estimated remaining life 10%

Cooling fan Approx. less than 1700 r/min

NOTE

• Refer to the FR-A800 Instruction Manual (Detailed) to perform the life check of the inverter parts.

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

Inspection item



AIR FLOW

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.

 Removal

1) Remove the fan cover fixing screws, and remove the fan cover.

2) Disconnect the fan connector and remove the fan block.

3) Remove the fan fixing screws, and remove the fan.

Fan

Fan block

Fan connection connector

 The number of cooling fans differs according to the inverter capacity.

 Reinstallation

1) After confirming the orientation of the fan, reinstall the fan so that the "AIR FLOW" faces up.

Fan cover

2) For reconnection of the fan, refer to the above figure.

NOTE

• Installing the fan in the opposite direction of air flow can cause the inverter life to be shorter.

• Prevent the cable from being caught when installing a fan.

• Switch the power OFF before replacing fans. Since the inverter circuits are charged with voltage even after power OFF,

replace fans only when the inverter cover is on the inverter to prevent an electric shock accident.

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

Inspection item

NOTE

Smoothing capacitors

A large-capacity aluminum electrolytic capacitor is used for smoothing in the main circuit DC section, and an aluminum

electrolytic capacitor is used for stabilizing the control power in the control circuit. Their characteristics are deteriorated by the

adverse effects of ripple currents, etc. The replacement intervals greatly vary with the surrounding air temperature and

operating conditions. When the inverter is operated in air-conditioned, normal environment conditions, replace the capacitors

about every 10 years.

The appearance criteria for inspection are as follows:

• Case: Check the side and bottom faces for expansion.

• Sealing plate: Check for remarkable warp and extreme crack.

• heck for external crack, discoloration, liquid leakage, etc. Judge that the capacitor has reached its life when the measured

capacitance of the capacitor reduced below 80% of the rating.

• The inverter diagnoses the control circuit capacitor by itself and can judge its life. (Refer to the FR-A800 Instruction Manual

(Detailed))

Relays

To prevent a contact fault, etc., relays must be replaced according to the cumulative number of switching times (switching life).

Main circuit fuse

A fuse is used inside the inverter. The replacement intervals vary with the surrounding air temperature and operating

conditions. When the converter unit is operated in air-conditioned, normal environment conditions, replace the capacitors

about every 10 years.

5.1.7 Inverter replacement

The inverter can be replaced with the control circuit wiring kept connected. Before replacement, remove the wiring cover of

the inverter.

1) Loosen the two mounting screws at the both side of the control circuit terminal block. (These screws cannot be removed.) Slide down the control circuit terminal block to remove it.

Loosen the screws

2) Be careful not to bend the pins of the inverter's control circuit connector, reinstall the control circuit terminal block and fix it with the mounting screws.

NOTE

• Before starting inverter replacement, switch power OFF, wait for at least 10 minutes, and then check the voltage with a tester

and such to ensure safety.

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

Measurement of main circuit voltages, currents and powers

5.2 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.

NOTE

• When installing meters etc. on the inverter output side

When the wiring length between the inverter and the motor is large, the meters and CTs may generate heat due to line-to-line

leakage current. Therefore, choose the equipment which has enough allowance for the current rating.

To measure and display the output voltage and output current of the inverter, it is recommended to use the terminal AM and

FM/CA output functions of the inverter.

Examples of measuring points and instruments

Three-phase power supply

Instrument types

Input voltage

Input current

Inverter/

converter unit

W11

W12

W13

R/L1

S/L2

T/L3

N/-

P/+

W21

W22

Output voltage

Output current

To the motor

: Moving-iron type

: Electrodynamometer type

: Moving-coil type

: Rectifier type

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

Measurement of main circuit voltages, currents and powers

Pf1

3V1 I 1

------------------------

100=

Pf2

3V2 I2

------------ ------------

100=

Measuring points and instruments

Item Measuring point Measuring instrument Remarks (reference measured value)

Power supply voltage V

Power supply side current

Power supply side power P

Power supply side power factor

Converter output Across P/+ and N/-

Operation enable

Converter unit (FR-CC2)

signal External thermal relay signal Reset signal

Alarm signal

Output side voltage

V Output side current

Output side power P

Output side power factor Pf

Frequency setting signal

Frequency setting power supply

Inverter

Frequency meter signal

Across R/L1 and S/L2, S/L2 and T/L3, T/L3 and R/L1

R/L1, S/L2, T/L3 line current

R/L1, S/L2, T/L3 and Across R/L1 and S/L2, S/L2 and T/L3, T/L3 and R/L1 Calculate after measuring power supply voltage, power supply side current and power supply side power.

Across RDI, OH, RES(+) and SD (for sink logic)

Across A1 and C1 Across B1 and C1

Across U and V, V and W, and W and U

U, V and W line currents

U, V, W and across U and V, V and W Calculate in similar manner to power supply side power factor.

Across 2, 4(+) and 5 Across 1(+) and 5 0 to 5 VDC and 0 to 10 VDC Across 10(+) and 5 5.2 VDC Across 10E(+) and 5 10 VDC

Across AM(+) and 5

Across CA(+) and 5

Across FM(+) and SD

Moving-iron type AC voltmeter

Moving-iron type AC ammeter

Digital power meter (for inverter) or electrodynamic type single-phase wattmeter

Moving-coil type (such as tester)

Moving-coil type (tester and such may be used.) (internal resistance 50 k or more)

Moving-coil type (such as tester)

Rectifier type AC voltage meter (moving-iron type cannot measure.)

Moving-iron type AC ammeter

Digital power meter (for inverter) or electrodynamic type single-phase wattmeter

Moving-coil type (tester and such may be used.) (internal resistance 50 k or more)

Commercial power supply



Within permissible AC voltage fluctuation (Refer to page 98.)



1 = W11 + W12 + W13 (3-wattmeter method)

Inverter LED is lit. 1.35  V

When open 20 to 30 VDC ON voltage: 1 V or less

Continuity check

Across A1 and C1 Discontinuity Continuity Across B1 and C1 Continuity Discontinuity



Difference between the phases is within 1% of the maximum output voltage.

Difference between the phases is 10% or lower



of the rated inverter current.

2 = W21 + W22

P 2-wattmeter method (or 3-wattmeter method)

0 to 10 VDC, 4 to 20 mA

Approximately 10 VDC at maximum frequency (without frequency meter) Approximately 20 mADC at maximum frequency Approximately 5 VDC at maximum frequency (without frequency meter)

8VDC

[Normal] [Fault]

"SD" is common

"5" is . common

Start signal Select signal Reset signal Output stop signal

Fault signal

Across STF, STR, RH, RM, RL, JOG, RT, AU, STOP, CS, RES, MRS(+) and SD (for sink logic)

Across A1 and C1 Across B1 and C1

Pulse width T1: Adjust with C0 (Pr.900). Pulse cycle T2: Set with Pr.55. (frequency monitor only)

When open 20 to 30 VDC ON voltage: 1 V or less

Moving-coil type (such as tester)

Continuity check

Across A1 and C1 Discontinuity Continuity Across B1 and C1 Continuity Discontinuity



[Normal] [Fault]

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

"SD" is common

Measurement of main circuit voltages, currents and powers

3-wattmeter method (Electro-dynamometer type) 2-wattmeter method (Electro-dynamometer type) Clip AC power meter (For balanced three-phase load) Clamp-on wattmeter (Hall device power arithmetic type)

0 20 40 60 80 100 120Hz

100

120

3-wattmeter method (Electro-dynamometer type) 2-wattmeter method (Electro-dynamometer type) Clip AC power meter (For balanced three-phase load) Clamp-on wattmeter (Hall device power arithmetic type)

0 20 40 60 80 100 120Hz

100

120

 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. In this case, use an approximate-effective value type.

 When the setting of Pr.195 ABC1 terminal function selection is the positive logic  A digital power meter (designed for inverter) can also be used to measure.

5.2.1 Measurement of powers

Use a digital power meter (for inverter) for the input side of the converter unit (FR-CC2) and the output side of the inverter.

Alternatively, measure using electrodynamic type single-phase wattmeters for the input side of the converter unit and output

side of the inverter in two-wattmeter or three-wattmeter method. As the current is liable to be imbalanced especially in the

input side, it is recommended to use the three-wattmeter method.

Examples of measured value differences produced by different measuring meters are shown below.

An error will be produced by difference between measuring instruments, e.g. power calculation type and two- or three-

wattmeter type three-phase wattmeter. When a CT is used in the current measuring side or when the meter contains a PT on

the voltage measurement side, an error will also be produced due to the frequency characteristics of the CT and PT.

[Measurement conditions]

Constant output of 60 Hz or more frequency with a constant-

torque (100%). The value obtained by the 3-wattmeter

method with a 4-pole 3.7 kW induction motor is assumed to

be 100%.

[Measurement conditions]

Constant output of 60 Hz or more frequency with a constant-

torque (100%). The value obtained by the 3-wattmeter

method with a 4-pole 3.7 kW induction motor is assumed to

be 100%.

Example of measuring inverter input power

Example of measuring inverter output power

5.2.2 Measurement of voltages and use of PT

Converter unit (FR-CC2) input side

As the input side voltage has a sine wave and it is extremely small in distortion, accurate measurement can be made with an

ordinary AC meter.

Inverter output side

Since the output side voltage has a PWM-controlled rectangular wave, always use a rectifier type voltmeter. A needle type

tester cannot be used to measure the output side voltage as it indicates a value much greater than the actual value. A moving-

iron type meter indicates an effective value which includes harmonics and therefore the value is larger than that of the

fundamental wave. The value monitored on the operation panel is the inverter-controlled voltage itself. Hence, that value is

accurate and it is recommended to monitor values (analog output) using the operation panel.

PT

No PT can be used in the output side of the inverter. Use a direct-reading meter. (A PT can be used in the input side of the

converter unit (FR-CC2).)

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

Measurement of main circuit voltages, currents and powers

120

100

60Hz40

Moving-iron type

Clip AC power meter

Clamp-on wattmeter current measurement

Clamp meter

5.2.3 Measurement of currents

Use moving-iron type meter on the input side of the converter unit (FR-CC2) and the output side of the inverter. However, if

the carrier frequency exceeds 5 kHz, do not use that meter since an overcurrent losses produced in the internal metal parts of

the meter will increase and the meter may burn out. In this case, use an approximate-effective value type.

Since current on the converter unit input side tends to be unbalanced, measurement of three phases is recommended.

Correct value cannot be obtained by measuring only one or two phases. On the other hand, the unbalanced ratio of each

phase of the output side current should be within 10%.

When a clamp ammeter is used, always use an effective value detection type. A mean value detection type produces a large

error and may indicate an extremely smaller value than the actual value. The value monitored on the operation panel is

accurate if the output frequency varies, and it is recommended to monitor values (provide analog output) using the operation

panel.

Examples of measured value differences produced by different measuring meters are shown below.

[Measurement conditions]

Indicated value of the moving-iron type ammeter is 100%.

120

Moving-iron type

100

Clip AC power meter

[Measurement conditions]

Indicated value of the moving-iron type ammeter is 100%.

Clamp meter

Example of measuring converter unit input current

Clamp-on wattmeter current measurement

60Hz40

Example of measuring inverter output current

5.2.4 Use of CT and transducer

A CT may be used in both the input side of the converter unit and the output side of the inverter. Use the one with the largest

possible VA ability because an error will increase if the frequency gets lower.

When using a transducer, use the effective value calculation type which is immune to harmonics.

5.2.5 Example of measuring converter unit (FR-CC2)

input power factor

Calculate using effective power and apparent power. A power-factor meter cannot indicate an exact value.

Total power factor of the converter unit =

Effective power

Apparent power

Three-phase input power found by the 3-wattmeter method

 V (power supply voltage)  I (input current effective value)

5.2.6 Measurement of converter output voltage

(across terminals P and N)

The output voltage of the converter is output across terminals P and N and can be measured with a moving-coil type meter

(tester). Although the voltage varies according to the power supply voltage, approximately 540 to 600 V is output when no

load is connected and voltage decreases during driving load operation.

When energy is regenerated from the motor during deceleration, for example, the converter output voltage rises to nearly 800

to 900 V maximum.

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

Measurement of main circuit voltages, currents and powers

5.2.7 Measurement of inverter output frequency

In the initial setting of the FM-type inverter, a pulse train proportional to the output frequency is output across the pulse train

output terminals FM and SD of the inverter. This pulse train output can be counted by a frequency counter, or a meter

(moving-coil type voltmeter) can be used to read the mean value of the pulse train output voltage. When a meter is used to

measure the output frequency, approximately 5 VDC is indicated at the maximum frequency.

For detailed specifications of the pulse train output terminal FM, refer to the FR-A800 Instruction Manual (Detailed).

In the initial setting of the CA-type inverter, a pulse train proportional to the output frequency is output across the analog

current output terminals CA and 5 of the inverter. Measure the current using an ammeter or tester.

For detailed specifications of the analog current output terminal CA, refer to the FR-A800 Instruction Manual (Detailed).

5.2.8 Insulation resistance test using megger

• For the inverter and the converter unit (FR-CC2), conduct the insulation resistance test on the main circuit only as shown

below and do not perform the test on the control circuit. (Use a 500 VDC megger.)

NOTE

• Before performing the insulation resistance test on the external circuit, disconnect the cables from all terminals of the inverter

and the converter unit so that the test voltage is not applied to the inverter and the converter unit.

• For the continuity test of the control circuit, use a tester (high resistance range) and do not use the megger or buzzer.

Power supply

500VDC megger

R/L1

Converter

S/L2 T/L3

Earth (ground) terminal Earth (ground) terminal

unit

P/+

N/-

5.2.9 Pressure test

Do not conduct a pressure test. Deterioration may occur.

P/+ N/-

Inverter

Motor

500VDC megger

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

6 SPECIFICATIONS

This chapter explains the "SPECIFICATIONS" of this product.

Always read the instructions before using the equipment.

6.1 Inverter rating............................................................................98

6.2 Common specifications ...........................................................100

6.3 Outline dimension drawings....................................................102

SPECIFICATIONS

Inverter rating

6.1 Inverter rating

 400 V class

• Inverter

Model FR-A842-[ ]

SLD 400 450 500 — —

Applicable motor capacity (kW)

Rated capacity (kVA)

Rated current (A)

Overload current

Output

rating

Rated voltage Regenerative

brakingtorque (When the converter unit (FR-CC2) is used)

DC power supply voltage 430 to 780 VDC Control power supply auxiliary input Single phase 380 to 500 V 50 Hz/60 Hz

Permissible control power supply auxiliary input fluctuation

Input power

Protective structure (IEC 60529) Cooling system Forced air cooling Approx. mass (kg) 163 163 243 243 243







 The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi 4-pole standard motor.  The rated output capacity indicated assumes that the output voltage is 440 V.  The % value of the overload current rating indicated is the ratio of the overload current to the inverter's rated output current. For repeated duty,

 The maximum output voltage does not exceed the power supply voltage. The maximum output voltage can be changed within the setting range.

 ND rating reference value  FR-DU08: IP40 (except for the PU connector section)  For the power voltage exceeding 480 V, set Pr.977 Input voltage mode selection. (For details, refer to the FR-A800 Instruction Manual

LD 355 400 450 500 — ND (initial setting) 315 355 400 450 500 HD 280 315 355 400 450 SLD 587 660 733 834 924 LD 521 587 660 733 834 ND (initial setting) 465 521 587 660 733 HD 417 465 521 587 660 SLD 770 866 962 1094 1212 LD 683 770 866 962 1094 ND (initial setting) 610 683 770 866 962 HD 547 610 683 770 866 SLD 110% 60 s, 120% 3 s (inverse-time characteristics) at surrounding air temperature 40°C LD 120% 60 s, 150% 3 s (inverse-time characteristics) at surrounding air temperature 50°C ND (initial setting) 150% 60 s, 200% 3 s (inverse-time characteristics) at surrounding air temperature 50°C HD 200% 60 s, 250% 3 s (inverse-time characteristics) at surrounding air temperature 50°C

 Three-phase 380 to 500 V



Maximum brake torque

 Open type (IP00)

allow time for the inverter and motor to return to or below the temperatures under 100% load.

However, the maximum point of the voltage waveform at the inverter output side is the power supply voltage multiplied by about .

(Detailed).)

315K 355K 400K 450K 500K

07700 08660 09620 10940 12120

10% torque/continuous



Frequency 5%, voltage 10%

SPECIFICATIONS

Inverter rating

• Converter unit (FR-CC2)

Model FR-CC2-H[ ] 315K 355K 400K 450K 500K

Applicable motor capacity (kW) 315 355 400 450 500

Overload current rating  150% 60 s, 200% 3 s

Rated voltage

Output

Rated input AC voltage/frequency Three-phase 380 to 500 V 50 Hz/60 Hz Permissible AC voltage fluctuation Three-phase 323 to 550 V 50 Hz/60 Hz Permissible frequency fluctuation 5% Rated input current (A) 610 683 770 866 962 Power supply capacity (kVA)

Power supply

Protective structure (IEC 60529) Cooling system Forced air cooling DC reactor Built-in Approx. mass (kg) 210 213 282 285 288

 430 to 780 VDC 

 465 521 587 660 733

 Open type (IP00)

 The % value of the overload current rating indicated is the ratio of the overload current to the inverter's rated output current. For repeated duty,

allow time for the converter unit and the inverter to return to or below the temperatures under 100% load.

 The converter unit output voltage varies according to the input power supply voltage and the load. The maximum point of the voltage waveform

at the converter unit output side is approximately the power supply voltage multiplied by .

 The power supply capacity is the value when at the rated output current. It varies by the impedance at the power supply side (including those of

the input reactor and cables).

 FR-DU08: IP40 (except for the PU connector section)  The permissible voltage imbalance ratio is 3% or less. (Imbalance ratio = (highest voltage between lines - average voltage betw een three lines )

/ average voltage between three lines  100)

SPECIFICATIONS

Mitsubishi Electronics A800 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Instructions

CONTENTS

1 INTRODUCTION

1.1 Product checking and accessories

1.2 Inverter component names

1.3 About the related manuals

INSTALLATION AND WIRING

2.1 Peripheral devices

2.1.1 Inverter and peripheral devices

2.1.2 Peripheral devices

2.2 Removal and reinstallation of the front cover

2.3 Installation of the inverter and enclosure design

2.3.1 Inverter installation environment

2.3.2 Cooling system types for inverter enclosure

2.3.3 Inverter installation

2.3.4 Protruding the heatsink

2.4 Terminal connection diagrams

2.5 Main circuit terminals

2.5.4 Applicable cables and wiring length

2.5.5 Earthing (grounding) precautions

2.6 Control circuit

2.6.3 Control logic (sink/source) change

2.6.4 Wiring of inverter control circuit

2.6.5 Wiring precautions

2.6.8 Safety stop function

2.7 Communication connectors and terminals

2.7.1 PU connector

2.7.2 USB connector

2.7.3 RS-485 terminal block

Connection of motor with encoder (vector control)

2.9 Connection of stand-alone option units

2.9.1 Connection of the brake unit (FR-BU2)

PRECAUTIONS FOR USE OF THE INVERTER

Electro-magnetic interference (EMI) and leakage currents

3.1.1 Leakage currents and countermeasures

3.1.3 Converter unit (FR-CC2) built-in EMC filter

3.2 Power supply harmonics

3.2.1 Power supply harmonics

3.2.2 Harmonic Suppression Guidelines in Japan

3.3 Installation of a reactor

3.4 Power-OFF and magnetic contactor (MC)

Countermeasures against deterioration of the 400 V class motor insulation

3.6 Checklist before starting operation

3.7 Failsafe system which uses the inverter

PROTECTIVE FUNCTIONS

4.1 Inverter fault and alarm indications

4.2 Reset method for the protective functions

4.3 Check and clear of the faults history

4.4 List of fault displays

PRECAUTIONS FOR MAINTENANCE AND INSPECTION

5.1 Inspection item

5.1.1 Daily inspection

5.1.2 Periodic inspection

5.1.3 Daily and periodic inspection

5.1.4 Checking the inverter and converter modules

5.1.5 Cleaning

5.1.6 Replacement of parts

5.1.7 Inverter replacement

Measurement of main circuit voltages, currents and powers

5.2.1 Measurement of powers

5.2.2 Measurement of voltages and use of PT

5.2.3 Measurement of currents

5.2.4 Use of CT and transducer

5.2.7 Measurement of inverter output frequency

5.2.8 Insulation resistance test using megger

5.2.9 Pressure test

6 SPECIFICATIONS

6.1 Inverter rating