Mitsubishi Electronics FR-A800, F800 User Manual

INVERTER
FR-A800/F800

Safety Stop Function Instruction Manual

CONTENTS

1. GENERAL DESCRIPTION ............................................ 2

2. INSTALLATION AND WIRING...................................... 3

3. EXAMPLE OF SAFETY SYSTEM CONFIGURATION .... 7

4. TEST AND CHECKING FAILURE ............................... 10

5. SAFETY PARAMETERS OF FR-A800/F800 ................ 11

Compliance with the EU Machinery Directive – Functional Safety

WARNING

 Any misuse of safety function could lead to personal injury or death, property damage, or economic

loss. To ensure that the system complies fully with requirement of safety, make a system-level risk
assessment. Mitsubishi Electric Co. cannot assume responsibility for any system to comply with
safety directive.

CAUTION

 The information of this manual is merely a guide for proper installation.
 Mitsubishi Electric Co. cannot assume responsibility for the compliance or the noncompliance to

any code, national, local or otherwise for the proper installation of this equipment.

 A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

WARNING

 To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged

before performing any work on the drive. Measure the DC bus voltage at the P(+) and N(-) terminals
or test points (refer to your drive’s User Manual for locations and discharging time). The voltage
must be zero.

WARNING

 The safety stop function do not isolate electrically between drive and motor. To avoid an electric

shock hazard, disconnect/isolate power to the drive and verify to ensure that the voltage is zero
before performing any work on the motor (refer to your drive’s User Manual for discharging time).

1

1 GENERAL DESCRIPTION

Features

Mitsubishi FR-A800/F800 safety stop function prevents a drive from supplying rotational energy to motors. Dual

safety channels ‘S1’ and ‘S2’ cut off the gate-drive power for IGBT to turn off.

RESET

Emergency
stop button

SO

SOC

PC

24VDC

SIC

SD

Safety relay module

/ Safety programmable controller

S2

S1

Fuse

+24V

CPU

Logic

FR-A800/F800

Gate

ASIC

Driver

Gate

Driver

G G

R/L1 S/L2 T/L3

IGBTs

U

V

M

W

Fig.1 FR-A800/F800 safety stop function diagram

WARNING

 Disconnecting the power to the gate driver by the safety stop function does not isolate electrically

between drive and motor. To avoid an electric shock hazard, disconnect power to the drive and verify
that the main circuit capacitor voltage is zero (across P and N terminals) before performing any work
on the motor (refer to your drive’s User Manual for discharging time).

Standards

Mitsubishi FR-A800/F800 safety stop function meets the following directives and categories.

ISO13849-1:2008 Category 3/PLd

IEC62061:2005 / IEC61800-5-2:2007 / IEC61508 SIL2

IEC60204-1:2010 / IEC61800-5-2:2007 Stop category 0

WARNING

 The misuse of safety function leads to personal injury or death, property damage, or economic loss.

To ensure that the system complies fully with requirement of safety, make a system-level risk
assessment. Mitsubishi Electric Co. cannot assume responsibility for any system to comply with
safety directive.

2

GENERAL DESCRIPTION

2 INSTALLATION AND WIRING

CAUTION

 The following information is merely a guide for proper installation.
 Mitsubishi Electric Co. cannot assume responsibility for the compliance or the noncompliance to

any code, national, local or otherwise for the proper installation of this equipment.

 A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

CAUTION

 Ensure the safety relay unit and the FR-A800/F800 unit is mounted closely in enclosure meeting IP54

and all interconnection wiring is short and protected against open and short circuit faults. Refer ISO/
IEC13849-2.

Installation

Mitsubishi FR-A800/F800 safety stop function should be used under following condition and environment.

Table.1 The condition and environment for using safety stop function

Item Condition

Surrounding air
temperature

Storage temperature -20ºC to +65ºC

Ambient humidity

Vibration

Altitude Maximum 2500 above sea level

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

Over voltage category III or less

Pollution degree II or less

Mounting Wall mounting / vertical orientation

LD, ND, HD

SLD -10ºC to +40ºC (non-freezing)

 -10ºC to +50ºC (non-freezing)



With circuit board coating (conforming to IEC60721-3-3 3C2/3S2): 95% RH or
less (non-condensing),
Without circuit board coating: 90% RH or less (non-condensing)

2

5.9m/s

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



 The ND and HD ratings can be selected only for the FR-A800.
 Temperature applicable for a short time, e.g. in transit.
 For the installation at an altitude above 1,000 m (3280.80 feet) up to 2,500 m (8202 feet), derate the rated current 3% per 500

m (1640.40 feet).

INSTALLATION AND WIRING

3

CAUTION

 In order to meet safety stop, an approved safety relay unit to ISO13849-1 safety category 3 or better

shall be used in conjunction with FR-A800/F800 as shown in example. In addition, all other
components with in the safety stop loop shall be ‘safety approved’ types.

WARNING

 To avoid an electric shock hazard, insert the magnetic contactor (MC) between power source and

drive.

 Open the contact of MC and keep away from drive for discharging time (refer to your drive’s User

Manual for information) before performing any work on the drive. And verify that the voltage on the
bus capacitors has discharged before Measuring the DC bus voltage at the P(+) and N(-) terminals or
test points (refer to your drive’s User Manual for locations). The voltage must be zero.

CAUTION

 To avoid systematic faults, a test even for faulty demands of the safety function has to be performed

in order to check the correct function of the monitor signal. This test shall be carried out at system
installation, any software changes, parameterization changes, and/or at least once per year. Refer to
‘4. Test and checking failure’.

●Wiring

The safety related terminals are described in Table.2 and Table.3

Table.2 The safety related terminals

Term i nal

symbol

For input of safety stop channel 1.

S1

S2

SIC Common terminal for S1 terminal and S2 terminal.

SO

SOC Common terminal for SO terminal.

S1-SIC is
OFF: In safety stop mode.
ON: Non safety stop mode.

For input of safety stop channel 2.
S2-SIC is
OFF: In safety stop mode.
ON: Non safety stop mode.

As output for failure detection and alarm. SO terminal type is
‘Open collector output’.
SO-SOC is
OFF: Detect failure or alarm.
ON: No failure detected.

Note: This terminal cannot be used to output safety outputs in a

safety system. This terminal can be used for alarm or to
prevent restart only, no other safety function.

 Specifications for conforming safety standards.
 ON: The transistor is conducted. OFF: The transistor is not conducted.

Description  Rating 

Input resistance: 4.7kΩ
Input current : 4 to 6 mADC
(In case of 24VDC input)

Load: 24VDC/0.1A max.
Voltage drop: 3.4V max.
(In case of ‘ON’ state)

4

INSTALLATION AND WIRING

Table.3 Truth table of safety related signals

Error definition 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

CPU fault

E.CPU

E.5 to E.7

Internal circuit fault E.13

Error definition Operation panel indication

Input

power

Internal

safety
circuit
status

Input terminal , 

S1 S2 SO E.SAF  SA 

Output

terminal

Inverter running status

OFF OFF Output shutoff (Safe state)

 Drive enabled

 Output shutoff (Safe state) Displayed Displayed
 Output shutoff (Safe state) Displayed Displayed

 Output shutoff (Safe state)

ON

Normal ON ON ON

Normal ON OFF OFF
Normal OFF ON OFF

Normal OFF OFF ON

Fault ON ON OFF Output shutoff (Safe state) Displayed

Fault ON OFF OFF Output shutoff (Safe state) Displayed Displayed
Fault OFF ON OFF Output shutoff (Safe state) Displayed Displayed
Fault OFF OFF OFF Output shutoff (Safe state) Displayed Displayed

 ON: The transistor is conducted. OFF: The transistor is not conducted.
 When not using the safety stop function, short across terminals S1 and PC, S2 and PC, and SIC and SD to use the inverter.

(In the initial status, terminals S1 and PC, S2 and PC, and SIC and SD are respectively shorted with shorting wires.)

 If any of the protective functions shown in the following table is activated, the terminal SO turns OFF.

Operation panel

indication

Not
displayed

Not
displayed

Not
displayed

Not
displayed

Not
displayed

Displayed

Not
displayed



 If the internal safety circuit is operated normally, the terminal SO remains ON until E.SAF is displayed, and the terminal SO

turns OFF when E.SAF is displayed.

 SA is displayed when the terminals S1 and S2 are identified as OFF due to the internal safety circuit failure.
 If another fault occurs at the same time as E.SAF, the other fault can be displayed.
 If another warning occurs at the same time as SA, the other warning can be displayed.

NOTE

• The response time from safety stop signal input to drive shutoff (safe state) is faster than 8ms.

• Hold the ON or OFF status for 2ms or longer to input signal to terminal S1 or S2.
Signal input shorter than 2ms is not recognized.

INSTALLATION AND WIRING

5

●Wire and ferrule specification

Table.4 Wire and ferrule specification

Wire size (mm2)

Ferrule with insulation collar  Crimping tool name 

0.3 / 0.5 AI 0,5-10WH

0.75 AI 0,75-10GY

1AI 1-10RD

CRIMPFOX 6

1.25 / 1.5 AI1,5-10BK

0.75 (combined 2 wire) AI TWIN 2 X 0,75-10GY

 Ferrules and tools are distributed by Phoenix Contact.

●Jumper cable

The jumper cable between S1,S2 and PC terminal between SIC and SD terminal has been installed in the factory

as shown in Fig.2.

2 5 4 1 F/C

AM

5 10E 10 SE SE SU

+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

STF STR

JOG

Terminal block of FR-A800/F800

Fig.2. Short wire

Before connecting safety input wire to S1,S2 and SIC terminal, remove this jumper cable.

6

INSTALLATION AND WIRING

3 EXAMPLE OF SAFETY SYSTEM

S 2

FR-A800/F800

SO

R/L1 S/L2

T/L3

IGBTs

SOC

RESET

+24V

X0

X1

24G

XS0

XS1

Z10

Z00

Z20

Z11

Z01 Z21

24V
DC

S a f e t y r e l a y module

M E L S E C Q S 9 0 S R 2 S N-Q

STF

START

STOP

Emergency
stop button

G

PC

*1

Fuse

ASIC

Gate

Drive r

G

Gate

CPU

SD

U

V

W

M

STOP

COM0

COM1

Internal

Safety
Circuit

24V
DC

Drive r

CONFIGURATION

●FR-A800/F800 configuration example

Logic

S 1

K1

K 2

SIC

NOTE

CAUTION

 To prevent restart in case of recovering from input power loss of drive, 3-wired connection for

START/STOP control is recommended. In case of 2-wire connection and using latching type switch
to short between STF and SD/PC for starting, ensure the compliance with safety requirement for the
restarting when the drive recover from input power loss.

+24V

 If the control logic is SINK logic, the common terminal is terminal SD.

Fig.3 Safety system example with FR-A800/F800

• When starting up the system’s operation, press the RESET switch to reset the safety stop function first,

then turn ON the START switch to run the motor.

• In the above configuration, after reset of emergency stop button, drive will be in safe-state until RESET

switch is pressed.

EXAMPLE OF SAFETY SYSTEM CONFIGURATION

7

●Multiple inverter configuration example

NOTE

RESET

SO

SOC

R/L1 S/L2

T/L3

Logic

Emergency
stop button

24V
DC

COM0

X1

Internal

Safety

Circuit

COM1

X0

+24V

24G

S a f e t y r e l a y module

M E L S E C Q S 9 0 S R 2 S N-Q

XS0

K1

K 2

XS1

Z00

Z10

Z11

Z01 Z21

24V
DC

Z20

SO

SOC

SIC

SD

PC

S 2

S 1

CPU

ASIC

Gate

Drive r

G

Gate

Drive r

IGBTs

G

+24V

Fuse

FR-A800/F800

W

U

V

M

R/L1 S/L2

T/L3

Logic

CPU

ASIC

Gate

Drive r

Gate
Drive r

IGBTs

S 2

S 1

SIC

SD

PC

G

+24V

Fuse

FR-A800/F800

G

W

U

V

M

Fig.4 When using multiple safety stop function inverters (FR-A800/F800)

• Some models cannot be used together because their control logics are different. Refer to the SAFETY

STOP FUNCTION MANUAL of each model.

8

EXAMPLE OF SAFETY SYSTEM CONFIGURATION

●Safety controller configuration example

WS0-C PU0

24VDC

X1

X2

FLEXBUS+

FLEXBUS+

I8

I7

I6

I5

I4

24V 0V

WS0-X TIO

Q4

Q3

Q2

Q1

I1

I2
I3

WS0-CPU0

A1(24V)

A2(0V)

A2(0V)

Application

FLEXBUS+

FLEXBUS+

I8

I7

I6

I5

I4

24V 0V

WS0-XTIO

I1
I2

I3

A1(24V)

RESET

MITSUBISHI safety controller MELSEC-WS series
CPU module WS0-CPU0
Safety I/O combined module WS0-XTIO

Emergency
stop button

Application

R/L1 S/L2 T/L3

UV W

M

SO

SOC

S1

S2

G G

FR-A800/F800

SIC

SD

PC

Gate

Driver

Gate

Driver

IGBTs

Fuse

CPU

+24V

Logic

ASIC

Fig.5 Safety system example with FR-A800/F800

NOTE

• When starting up the system’s operation, press the RESET switch to reset the safety stop function first.

• In the above configuration, after reset of emergency stop button, drive will be in safe-state until RESET

switch is pressed.

EXAMPLE OF SAFETY SYSTEM CONFIGURATION

9

4 TEST AND CHECKING FAILURE

NOTE

Error definition 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

CPU fault

E.CPU

E.5 to E.7

Internal circuit fault E.13

Error definition Operation panel indication

CAUTION

 To avoid systematic faults, a test even for faulty demands of the safety function has to be performed

in order to check the correct function of the monitor signal. This test shall be carried out at system
installation, any software changes, parameterization changes, and/or at least once per year.

I/O status and failure

FR-A800/F800 safety related I/O status obeys the following truth table.

Table.5 Truth table of safety related signals

Input

power

Internal

safety
circuit
status

Input terminal , 

S1 S2 SO E.SAF  SA 

OFF OFF Output shutoff (Safe state)

Normal ON ON ON

Normal ON OFF OFF
Normal OFF ON OFF

ON

Normal OFF OFF ON

Fault ON ON OFF Output shutoff (Safe state) Displayed

Fault ON OFF OFF Output shutoff (Safe state) Displayed Displayed
Fault OFF ON OFF Output shutoff (Safe state) Displayed Displayed
Fault OFF OFF OFF Output shutoff (Safe state) Displayed Displayed

 ON: The transistor is conducted. OFF: The transistor is not conducted.
 When not using the safety stop function, short across terminals S1 and PC, S2 and PC, and SIC and SD to use the inverter.

(In the initial status, terminals S1 and PC, S2 and PC, and SIC and SD are respectively shorted with shorting wires.)

 If any of the protective functions shown in the following table is activated, the terminal SO turns OFF.

Output

terminal

Inverter running status

Operation panel

indication

Not
displayed

 Drive enabled

 Output shutoff (Safe state) Displayed Displayed
 Output shutoff (Safe state) Displayed Displayed

 Output shutoff (Safe state)

Not
displayed

Not
displayed

Not
displayed

Not
displayed

Displayed

Not
displayed



 If the internal safety circuit is operated normally, the terminal SO remains ON until E.SAF is displayed, and the terminal SO

turns OFF when E.SAF is displayed.

 SA is displayed when the terminals S1 and S2 are identified as OFF due to the internal safety circuit failure.
 If another fault occurs at the same time as E.SAF, the other fault can be displayed.
 If another warning occurs at the same time as SA, the other warning can be displayed.

• The response time from safety stop signal input to drive shutoff (safe state) is faster than 8ms.

• Hold the ON or OFF status for 2ms or longer to input signal to terminal S1 or S2.
Signal input shorter than 2ms is not recognized.

10

TEST AND CHECKING FAILURE

Diagnostic

If the failure detected, FR-A800/F800 output alarm signal and indicate ‘E.SAF’ at the display.

In case of FR-A800/F800 output the alarm, please take following action.

1) Check the S1-SIC and S2-SIC input signal logic is the same. If these are different logic, collect the input signal

and reset the FR-A800/F800.

2) Disconnect the wire from S1, S2, SIC terminal, then reset or power-off and on. If the ‘SA’ letter is flashed up at

display, there is failure in system except FR-A800/F800. But, still ‘E.SAF’ is displayed and alarm output, there

is malfunction on FR-A800/F800.

Self diagnostic test

FR-A800/F800 does the self-diagnostic test on the power-ON.

If FR-A800/F800 output alarm (SA, E.SAF) at power-up, please take the action described in ‘Diagnostic’ at

above.

Test procedure for functionality

As depicted ‘CAUTION’ in above, the test for the functionality is important.

Please do the test following procedure.

1) Please make each state of S1-SIC and S2-SIC depicted at Table.5.

2) If there is any different state from Table.5, FR-A800/F800 has some malfunction.

3) If there is no different state from Table.5, check the systematic performance, such as, press the emergency

switch, press the start/restart button at the failure detected (SO-SOC opened), and so on.

4) Finally clear the error record of the FR-A800/F800 (see the user manual how to clear the error record).

5 SAFETY PARAMETERS OF FR-A800/F800

The safety parameters of FR-A800/F800 are depicted as follows.

Table.6 Safety parameters of FR-A800/F800

Parameter Value

PFDAVG

PFHD

PL d

MTTF

D 670 years

AVG 60%

DC

5.16x10

5.89x10

-4

-9

SAFETY PARAMETERS OF FR-A800/F800

11

REVISIONS

Modification

Print Date Manual Number Revision

Apr. 2013 BCN-A23228-001(E) First edition

Jun. 2013 BCN-A23228-001-A(E)

Jul. 2014 BCN-A23228-001-B(E) Compatibility with the FR-F800 series

● Multiple inverter configuration example

12

BCN-A23228-001-B(E)

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RUS-109240 Moskow

Phone: +7 (0) 95 / 915-8624/02
Fax: +7 (0) 95 / 915-8603
e mall: ——

STC Drive Technique RUSSIA
Poslannikov per., 9, str. 1

RUS-107005 Moskow

Phone: +7 (0) 95 / 786 21 00
Fax: +7 (0) 95 / 786 21 01
e mall: ——

JV-CSC Automation UKRAINE
15, M. Raskovoyi St., Floor 10,
Office 1010

U-02002 Kiev

Phone: +380 (4) 4 / 238 83 16
Fax: +380 (4) 4 / 238 83 17
e-Mail: [e-mail]

MIDDLE EAST REPRESENTATIVE

SHERF Motion Techn. LTD ISRAEL
Rehov Hamerkava 19

IL-58851 Holon

Phone: +972 (0) 3 / 559 54 62
Fax: +972 (0) 3 / 556 01 82
e mall: ——

HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

BCN-A23228-001-B(E)(1407)MEE Printed in Japan Specifications subject to change without notice.