Mitsubishi Electric F800-E, 800, FR-F862-E, FR-F862-08500, FR-F862-05450 Instruction Manual

...

INVERTER F800-E

FR-F862-E (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE)

Inverter for fans and pumps

FR-F862-05450 to 08500-E

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-F862 (separated converter type) that are different from the FR-F860. Information about the software, such as basic operations and parameters, is described in the FR-F860 Instruction Manual (Detailed) in the CD-ROM enclosed with the product. For the details of Ethernet communication, refer to the Ethernet Function Manual in the enclosed CD-ROM. 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 remove 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, power lamp 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).

 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.

 A 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 models must be

between -10 and +50°C (non-freezing). The surrounding air temperature for SLD (initial setting) models 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 a PM motor to the commercial power supply.

Applying the commercial power supply to input terminals (U,V, W) of a 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 the STOP/RESET 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 a 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 a

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

 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 600V 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.  A PM motor must be used under PM motor control. Do not use a

synchronous motor, induction motor, or synchronous induction motor.

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

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

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

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

 In order to protect the inverter and the system against

unauthorized access by external systems via network, take security measures including firewall settings.

 Depending on the network environment, the inverter may not

operate as intended due to delays or disconnection in communication. Carefully consider the conditions and safety for the inverter on site.

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, the wiring must

be checked for fault (short circuit), and internalparts of the inverter 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.

Safety Instructions

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.

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 through a panel.........................................................................................................22

2.4 Terminal connection diagrams 24

2.5 Main circuit terminals 26

2.5.1 Details on the main circuit terminals of the inverter ........................................................................................26

2.5.2 Details on the main circuit terminals of the converter unit (FR-CC2-C)..........................................................26

2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor......................................27

2.5.4 Applicable cables and wiring length................................................................................................................28

2.5.5 Earthing (grounding) precautions ...................................................................................................................30

2.6 Control circuit 31

2.6.1 Details on the control circuit terminals of the inverter .....................................................................................31

2.6.2 Details on the control circuit terminals of the converter unit (FR-CC2-C).......................................................34

2.6.3 Control logic (sink/source) change .................................................................................................................35

2.6.4 Wiring of inverter control circuit ......................................................................................................................37

2.6.5 Wiring precautions ..........................................................................................................................................39

2.6.6 When using separate power supplies for the control circuit and the main circuit ...........................................40

2.6.7 When supplying 24 V external power to the control circuit .............................................................................41

2.7 Communication connectors and terminals 43

2.7.1 PU connector ..................................................................................................................................................43

2.7.2 Ethernet connector .........................................................................................................................................44

2.7.3 USB connector................................................................................................................................................45

2.8 Installing a communication option 46

3 PRECAUTIONS FOR USE OF THE INVERTER 47

3.1 Electro-magnetic interference (EMI) and leakage currents 48

3.1.1 Leakage currents and countermeasures ........................................................................................................48

CONTENTS

3.1.2 Countermeasures against inverter-generated EMI ........................................................................................49

3.2 Power supply harmonics 51

3.2.1 Power supply harmonics ................................................................................................................................51

3.3 Installation of a reactor 51

3.4 Power-OFF and magnetic contactor (MC) 52

3.5 Countermeasures against deterioration of the 600 V class motor insulation 53

3.6 Checklist before starting operation 54

3.7 Failsafe system which uses the inverter 57

4 PROTECTIVE FUNCTIONS 59

4.1 Inverter fault and alarm indications 60

4.2 Reset method for the protective functions 60

4.3 List of fault displays 61

5 PRECAUTIONS FOR

MAINTENANCE AND INSPECTION 63

5.1 Inspection item 64

5.1.1 Daily inspection .............................................................................................................................................. 64

5.1.2 Periodic inspection ......................................................................................................................................... 64

5.1.3 Daily and periodic inspection.......................................................................................................................... 65

5.1.4 Checking the inverter and converter modules................................................................................................ 66

5.1.5 Cleaning ......................................................................................................................................................... 67

5.1.6 Replacement of parts .....................................................................................................................................67

5.1.7 Inverter replacement ......................................................................................................................................69

5.2 Measurement of main circuit voltages, currents and powers 70

5.2.1 Measurement of powers ................................................................................................................................. 72

5.2.2 Measurement of voltages and use of PT........................................................................................................ 72

5.2.3 Measurement of currents ............................................................................................................................... 73

5.2.4 Use of CT and transducer .............................................................................................................................. 73

5.2.5 Example of measuring converter unit (FR-CC2-C) input power factor...........................................................73

5.2.6 Measurement of converter output voltage (across terminals P and N) ..........................................................73

5.2.7 Measurement of inverter output frequency..................................................................................................... 74

5.2.8 Insulation resistance test using megger ......................................................................................................... 74

5.2.9 Pressure test .................................................................................................................................................. 74

6 SPECIFICATIONS 75

6.1 Inverter rating 76

6.2 Common specifications 77

CONTENTS

6.3 Outline dimension drawings 79

6.3.1 Inverter outline dimension drawings ...............................................................................................................79

APPENDIX 81

Appendix 1 Comparison with FR-F860 ...................................................................................................... 82

Appendix 2 Instructions for UL and cUL ................................................................................................... 83

Appendix 3 Restricted Use of Hazardous Substances in Electronic and Electrical Products............. 84

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

Operation panel ................ LCD operation panel (FR-LU08)

Parameter unit .................. Parameter unit (FR-PU07)

PU..................................... Operation panel and parameter unit

Inverter.............................. Mitsubishi inverter FR-F800-E series (Separated converter type)

Ethernet board .................. Ethernet communication board (FR-A8ETH)

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

PU operation..................... Operation using the PU (operation panel/parameter unit)

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

Combined operation ......... Combined operation using the PU (operation panel/parameter unit) and External

operation

• Ethernet is a registered trademark of Fuji Xerox Co., Ltd.

• 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 35.)

INTRODUCTION

Product checking and accessories

1.1 Product checking and accessories

Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model agrees with the

order and the product is intact.

Applicable inverter model

Symbol Voltage class

600 V class

Symbol Structure, functionality

F R - F 8 6 2 -

Symbol

60 06

Rating plate

Inverter model

Country of origin

Circuit board coating

(conforming to IEC60721-3-3 3C2/3S2)

With With

Input rating

Output rating

SERIAL

Separated converter type

05450

Plated

conductor

Without

FR-F862-05450-E3-60

With

Symbol Description

05450 to 08500

inverter current (A)

- E3 - 60

SLD rated

Symbol

Communication

Type

CA3

type

Ethernet

How to read the SERIAL number

Rating plate example

   

Symbol Year Month Control number

SERIAL

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).

Accessory

• Earthing (grounding) cable (1): For connection with a communication option. (Refer to page 46.)

• CD-ROM (1): Including the FR-F860 Instruction Manual (Detailed) and other documents.

INTRODUCTION

1.2 Inverter component names

OFF

Component names are shown below.

(g)

(b)

(a)

(c)

(d)

(e)

(f)

(h)

(i)

(r)

(j)

Inverter component names

(q)

(m)

(o)

(k)

(n)

(l)

(p)

Symbol Name Description

(a) Plug-in option connector 1

(b) Plug-in option connector 3

(d) Voltage/current input switch (SW2) Selects between voltage and current for the terminal 2 and 4 inputs.

(e) (f) Control circuit terminal block Connects cables for the control circuit. 31

(g) PU connector

(h) USB A connector Connects a USB memory device. 45 (i) USB mini B connector Connects a personal computer. 45

(j) Front cover (upper side)

(k) Power lamp Stays ON while the power is supplied to the control circuit (R1/L11, S1/L21). 27 (l) Alarm lamp Turns ON when the protective function of the inverter is activated. 59 (m) Charge lamp Stays ON while the power is supplied to the main circuit. 27

(n) Accessory cover Remove this cover for using the PU connector.

(o) Front cover (lower side) Remove this cover for wiring. 15 (p) Main circuit terminal block Connects cables for the main circuit. 26 (q) Cooling fan Cools the inverter. 68

(r)

Ethernet communication connector

Switches for manufacturer setting (SW3 and SW4)

 Refer to the FR-F860 Instruction Manual (Detailed)

Connects a plug-in option or a communication option.

The connector 2 cannot be used because the Ethernet board is installed in the initial status. The Ethernet board must be removed to install a plug-in option to the connector 2. (However, Ethernet communication is disabled in that case.)

Connect the Ethernet dedicated cable for connection to the network. 44

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

Remove this cover for wiring to the control circuit terminals, installation of a plugin (communication) option, switching of the voltage/current input switch, etc.

Do not change the initial setting (OFF ).

Instruction Manual of the option

─

Refer to

page



INTRODUCTION

About the related manuals

1.3 About the related manuals

The manuals related to FR-F862-E are shown below.

Manual name Manual number

FR-F860 Instruction Manual (Detailed) IB-0600688ENG

Ethernet Function Manual IB-0600628ENG

FR-CC2-C (Converter unit) Instruction Manual IB-0600572ENG

PLC Function Programming Manual IB-0600492ENG

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 ...............................................................26

2.6 Control circuit ...........................................................................31

2.7 Communication connectors and terminals............................43

2.8 Installing a communication option..........................................46

INSTALLATION AND WIRING

Peripheral devices

NOTE

Earth

(Ground)

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

: Install these options as required.

UVW

Earth (Ground)

(d) Molded case

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

(i) Noise filter

(k) Contactor

Example) No-fuse switch (DSN type)

(l) PM motor

(g) Noise filter

(e) Magnetic

contactor (MC)

(a) Inverter

(FR-F862)

(b) Converter unit

(FR-CC2-C)

(h) USB connector

Personal computer

USB

USB host (A connector)

USB device (Mini B connector)

Communication status indicator (LED)(USB host)

Earth

(Ground)

(j) Induction

motor

(f) AC reactor

IM connection

PM connection

Earth

(Ground)

2.1 Peripheral devices

2.1.1 Inverter and peripheral devices

• 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. Refer to page 49 for countermeasures.

• 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-F862)

(b) Converter unit (FR-CC2-C)

Molded case circuit breaker (MCCB),

(d)

(e) Magnetic contactor (MC)

(f) AC reactor

(g) Noise filter

(h) USB connection

(i) Noise filter

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

(k)

(l) PM motor

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.

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 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.

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

—

INSTALLATION AND WIRING

Peripheral devices

NOTE

MCCB Converter unit

INV

2.1.2 Peripheral devices

Selecting the converter unit (FR-CC2-C)

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

Converter unit

FR-CC2-[ ]

C355K 05450

C400K 06470

C560K 08500

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

Model

FR-F862-[ ]

SLD 545 400

LD 496 355

SLD 647 450

LD 589 400

SLD 850 630

LD 773 560

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.

Motor

output

(kW)

400 FR-CC2-C355K FR-F862-05450 700 A 700 A 475 A 469 A

450 FR-CC2-C400K FR-F862-06470 900 A 800 A 592 A 589 A

630 FR-CC2-C560K FR-F862-08500 1200 A 1000 A 776 A 773 A

Applicable converter



model

Inverter

Rated current

Motor capacity

(A)

Applicable inverter

model

(kW)



Molded case circuit breaker (MCCB)

earth leakage circuit breaker (ELB)

(NF, NV type)

SLD LD SLD LD

Input-side

magnetic

contactor



 Assumes the use of a 4-pole standard motor with the power supply voltage of 575 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 that is suitable for branch circuit protection. (Refer to page 83.)

 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.

• 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

(a) (b)

Loosen

2.2 Removal and reinstallation of the front cover

Removal of the front cover (lower side)

(a) Remove the mounting screws to remove the front cover (lower side). (The number of the mounting screws differs by the

capacity.)

(b) With the front cover (lower side) removed, wiring of the main circuit terminals can be performed.

Removal of the front cover (upper side)

(a) (b)

Loosen

(c)

(a) With the front cover (lower side) removed, loosen the mounting screws on the front cover (upper side). These screws cannot be

removed.

(b) While holding the areas around the installation hooks on the sides of the front cover (upper side), pull out the front cover (upper

side) using its upper side as a support.

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

option can be performed.

INSTALLATION AND WIRING

Removal and reinstallation of the front cover

NOTE

(b) (c)

(a)

FastenFastenFasten

Reinstallation of the front covers

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

Securely install the front cover (upper side) to the inverter by fixing the hooks on the sides of the cover into place. (b) Tighten the mounting screw at the lower part of the front cover (upper side). (c) Fasten the front cover (lower side) with the mounting screws. (The number of the mounting screws differs by the capacity.)

• Fully make sure that the front covers are installed securely. Always tighten the mounting screws of the front covers.

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

Enclosure

Surrounding air temperature



LD -10 to +50°C (non-freezing)

SLD (initial setting) -10 to +40°C (non-freezing)

5 cm 5 cm

Measurement position

Inverter

Measurement position

5 cm

Surrounding air humidity 95% RH or less (non-condensing)

Storage temperature -20 to + 65°C

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

Altitude Maximum 1,000 m

Vibration

 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.  Surrounding Air Temperature is a temperature measured at a measurement position in an enclosure.

Ambient Temperature is a temperature outside an enclosure.

2.9 m/s





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

Temperatur e

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

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.

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

Humidity

Operate the inverter within the ambient air humidity of usually 45 to 95%. 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%.

(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.

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

INV

Heatsink

INV

Heat pipe

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.

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.)

Natural cooling

Forced cooling

Cooling system Enclosure structure Comment

Natural ventilation (enclosed ventilated type)

Natural ventilation (totally enclosed type)

Heatsink cooling

Forced ventilation

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.

Heat pipe This is a totally enclosed for enclosure downsizing.

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

VerticalVerticalVertical

Allow clearance.

Clearances (side)Clearances (front)

Inverter

5 cm or more

∗1

10 cm or more

10 cm

or more

20 cm or more

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.

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.

 For replacing the cooling fan, 30 cm or more of space is necessary in front of the inverter. Refer to page 6 8 for fan replacement.

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

660

Hole

240 240

6-M10 screw

15152015

1550

2.3.4 Protruding the heatsink through a panel

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-F862-05450

1300

1515 1270

200

520

Hole

200

6-M10 screw

(Unit: mm)

FR-F862-06470

FR-F862-08500

(Unit: mm)

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

Upper installation frame (rear side)

Lower installation frame (rear side)

185 mm

Exhausted air

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.

140 mm

6 mm

Inverter

Inside the enclosure

Enclosure

Installation frame

Dimension of the outside of the enclosure

Cooling

wind

Enclosure

Finger guard

10 mm

∗1

 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.

NOTE

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

oil, mist, dust, etc.

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

INSTALLATION AND WIRING

Terminal connection diagrams

2.4 Terminal connection diagrams

Sink logic

Main circuit terminal

Control circuit terminal

Converter unit

RUN

IPF

F/C

(CA)

So (SO)

SOC

R/L1

P/+

S/L2

N/-

T/L3

RDI

RES

+24

RDB

RDA

RSO

IPF

FAN

Jumper



Earth

(Ground)

Control input signals (No voltage input allowed) 

Forward rotation start

Reverse rotation start

Start self-holding selection

High speed

Multi-speed selection

Second function selection

Terminal 4 input selection

Contact input common

(Common for external power supply transistor)

Frequency setting signals (Analog)

Frequency setting potentiometer 1/2W1kΩ

Connector for plug-in option connection

For manufacturer

Middle speed

Low speed

Jog operation

Output stop

Reset

24VDC power supply

24V external power

supply input

Common terminal



Terminal 4 input (Current input)

Auxiliary input



(+) (-)

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

SIC

SINK

SOURCE

24V

Voltage/current



input switch

OFF

Initial value

selectable

Initial value

selectable





PU connector

USB A connector

USB mini B connector

Ethernet

connector



Relay output 

Relay output 1 (Fault output)

Relay output 2

Running

Up to frequency



Overload

Frequency detection

Open collector output common

Sink/source common

Open collector output 

(+)

Analog current output (0 to 20mADC)

(-)

(+)

Analog signal output (0 to ±10VDC)

(-)

Motor

Earth (Ground)

INSTALLATION AND WIRING

Terminal connection diagrams

Inverter

Converter unit

(FR-CC2-C)

R1/L11 S1/L21

R/L1

S/L2

T/L3

Power supply

MCCB

R1/L11 S1/L21

P/+P/+ N/-

N/-

X11

RES

IPF

RSO

MRS(X10)



RDA







RDB

 Terminals R1/L11 and S1/L21 are connected to 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.

 No function is assigned in the initial setting. Use Pr.186 for function assignment.  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 option connector 2 cannot be used because the Ethernet board is installed in the initial status. The Ethernet board must be removed to

install a plug-in option to the option connector 2. (However, Ethernet communication is disabled in that case.)

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.

• Terminals S1, S2, SIC, So (SO), and SOC are for manufacturer setting. Do not remove the shorting wires across terminals S1

and PC, terminals S2 and PC, and terminals SIC and SD. When the shorting wires are removed, the inverter does not

operate.

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

For the cable gauge of the cable across the main circuit terminals P/+ and N/- (P and P, N and N), refer to page 28.

 Do not install an MCCB across 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 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 terminal RDA of the converter unit and terminal MRS (X10) of the inverter, and terminal SE of the converter unit and terminal SD

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

Across terminals P and P and terminals N and N 50 m or less

Other control signal cables 30 m or less

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 Connect the converter unit (FR-CC2-C). 24

Terminal name Terminal function description

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

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

output, or to use the converter unit (FR-CC2-C), remove the jumpers installed Power supply for the control circuit

Earth (ground)

in terminals R1/L11 and S1/L21, and apply external power supply to these

terminals.

When using a separate power supply from R1/L11 and S1/L21, the

necessary power capacity of the separate power supply is 80 VA.

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-C)

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.

When using a separate power supply from R1/L11 and S1/L21, the

necessary power capacity of the separate power supply is 80 VA.

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

(grounded).

Refer

to page

Refer

to page

INSTALLATION AND WIRING

+ 63 hidden pages

Mitsubishi Electric F800-E, 800, FR-F862-E, FR-F862-08500, FR-F862-05450 Instruction 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 through a panel

2.4 Terminal connection diagrams

2.5 Main circuit terminals