Mitsubishi Electric A800 Plus, FR-A842-10940, FR-A842-09620, FR-A802-R2R, FR-A842-12120 Instruction Manual

...

INVERTER

FR-A802-R2R (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE)

Roll to Roll Function

FR-A842-07700(315K) to 12120(500K)-R2R

INTRODUCTION

INSTALLATION AND WIRING

PRECAUTIONS FOR USE OF

THE INVERTER

PROTECTIVE FUNCTIONS

PRECAUTIONS FOR

MAINTENANCE AND

INSPECTION

SPECIFICATIONS

Thank you for choosing this Mitsubishi Electric 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-A800. 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. For details of Ethernet communication, refer to the FR-A800-E-R2R Ethernet Function Manual on the enclosed CD-ROM. In addition to this manual, please read the manuals on the enclosed CD-ROM carefully. Do not use this product until you have 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 this product until you have read through this Instruction Manual and supplementary 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, 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.

Note that even the level may even lead

to a serious consequence depending on conditions. Be sure to follow the instructions of both levels as they are critical to personal safety.

 Electric shock prevention

WARNING

 Do not remove the front cover or the wiring cover of the inverter

while the inverter power is ON. Do not operate this product with any cover or wiring cover removed, as accidental contact with exposed high-voltage terminals and internal components may occur, resulting in an electrical shock.

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

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

 Before wiring or inspection, check that the display of the inverter

operation panel is OFF. Any person who is involved in wiring or inspection shall wait for 10 minutes or longer after the power supply has been cut 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 product must be earthed (grounded). Earthing (grounding)

must conform to the requirements of national and local safety regulations and electrical code (NEC section 250, IEC 61140 class 1 and other applicable standards). A neutral-point earthed (grounded) power supply must be used for 400 V class of this product to be compliant with EN standard.

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

shall be fully competent to do the work.

 This product 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. Doing so may cause an electric shock.

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

loads or pinching. Doing so may cause an electric shock.

 Do not change the cooling fan while power is ON as it is

dangerous.

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

wet hands. Doing so may cause an electric shock.

 Fire prevention

CAUTION

 The product must be installed on a nonflammable wall without

any through holes so that nobody touches the heat sink, etc. on the rear side of the product. Installing it on or near flammable material may cause a fire.

 If this product has become faulty, the product 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 this product as it will be extremely hot. Doing so may cause a burn.

 Additional instructions The following instructions must be also followed. If this product is handled incorrectly, it may cause unexpected fault,

an injury, or an electric shock.

CAUTION

Transportation and installation

 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.

 This 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 this product.  Do not stack the boxes containing this product higher than the

number recommended.

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

may fall off or fail.

 During installation, caution must be taken not to drop this

product as doing so may cause injuries.

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

weight of the product.

 Do not install this product on a hot surface.  The installation orientation of this product must be correct.  This product must be installed on a strong surface securely with

screws so that it will not drop.

 Do not install or operate this product if it is damaged or has parts

missing.

 Foreign conductive objects must be prevented from entering this

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

 As this product is a precision instrument, do not drop or subject it

to impact.

 The surrounding air temperature for LD, SND, ND (initial

setting), and HD models must be between -10 and +50°C (nonfreezing). The surrounding air temperature for SLD must be between -10 and +40°C (non-freezing). Otherwise this product may be damaged.

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

condensing). Otherwise this product may be damaged. (Refer to

page 20 for details.)

Safety instructions

CAUTION

Transportation and installation

 The temporary storage temperature (applicable to a short limited

time such as a transportation time) must be between -20 and +65°C. Otherwise this product may be damaged.

 This product must be used indoors (without corrosive gas,

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

 Do not use this product at an altitude above 2500 m. Vibration

should not exceed 2.9 m/s2 at 10 to 55 Hz in X, Y, and Z directions. Otherwise the product may be damaged. (For installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude.) (Refer to

page 20 for details.)

 If halogens (including fluorine, chlorine, bromine, and iodine)

contained in fumigants for wood packages enter this product, the product may be damaged. Prevent the entry of fumigant residuals or use an alternative method such as heat disinfection. Note that sterilization or disinfection of wood packages should be performed before packing the product.

Wiring

 Do not install a power factor correction capacitor, surge

absorber, or radio noise filter on the output side of this product. These devices may overheat or burn out.

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

to a motor correctly. Otherwise the motor will rotate inversely.

Trial run

 Before starting the test operation, confirm or adjust the

parameter settings. Failure to do so may cause some machines to make unexpected motions.

WARNING

Usage

 Stay away from the equipment after using the retry function in

this product as the equipment will restart suddenly after the output shutoff of this product.

 Depending on the function settings of this product, the product

does not stop its output even when the STOP/RESET key on the operation panel is pressed. To prepare for it, provide a separate circuit and switch (to turn OFF the power of this product, or apply a mechanical brake, etc.) for an emergency stop.

 Be sure to turn OFF the start (STF/STR) signal before clearing

the fault as this product will restart the motor suddenly after a fault is cleared.

 Use only a three-phase induction motor as a load on this

product. Connection of any other electrical equipment to the output of this product 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. This product with the start command ON may also rotate the motor at a low speed when the speed limit value is set to zero. Confirm that the motor running will not cause any safety problems before performing pre-excitation.

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

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

CAUTION

Usage

 The electronic thermal O/L relay function may not be enough for

protection of the motor from overheating. It is recommended to install an external thermal relay or a PTC thermistor for overheat protection.

 Do not repeatedly start or stop this product with a magnetic

contactor on its input side. Doing so may shorten the life of this product.

 Use a noise filter or other means to minimize the

electromagnetic interference with other electronic equipment used nearby this product.

 Appropriate precautions must be taken to suppress harmonics.

Otherwise power harmonics from this product may heat/damage a power factor correction capacitor or a generator.

 To drive a 400 V class motor with this product, use an insulation-

enhanced motor, or take measures to suppress surge voltage. Otherwise surge voltage, which is attributed to the length and thickness of wire, may occur at the motor terminals, causing the motor insulation to deteriorate.

 As all parameters return to their initial values after the Parameter

clear or All parameter clear is performed, the parameters must be set again as required before the operation is started.

 This product can be easily set for high-speed operation.

Therefore, consider all things related to the operation such as the performance of a motor and equipment in a system before the setting change.

 This product's brake function cannot be used as a mechanical

brake. Use a separate device instead.

 Perform an inspection and test operation of this product if it has

been stored for a long period of time.

 To avoid damage to this product due to static electricity, static

electricity in your body must be discharged before you touch this product.

 In order to protect this product and the system against

unauthorized access from external sources through Ethernet communication, take security measures such as setting up a firewall.

 Depending on the Ethernet network environment, this product

may not operate as intended due to delays or disconnection in communication. Carefully consider what type of environment this product will be used in and any safety issues related to its use.

Emergency stop

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

for devices or equipment in a system to prevent hazardous conditions in case of failure of this product or an external device controlling this product.

 If the breaker installed on the input side of this product trips,

check for wiring faults (short circuits etc.) and damage to internal parts of this product. Identify and remove the cause of the trip before resetting the tripped breaker and applying the power to the product again.

 When any protective function is activated, take an appropriate

corrective action before resetting this product to resume the operation.

Maintenance, inspection and parts replacement

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

control circuit of this product. Doing so will cause a failure.

Disposal

 This product must be treated as industrial waste.

Safety instructions

Application of caution labels

Stay away from the motor and machine. They will start suddenly (after reset time has elapsed) when instantaneous power failure occurs.

CAUTION

Automatic Restart after Instantaneous Power Failure Has Been Selected

Caution labels are used to ensure safety during use of Mitsubishi Electric inverters. Apply the following labels to the inverter if the "retry function" and/or "automatic restart after instantaneous power failure" have been enabled.

 For the retry function

CAUTION

Retry Function Has Been Selected

Stay away from the motor and machine. They will start suddenly (after given time has elapsed) when alarm occurs.

 For automatic restart after instantaneous power failure

General instruction

 For clarity, illustrations in this Instruction Manual may be drawn

with covers or safety guards removed. Ensure all covers and safety guards are properly installed prior to starting operation.

Safety instructions

1 INTRODUCTION 7

1.1 Product checking and accessories 8

1.2 Inverter component names 10

1.3 About the related manuals 12

2 INSTALLATION AND WIRING 13

2.1 Peripheral devices 14

2.1.1 Inverter and peripheral devices......................................................................................................................14

2.1.2 Peripheral devices .......................................................................................................................................... 16

2.2 Removal and reinstallation of the front cover 18

2.3 Installation of the inverter and enclosure design 20

2.3.1 Inverter installation environment ....................................................................................................................20

2.3.2 Cooling system types for inverter enclosure ..................................................................................................22

2.3.3 Inverter installation .........................................................................................................................................23

2.3.4 Protruding the heat sink through a panel .......................................................................................................25

2.4 Terminal connection diagrams 27

2.5 Main circuit terminals 36

2.5.1 Details on the main circuit terminals of the inverter........................................................................................ 36

2.5.2 Details on the main circuit terminals of the converter unit (FR-CC2) ............................................................. 36

2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor ..................................... 37

2.5.4 Applicable cables and wiring length ...............................................................................................................38

2.5.5 Earthing (grounding) precautions...................................................................................................................40

2.6 Control circuit 41

2.6.1 Details on the control circuit terminals of the inverter..................................................................................... 41

2.6.2 Details on the control circuit terminals of the converter unit (FR-CC2) .......................................................... 45

2.6.3 Control logic (sink/source) change ................................................................................................................. 46

2.6.4 Wiring of inverter control circuit ......................................................................................................................48

2.6.5 Wiring precautions..........................................................................................................................................50

2.6.6 When using separate power supplies for the control circuit and the main circuit...........................................51

2.6.7 When supplying 24 V external power to the control circuit............................................................................. 52

2.6.8 Safety stop function ........................................................................................................................................ 54

2.7 Communication connectors and terminals 56

2.7.1 PU connector.................................................................................................................................................. 56

2.7.2 USB connector ............................................................................................................................................... 57

2.7.3 RS-485 terminal block (RS-485 model).......................................................................................................... 58

2.7.4 Ethernet port (Ethernet model)....................................................................................................................... 59

2.8 Connection of motor with encoder (vector control) 60

2.9 Parameter settings for a motor with encoder 65

2.10 Connection of stand-alone option units 66

2.10.1 Connection of the brake unit (FR-BU2) .......................................................................................................... 66

2.10.2 Connection of the high power factor converter (FR-HC2) ..............................................................................67

2.10.3 Connection of the power regeneration converter (MT-RC) ............................................................................ 68

CONTENTS

2.11 Installing a communication option 69

3 PRECAUTIONS FOR USE OF THE INVERTER 71

3.1 Electro-magnetic interference (EMI) and leakage currents 72

3.1.1 Leakage currents and countermeasures ........................................................................................................72

3.1.2 Precautions against inverter-generated EMI ..................................................................................................75

3.1.3 Converter unit (FR-CC2) built-in EMC filter ....................................................................................................78

3.2 Power supply harmonics 79

3.2.1 Power supply harmonics.................................................................................................................................79

3.2.2 Harmonic Suppression Guidelines in Japan...................................................................................................80

3.3 Installation of a reactor 82

3.4 Power-OFF and magnetic contactor (MC) 83

3.5 Countermeasures against deterioration of the 400 V class motor insulation 84

3.6 Checklist before starting operation 85

3.7 Failsafe system which uses the inverter 88

4 PROTECTIVE FUNCTIONS 91

4.1 Inverter fault and indications 92

4.2 Reset method for the protective functions 92

4.3 Check and clear of the fault history 93

4.4 List of fault displays 95

5 PRECAUTIONS FOR

MAINTENANCE AND INSPECTION 97

5.1 Inspection item 98

5.1.1 Daily inspection...............................................................................................................................................98

5.1.2 Periodic inspection..........................................................................................................................................98

5.1.3 Daily and periodic inspection ..........................................................................................................................99

5.1.4 Checking the inverter and converter semiconductor devices .......................................................................100

5.1.5 Cleaning........................................................................................................................................................101

5.1.6 Replacement of parts....................................................................................................................................101

5.1.7 Removal and reinstallation of the control circuit terminal block ....................................................................104

5.2 Measurement of main circuit voltages, currents and powers 105

5.2.1 Measurement of powers ...............................................................................................................................107

5.2.2 Measurement of voltages .............................................................................................................................107

5.2.3 Measurement of currents ..............................................................................................................................107

5.2.4 Example of measuring converter unit (FR-CC2) input power factor.............................................................107

5.2.5 Measurement of converter output voltage (across terminals P and N).........................................................107

CONTENTS

5.2.6 Measurement of inverter output frequency................................................................................................... 108

5.2.7 Insulation resistance test using megger ....................................................................................................... 108

5.2.8 Pressure test ................................................................................................................................................ 108

6 SPECIFICATIONS 109

6.1 Inverter rating 110

6.2 Common specifications 111

6.3 Outline dimension drawings 113

6.3.1 Inverter outline dimension drawings............................................................................................................. 113

APPENDIX 115

Appendix 1 Comparison with FR-A840-R2R............................................................................................ 116

Appendix 2 Instructions for compliance with the EU Directives........................................................... 117

Appendix 3 Instructions for UL and cUL ................................................................................................. 120

Appendix 4 Instructions for EAC.............................................................................................................. 122

Appendix 5 Restricted Use of Hazardous Substances in Electronic and Electrical Products ........... 123

Appendix 6 Referenced Standard (Requirement of Chinese standardized law).................................. 123

CONTENTS

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 ......................................................10

1.3 About the related manuals.......................................................12

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

Operation panel ..............................Operation panel and LCD operation panel

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

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

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

FR-A800-E......................................Mitsubishi Electric inverter FR-A800 series (Ethernet model)

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

Vector control compatible option..... FR-A8AP/FR-A8AL/FR-A8APR/FR-A8APS (plug-in option), FR-A8TP

(control terminal option)

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 Corporation in Japan.

• Other company and product names herein are the trademarks and registered trademarks of their respective

owners.

• 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 46.)

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 80.

INTRODUCTION

Product checking and accessories

NOTE

Rating plate

Input rating

Output rating

SERIAL

Inverter model

,1387;;;;;

02'(/)5$55

287387;;;;;

6(5,$/;;;;;;;;;

0$'(,1;;;;;

F R - A 8 4 2 -

07700

- 1 -

400 V class

Symbol Voltage class

Symbol

Circuit board coating

(conforming to IEC 60721-3-3 3C2/3S2)

WithoutNone

With

Plated

conductor

Without

With

Without

Structure, functionalitySymbol

Separated converter type

Symbol Function

Roll to roll dedicated model

R2R

Symbol Type

∗1

FM CA

E1 E2

Communication

RS-485

Ethernet

Country of origin

Symbol Description

315K

to 500K

07700

to 12120

Inverter ND

rated capacity (kW)

Inverter SLD

rated current (A)

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

∗1 Specification differs by the type as follows.

Typ e Monitor output

FM (terminal FM equipped model)

CA (terminal CA equipped model)

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

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

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))

Built-in

EMC filter

OFF Sink logic 60 Hz

ON Source logic 50 Hz

Control logic

Initial setting

frequency

Rated

Pr.19 Base frequency

voltage

9999 (same as the power supply voltage)

8888 (95% of the power supply voltage)

INTRODUCTION

Product checking and accessories

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.(Ethernet model) (Refer to page 69.)

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

INTRODUCTION

Inverter component names

OFF

1.2 Inverter component names

Component names are shown below.

RS-485 model

(a)

(d)

(b)

(c)

(e)

(f)

(g)

(h)

(i)

(r)

(j)

(k)

(l)

(q)

(n)

(o)

(m)

(p)

Symbol Name Description

(a) RS-485 terminals Enables RS-485 and MODBUS RTU communication. 58 (b) Plug-in option connector 1 (c) Plug-in option connector 2 (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. 41

(g) PU connector

(h) USB A connector Connects a USB memory device. 57

(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). 37 (l) Alarm lamp Turns ON when the protective function of the inverter is activated. 91 (m) Charge lamp Stays ON while the power is supplied to the main circuit. 37 (n) Operation panel (FR-DU08) Operates and monitors the inverter. (o) Terminal block cover Remove this cover for wiring. 18 (p) Main circuit terminal block Connects cables for the main circuit. 36 (q) Cooling fan Cools the inverter. 102

(r)

Switches for manufacturer setting (SW3 and SW4)

∗1 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 Configurator 2. 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.

Do not change the initial setting (OFF ).

Instruction Manual of the option

∗1

─

Refer to

page

INTRODUCTION

Ethernet model

(g)

(f)

(d)

(e)

(b)

(a)

(c)

(h)

(i)

(r)

(p)

(k)

(m)

(n)

(l)

(j)

(o)

(q)

OFF

Inverter component names

Symbol Name Description

(a) Plug-in option connector 1

(b) Plug-in option connector 3

(d)

(e)

(f) Control circuit terminal block Connects cables for the control circuit. 41

(g) PU connector

(h) USB A connector Connects a USB memory device. 57 (i) USB mini B connector Connects a personal computer and enables communication with FR Configurator2. 57

(j) Upper front cover

(k) Power lamp Stays ON while the power is supplied to the control circuit (R1/L11, S1/L21). 37 (l) Alarm lamp Turns ON when the protective function of the inverter is activated. 37 (m) Charge lamp Stays ON while the power is supplied to the main circuit. 37 (n) Operation panel (FR-DU08) Operates and monitors the inverter. (o) Lower front cover Remove this cover for wiring. 18 (p) Main circuit terminal block Connects cables for the main circuit. 36 (q) Cooling fan Cools the inverter. 102

(r)

Voltage/current input switch (SW2) Ethernet communication connector

Switches for manufacturer setting (SW3 and SW4)

∗1 Refer to the FR-A800 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.)

Selects between voltage and current for the terminal 2 and 4 inputs.

Connect the Ethernet dedicated cable for connection to the network. 59

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

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.

Do not change the initial setting (OFF ).

Refer to

page

Instruction Manual of the option

∗1

─

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

Roll to Roll Function Manual IB-0600622ENG

FR-A800-E-R2R Ethernet Function Manual IB-0600813ENG

FR-CC2 Instruction Manual IB-0600543ENG

FR Configurator2 Instruction Manual IB-0600516ENG

FR-A800 PLC Function Programming Manual IB-0600492ENG

FR-A800 Safety stop function instruction manual BCN-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 ....................................................................14

2.2 Removal and reinstallation of the front cover........................18

2.3 Installation of the inverter and enclosure design ..................20

2.4 Terminal connection diagrams ................................................27

2.5 Main circuit terminals...............................................................36

2.6 Control circuit ...........................................................................41

2.7 Communication connectors and terminals ............................56

2.8 Connection of motor with encoder (vector control) ..............60

2.9 Parameter settings for a motor with encoder ........................65

2.10 Connection of stand-alone option units .................................66

2.11 Installing a communication option..........................................69

INSTALLATION AND WIRING

Peripheral devices

NOTE

Earth

(Ground)

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

P/+

: Install these options as required.

UVW

(d) Moulded case

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

(l) Noise filter

(g) Noise filter

(h) High power factor converter

(FR-HC2)

(j) Resistor unit

(MT-BR5)

(i) Brake unit

(FR-BU2)

(e) Magnetic

contactor (MC)

(a) Inverter

(FR-A802)

(b) Converter unit

(FR-CC2)

(k) USB connector

Personal computer (FR Configurator 2)

USB

USB host (A connector)

USB device (Mini B connector)

Communication status indicator (LED)(USB host)

Earth

(Ground)

(m) Induction

motor

(f) AC reactor

(FR-HAL)

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. In this case, activating the EMC filter of the converter unit may minimize interference. (Refer to page 78.)

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

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. —

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

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.

Refer

to page

20 27 78

110

INSTALLATION AND WIRING

Peripheral devices

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)

280H315---------

315 H315K - - - - - - - - -

355 H355K - - - 315K 07700 683 315K 07700 683

400 H400K 315K 07700 770 355K 08660 770 355K 08660 770

450 H450K 355K 08660 866 400K 09620 866 400K 09620 866

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

560 H560K 450K 10940 1094 500K 12120 1094 500K 12120 1094

630 H630K 500K 12120 1212 - - - - - -

Motor

capacity

(kW)

280 H315 - - - 315K 07700 547

315 H315K 315K 07700 610 355K 08660 610

355 H355K 355K 08660 683 400K 09620 683

400 H400K 400K 09620 770 450K 10940 770

450 H450K 450K 10940 866 500K 12120 866

500 H500K 500K 12120 962 - - -

560 H560K - - - - - -

630 H630K - - - - - -

Converter

unit

FR-CC2-[ ]

∗1

Converter

unit

FR-CC2-[ ]

∗1

∗1 The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric 4-pole standard motor.

SLD (superlight duty) LD (light duty) SND (super normal duty)

Model

FR-A842-[ ]

ND (normal duty, initial value) HD (heavy duty)

Model

FR-A842-[ ]

Rated

current

(A)

Inverter

Rated

current

(A)

Model

FR-A842-[ ]

Model

FR-A842-[ ]

Rated

current

(A)

Rated

current

(A)

Model

FR-A842-[ ]

Rated

current

(A)

INSTALLATION AND WIRING

Peripheral devices

MCCB Converter unit

INV

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)

∗1

315 FR-CC2-H315K 700 A S-N600

355 FR-CC2-H355K 800 A S-N600

400 FR-CC2-H400K 900 A S-N800

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

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

560 FR-CC2-H560K 1500 A 1200 A rated product

630 FR-CC2-H630K 2000 A 1400 A rated product

∗1 Assumes the use of a Mitsubishi Electric 4-pole standard motor with the power supply voltage

of 400 VAC 50 Hz.

∗2 Select an MCCB according to the power supply capacity.

Install one MCCB per converter. (For the use in the United States or Canada, refer to page 120 to select an appropriate fuse.)

∗3 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 JEM 1038-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 JEM 1038-AC-3 class rated current.

Applicable

converter model

Molded case circuit breaker (MCCB) ∗2 or

earth leakage circuit breaker (ELB) (NF, NV type)

Input-side magnetic

contactor

∗3

NOTE

• The above shows a selection example for the ND rating. For selecting the SLD rating, LD rating, SND rating, or HD rating,

refer to the Technical News (MF-X-130) contained in the enclosed CD-ROM.

• 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)

• Press the upper edge of the operation panel while pulling

out the operation panel.

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, the main circuit terminals can be wired.

INSTALLATION AND WIRING

Removal of the front cover

Loosen

Tighten

Removal and reinstallation of the front cover

(a) (b)

Loosen

(a) With the terminal block cover removed, loosen the 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, the control circuit and the RS-485 terminals can be wired, and the plug-in option can be installed.

(c)

Reinstallation of the front cover and the terminal block cover

(a)

(a) Clip on the front cover as illustrated.

Check that it is properly secured.

(b) Tighten the screws on the lower part of the front cover. (c) Attach the terminal block cover using the screws. (The number of screws differs depending on the capacity of the inverter.)

(b) (c)

Tighten

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

Measurement position

Inverter

5 cm

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 2500 m

Vibration

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

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)

∗1

∗2

2.9 m/s

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

∗1 Temperature applicable for a short time, e.g. in transit. ∗2 For the installation at an altitude above 1000 m, derate the rated current 3% per 500 m.

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 22.)

• 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 JEM 1103 "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 22.)

• 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 2500 m. For use at an altitude above 1000 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.

Precautions

• 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

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 heat sink (aluminum fin, etc.)

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

Cooling system Enclosure structure Comment

Natural

Forced air

Natural ventilation (enclosed type / open type)

Natural ventilation (totally enclosed type)

Heat sink cooling

Forced ventilation

Heat pipe This is a totally enclosed for enclosure downsizing.

Heat sink

INV

Heat pipe

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 heat sink 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

2.3.3 Inverter installation

Vertical

Inverter placement

Installation of the inverter and enclosure design

• 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.

• When designing or building an enclosure for the inverter, carefully consider influencing factors such as heat generation of

the contained devices and the operating environment.

Clearances (side)Clearances (front)

20 cm or more

5 cm or more

∗1

Inverter

Vertical

10 cm

or more

10 cm or more

Allow clearance.

∗1 There needs to be a space of at least 30 cm in front of the inverter to replace the cooling fan. Refer to page 102 for fan replacement.

20 cm or more

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

Encasing multiple inverters and converter units

When multiple inverters and converter units are placed in the

same enclosure, arrange them horizontally as shown in the

figure on the right.

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

Inverter Inverter

Converter

Enclosure

unit

Inverter

Arrangement of the ventilation fan and inverter

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

2.3.4 Protruding the heat sink through a panel

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

heat sink of the inverter.

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

(Unit: mm)

FR-A842-09620(400K)

FR-A842-10940(450K)

FR-A842-12120(500K)

15152015

1550

660

240 240

Hole

6-M10 screw

(Unit: mm)

INSTALLATION AND WIRING

Installation of the inverter and enclosure design

NOTE

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.

Upper installation frame (rear side)

Lower installation frame (rear side)

 Installation of the inverter

Push the inverter heat sink portion outside the enclosure and fix the enclosure and inverter with upper and lower

installation frame.

• 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

R1/L11 S1/L21

Frequency setting signals (Analog)

10E(+10V)

10(+5V)

(Analog common)

Auxiliary input

Terminal 4 input (Current input)

Frequency setting potentiometer 1/2W1kΩ

Running

Up to frequency

Overload

Frequency detection

Open collector output common

Sink/source common

F/C

(FM)

Motor

Relay output 1 (Fault output)

U V

Indicator (Frequency meter, etc.)

(-)

(+)

Analog signal output (0 to ±10VDC)

Earth

(Ground)

0 to ±5VDC selectable

0 to ±10VDC

Open collector output ∗8

Moving-coil type 1mA full-scale

Calibration resistor

∗11

Main circuit terminal

Control circuit terminal

0 to 5VDC

0 to 10VDC

Relay output 2

Relay output ∗7

0 to 20mADC

0 to 5VDC 0 to 10VDC

selectable

4 to 20mADC

TXD+

TXD-

RXD+

RXD-

GND

(SG)

Data transmission

GND

RS-485 terminals

SINK

SOURCE

∗3

∗5

∗10

∗5

Connector for plug-in option connection

STF

STR

STP(STOP)

JOG

MRS

X10

RES

RUN

IPF

Data reception

(+) (-)

VCC

(+) (-)

Sink logic

∗6

Earth (Ground)

N/-

P/+

Initial value

OFF

Safety stop signal

Safety monitor output

Safety monitor output common

So (SO)

SOC

Safety stop input (Channel 1)

Shorting wire

Safety stop input common

Safety stop input (Channel 2)

SIC

+24

Brake unit (Option)

Jumper

∗1

(Permissible load current 100mA)

connector 1 connector 2

connector 3

24V external power

supply input

Common terminal

24VDC power supply

(Common for external power supply transistor)

Forward rotation start

Reverse rotation start

Start self-holding selection

Middle speed

High speed

Low speed

Jog operation

Second function selection

Reset

Terminal 4 input selection

Selection of automatic restart

after instantaneous power failure

Control input signals (No voltage input allowed) ∗2

Multi-speed selection

Contact input common

Main circuit

Control circuit

PU connector

USB A connector

USB mini B connector

Voltage/current input switch

selectable

Terminating

resistor

Initial value

Output stop

RDA

RDI

Converter unit

RSO

N/-

P/+

IPF

RDB

FAN

R/L1 S/L2 T/L3

RES

+24

∗4

∗9

24V

Output shutoff circuit

Terminal connection diagrams

2.4 Terminal connection diagrams

FM type (RS-485 model)

INSTALLATION AND WIRING

Terminal connection diagrams

NOTE

∗1 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.

∗2 The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). ∗3 Terminal JOG is also used as the pulse train input terminal. Use Pr.291 to choose JOG or pulse. ∗4 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.

∗5 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)

∗6 It is recommended to use 2 W 1 kΩ when the frequency setting signal is changed frequently. ∗7 The function of these terminals can be changed with the output terminal assignment (Pr.195, Pr.196). ∗8 The function of these terminals can be changed with the output terminal assignment (Pr.190 to Pr.194). ∗9 No function is assigned in the initial setting. Use Pr.192 for function assignment. ∗10 The terminal FM can be used to output pulse trains as open collector output by setting Pr.291. ∗11 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

R1/L11 S1/L21

Frequency setting signals (Analog)

10E(+10V)

10(+5V)

(Analog common)

Auxiliary input

Terminal 4 input (Current input)

Frequency setting potentiometer 1/2W1kΩ

Running

Up to frequency

Overload

Frequency detection

Open collector output common

Sink/source common

Motor

Relay output 1 (Fault output)

U V

Earth

(Ground)

0 to ±5VDC selectable

0 to ±10VDC

Open collector output ∗8

Main circuit terminal

Control circuit terminal

0 to 5VDC

0 to 10VDC

Relay output 2

Relay output ∗7

0 to 20mADC

0 to 5VDC 0 to 10VDC

selectable

4 to 20mADC

TXD+

TXD-

RXD+

RXD-

GND (SG)

Data transmission

GND

RS-485 terminals

SINK

SOURCE

∗3

∗5

Connector for plug-in option connection

STF

STR

STP(STOP)

JOG

MRS

X10

RES

RUN

IPF

Data reception

(+) (-)

VCC

(+) (-)

Source logic

∗6

Earth (Ground)

N/-

P/+

Initial value

OFF

Safety stop signal

Safety monitor output

Safety monitor output common

So (SO)

SOC

Safety stop input (Channel 1)

Shorting wire

Safety stop input common

Safety stop input (Channel 2)

SIC

+24

Brake unit (Option)

Jumper

∗1

(Permissible load current 100mA)

connector 1 connector 2

connector 3

24V external power

supply input

Common terminal

24VDC power supply

Forward rotation start

Reverse rotation start

Start self-holding selection

Middle speed

High speed

Low speed

Jog operation

Second function selection

Reset

Terminal 4 input selection

Selection of automatic restart

after instantaneous power failure

Control input signals (No voltage input allowed) ∗2

Multi-speed selection

Contact input common

Main circuit

Control circuit

PU connector

USB A connector

USB mini B connector

Voltage/current input switch

selectable

Terminating

resistor

Initial value

Output stop

24V

Output shutoff circuit

Common for external

power supply transistor

(-)

(+)

Analog signal output (0 to ±10VDC)

(-)

(+)

Analog current output (0 to 20mADC)

F/C

(CA)

RDA

RDI

Converter unit

RSO

N/-

P/+

IPF

RDB

FAN

R/L1 S/L2 T/L3

RES

+24

∗4

∗9

CA type (RS-485 model)

INSTALLATION AND WIRING

Terminal connection diagrams

+ 98 hidden pages

Mitsubishi Electric A800 Plus, FR-A842-10940, FR-A842-09620, FR-A802-R2R, FR-A842-12120 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FR-A802-R2R (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE)

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 heat sink through a panel

2.4 Terminal connection diagrams