Mitsubishi Electronics FR-HC2 User Manual

INVERTER
FR-HC2

INSTRUCTION MANUAL

High power factor converter

FR-HC2-7.5K to 75K
FR-HC2-H7.5K to H560K

OUTLINE

1

INSTALLATION AND

WIRING

MON

P

.C

P

Y

PWR

R

E

G

E

N

D

R

IV

E

PSCLR

M

O

D

E

S

S

T

E

O

T

P

R

E

S

E

T

PARAMETERS

2

3

PROTECTIVE FUNCTIONS

4

MAINTENANCE AND

INSPECTION

5

SPECIFICATIONS

6

Thank you for choosing the Mitsubishi High Power Factor Converter.

WARNING

CAUTION

CAUTION

WARNING

CAUTION

CAUTION

CAUTION

Environment

Surrounding air
temperature

-10°C to +50°C (non-freezing)

Ambient
humidity

90%RH or less (non-condensing)

Storage
temperature

-20°C to +65°C 

Atmosphere

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

Altitude/
vibration

Maximum 1,000m above sea level. 5.9m/s

2

or

less

 at 10 to 55Hz (directions of X, Y, Z axes)

This Instruction Manual gives handling information and precautions for use of this equipment. Incorrect handling
might cause an unexpected fault. Before using the converter, please read this manual carefully to use the equipment
to its optimum.
Please forward this manual to the end user.

Do not attempt to install, operate, maintain or inspect the
converter until you have read through this Instruction
Manual 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.
In this Instruction Manual, the safety instruction levels are
classified into "WARNING" and "CAUTION"

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.

SAFETY INSTRUCTIONS

1. Electric Shock Prevention

 While the converter power is ON, do not open the front

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

 Before wiring or inspection, power must be switched OFF.

 This converter must be earthed (grounded). Earthing

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

 The product body must be installed before wiring.

 Setting dial and key operations must be performed with

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

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



Safety Instructions

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.

cover or the wiring cover. Do not run the converter 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.

except for wiring or periodic inspection. You may
accidentally touch the charged converter and get an
electric shock.

To confirm that, LED indication of the operation panel
must be checked. (It must be 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 is 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.

(grounding) must conform with the requirements of
national and local safety regulations and electrical code
(NEC section 250, IEC 536 class 1 and other applicable
standards).

equipment shall be fully competent to do the work.

Otherwise you may get an electric shock or be injured.

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

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

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.

2. Fire Prevention



The converter must be installed on a nonflammable wall
without holes. Mounting it to or near flammable material
can cause a fire.

 If the converter has become faulty, the power of the

converter must be switched OFF. A continuous flow of
large current could cause a fire.

 Daily and periodic inspections must be performed as

instructed in the Instruction Manual. If the product is used
without receiving any inspection, it may cause a burst,
break, or fire.

3.Injury Prevention

 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.

 Polarity must be correct. Otherwise burst, damage, etc.

may occur.

 While power is ON or for some time after power-OFF, do

not touch the converter, reactor 1, reactor 2, outside box,
filter capacitor, and limit resistor as they will be extremely
hot. Touching these devices can cause a burn.

4. 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.

(1) Transportation and mounting

 The product must be transported in a suitable method

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

 Do not stack the boxes containing products higher than

the number recommended.

 The product must be installed to the position where

withstands the weight of the product according to the
information in the Instruction Manual.

 Do not install or operate the converter if it is damaged or

has parts missing.



When carrying the converter, do not hold it by the front
cover or setting dial; it may fall off or fail.

 Do not stand or rest heavy objects on the product.
 The mounting orientation must be correct.


Foreign conductive objects must be prevented from
entering the converter. That includes screws and metal
fragments or other flammable substance such as oil.

 As the converter is a precision instrument, do not drop or

subject it to impact.

 The product must be used under the following

environment. Otherwise the converter may be damaged.

 Temperature applicable for a short time, e.g. in transit.
 2.9m/s

2

or less for the 160K or higher.

A-1

(2) Trial run

CAUTION

WARNING

CAUTION

CAUTION

CAUTION

CAUTION

(6) Disposal

 Before starting the operation, each parameter must be

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

 Before starting the operation, the wiring of each

peripheral device must be checked. Faulty wiring may
cause some machines to make unexpected motions.

(3) Usage

 Any person must stay away from the equipment when the

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

 Since pressing the key may not stop the operation

depending on the function setting status, separate circuit
and switch that make an emergency stop (power OFF,
etc.) must be provided.

 OFF status of the inverter start signal must be confirmed

before resetting a fault of the converter. If reset is
performed with the start signal ON, the converter starts
suddenly.

 The load must be always inverters. Connection of any

other electrical equipment to the converter 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.

 The converter must be treated as industrial waste.

(7) General instruction

Many of the diagrams and drawings in this Instruction

Manual show the converter without a cover or partially open

for explanation. Never operate the converter in this manner.

The cover must be always reinstalled and the instruction in

this Instruction Manual must be followed when operating

the converter.

 Do not use a magnetic contactor on the power input side

for frequent starting/stopping of the converter or the
inverter. Otherwise the life of the converter or the inverter
decreases.

 The effect of electromagnetic interference must be

reduced by using a noise filter or by other means.
Otherwise the electronic equipment used near the
converter or the inverter may be affected.

 When parameter clear or all parameter clear is performed,

the required parameters must be set again before starting
operations because all parameters return to the initial
value.

 Before running a converter or 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 before you
touch the product. Otherwise the product may be damaged.

(4) Emergency stop



A safety backup such as an emergency brake must be
provided to prevent hazardous condition to the machine and
equipment in case of the converter and inverter failure.

 When the breaker, which is installed in the input side of

the converter, trips, the wiring must be checked for a fault
(short circuit), and internal parts of the converter and 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 any fault occurs, take an appropriate corrective

action, then reset the converter, and resume the
operation.

(5) Maintenance, inspection and parts replacement

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

the control circuit of the converter.

A-2

CONTENTS

1 OUTLINE 1

1.1 Pre-operation instructions ..................................................................2

1.1.1 Features of FR-HC2 (high power factor converter) ........................................................................ 2

1.1.2 Japanese harmonic suppression guideline ................................................................................... 2

1.1.3 Product checking and parts identification ...................................................................................... 5

1.2 Converter and peripheral devices.......................................................7

1.3 Precautions for selecting peripheral devices .................................... 8

1.3.1 Measures against noises (EMI) ...................................................................................................... 8

1.3.2 Peripheral device list .................................................................................................................... 11

1.3.3 Selecting the rated sensitivity current for the earth leakage circuit breaker ................................. 14

2 INSTALLATION AND WIRING 15

2.1 Removal and installation of the converter (FR-HC2) front cover.....16

2.2 Removal and installation of the outside box (FR-HCB2) front

cover .................................................................................................. 18

2.3 Installation.........................................................................................19

2.3.1 Converter placement .................................................................................................................... 19

2.4 Protruding the heatsink..................................................................... 21

2.4.1 When using a heatsink protrusion attachment (FR-A7CN) .......................................................... 21

2.4.2 Heatsink protrusion for 160K or higher......................................................................................... 21

CONTENTS

2.5 Installation of peripheral devices ..................................................... 23

2.5.1 Installation of reactor 1 and reactor 2 ........................................................................................... 23

2.5.2 Installation of the outside box (FR-HCB2-7.5K to 75K, FR-HCB2-H7.5K to H220K) ................... 24

2.5.3 Installation of filter capacitor (FR-HCC2-H280K to H560K).......................................................... 25

2.5.4 Installation of inrush current limit resistor (FR-HCR2-H280K to H560K) ...................................... 25

2.5.5 Installation of MC power supply stepdown transformer (FR-HCM2-H280K to H560K) ................ 26

2.6 Main circuit terminal specifications.................................................27

2.6.1 Description of main circuit terminal............................................................................................... 27

2.6.2 Terminal arrangement of the main circuit terminal ....................................................................... 28

2.6.3 Cable sizes of the main control circuit terminals and earth (ground) terminals ........................... 31

2.7 Wiring of main circuit

(FR-HC2-7.5K to 75K, FR-HC2-H7.5K to H220K)............................... 34

2.7.1 Connection diagram (when using with the FR-A700 series) ........................................................ 34

2.7.2 Wiring of main circuit .................................................................................................................... 35

2.8 Wiring of main circuit (FR-HC2-H280K)............................................. 41

2.8.1 Connection diagram (when using with the FR-A700 series) ........................................................ 41

2.8.2 Wiring of main circuit .................................................................................................................... 43

2.9 Wiring of main circuit (FR-HC2-H400K, H560K)................................47

I

2.9.1 Connection diagram (when using with the FR-A700 series)......................................................... 47

2.9.2 Wiring of main circuit .................................................................................................................... 48

2.10 Notes on earthing (grounding).......................................................... 53

2.11 Compatible inverter for the high power factor converter................ 54

2.11.1 Applicable inverter capacity .......................................................................................................... 54

2.11.2 Inverter parameter settings........................................................................................................... 55

2.12 Wiring of several inverters to one converter ................................... 56

2.13 Wiring of control circuit .................................................................... 58

2.13.1 Description of control circuit terminal............................................................................................ 58

2.13.2 Changing the control logic ............................................................................................................ 60

2.13.3 Control circuit terminal layout ....................................................................................................... 62

2.13.4 Wiring instructions ........................................................................................................................ 63

2.13.5 When connecting the operation panel or parameter unit using a connection cable ..................... 64

2.13.6 Communication operation (computer link operation) .................................................................... 64

3 PARAMETERS 65

3.1 Operation panel (FR-DU07-CNV) ....................................................... 66

3.1.1 Names and functions of the operation panel (FR-DU07-CNV)..................................................... 66

3.1.2 Basic operation (factory setting) ................................................................................................... 67

3.1.3 Changing the parameter setting value.......................................................................................... 68

3.2 Parameter unit (FR-PU07),

parameter unit with battery pack (FR-PU07BB(-L)) ......................... 69

3.2.1 Parts identification of the parameter unit ...................................................................................... 69

3.2.2 Explanation of keys....................................................................................................................... 69

3.2.3 Monitoring function ....................................................................................................................... 70

3.2.4 Function menu .............................................................................................................................. 71

3.3 Parameter list ................................................................................... 73

3.4 Description of parameters ................................................................ 75

3.4.1 Displaying and hiding extended parameters (Pr. 0)..................................................................... 75

3.4.2 Input frequency to converter (Pr. 1, Pr. 2) ................................................................................... 75

3.4.3 Input terminal function selection (Pr. 3 to Pr. 7)........................................................................... 76

3.4.4 Operation selection of SOF signal and OH signal (Pr. 8, Pr. 9)................................................... 77

3.4.5 Output terminal function selection (Pr. 10 to Pr. 16).................................................................... 78

3.4.6 DC voltage control (Pr. 22 to Pr. 24, Pr. 80, Pr. 81) .................................................................... 79

3.4.7 Input current detection function (Y12 signal, Y13 signal, Pr. 25 to Pr. 30) .................................. 80

3.4.8 Displaying the life of the converter parts (Pr. 31 to Pr. 33) .......................................................... 81

3.4.9 Maintenance timer alarm (Pr. 34, Pr. 35)..................................................................................... 82

3.4.10 Cooling fan operation selection (Pr. 36) ...................................................................................... 83

3.4.11 Instantaneous power failure detection hold (Pr. 44) .................................................................... 83

3.4.12 Reference of the terminal FM (pulse train output) and terminal AM (analog output) (Pr. 45, Pr. 49,

Pr. 51, Pr. 53, Pr. 55, Pr. 56) ....................................................................................................... 84

II

3.4.13 DU/PU, terminal FM/AM monitor display selection (Pr. 46 to Pr. 48, Pr. 50, Pr. 52, Pr. 54) ....... 86

3.4.14 Operation selection at instantaneous power failure (Pr. 57)........................................................ 89

3.4.15 Free parameter (Pr. 58, Pr. 59) ................................................................................................... 90

3.4.16 Key lock selection of operation panel(Pr. 61) .............................................................................. 90

3.4.17 Retry function (Pr. 65, Pr. 67 to Pr. 69) ....................................................................................... 91

3.4.18 Reset selection/disconnected PU detection/PU stop selection (Pr. 75) ...................................... 92

3.4.19 Parameter write disable selection (Pr. 77)................................................................................... 94

3.4.20 Current control (Pr. 82, Pr. 83) .................................................................................................... 95

3.4.21 Wiring and configuration of PU connector ................................................................................... 95

3.4.22 Initial settings and specifications of RS-485 communication (Pr. 117 to Pr. 124) ....................... 97

3.4.23 Mitsubishi inverter protocol (computer link communication) ........................................................ 98

3.4.24 Initial setting and specification for the CC-Link communication function (Pr. 542 to Pr. 544) ... 109

3.4.25 Operation at a communication error (Pr. 500 to Pr. 502) .......................................................... 115

3.4.26 Communication EEPROM write selection (Pr. 342) .................................................................. 116

3.4.27 Setting of the parameter unit and operation panel (Pr. 145, Pr. 990, Pr. 991) .......................... 117

3.4.28 Terminal FM and AM calibration (calibration parameter C0 (Pr. 900), C1 (Pr. 901)) ................ 118

3.5 Parameter clear / All parameter clear ............................................120

3.6 Parameter copy and parameter verification................................... 121

CONTENTS

4 PROTECTIVE FUNCTIONS 123

4.1 Troubleshooting............................................................................... 124

4.2 Reset method of protective function.............................................. 124

4.3 List of fault and alarm indications.................................................. 125

4.4 Causes and corrective actions ....................................................... 126

4.5 Correspondences between digital and actual characters............. 133

4.6 Check and clear of the faults history ............................................. 134

4.7 Check first when you have a trouble .............................................. 136

5 MAINTENANCE AND INSPECTION 137

5.1 Inspection items..............................................................................138

5.1.1 Daily inspection .......................................................................................................................... 138

5.1.2 Periodic inspection ..................................................................................................................... 138

5.1.3 Daily and periodic inspection list ................................................................................................ 139

5.1.4 Checking the converter module.................................................................................................. 140

5.1.5 Cleaning ..................................................................................................................................... 140

5.1.6 Replacement of parts ................................................................................................................. 141

5.2 Measurement of main circuit voltages, currents and powers ....... 145

5.2.1 Insulation resistance test using megger ..................................................................................... 146

5.2.2 Pressure test .............................................................................................................................. 146

III

6 SPECIFICATIONS 147

6.1 Rated specifications ....................................................................... 148

6.2 Common specifications .................................................................. 149

6.3 Outline dimensions ......................................................................... 150

6.3.1 Converter (FR-HC2) ................................................................................................................... 150

6.3.2 Reactor 1 (FR-HCL21)................................................................................................................ 157

6.3.3 Reactor 2 (FR-HCL22)................................................................................................................ 165

6.3.4 Difference between the reactor 1 (FR-HCL21) and the reactor 2 (FR-HCL22). ......................... 172

6.3.5 Outside box (FR-HCB2)............................................................................................................. 172

6.3.6 Filter capacitor (FR-HCC2)........................................................................................................ 179

6.3.7 FR-HCM2................................................................................................................................... 181

6.3.8 Inrush current limit resistor (FR-HCR2) ..................................................................................... 185

6.3.9 Parameter unit ............................................................................................................................ 186

APPENDICES 187

Appendix 1 Instruction code list ..................................................................................188

Appendix 2 Instructions for compliance with the EU Directives .............................. 189

Appendix 3 Instructions for UL and cUL.....................................................................191

<Abbreviations>

 Converter: Mitsubishi high power factor converter (FR-HC2)
 FR-HC2: Mitsubishi high power factor converter
 Inverter: Mitsubishi inverter that supports FR-HC2
 Reactor 1: Filter reactor 1 (FR-HC21)
 Reactor 2: Filter reactor 2 (FR-HC22)
 Limit resistor: Inrush current limit resistor (FR-HCR2)
 Stepdown transformer: Stepdown transformer for power source of MCs
 Limit MC: Inrush current limit MC
 Pr. : Parameter number (Number assigned to function)
 PU: Operation panel or option parameter unit (FR-PU07/FR-PU07BB)
 FR-PU07: Option parameter unit (FR-PU07/FR-PU07BB)
 PU operation: Operation using the PU
 External operation: Operation using the control circuit signals

<Trademarks>

 Microsoft and Visual C++ are registered trademarks of Microsoft Corporation in the United States.
 Company and product names herein are the trademarks and registered trademarks of their respective owners.

<Marks>

REMARKS: Additional helpful contents and relations with other functions are written.

Note: Contents requiring caution or cases when set functions are not activated are written.

POINT: Useful contents and points are written.

: Content and description of an alarm or fault are written.

IV

1 OUTLINE

This chapter explains the "OUTLINE" for use of this product.
Always read the instructions before using the equipment.

1.1 Pre-operation instructions........................................................... 2

1.2 Converter and peripheral devices............................................... 7

1.3 Precautions for selecting peripheral devices ............................ 8

1

2

3

4

5

6

1

Pre-operation instructions

1.1 Pre-operation instructions

Incorrect handling may cause the equipment to operate improperly, its life to be reduced considerably, and in the worst case,
the converter and inverter to be damaged. Please handle the unit properly in accordance with the information on each section
as well as the precautions and instructions of this manual.

1.1.1 Features of FR-HC2 (high power factor converter)

Power supply harmonics generated from the converter part of an inverter may affect devices including a dynamo and a static
capacitor. Power supply harmonics differ from noise and leakage current in their generating source, frequency range and
transmission method. Power supply harmonic may be suppressed by using this converter, allowing the compliance with the
harmonic suppression guideline issued by the former Japanese Ministry of International Trade and Industry (currently the
Ministry of Economy, Trade and Industry). Conversion factor of the converter is K5=0 in the self-excitation three-phase bridge
circuit.

REMARKS

Inverter parameters must be set.
The parameter settings differ by the inverter series. Refer to page 55 for details.

Power supply harmonic suppression effect

(Example) FR-HC2-7.5K
(Condition) Load: 100%
Power factor: 1

[When the converter is not connected]

[When the converter is connected]

Input phase voltage(100V/div)

Input phase current
(50A/div)

Input phase voltage(100V/div)

Input phase current
(50A/div)

NOTE

 When the load is light, harmonic suppression effect declines.
 When the power supply voltage is unstable, harmonics from electric power system flow in, making the harmonic

current larger.

1.1.2 Japanese harmonic suppression guideline

Harmonic currents flow from the inverter to a power receiving point via a power transformer. The harmonic suppression
guideline was established to protect other consumers from these outgoing harmonics.
The all capacities and all models of the inverters used by the specific consumers became subject to the Harmonic
Suppression Guideline for the Consumers Who Receive High-voltage or Special High-voltage (hereafter referred to as
"Harmonic Suppression Guideline for Specific Consumers").

[Harmonic suppression guideline for specific consumers]

This guideline sets the maximum values of outgoing harmonic currents generated from a high-voltage or specially high­voltage consumer who will install, add or renew harmonic generating equipment. If any of the maximum values are
exceeded, this guideline requires the consumer to take certain suppression measures.

Table 1 Maximum outgoing harmonic current per 1kW contract

Received Power

Vol tag e

6.6kV 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70

22kV 1.8 1.3 0.82 0.69 0.53 0.47 0.39 0.36

33kV 1.2 0.86 0.55 0.46 0.35 0.32 0.26 0.24

5th 7th 11th 13th 17th 19th 23rd Over 23rd

2

1

OUTLINE

Pre-operation instructions

Install, add or renew

equipment

Calculation of equivalent

capacity total

Equivalent

capacity total

Calculation of outgoing

harmonic current

Not more than

harmonic current upper

limit?

Harmonic suppression
measures unnecessary

Harmonic suppression

measures necessary

Equal to or less
than upper limit

More than upper limit

Above reference
capacity

Equal to or less
than reference
capacity

(1) Application of the Harmonic Suppression Guideline for Specific Consumers

Table 2 Conversion Factors for FR-A700 Series

Classification Circuit Type Conversion Factor Ki

Without a reactor K31=3.4

3

5

Three-phase bridge
(Capacitor smoothed)

Self-excitation three-phase
bridge

With a reactor (on AC side) K32=1.8

With a reactor (on DC side) K33=1.8

Without a reactor (on AC/DC side) K34=1.4

With the converter K5=0

Table 3 Equivalent Capacity Limits

Received

Power Voltage

6.6kV 50kVA

22/33kV 300kVA

66kV or more

Reference

Capacity

2000kVA

Table 4 Harmonic Content (Values at the fundamental current of 100%)

Reactor 5th 7th 11th 13th 17th 19th 23rd 25th

Not used 65 41 8.5 7.7 4.3 3.1 2.6 1.8

Used (AC side) 38 14.5 7.4 3.4 3.2 1.9 1.7 1.3

Used (DC side) 30 13 8.4 5.0 4.7 3.2 3.0 2.2

Used (on AC/DC side) 28 9.1 7.2 4.1 3.2 2.4 1.6 1.4

(a) Calculation of equivalent capacity P0 of harmonic generating equipment

The "equivalent capacity" is the capacity of a 6-pulse converter converted from the capacity of a consumer's harmonic
generating equipment and is calculated with the following equation. When the sum of equivalent capacity exceeds the limits
in Table 3, harmonics must be calculated in the following procedure.

P0 =  (Ki Pi) [kVA]

Ki: Conversion factor(According to Table 2)

Pi: Rated capacity of harmonic generating equipment

 [kVA]

i : Number indicating the conversion circuit type

(b) Calculation of outgoing harmonic current

Outgoing harmonic current=fundamental wave current (value converted from received power voltage)

 Rated capacity: Rated capacity is determined by the capacity of the applied

motor and found in Table 5. It should be noted that the rated capacity used here

is used to calculate generated harmonic amount and is different from the power

supply capacity required for actual inverter drive.

 operation ratio 

harmonic content

Operation ratio: Operation ratio = actual load factor  operation time ratio during 30 minutes
Harmonic content: Found in Table 4.

3

Pre-operation instructions

Table 5 Rated Capacity and Outgoing Harmonic Current during Inverter Run

Applied

Motor

(kW)

0.4 1.61 0.81 49 0.57 31.85 20.09 4.165 3.773 2.107 1.519 1.274 0.882

0.75 2.74 1.37 83 0.97 53.95 34.03 7.055 6.391 3.569 2.573 2.158 1.494

1.5 5.50 2.75 167 1.95 108.6 68.47 14.20 12.86 7.181 5.177 4.342 3.006

2.2 7.93 3.96 240 2.81 156.0 98.40 20.40 18.48 10.32 7.440 6.240 4.320

3.7 13.0 6.50 394 4.61 257.1 161.5 33.49 30.34 16.94 12.21 10.24 7.092

5.5 19.1 9.55 579 6.77 376.1 237.4 49.22 44.58 24.90 17.95 15.05 10.42

7.5 25.6 12.8 776 9.07 504.4 318.2 65.96 59.75 33.37 24.06 20.18 13.97

15 49.8 24.9 1509 17.6 980.9 618.7 128.3 116.2 64.89 46.78 39.24 27.16

18.5 61.4 30.7 1860 21.8 1209 762.6 158.1 143.2 79.98 57.66 48.36 33.48

22 73.1 36.6 2220 25.9 1443 910.2 188.7 170.9 95.46 68.82 57.72 39.96

30 98.0 49.0 2970 34.7 1931 1218 252.5 228.7 127.7 92.07 77.22 53.46

37 121 60.4 3660 42.8 2379 1501 311.1 281.8 157.4 113.5 95.16 65.88

45 147 73.5 4450 52.1 2893 1825 378.3 342.7 191.4 138.0 115.7 80.10

55 180 89.9 5450 63.7 3543 2235 463.3 419.7 234.4 169.0 141.7 98.10

Applied

Motor

(kW)

75 245 123 7455 87.2 2237 969 626 373 350 239 224 164

90 293 147 8909 104 2673 1158 748 445 419 285 267 196

110 357 179 10848 127 3254 1410 911 542 510 347 325 239
132  216 13091 153 3927 1702 1100 655 615 419 393 288
160  258 15636 183 4691 2033 1313 782 735 500 469 344
220  355 21515 252 6455 2797 1807 1076 1011 688 645 473
250  403 24424 286 7327 3175 2052 1221 1148 782 733 537
280  450 27273 319 8182 3545 2291 1364 1282 873 818 600
315  506 30667 359 9200 3987 2576 1533 1441 981 920 675
355  571 34606 405 10382 4499 2907 1730 1627 1107 1038 761
400  643 38970 456 11691 5066 3274 1949 1832 1247 1169 857
450  723 43818 512 13146 5696 3681 2191 2060 1402 1315 964
500  804 48727 570 14618 6335 4093 2436 2290 1559 1462 1072
560  900 54545 638 16364 7091 4582 2727 2564 1746 1636 1200

Rated Current

[A]

200V 400V 5th 7th 11th 13th 17th 19th 23rd 25th

11 36.9 18.5 1121 13.1 728.7 459.6 95.29 86.32 48.20 34.75 29.15 20.18

Rated Current

[A]

200V 400V 5th 7th 11th 13th 17th 19th 23rd 25th

Fundamental

Wave Current

Converted from

6.6kV (mA)

Fundamental

Wave Current

Converted from

6.6kV (mA)

Rated

Capacity

(kVA)

Rated

Capacity

(kVA)

Harmonic Current Converted from 6.6kV (mA)

(No reactor, 100% operation ratio)

Harmonic Current Converted from 6.6kV (mA)

(With a DC reactor, 100% operation ratio)

(c)Deciding whether to take harmonic suppression measures

When the outgoing harmonic current > the maximum value per 1kW contract  contract kW, a harmonic suppression
measures are required.

(d) Harmonic suppression measures

No. Item Description

Reactor

1

(FR-HAL, FR-HEL)

High power factor

2

converter
(FR-HC2)

Power

3

factor improving static
capacitor

Multi-phase operation

4

with transformers

Passive filter

5

(AC filter)

6 Active filter

Harmonic current is suppressed by installing an AC reactor (FR-HAL) in the AC input side of the inverter
or a DC reactor (FR-HEL) in the DC bus line of the inverter, or by installing both.

FR-HC2 is designed to switch ON/OFF the converter circuit to convert an input current waveform into a
sine wave, suppressing the harmonic current considerably. The converter (FR-HC2) is used with the
standard-equipped peripheral devices and accessories.

Using the power factor improving static capacitor with a series reactor has an effect of absorbing
harmonic currents.

Using two transformers with a phase angle difference of 30 as in - and ­provides an effect corresponding to 12 pulses and reduces low-degree harmonic currents.

A capacitor and a reactor are used together to reduce impedance at specific frequencies, producing a
great effect of absorbing harmonic currents.

This filter detects the current of the circuit, where harmonic current is generated, and generates the
harmonic current equivalent to the difference between that current and a fundamental wave current.
By doing so, the harmonic current at where it was detected can be suppressed, and great absorption of
harmonic current can be expected.

combinations

4

1

OUTLINE

Pre-operation instructions

Symbol Voltage class

H 400V class

Not used 200V class

Represents the inverter capacity [kW]

FR-HC2-

7.5

K

Converter capacity

(Refer to page 141)

(Refer to page 59)

(Refer to page 58)

(Refer to page 28)

(Refer to page 16)

(Refer to page 27)

(Refer to page 66)

1.1.3 Product checking and parts identification

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

and rated output agree with your order and the product is intact.

When combined with a Mitsubishi general-purpose inverter and other converter accessories, this converter suppresses

harmonics according to the harmonic suppression guideline of the former Japanese Ministry of International Trade and

Industry (currently the Ministry of Economy, Trade and Industry). Carefully check the specifications including the applicable

capacities.

 High power factor converter model

PU connector

Alarm lamp

Lit when the converter is in
fault.

Power lamp

Lit when the control circuit
(R1/L11, S1/L21) is supplied
with power.

MON

P.CP Y

PWR

REGEN

DRIVE

P

S

C

L

R

MODE

STOP

SET

RESET

Operation panel
(FR-DU07-CNV)

Front cover

Charge lamp

Lit when power is supplied
to the main circuit

Dedicated circuit board
for HC2

Main circuit terminal block

Control circuit
terminal block

Cooling fan

Connector for plug-in option
connection

(Refer to the instruction manual of options.)

Capacity plate

Capacity plate

FR-HC2-7.5K

Converter model name

Serial number

Combed shaped wiring cover

Rating plate

Rating plate

Converter model name

Applicable inverter capacity

Input rating

Rated output

Serial number

FR-HC2-7.5K

5

Pre-operation instructions

Model Screw Size (mm) Quantity

FR-HC2-7.5K

FR-HC2-H7.5K, H15K

M4 40 2

FR-HC2-15K M4 50 1

Model Eyebolt Size Quantity

FR-HC2-30K, 55K

FR-HC2-H30K to H75K

M8 2

FR-HC2-75K

FR-HC2-H110K

M10 2

FR-HC2-H280K M12 2

 Checking peripheral devices

 Peripheral devices

Always install the included peripheral devices. Check the model name of the each peripheral device.

For the 400V class peripheral devices, H is indicated in front of the model name.

 FR-HC2-7.5K to 75K, FR-HC2-H7.5K to H220K

Peripheral Device

Model Name

FR-HC2-(H)K High power factor converter 1

FR-HCL21-(H)K Filter reactor 1 1

FR-HCL22-(H)K Filter reactor 2 1
FR-HCB2-(H)K Outside box  1

Terminal screws are enclosed for FR-HCB2-7.5K, 15K, FR-HCB2-H7.5K to H30K. (M5  6)

Description Quantity

 FR-HC2-H280K to H560K

Peripheral

Device Model

Model Name of Consisting Parts Description

Name

FR-HC2-HK FR-HC2-HK High power factor converter 1 1 1

FR-HCL21-HK FR-HCL21-HK Filter reactor 1 1 1 1

FR-HCL22-HK FR-HCL22-HK Filter reactor 2 1 1 1

FR-HCC2-HK

FR-HCR2-HK

FR-HCM2-HK

FR-HCC2-HK Filter capacitor 1 2 3

MDA-1 filter capacitor alarm detector — 2 3

0.96OHM BKO-CA1996H21 Inrush current limit resistor (without thermostat) 8 15 15

0.96OHM BKO-CA1996H31 Inrush current limit resistor (with thermostat) 1 3 3

1PH 630VA BKO-CA2001H06

S-N400FXYS AC200V 2A2B Inrush current limit MC — 3 3

S-N600FXYS AC210V 2A2B Inrush current limit MC 1 — —

SR-N4FX AC210V 4A Buffer relay 1 2 2

TS-807BXC-5P Terminal block 6 — —

C152C481H21 Terminal block shorting conductor 6 — —

C152C423H21 MC shorting conductor — 6 6

MYQ4Z AC200/220 Mini relay for filter capacitor alarm detector — 1 1

PYF14T Mini relay terminal block — 1 1

PYC-A1 Mini relay clip — 2 2
M1250 ZENNEJI MC shorting conductor bolt (M12  50) — 24 24

M12 MC shorting conductor nut (M12) — 24 24

MIGAKI 12 MC shorting conductor washer (flat washer) — 48 48

BANE 12 MC shorting conductor washer (spring washer) — 24 24
SW-PW-P-NA M5 12 Inrush current limit resistor screw (M5  12) — 54 54

MC power supply stepdown transformer

(400V-200V)

Quantity

280K 400K

111

560K

Eyebolt for hanging the converter

 Fan cover fixing screws (7.5K, 15K)

Use the screws to tighten the fan cover so that



(30K to 75K (200V class), 30K to 110K and 280K (400V class))

the cover will not open easily.

 Instruction Manual

If you have any inquiry, or if damage is found on the product, please contact your sales representative.

6

1

OUTLINE

1.2 Converter and peripheral devices

Earth

(Ground)

Three-phase AC power supply

Use within the permissible power
supply specifications of the converter.

High power factor converter
(FR-HC2)

Install and wire correctly.
Do not install the moulded case circuit
breaker (MCCB) between terminals P
and P, or N and N of the converter
and the inverter.

Inverter

Confirm that this is a FR-HC2
supporting inverter. (Refer to the
inverter catalogs for compatible
inverters.)
Connect an inverter that corresponds
with the each capacity of the converter.
Match the control logic (sink logic /
source logic) of the converter and the
inverter.

Motor

Connect the motor corresponds to the
each capacity.

Magnetic contactor (MC)

Install the magnetic contactor to
ensure safety.

Do not use this magnetic contactor to
start and stop the high power factor
converter and the inverter. Doing so will
shorten the life of the inverter and the
converter.

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

The breaker must be selected carefully since
an inrush current flows in the converter at
power ON.

Reactor 1 (FR-HCL21)

Confirm that the capacity of the reactor
is selected according to the capacity of
the converter.

Reactor 2 (FR-HCL22)

Confirm that the capacity of the reactor
is selected according to the capacity of
the converter.

R4S4 T4

Devices connected to the output

Do not install a power factor correction capacitor,
surge suppressor or radio noise filter on the output
side of the inverter. When installing a moulded case
circuit breaker on the output side of the inverter,
contact each manufacturer for selection of the
moulded case circuit breaker.

Earth (Ground)

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

PN

Fuse

Installation of a fuse is recommended
for safety.
Select a fuse according to the
connected motor capacity.

Outside box (FR-HCB2)∗

Check that the capacity of the outside box
matches with the capacity of the high power
factor converter.

∗Outside box is not available for 280K or higher.

Connect filter capacitors, inrush current limit
resistors, and magnetic contactors.

(Refer to page 35, 49)

(Refer to page 35, 49)

(Refer to page 34, 47)

(Refer to page 60)

(Refer to page 34)

(Refer to page 12)

Converter and peripheral devices

7

Precautions for selecting peripheral devices

Noise propagated through
power supply cable

Path 3)

Path 2)

Path 1)

Noise directly radiated
from the converter

Path 4), 5)

Air propagated

noise

Path 6)

Electrical path

propagated noise

Path 8)

Path 7)

Converter
generated noise

Electromagnetic

induction noise

Electrostatic

induction noise

Noise radiated from
power supply cable

Noise radiated from
motor connection cable

Noise from earth (ground)
cable due to leakage
current

Inverter

Converter

Reactor 2

Reactor 1

Outside box

Instrument

Receiver

IM

Motor

Telephone

Sensor

1)

2)

3)

3)

8)

7)

5)

7)

4)

6)

1)

Sensor

power supply

1.3 Precautions for selecting peripheral devices

1.3.1 Measures against noises (EMI)

In this section, noises indicate those of more than 40th to 50th high frequencies in a power distribution system, which

generally assume irregular conditions.

Some noises enter the converter to adversely affect it, and others are radiated by the converter to adversely affect peripheral

devices. Though the converter is designed to be immune to noises, it handles low-level signals, so it requires the following

basic measures. Also, since the converter chops input voltage at high carrier frequency, it could generate noises. If these

noises affect peripheral devices, measures should be taken to suppress noises (EMI measures). The EMI measures differ

slightly depending on the noise transmission paths.

(1) Basic measures

Do not place the power cables (I/O cables) and signal cables of the converter in parallel with each other and do not

bundle them.

For the control signal cable and the connection cable with a detector, use twisted pair shield cables, and connect the

sheath of the shielded cables to the terminal SD.

Ground (earth) the reactor 1, reactor 2, outside box, converter, etc. at one point. (Refer to page 53)

(2) Measures against noises which enter and affect the converter

When devices, which generate many noises, (for example, magnetic contactors, magnetic brakes, many relays) are

installed near the converter, the converter may malfunction because of the noises. In that case, the following measures

must be taken.

Provide surge suppressors for the devices that generate many noises, and suppress the noises.

Install data line filters to signal cables.

Ground (earth) the connection cable with a detector and a control signal cable with a metal cable clamp.

(3) Measures against the noises that are radiated by the converter to affect peripheral devices

Noises radiated by the converter are largely classified into three types: those radiated by the cables connected to the

converter and converter's main circuit (I/O), those electromagnetically and electrostatically inducted to the signal cables

of the peripheral devices close to the main circuit cable, and those transmitted through the power supply cables.

8

1

OUTLINE

Precautions for selecting peripheral devices

Sensor

Use 4-core cable for motor power
cable and use one cable as
earth (ground) cable.

Use a shielded twisted pair cable

Power supply

Control power supply

Do not earth (ground) shield
but connect it to signal common cable.

Enclosure

Decrease carrier
frequency

Motor

M

Install line noise filter
(FR-BLF, FR-BSF01) on the inverter
output side

Do not earth (ground)
enclosure directly

Do not earth (ground)
control cable

Separate the inverter and
power line by more than
30cm (at least 10cm) from
sensor circuit.

Power
supply

for sensor

FR­BLF

FR­BIF

FR­BLF

Inverter

Converter

Reactor 2

Reactor 1

Outside box

Refer to page 53 for earthing
(grounding) the high power
factor converter and
accessories.

Noise

Transmission Path

1) 2) 3)

4) 5) 6)

7)

8)

Measures

When the devices, which handle low-level signals and are susceptible to noises (such as measuring

instruments, receivers and sensors), are installed near or in the same enclosure with the converter, or their

signal cables are placed near of in the same enclosure with the converter, the devices may malfunction due to

air-propagated electromagnetic noises. In that cases, following measures must be taken.

(1) Install the easily affected devices as far away from the converter and inverter as possible.

(2) Place the easily affected signal cables as far away from the converter and inverter as possible.

(3) Do not place the signal cables and power cables (converter I/O cables) in parallel with each other and do

not bundle them.

(4)Insert line noise filters ( FR-BLF, RC5128 (available product manufactured by Soshin Electric Co., Ltd.)) and

radio noise filters (FR-BIF) into the input side of the converter, and insert line noise filters (FR-BLF, RC5128

(available product manufactured by Soshin Electric Co., Ltd.)) into the output side of the inverter to

suppress cable-radiated noises.

(5) Use shield cables for signal cables and power cables and place them in individual metal conduits to

produce further effects.

When the signal cables are placed in parallel with or bundled with the power cables, magnetic and static

induction noises may be transmitted to the signal cables which causes the devices to malfunction. In that case,

the following measures must be taken.

(1) Install the easily affected devices as far away from the converter and inverter as possible.

(2) Place the easily affected signal cables as far away from the converter, inverter, and their I/O cables as

possible.

(3) Do not place the signal cables and power cables ( I/O cables of the converter and inverter) in parallel with

each other and do not bundle them.

(4) Use shield cables for signal cables and power cables and place them in individual metal conduits to

produce further effects.

When the peripheral devices are connected to the same power supply line with the converter, converter-

generated noises may flow back through the power supply cable to the devices, causing malfunction of the

devices. In that case, the following measures must be taken.

(1) Install radio noise filters (FR-BIF) to the power cable (input cable) of the converter.

(2) Install the line noise filters (FR-BLF, RC5128 (available product manufactured by Soshin Electric Co., Ltd.))

to the power cable (input cable) of the converter and to the power cable (output cable) of the inverter.

When a closed loop circuit is configured by connecting the wiring of a peripheral device to the converter,

leakage current may flow through the ground (earth) cable of the converter, causing malfunction of the device.

In that case, disconnecting the ground (earth) cable of the device may remove the malfunction.

EMC measures

9

Precautions for selecting peripheral devices

ROH2

ROH1

MC1

P/+P/+
N/-

N/-

R1/L11
S1/L21

X10

RES

SD

RDY

SE

R/L1
S/L2
T/L3

U
V

W

R1/L11
S1/L21

88R

88R

88S

88S

FR-BIF

ROH

SD

MC

R4/
L14

R4/L14

S4/

L24

S4/L24

T4/

L34

T4/L34

R3/
L13

R3/
L13

S3/
L23

S3/
L23

T3/
L33

T3/
L33

R2/
L12

R2/
L12

S2/

L22

S2/

L22

T2/

L32

T2/

L32

R/
L1

S/
L2

T/
L3

R/L1
S/L2
T/L3

SOF

X1

X2

RES

SD

RSO

CVO

Y1

Y2

Y3

SE2

FM

SD

(-)

(+)

AM

5

A

B

C

PC

Line noise filter

(FR-BLF, RC5128 ∗2)

Line noise filter

∗1

(

FR-BLF, RC5128 ∗2)

or

Radio noise filter (FR-BIF)

Power
supply

MCCB

Reactor 1

(FR-HCL21)

Limit resistor

Outside box (FR-HCB2)

Reactor 2

(FR-HCL22)

Limit MC1

Filter capacitors

Inverter

Converter
(FR-HC2)

Motor

Earth

(Ground)

Auxiliary contact
(NO contact)

Overheat detection thermostat
for the limit resistor (NC contact)

Contact
input
common

MC
connection
terminal

MC
connection
terminal

Converter stop

Monitor switching

Monitor switching

Contact input common

Reset

24VDC power supply

(External transistor common)

Relay
output
(fault
output)

Inverter run
enable signal

Converter
reset

During
converter run

Multi-purpose
output 1

Multi-purpose
output 2

Open collector output common

Multi-purpose output 3

Open collector output common

Analog signal output
(0 to 10VDC)

PU

connector

Inrush current limit

resistor overheat

protection

+

-

Indicator

(4) Using options to suppress noises

By using the radio noise filter (FR-BIF) and the line noise filter (FR-BLF), the noise radiated from the connection cable

can be suppressed. Refer to the Instruction Manual of each option for the detail of the radio noise filter (FR-BIF) and the

line noise filter (FR-BLF).

Example (FR-A700 series)

 Install the line noise filter to the terminal R, S, and T of the converter, but not to the power supply. Refer to the Instruction Manual of the noise filter for the

installation procedure of the noise filter.

 Product available on the market ............ RC5128: manufactured by Soshin Electric Co., Ltd.

NOTE

 Configure a system where the magnetic contactor at the converter input side shuts off the power supply at a failure of

the converter or the connected inverter. (The converter does not shut off the power supply by itself.)

Failure to do so may overheat and burn the resistors in the converter and the connected inverter.

10

1

OUTLINE

Precautions for selecting peripheral devices

MCCB

MCCB

IM

IM

Inverter

Inverter

Converter

Converter

1.3.2 Peripheral device list

(1) Circuit breakers and magnetic contactors

Check the model of the converter and select peripheral devices according to the capacity. Refer to the table below to prepare
appropriate peripheral devices.
200V class

Moulded Case Circuit Breaker (MCCB) 

Converter Model

or Earth Leakage Circuit Breaker (ELB)

(NF, NV type)

FR-HC2-7.5K 50A S-N25

FR-HC2-15K 75A S-N50

FR-HC2-30K 150A S-N80

FR-HC2-55K 300A S-N180

FR-HC2-75K 350A S-N300

400V class

Moulded Case Circuit Breaker (MCCB) 

Converter Model

or Earth Leakage Circuit Breaker (ELB)

(NF, NV type)

FR-HC2-H7.5K 30A S-N18

FR-HC2-H15K 50A S-N20

FR-HC2-H30K 75A S-N35

FR-HC2-H55K 150A S-N80

FR-HC2-H75K 175A S-N95

FR-HC2-H110K 250A S-N180

FR-HC2-H160K 400A S-N300

FR-HC2-H220K 500A S-N400

FR-HC2-H280K 700A S-N600

FR-HC2-H400K 900A S-N800

FR-HC2-H560K 1500A S-N400 (three in parallel)

 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 191)

 Magnetic contactor is selected based on the AC-1 class.The electrical durability of magnetic contactor is 100,000 times.When the magnetic contactor is

used for emergency stop during motor driving, the electrical durability is 25 times.
When using the MC for emergency stop during motor driving or using on the motor side during commercial-power supply operation, select the MC with class
AC-3 rated current for the motor rated current.

Magnetic Contactor

(MC)



Magnetic Contactor

(MC)



NOTE

 When the MCCB on the converter input side trips, check for the wiring fault (short circuit), damage to internal parts of

the converter, etc. Identify the cause of the trip, then remove the cause and power ON the breaker.

11

Precautions for selecting peripheral devices

(2) Fuse

Installation of a fuse is recommended between a high power factor converter and an inverter.
Select a fuse according to the capacity of the connected motor. When using a motor, of which the capacity is smaller than the
inverter capacity by two ranks or more, select the fuse with the capacity that is one rank lower than the inverter capacity. (

page 38, 45 and 51 for details.

)

[Fuse selection table]

200V class

Motor

capacity (kW)

0.1 5 6.900 CP GR 10.38 0005

0.2 10 6.900 CP GR 10.38 0010

0.4 16 6.900 CP GR 10.38 0016

0.75 20 6.900 CP GR 10.38 0020

1.5 25 6.900 CP GR 10.38 0025

2.2 50 6.9 URD 30 TTF 0050 —

3.7 63 6.9 URD 30 TTF 0063 —

5.5 100 6.9 URD 30 TTF 0100 —

7.5 125 6.9 URD 30 TTF 0125 —
11 160 6.9 URD 30 TTF 0160 —
15 200 6.9 URD 30 TTF 0200 —

18.5 250 6.9 URD 30 TTF 0250 —
22 315 6.9 URD 30 TTF 0315 —
30 400 6.9 URD 30 TTF 0400 —
37 500 6.9 URD 30 TTF 0500 —
45 630 6.9 URD 31 TTF 0630 —
55 700 6.9 URD 31 TTF 0700 —
75 800 6.9 URD 31 TTF 0800 —

 Manufacturer: Mersen Japan K.K.

Contact: Sun-Wa Technos Corporation

Fuse rating (A) Model  Fuse holder (2 poles)

Recommended fuse

US102 (without fuse light melting indicator)

or US102I (with fuse light melting indicator)

Refer to

12

1

OUTLINE

Precautions for selecting peripheral devices

400V class

Motor

capacity (kW)

0.4 12.5 6.900 CP GR 10.38 0012.5

0.75 16 6.900 CP GR 10.38 0016

1.5 16 6.900 CP GR 10.38 0016

2.2 20 6.900 CP GR 10.38 0020

3.7 30 6.900 CP GR 10.38 0030

5.5 50 6.9 URD 30 TTF 0050 —

7.5 50 6.9 URD 30 TTF 0050 —

11 80 6.9 URD 30 TTF 0080 —

15 125 6.9 URD 30 TTF 0125 —

18.5 125 6.9 URD 30 TTF 0125 —

22 160 6.9 URD 30 TTF 0160 —

30 200 6.9 URD 30 TTF 0200 —

37 250 6.9 URD 30 TTF 0250 —

45 315 6.9 URD 30 TTF 0315 —

55 350 6.9 URD 30 TTF 0350 —

75 450 6.9 URD 30 TTF 0450 —

90 500 6.9 URD 30 TTF 0500 —

110 550 6.9 URD 31 TTF 0550 —

132 630 6.9 URD 31 TTF 0630 —

160 800 6.9 URD 31 TTF 0800 —

185 900 6.9 URD 32 TTF 0900 —

220 1000

250 1250

280 1400

315 1600

355 1800

400 1800

450 2500 6.9 URD 33 TTF 1250 2 in parallel
500 2700 6.9 URD 32 TTF 0900 3 in parallel
560 2700 6.9 URD 32 TTF 0900 3 in parallel

Fuse rating (A) Model  Fuse holder (2 poles)

6.9 URD 32 TTF 1000 or

6.9 URD 31 TTF 0630 2 in parallel

6.9 URD 33 TTF 1250 or

6.9 URD 31 TTF 0700 2 in parallel

6.9 URD 33 TTF 1400 or

6.9 URD 31 TTF 0800 2 in parallel

6.9 URD 232 TTF 1600 or

6.9 URD 31 TTF 0800 2 in parallel

6.9 URD 232 TTF 1800 or

6.9 URD 32 TTF 0900 2 in parallel

6.9 URD 232 TTF 1800 or

6.9 URD 32 TTF 0900 2 in parallel

Recommended fuse

US102 (without fuse light melting indicator)

or US102I (with fuse light melting indicator)













 —

 —

 —

—

—

—

—

—

—

 Manufacturer: Mersen Japan K.K.

 When installing several fuses in parallel, leave 12mm or more between the fuses.

[Estimated lifespan of fuse]

 Estimated lifespan for when the yearly average surrounding air temperature is 50°C (without corrosive gas, flammable gas, oil mist, dust and dirt etc.)

Contact: Sun-Wa Technos Corporation

NOTE

 Install a fuse across terminal P/+ of the inverter and the converter and across terminal N/- of the inverter and the

converter.

Part Name Estimated lifespan Replacement method

Fuse 10 years Replace with a new one

NOTE

 If the fuse melts down, wiring failure such as a short circuit may be the cause. Identify the problem and fix it before

replacing the fuse.

13

Precautions for selecting peripheral devices

lg1, lg2, lg3

: leakage current of cable path during

commercial power supply operation

lgn : leakage current of noise filter on the

converter input side

lgm :

leakage currents of motor during commercial
power supply operation

(200V 60Hz)

(200V 60Hz)

1. 5 3. 7

2. 2

7. 5 152211373055

455.5 18. 5

0. 1

0. 2

0. 3

0. 5

0. 7

1. 0

2. 0

0

20

40

60

80

100

120

2 3.5

5.5

8142230386080

100

150

Motor capacity (kW)

Example of leakage current of
cable path per 1km during the
commercial power supply operation
when the CV cable is routed in
metal conduit

Leakage current example of
three-phase induction motor
during the commercial
power supply operation

Leakage currents (mA)

Leakage currents (mA)

Cable size (mm2)

Motor capacity (kW)

For " " connection, the amount of leakage current is appox.1/3 of the above value.

(Three-phase three-wire delta
connection 400V60Hz)

Example of leakage current per 1km during
the commercial power supply operation
when the CV cable is routed in metal conduit

Leakage current example of three­phase induction motor during the
commercial power supply operation

(Totally-enclosed fan-cooled
type motor 400V60Hz)

0

20

40

60

80

100

120

leakage currents (mA)

leakage currents (mA)

2 3.5

5.5

8142230386080

100

150

Cable

size (mm2)

0. 1

0. 2

0. 3

0. 5

0. 7

1. 0

2. 0

1. 5 3. 7

2. 2

7. 5 152211373055

455.5 18. 5

Selection Example

(for the diagram shown on the left) (mA)

Breaker for

harmonic

and surge

Standard

breaker

Leakage current lg1 (mA)

33  =0.17

Leakage current lgn (mA) 0 (without noise filter)

Leakage current lg2 (mA)

33 = 0.17

Leakage current lg3 (mA)

33 = 2.31

Leakage current lgm (mA) 0.18

Total leakage current (mA) 2.83 7.81

Rated sensitivity current

(

lg10)(mA)

30 100

5m

1000m

----------------

5m

1000m

----------------

70m

1000m

----------------

1.3.3 Selecting the rated sensitivity current for the earth leakage circuit breaker

When using the earth leakage circuit breaker with the inverter circuit, select its rated sensitivity current as follows.

 Breaker for harmonic and surge

Rated sensitivity current ln 10 (lg1+lgn+lg2+lg3+lgm)

 Standard breaker

Rated sensitivity current ln 10  {lg1+lgn+lg2+3(lg3+lgm)}

<Example>

5.5mm2 × 5m 5.5mm

ELB

Noise

filter

Converter

Inverter

lg1 lgn lg2 lg3

NOTE

 Install the earth leakage circuit breaker (ELB) on the input side of the converter.

 In the connection earthed-neutral system, the sensitivity current is blunt against an earth (ground) fault in the

inverter output side. Earthing (Grounding) must conform with the requirements of national and local safety

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

14

 When the breaker is installed on the output side of the inverter, it may be unnecessarily operated by harmonics even

if the effective value is less than the rating.

In this case, do not install the breaker since the eddy current and hysteresis loss will increase, leading to temperature

rise.

 The following models are the standard breakers

relay (except NV-ZHA), NV with AA neutral wire open-phase protection

The other models are designed for harmonic and surge suppression

C2, earth leakage alarm breaker (NF-Z), NV-ZHA, NV-H

2 ×

70m5.5mm2 × 5m

3φ

IM

200V 2.2kW

lgm

....BV-C1, BC-V, NVB, NV-L, NV-G2N, NV-G3NA, NV-2F earth leakage

....NV-C/NV-S/MN series, NV30-FA, NV50-FA, BV-

2

INSTALLATION

AND WIRING

This chapter provides an "INSTALLATION AND WIRING" of
this product.
Always read the instructions before using the equipment.

2.1 Removal and installation of the converter (FR-HC2) front

cover .............................................................................................. 16

2.2 Removal and installation of the outside box (FR-HCB2) front

cover .............................................................................................. 18

2.3 Installation ..................................................................................... 19

2.4 Protruding the heatsink................................................................ 21

2.5 Installation of peripheral devices ................................................ 23

2.6 Main circuit terminal specifications ............................................ 27

2.7 Wiring of main circuit (FR-HC2-7.5K to 75K, FR-HC2-H7.5K to

H220K)............................................................................................ 34

2.8 Wiring of main circuit (FR-HC2-H280K) ...................................... 41

2.9 Wiring of main circuit (FR-HC2-H400K, H560K) ......................... 47

2.10 Notes on earthing (grounding) .................................................... 53

2.11 Compatible inverter for the high power factor converter ......... 54

2.12 Wiring of several inverters to one converter.............................. 56

2.13 Wiring of control circuit ............................................................... 58

1

2

3

15

4

5

6

Removal and installation of the converter (FR-HC2) front cover

1)Loosen the installation screws of the front
cover.

2)Pull the front cover toward you to remove by pushing an
installation hook using left fixed hooks as supports.

Installation hook

Front cover

Front cover

Front
cover

Front cover

R

E
G

E
N

PWR

P

.
C

P
Y

D
R

IV
E

M

O

N

R

EG

EN

P
W

R

P
.CPY

DRIVE

M

O

N

R
E
G

E
N

PWR

P
.
C
P

Y

D

R

I
V
E

MON

1) Insert the two fixed hooks on the left side
of the front cover into the sockets of the
inverter.

3) Tighten the installation
screws and fix the front
cover.

2)

Using the fixed hooks as supports,
securely press the front cover against
the inverter. (Although installation can
be done with the operation panel
mounted, make sure that a connector
is securely fixed.)

2.1 Removal and installation of the converter (FR-HC2) front cover

Removal of the operation panel

1) Loosen the two fixed screws on the operation panel.

(These screws cannot be removed.)

2) Push the left and right hooks of the operation panel and pull

the operation panel toward you to remove.

When reinstalling the operation panel, insert it straight to reinstall securely and tighten the screws of the operation panel.

15K or lower

Removal

Reinstallation

16

2

INSTALLATION AND WIRING

30K or higher

1) Loosen the installation screws of
the front cover 1, and remove the
front cover 1.

2) Loosen the installation screw of
the front cover 2.

3) Push the two installation hooks on the right to
remove, and pull the front cover toward you
using the left fixed hooks as supports.

Front cover 2 Front cover 2

1) Insert the two fixed hooks on the left side of the front cover 2
into the sockets of the body.

2) Using the fixed hooks as supports, securely press
the front cover 2 against the body.
(Although installation can be done with the
operation panel mounted, make sure that a

connector is securely fixed.)

3) Tighten the installation screw of the front cover 2.

4) Fit the front cover 1 and fix it with the
installation screws.

REMARKS

For the 160K or higher, the front cover 1 is separated into two parts.

Removal

Front cover 1

Reinstallation

Removal and installation of the converter (FR-HC2) front cover

Installation hook

Front cover 2

NOTE



Fully make sure that the front cover has been reinstalled securely. Always tighten the installation screws of the front cover.

 The same serial number is printed on the capacity plate of the front cover and the rating plate of the converter. Before

reinstalling the front cover, check the serial numbers to ensure that the cover removed is reinstalled to the converter
from where it was removed.

Front cover 2

Front cover 1

17

Removal and installation of the outside box (FR-HCB2) front cover

Front cover

Front cover

1) Loosen the installation screws of the front cover. 2) For removal, pull off the front cover.

1)

Securely press the front cover
against the outside box.

2) Tighten the cover with mounting
screws.
(Tightening torque: 1.7N m)

2.2 Removal and installation of the outside box (FR-HCB2) front cover

Removal

Reinstallation

Front cover

NOTE



Fully make sure that the front cover has been reinstalled securely. Always tighten the installation screws of the front cover.

 The same serial number is printed on the capacity plate of the front cover and the rating plate of the outside box.

Before reinstalling the front cover, check the serial numbers to ensure that the cover removed is reinstalled to the
outside box from where it was removed.

Front cover

18

2

INSTALLATION AND WIRING

Installation

Fix six points for 160K to 280K, and eight
points for 400K and 560K.

7.5K, 15K

30K or higher

NOTE

 When encasing multiple converters, install

them in parallel as a cooling measure.



Install the converter vertically.

Refer to the clearance
on the next page.

Vertical

Direct sunlight

High temperature,
high humidity

Horizontal placement

Mounting to
combustible material

Oil mist, flammable
gas, corrosive gas,
fluff, dust, etc.

Vertical mounting
(When installing two or

more converters, install
them in parallel.)

Transportation by
holding the front cover

Vibration
(5.9m/s

2

or more at 10

to 55Hz (directions of X,
Y, Z axes))

 2.9m/s2 or more for the

160K or higher

2.3 Installation

Incorrect installation and connection may cause the equipment to operate improperly and its lifespan to be reduced

considerably. Please handle the unit properly in accordance with the information on each section as well as the precautions in

this manual.

2.3.1 Converter placement

(1) Installation of the converter

Installation on the enclosure

MO

N

P
.
C
P

Y

PW
R

R
E
G

E
N

D
R

I
V
E

 The converter consists of precision mechanical and electronic parts. Never install or handle it in any of the following

conditions as doing so could cause an operation fault or failure.

19

Installation

5cm
or more

Clearance (front)Surrounding air temperature and humidity

Measurement
position

Measurement
position

Converter

Leave enough clearance and take
cooling measures.

5cm

5cm

5cm

20cm or more

75K or higher55K or lower

20cm or more

10cm
or more

10cm
or more

10cm
or more

5cm
or more

5cm
or more

Temperature:

-10°C to 50°C
Ambient humidity:
90% RH maximum

Clearance (side)

Converter

Guide Guide

Enclosure Enclosure

Guide

(a) Horizontal arrangement

(b) Vertical arrangement

Converter

Inverter

Inverter

Converter

Inverter

Converter

Converter Converter

<Good example> <Bad example>

(2) Clearances around the converter

To ensure ease of heat radiation and maintenance, leave at least the shown clearance around the converter. At least the
following clearance are required under the converter as a wiring space, and above the converter as a heat radiation space.

REMARKS

For replacing the cooling fan of the 160K or higher, 30cm of space is necessary in front of the inverter. Refer to page 141 for fan

replacement.

(3) Converter mounting orientation

Mount the converter on a wall as specified. Do not mount it horizontally or any other way.

(4) Above the converter

Heat is blown up from inside the converter by the small fan built in the unit. Any equipment placed above the converter should
be heat resistant.

(5) Arrangement of multiple inverters and converters

When installing multiple inverters and converters in the
same enclosure, generally arrange them horizontally as
shown in the right figure (a). When it is inevitable to
arrange them vertically to minimize space, take such
measures as to provide guides since heat from the
bottom converters can increase the temperatures in the
top inverters, causing inverter failures.

When installing multiple inverters and converters, full
caution must be taken not to let the surrounding air
temperature of the converters and inverters exceed the
permissible value. Avoid the temperature to exceed the
value by providing ventilation and increasing the
enclosure size, etc.

Arrangement of multiple inverters and converters

(6) Placement of ventilation fan and converter

Heat generated in the converter 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 converter to cool air.)

20

Placement of ventilation fan and converter

2

INSTALLATION AND WIRING

Protruding the heatsink

200 200

484

13954

18

985

6-M10 screw

Hole

771

1300

21125821

315

315

Hole

6-M10 screw

2.4 Protruding the heatsink

When installing a converter inside an enclosure, the heat generated in the enclosure can be greatly reduced by protruding the
heatsink of the converter.
This installation method is recommended when downsizing the enclosure and such.

2.4.1 When using a heatsink protrusion attachment (FR-A7CN)

For the FR-HC2-7.5K to 75K and FR-HC2-H7.5K to H110K, a heatsink can be protruded outside the enclosure using a
heatsink protrusion attachment (FR-A7CN). (For the 160K or higher, the attachment is not necessary when the heatsink is to
be protruded.)
Refer to the table below for the applicable heatsink protrusion attachments.
For a panel cut dimension drawing and an installation procedure of the heatsink protrusion attachment (FR-A7CN) to the
converter, refer to a manual of "heatsink protrusion attachment".

Heatsink protrusion attachments

Model Name Applicable converter

FR-A7CN02 FR-HC2-7.5K

FR-A7CN03 FR-HC2-H7.5K, H15K

FR-A7CN04 FR-HC2-15K

FR-A7CN05

FR-A7CN09

FR-A7CN12 FR-HC2-55K

FR-A7CN13 FR-HC2-H75K

FR-A7CN14 FR-HC2-H55K

FR-HC2-30K

FR-HC2-H30K

FR-HC2-75K

FR-HC2-H110K

2.4.2 Heatsink protrusion for 160K or higher

(1) Enclosure cut
Cut the enclosure according to the capacity of the converter.

FR-HC2-H160K, H220K FR-HC2-H280K

984

FR-HC2-H400K, H560K

662

6-M10 screw

300 300

15

Hole

95415

21

Protruding the heatsink

Upper installation

frame (rear side)

Lower installation

frame (rear side)

Removal

Removal

Converter

Inside the
enclosure

Enclosure

Exhausted air

Installation

frame

Dimension of
the outside of
the enclosure

Cooling

wind

D1

∗

Converter model D1
FR-HC2-H160K, H220K 185
FR-HC2-H280K to H560K 184

The enclosure enclosing FR-HC2-H160K and higher

has a finger guard on its back. The thickness of the
enclosure should be less than 10mm (), and do not

place anything around the finger guard to avoid

contact with the finger guard.

Enclosure

Finger guard

10∗

140

6

(2) Moving and removing the back installation frames

FR-HC2-H160K to H280K

One installation frame is attached to each of the upper and lower parts

of the converter. Change the position of the rear side installation frame

on the upper and lower sides of the converter to the front side as

shown on the right. When changing the installation frames, make sure

that the installation orientation is correct.

FR-HC2-H400K, H560K

The converter has installation frames: two on the top and the two on

the bottom. As shown on the right, remove the back installation frames

on the top and bottom of the converter.

Shift

Shift

Upper
installation
frame

Lower
installation
frame

(3) Installing the converter to the enclosure
Protrude the heatsink of the converter from the installation enclosure, and secure the converter using the top and bottom
installation frames.

NOTE

22

• Protruding area contains a cooling fan, so it cannot be used in the environment where water drops, oil mist, dust and
other substances exist.

• Foreign substances such as screws and dust must be prevented to enter in the converter or the cooling fan section.

2

INSTALLATION AND WIRING

Installation of peripheral devices

MODEL
FR-HCL21-XXX

AC REACTOR

SERIAL XXXXX

MODEL
FR-HCL22-XXX

AC REACTOR

SERIAL XXXXX

Reactor 1(FR-HCL21)

Reactor 2(FR-HCL22)

Check "MODEL" on the rating plates of the reactor 1
(FR-HCL21) and the reactor 2 (FR-HCL22).

2.5 Installation of peripheral devices

2.5.1 Installation of reactor 1 and reactor 2

(1) Model name confirmation

Take caution as the appearances of the reactor 1 (FR-HCL21) and the reactor 2 (FR-HCL22) are very similar.

(2) Clearance

Because the reactor 1 (FR-HCL21) and the reactor 2 (FR-HCL22) generate heat, leave sufficient space around them.

10cm or more

5cm or more

5cm or more

(3) Installation place

Install the reactor 1 (FR-HCL21) and the reactor 2 (FR-HCL22) on nonflammable material. Direct installation on a

flammable material will cause a fire.

(4) Environment

Avoid places where the equipment is subjected to oil mist, flammable gases, fluff, dust, dirt, etc.

Install the equipment in a clean place or protect them from suspended substances.

23