Mitsubishi Electric FR-XC-18.5K-PWM, FR-XC-11K, FR-XC-7.5K, FR-XC-22K, FR-XC-15K Instruction Manual

INVERTER

XC
INSTRUCTION MANUAL

Multifunction regeneration converter

FR-XC-7.5K to 55K
FR-XC-18.5K-PWM to 55K-PWM
FR-XC-H7.5K to H55K
FR-XC-H18.5K-PWM to H55K-PWM

OUTLINE

INSTALLATION AND WIRING

PARAMETERS

PROTECTIVE FUNCTIONS

PRECAUTIONS FOR

MAINTENANCE AND

INSPECTION

SPECIFICATIONS

1

2

3

4

5

6

Thank you for choosing this Mitsubishi Electric multifunction regeneration converter.

WARNING

CAUTION

CAUTION

∗1 10 to +40°C (non-freezing) at the +40°C rating.

This Instruction Manual provides handling information and precautions for use of the this product. Incorrect handling might cause
an unexpected fault. Before using this product, always read this Instruction Manual carefully to ensure proper use of this product.
Please forward this Instruction Manual to the end user.

 Fire prevention

Safety instructions

Do not attempt to install, operate, maintain or inspect the
product until you have read through this Instruction Manual
and supplementary documents carefully to 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, qualified personnel
means a person who meets all the following conditions.

• A person who possesses a certification in regard with
electric appliance handling, or person 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 (for example, light curtain) connected to
the safety control system, or a person who has read these
manuals thoroughly and familiarized themselves with the
protective devices.

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 lead to a

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

 Electric shock prevention

WARNING

 Do not remove the front cover or the wiring cover while the power

of this product 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 circuits and get an electric shock.

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

operation panel is OFF. Any person who is involved in wiring or
inspection shall wait for 10 minutes or longer after power 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
multifunction regeneration converter 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.

 The product body must be installed before wiring. Otherwise,

electric shock or injury may result.

 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.

CAUTION

 This product must be installed on a nonflammable wall without

any through holes so that nobody touches the heatsink, 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 this 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 as specified in the

Instruction Manual. Otherwise a burst, damage, etc. may occur.

 The cables must be connected to the correct terminals.

Otherwise a burst, damage, etc. may occur.

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

damage, etc. may occur.

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

touch the multifunction regeneration converter as it will be
extremely hot. Touching it may cause a burn.

 Additional instructions
The following instructions must be also followed. If the product
is handled incorrectly, it may cause an unexpected fault, injury,
or electric shock.

CAUTION

Transportation and installation

 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 place any heavy object on the product.
 Do not stack the boxes containing products higher than the

number recommended.

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

Doing so may cause a fall or failure of the product.

 The installing orientation of the product must be correct.
 Do not install or operate this product if it is damaged or has parts

missing.

 Prevent conductive items such as screws and metal fragments, or

flammable substances such as oil from entering this product.

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

to impact.

 The surrounding air temperature must be -10 to +50°C

freezing). Otherwise the product may be damaged.

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

Otherwise the product may be damaged. (For the details, refer to

page 29.)

 The temporary storage temperature (applicable to a short limited

time such as a transportation time) must be between -20 and
+65°C. Otherwise the 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.

 This product must be used at an altitude of 2500 m or less, with

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

2

5.9 m/s

or less vibration at 10 to 55 Hz (directions of X, Y, Z
axes). Otherwise the product may be damaged. (For the
installation at an altitude above 1000 m, consider a 3% reduction
in the rated current per 500 m increase in altitude.)

etc.), included in fumigants to sterilize or disinfect wooden
packages, infiltrate into this product, the product may be
damaged. Prevent residual fumigant components from being
infiltrated into the product when packaging, or use an alternative
sterilization or disinfection method (heat disinfection, etc.). Note
that sterilization of disinfection of wooden package should be
performed before packing the product.

∗1 (non-

CAUTION

Test operation

 Before starting the operation, confirm or adjust the parameter

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

 Before starting the operation, check the wiring of each peripheral

device. Faulty wiring may cause some machines to make
expected motions.

Safety instructions

1

WARNING

Usage

 Any person must stay away from the equipment after using the

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

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

inverter before clearing the fault in the product as the inverter will
restart a motor suddenly after a fault clear.

 Use only specified inverters. Connection of any other electrical

equipment to the output of this product may damage the
equipment.

 Do not modify this product.
 Do not remove any part which is not instructed to be removed in

the Instruction Manuals. Doing so may lead to a failure or
damage of this product.

CAUTION

Usage

 Do not start or stop this product frequently 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 and the inverter.

 As all parameters return to their initial values after Parameter

clear or All parameter clear is performed, the needed parameters
for the product operation must be set again before the operation
is started.

 Before running this product or the inverter which had been stored

for a long period, perform an inspection and a test operation.

 To avoid damage due to static electricity, static electricity in your

body must be discharged before you touch this product.

 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, inverter, or an
external device controlling the inverter.

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

check for the wiring fault (such as short circuit) and damage to
internal parts of this product, etc. 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 the 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.

General instruction

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

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

2

Safety instructions

CONTENTS

1 OUTLINE 7

1.1 Pre-operation instructions 8

1.1.1 Features of FR-XC series converters ...............................................................................................................8

1.1.2 Function selection switch assembly (SW2) ....................................................................................................10

1.1.3 Product checking and parts identification .......................................................................................................10

1.1.4 Harmonic suppression guidelines in Japan ....................................................................................................11

1.2 Component names 14

1.3 FR-XC series converter and peripheral devices 16

1.4 Precautions for selecting peripheral devices 17

1.4.1 Techniques and measures for electromagnetic compatibility (EMC)..............................................................17

1.4.2 Peripheral device list.......................................................................................................................................19

1.4.3 Selecting the rated sensitivity current for the earth leakage circuit breaker ...................................................23

2 INSTALLATION AND WIRING 25

2.1 Removal and reinstallation of the converter covers 26

2.1.1 30K converters or lower ..................................................................................................................................26

2.1.2 37K converters or higher ................................................................................................................................27

2.2 Removal and reinstallation of the FR-XCB reactor cover 28

2.3 Installation of the converter and enclosure design 29

2.3.1 Converter installation environment .................................................................................................................29

2.3.2 Cooling system types for converter enclosure ................................................................................................31

2.3.3 Converter installation ......................................................................................................................................32

2.3.4 Protruding the heat sink through a panel........................................................................................................34

2.4 Installation of peripheral devices 36

2.4.1 Installation of reactor (FR-XCL) ......................................................................................................................36

2.4.2 Installation of box-type reactor (FR-XCB) .......................................................................................................37

2.5 Connection of the converter and the inverter 38

2.5.1 Inverter selection ..............................................................................38

2.5.2 Switching between the common bus regeneration mode and the power regeneration mode ........................40

2.5.3 Function enable/disable selection (Pr.416).....................................................................................................40

2.5.4 Inverter parameter settings.............................................................................................................................40

2.5.5 Temperature derating selection ......................................................................................................................40

2.6 Main circuit terminal specification 41

2.6.1 Details on the main circuit terminals ...............................................................................................................41

2.6.2 Main circuit terminal block layout....................................................................................................................41

2.6.3 Cable size of the main circuit terminals and the earth (ground) terminal........................................................43

2.7 Control circuit specification 50

2.7.1 Details on the control circuit terminals ............................................................................................................50

2.7.2 Control logic switchover..................................................................................................................................51

2.7.3 Control circuit terminal layout .........................................................................................................................53

2.7.4 Wiring precautions ..........................................................................................................................................55

2.7.5 Details on the control circuit terminals on the FR-XCB...................................................................................56

2.8 Wiring 57

CONTENTS

3

2.8.1 Terminal connection diagram ......................................................................................................................... 57

2.8.2 Wiring (common bus regeneration mode with harmonic suppression disabled) ............................................ 60

2.8.3 Wiring (power regeneration mode) ................................................................................................................. 62

2.8.4 Wiring (common bus regeneration mode with harmonic suppression enabled)............................................. 64

2.8.5 When using separate power supplies for the control circuit and the main circuit ........................................... 65

2.9 Earthing (Grounding) precautions 66

2.10 Connection of the converter and the multiple inverters 67

2.10.1 Connection in common bus regeneration mode............................................................................................. 67

2.11 PU installation on converter 70

2.12 Communication operation 71

2.13 Before powering and starting operation 72

2.13.1 Installation ...................................................................................................................................................... 72

2.13.2 Powering ........................................................................................................................................................ 72

2.13.3 Operation........................................................................................................................................................72

2.14 Digital characters and their corresponding printed equivalents 73

3 PARAMETERS 75

3.1 Operation panel (FR-DU08) 76

3.1.1 Components of the operation panel ............................................................................................................... 76

3.1.2 Basic operation of the operation panel (factory setting) .................................................................................77

3.1.3 Digital characters and their corresponding printed equivalents...................................................................... 78

3.1.4 Changing the parameter setting value ........................................................................................................... 78

3.2 Monitoring the converter status 79

3.2.1 Monitoring of input voltage or bus voltage...................................................................................................... 79

3.2.2 First priority monitor screen ............................................................................................................................79

3.3 Parameter unit (FR-PU07) / Parameter unit with battery pack (FR-PU07BB(-L)) 80

3.3.1 Components of the parameter unit ................................................................................................................. 80

3.3.2 Monitoring function ......................................................................................................................................... 81

3.3.3 Function menu................................................................................................................................................82

3.4 Parameter list 84

3.5 Parameter details 86

3.5.1 Showing/hiding extended parameters (Pr.0) .................................................................................................. 86

3.5.2 Power frequency input to the converter (Pr.1 and Pr.2) .................................................................................86

3.5.3 Input terminal function selection (Pr.3, Pr.4, and Pr.7)...................................................................................87

3.5.4 Operation selection for the SOF signal and the OH signal (Pr.8 and Pr.9) .................................................... 88

3.5.5 Output terminal function selection (Pr.11, Pr.12, and Pr.16).......................................................................... 89

3.5.6 DC voltage control (Pr.22, Pr.23, Pr.80, and Pr.81) .......................................................................................90

3.5.7 Converter parts life display (Pr.31 to Pr.33) ...................................................................................................91

3.5.8 Maintenance timer alarm (Pr.34 and Pr.35) ...................................................................................................92

3.5.9 Instantaneous power failure detection hold signal (Pr.44) ............................................................................. 93

3.5.10 Setting status display of function selection switch assembly (SW2) .............................................................. 94

3.5.11 Function selection for monitor item indication (Pr.46 to Pr.48, Pr.52, and Pr.896) ........................................95

3.5.12 Operation selection at instantaneous power failure (Pr.57) ........................................................................... 97

3.5.13 Free parameter (Pr.58 and Pr.59) .................................................................................................................. 97

3.5.14 Disabling keys on the operation panel (Pr.61) ......................................................................................................97

3.5.15 Retry function (Pr.65, Pr.67 to Pr.69)............................................................................................................. 98

4

CONTENTS

3.5.16 Reset selection / disconnected PU detection / PU stop selection (Pr.75) ....................................................100

3.5.17 Parameter write disable selection (Pr.77) .....................................................................................................101

3.5.18 Current control (Pr.82 and Pr.83) .................................................................................................................102

3.5.19 Wiring and configuration of PU connector ....................................................................................................103

3.5.20 Initial settings and specifications of RS-485 communication (Pr.117 to Pr.124) ..........................................104

3.5.21 Mitsubishi inverter protocol (computer link communication) .........................................................................105

3.5.22 Initial setting and specification of the CC-Link communication function (Pr.542 to Pr.544)..........................117

3.5.23 Operation at a communication error (Pr.500 to Pr.502)................................................................................123

3.5.24 Communication EEPROM write selection (Pr.342) ......................................................................................124

3.5.25 Setting of parameter unit / operation panel (Pr.145, Pr.990, and Pr.991) ....................................................125

3.6 Parameter clear / All parameter clear on the operation panel 126

3.7 Copying and verifying parameters on the operation panel 126

3.7.1 Parameter copy ............................................................................................................................................127

3.7.2 Parameter verification...................................................................................................................................128

3.8 Checking parameters changed from their initial values (initial value change list) 129

4 PROTECTIVE FUNCTIONS 131

4.1 Converter fault and indication 132

4.2 Reset method for the protective functions 132

4.3 List of indications 133

4.4 Causes and corrective actions 134

4.5 Check and clear of the fault history 143

4.6 Check first when you have a trouble 144

5 PRECAUTIONS FOR MAINTENANCE AND

INSPECTION 145

5.1 Inspection item 146

5.1.1 Daily inspection.............................................................................................................................................146

5.1.2 Periodic inspection........................................................................................................................................146

5.1.3 Daily and periodic inspection list...................................................................................................................147

5.1.4 Continuity test ...............................................................................................................................................148

5.1.5 Cleaning........................................................................................................................................................148

5.1.6 Replacement of parts....................................................................................................................................149

5.2 Measurement of main circuit voltages, currents, and powers 152

5.2.1 Insulation resistance test using megger .......................................................................................................153

5.2.2 Pressure test.................................................................................................................................................153

6 SPECIFICATIONS 155

6.1 Rating 156

6.1.1 FR-XC-[ ]K ....................................................................................................................................................156

CONTENTS

5

6.1.2 FR-XC-[ ]K-PWM .......................................................................................................................................... 158

6.1.3 Combination matrix of FR-XCL and FR-XC(-PWM) ..................................................................................... 160

6.1.4 Combination matrix of FR-XCB and FR-XC(-PWM).....................................................................................160

6.2 Common specifications 161

6.3 Outline dimension drawings 162

6.3.1 Multifunction regeneration converter

(FR-XC (-PWM))........................................................................................................................................... 162

6.3.2 Dedicated stand-alone reactor (FR-XCL)..................................................................................................... 165

6.3.3 Dedicated box-type reactor (FR-XCB) ......................................................................................................... 171

APPENDIX 173

Appendix 1 Major differences between FR-XC and FR-XC-PWM ........................................................... 174

Appendix 2 Instruction code list................................................................................................................ 175

Appendix 3 Instructions for compliance with the EU Directives............................................................ 176

Appendix 4 Instructions for UL and cUL .................................................................................................. 179

Appendix 5 Instructions for EAC............................................................................................................... 181

Appendix 6 Restricted Use of Hazardous Substances in Electronic and Electrical Products ............ 182

Appendix 7 Referenced Standard (Requirement of Chinese standardized law)................................... 182

6

CONTENTS

1 OUTLINE

Thischapterexplainstheoutlineofthisproduct.
Alwaysreadtheinstructionsbeforeuse.

1.1 Pre-operation instructions .......................................................8

1.2 Component names....................................................................14

1.3 FR-XC series converter and peripheral devices ....................16

1.4 Precautions for selecting peripheral devices ........................17

<Abbreviations>

FR-XC series converter................... Multifunction regeneration converter (FR-XC or FR-XC-PWM converter)

PU ................................................... Operation panel (FR-DU08) and parameter unit (FR-PU07/FR-PU07BB(-L))

FR-PU07 ......................................... Parameter unit (FR-PU07/FR-PU07BB(-L))

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

<Trademarks>

• Microsoft and Visual C++ are registered trademarks of Microsoft Corporation in the United States and other countries.

• Other company and product names herein are the trademarks and registered trademarks of their respective owners.
<Notes on descriptions in this Instruction Manual>

• Connection diagrams in this Instruction Manual appear with the control logic of the input terminals as sink logic, unless

otherwise specified. (For the control logic, refer to page 51.)

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 details, refer to page 11.)

OUTLINE

1

7

Pre-operation instructions

1.1 Pre-operation instructions

Incorrect handling may cause the equipment to operate improperly or reduce its life considerably. Also, incorrect handling may

damage the FR-XC series converter and the inverter. Please handle the unit properly in accordance with the information on

each section as well as the precautions and instructions of the Instruction Manual.

1.1.1 Features of FR-XC series converters

NOTE

• It is not a fault if noise comes from the dedicated reactor during regenerative driving of the converter (in other words, it is a

fault if noise comes despite the stop state of the converter by the Converter stop (SOF) signal).

• If needed, devise methods of reducing noise by modifying the enclosure in which the reactor is installed.

Common bus regeneration mode

Enables continuous regenerative operation at 100% torque. This mode

supports continuous regenerative operations including line operation.

When the converter is connected to multiple inverters, regeneration

energy from an inverter is used for the other inverters. (The FR-XC series

converter can be used as a common converter.) Excessive energy is

returned to the power supply, saving on the energy consumption.

Use the FR-XC series converter in combination with the FR-XCL,

dedicated stand-alone reactor (option).

FR-XCLPower supply

FR-XC

MotorInverter

M

MotorInverter

M

NOTE

• Note that the applicable inverter capacity and current are different if using the FR-XC-(H)18.5K-PWM or FR-XC-(H)22K-PWM

converter with its harmonic suppression function disabled. (Refer to page 156.)

Power regeneration mode

For power driving, the converter section of inverter unit supplies power, and

for regenerative driving, the FR-XC series converter returns power to the

power supply. (The FR-XC series converter cannot be used as a common

converter.)

Since the capacity of power regeneration converter is selectable according to

the regenerative power, the compact and inexpensive power regeneration

converter is applicable when the regenerative power is smaller than the

inverter capacity.

Use the FR-XC series converter in combination with the FR-XCL, dedicated

stand-alone reactor (option).

NOTE

• When installing the converter in a common bus system, do not use the converter in the power regeneration mode.

AC reactor

(FR-HAL)

FR-XCL

Inverter

FR-XC

MotorPower supply

M

8

OUTLINE

Pre-operation instructions

Harmonic suppression

(FR-XC-(H)22K or higher, FR-XC-(H)18.5K-PWM or higher)

The inverter unit has a converter section (rectifier circuit) and generates

power supply harmonics, which may affect the power generator, power

factor correction capacitor, etc. Power supply harmonics are different from

noise and leakage currents in source, frequency band and transmission

path. Power supply harmonics may be suppressed by using the FR-XC

series converter with its harmonic suppression function enabled, allowing

the compliance with the harmonic suppression guidelines issued by the

former Japanese Ministry of International Trade and Industry (currently the

Ministry of Economy, Trade and Industry). The FR-XC series converter with

its harmonic suppression function enabled is classified as the self-excitation

three-phase bridge circuit, and achieves K5 (the conversion factor) = 0. (It is assumed that the FR-XC series converter

generates no harmonics.)

Use the FR-XC series converter in combination with the FR-XCB, dedicated box-type reactor (option).

To enable the harmonic suppression function of the FR-XC-(H)22K or higher, switch to the common bus regeneration mode

and set Pr.416 = "1".

The harmonic suppression function is pre-enabled in the FR-XC-(H)[]K-PWM.

Power supply

FR-XCB

FR-XC

MotorInverter

M

MotorInverter

M

NOTE

• The harmonic suppression function is not available in the power regeneration mode.

• FR-XC-(H)15K or lower does not have the harmonic suppression function.

• Note that the applicable inverter capacity and motor current are different depending on the harmonic suppression function

condition of the FR-XC-(H)22K or FR-XC-(H)30K converter. (Refer to page 156.)

• Power supply harmonic suppression effect

Example of the FR-XC-18.5K-PWM

Condition: Load = 100%

Power factor = 0.99 or more

[Harmonic suppression disabled]

Input phase voltage

Input phase current

[Harmonic suppression enabled]

Input phase voltage

1

Input phase current

NOTE

• It does not mean that harmonic components completely disappear.

• When the load is light, harmonic suppression effect declines.

• When the power supply voltage is unstable, power harmonics flow in, making the harmonic current increase.

Temperature derating selection

By limiting the surrounding air temperature of the multifunction regeneration converter up to 40°C (the surrounding air

temperature of 40°C rating), rated current and applicable current can be increased. (Refer to page 40.)

OUTLINE

9

Pre-operation instructions

Switch Function

1

ON Common bus regeneration mode
OFF Power regeneration mode

2 For manufacturer setting. (Do not change from ON)

3

ON Surrounding air temperature of 50°C rating
OFF Surrounding air temperature of 40°C rating

4 For manufacturer setting. (Do not change from ON)

1.1.2 Function selection switch assembly (SW2)

The function can be changed by the function selection switches.

NOTE

• The changed switch setting is applied at the next power-ON or converter reset.

• If the switch 1 setting (the connection mode setting) does not match the actual wiring of the main circuit terminals, the

connection mode fault "E.T" occurs.

• By checking the parameter prevents unintended operation of multifunction regeneration converter caused by incorrect setting

of switch. (Refer to page 94.)

•Use Pr.416 Control method selection to enable or disable the harmonic suppression function. (Refer to page 40.)

1.1.3 Product checking and parts identification

Unpack the product and check the rating plate and the capacity plate of the multifunction regeneration converter to ensure
that the model and the rated output agree with the order and the product is intact.

Multifunction regeneration converter model

FR-XC- - 60K

Symbol

None

H 400 V class

Rating plate

Multifunction regeneration
converter model

7.5

Voltage class

200 V class

Capacity plate

Multifunction regeneration
converter model

Input rating

Output rating

SERIAL

Country of origin

PWMH

Converter capacity

Capacity (kW)

SERIAL

‵⁁‿‿⁁⁀‟‿⁁‶‷

∗

⁄‷⁀‹‷⁀‟‿⁁‶‷

FR-XC-22K

ᵡᵭᵬᵴᵣᵰᵲᵣᵰ

FR-XC-22K

›⁅

Symbol Circuit board coating

None Without

60 With
06 With

0$'(,1

Plated conductor

Without
Without

With

Symbol

None
PWM Harmonic suppression enabled

∗1 when Pr.416 = "9999"

Functional specification∗1

Harmonic suppression disabled

The rating for "HS" (Harmonic suppression) is shown on the rating plate of the FR-XC-(H)22K

∗

to 55K and FR-XC-(H)18.5K-PWM to 55K-PWM.

Dedicated stand-alone reactor (option) model

FR-XCL- K

Symbol

None

H 400 V class

10

H

Voltage class

200 V class

OUTLINE

Reactor capacity

Capacity (kW)

Dedicated box-type reactor (option) model

FR-XCB- K-

H

Voltage class

200 V class

H 400 V class

Symbol Circuit board coating

None Without

60 With

Reactor capacity

Capacity (kW)

None

Symbol

How to read the SERIAL number

Pre-operation instructions

Ratingplateexample

   

Symbol Year Month Control number

SERIAL

The SERIAL consists of one symbol, two characters indicating the

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

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

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

Accessory

• Earthing (grounding) cable (1)

For connection with a communication option. (Refer to page 71.)

• Communication option LED label (1)

For checking the LED indications on the communication option. (Refer to page 71.)

1.1.4 Harmonic suppression guidelines in Japan

Harmonic currents flow from the inverter to a power receiving point via a power transformer. The Harmonic Suppression

Guidelines was established to protect other consumers from these outgoing harmonic currents.

All capacity and all models of general-purpose inverter used by specific consumers are now covered by "the Harmonic

Suppression Guidelines for Consumers Who Receive High Voltage or Special High Voltage" (hereinafter referred to as

"the Specific Consumer Guidelines").

"Specific Consumer Guidelines"

This guideline sets forth the maximum harmonic currents outgoing from a high-voltage or especially high-voltage receiving

consumer who will install, add or renew harmonic generating equipment. If any of the maximum values is exceeded, this

guideline requires that consumer to take certain suppression measures.

• Maximum values of outgoing harmonic currents per 1 kW contract power

Received

power

voltage

6.6 kV 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70
22 kV 1.8 1.3 0.82 0.69 0.53 0.47 0.39 0.36
33 kV 1.2 0.86 0.55 0.46 0.35 0.32 0.26 0.24

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

1

OUTLINE

11

Pre-operation instructions

 Application of the specific consumer guidelines

Install, add or renew
equipment

Calculation of equivalent

Equal to or less
than reference
capacity

capacity total

Equivalent

capacity total

Above reference
capacity

Calculation of outgoing
harmonic current

Not more than

harmonic current upper

limit?

Equal to or less
than upper limit

Harmonic suppression
measures unnecessary

More than upper limit

Harmonic suppression
measures necessary

• Conversion factor

Classification Circuit type Conversion factor Ki

Without reactor K31 = 3.4

3

5

Three-phase bridge
(capacitor smoothing)

Self-excitation three-phase
bridge

With reactor (AC side) K32 = 1.8
With reactor (DC side) K33 = 1.8
With reactors (AC, DC sides) K34 = 1.4
When a multifunction regeneration converter with
harmonic suppression enabled is used

K5 = 0

• Equivalent capacity limit

Received power voltage Reference capacity

6.6 kV 50 kVA

22/33 kV 300 kVA
66 kV or more 2000 kVA

• Harmonic contents (values of the fundamental current is 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 (AC, DC sides) 28 9.1 7.2 4.1 3.2 2.4 1.6 1.4

• Calculation of equivalent capacity P0 of harmonic generating equipment

"Equivalent capacity" is the capacity of a 6-pulse converter converted from the capacity of consumer's harmonic

generating equipment and is calculated by the following equation. If the sum of equivalent capacities is higher than the

limit (refer to page 12), harmonics must be calculated by the equation in next subheading.

P0 = Σ (Ki × Pi) [kVA]

Ki: Conversion factor (Refer to page 12.)
Pi: Rated capacity of harmonic generating equipment
i: Number indicating the conversion circuit type

∗1 [kVA]

∗1 Rated capacity: Determined by the capacity of the

applied motor and found in the following table. The
rated capacity used here is used to calculate the
generated harmonic amount and is different from
the power supply capacity required for actual
inverter drive.

• Calculation of outgoing harmonic currents

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

ratio × harmonic contents

• Operation ratio: actual load factor × operation time ratio during 30 minutes

• Harmonic contents: Refer to the list of the harmonic contents.

12

OUTLINE

• Rated capacities and outgoing harmonic currents of inverter-driven motors

Pre-operation instructions

Applicable

motor

(kW)

Fundamental

wave current

(A)

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

Fundamental

wave

current

converted

from 6.6 kV

Rated

capacity

(kVA)

Outgoing harmonic current converted from 6.6 kV (mA)

(No reactor, 100% operation ratio)

(mA)

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

• Determining if a countermeasure is required

A countermeasure for harmonics is required if the following condition is satisfied: outgoing harmonic currents >

maximum value per 1 kW contract power × contract power.

• Harmonic suppression techniques

No.

Reactor

1

(FR-HAL or FR-HEL)
Multifunction
regeneration

2

converter
(FR-XC series)

Power factor

3

improving capacitor

Transformer multi-

4

phase operation

Passive filter

5

(AC filter)

6 Active filter

Item Description

Install an AC reactor (FR-HAL) on the AC side of the inverter or a DC reactor (FR-HEL) on its DC side,
or install both to suppress outgoing harmonic currents.
The multifunction regeneration converter with harmonic suppression enabled switches the converter
section ON/OFF to reshape an input current waveform into a sine wave, greatly suppressing
harmonics.
Use the FR-XC series converter with the FR-XCB box-type reactor.

When used with a reactor connected in series, the power factor improving correction capacitor can
absorb harmonic currents.

Use two transformers and establish connections with a phase angle difference of 30° (the wye to delta
connection or the delta to delta connection) to provide an effect corresponding to 12 pulses, reducing
low-degree harmonic currents.

A capacitor and a reactor are used together to reduce impedances at specific frequencies. Harmonic
currents are expected to be absorbed greatly by using this technique.
This filter detects the current in a circuit generating a harmonic current and generates a harmonic
current equivalent to a difference between that current and a fundamental wave current to suppress
the harmonic current at the detection point. Harmonic currents are expected to be absorbed greatly by
using this technique.

1

OUTLINE

13

Component names

(d)

(f)

(e)

(h)

(a)

(c)

(l)

(i)

(i)

(i)

(b)

(m)

(k)

(g)

(j)

(i)

1.2 Component names

Component names are shown below.

30K converters or lower

Symbol Name Description

(a) Control circuit terminal block cover

(b)

(c)
(d) PU connector

(e)

(f) Control circuit terminal block Connect cables for the control circuit. 50
(g)
(h) Charge lamp Stays ON while the power is supplied to the main circuit. 72
(i) Main circuit terminal block Connect cables for the main circuit. 41
(j) Connector for manufacturer setting
(k) Cooling fan
(l) Connector for communication option Connect cables for the communication option (FR-A8NC). 71

(m)

Communication operation status
inspection port
(for the FR-A8NC)

Main control circuit terminal block cover

Operation status 7-segment LED
display

Control logic switchover jumper connector

Function selection switch assembly
(SW2)

Remove it for installing a communication option, wiring the control circuit
terminals, or changing the SW2 switches.

Check the state (ON/blinking) of the communication operation status
indicators on the communication option (FR-A8NC) when the option is
installed.

Remove it for wiring. 26
Connector for parameter units. Also used for the RS-485 communication.
Check the display indication or LED state (ON/blinking) for the operation

status of the converter.

Change the control logic of input signals as necessary. 51

Do not remove the cap from the connector.
Cools the multifunction regeneration converter.

1: Connection mode (common bus regeneration mode
/ power regeneration mode) selection
2: For manufacturer setting
3: Temperature derating selection
4: For manufacturer setting

to page

26

⎯

103

72

⎯

149

10

Refer

14

OUTLINE

37K converters or higher

Component names

(k)

(d)

(a)

(b)

(c)

(e)

(f)

(h)

(l)

(m)

(g)

(j)

(i)

(j)

Symbol Name Description

(a) Control circuit terminal block cover

Communication operation status

(b)

(c)
(d) PU connector

(e)

(f) Control circuit terminal block Connect cables for the control circuit. 50
(g)
(h) Charge lamp Stays ON while the power is supplied to the main circuit. 72
(i) Main circuit terminal block Connect cables for the main circuit. 41
(j) Connector for manufacturer setting
(k) Cooling fan
(l) Connector for communication option Connect cables for the communication option (FR-A8NC). 71

(m)

inspection port
(for the FR-A8NC)

Main control circuit terminal block cover

Operation status 7-segment LED
display

Control logic switchover jumper connector

Function selection switch assembly
(SW2)

Remove it for installing a communication option, wiring the control circuit
terminals, or changing the SW2 switches.

Check the state (ON/blinking) of the communication operation status
indicators on the communication option (FR-A8NC) when the option is
installed.

Remove it for wiring. 26
Connector for parameter units. Also used for the RS-485 communication.
Check the display indication or LED state (ON/blinking) for the operation

status of the converter.

Change the control logic of input signals as necessary. 51

Do not remove the cap from the connector.
Cools the multifunction regeneration converter.

1: Connection mode (common bus
regeneration mode / power regeneration
mode) selection
2: For manufacturer setting
3: Temperature derating selection
4: For manufacturer setting

to page

26

⎯

103

72

⎯

149

10

Refer

1

OUTLINE

15

FR-XC series converter and peripheral devices

(Refer to page 60.)

(Refer to page 57.)

(Refer to page 51.)

(Refer to page 21.)

(Refer to page 19.)

1.3 FR-XC series converter and peripheral

devices

<Example for the common bus regeneration mode>

Three-phase AC power supply
Use power supply within the
permissible specifications of the
converter.

Molded case circuit breaker (MCCB) or
earth leakage circuit breaker (ELB) and fuse
The breaker must be selected carefully since
an inrush current flows in the converter at
power ON.

FR-XC series converter
Install and wire correctly.

Magnetic contactor (MC)
Install the MC to ensure safety.
Do not use this MC to start and stop the
converter and the inverter. Doing so will
shorten the life of the inverter and the
converter.

Do not install a molded case
circuit breaker (MCCB) on the
main circuit cables between the
inverter and the converter
(terminals P to P and terminals N
to N).

Earth (ground)

Dedicated box-type reactor
FR-XCB
(used when harmonic
suppression enabled)
Confirm that the capacity of the
FR-XCB reactor is appropriate
for the capacity of the converter.

Dedicated stand-alone reactor
FR-XCL
(used when harmonic
suppression disabled)
Confirm that the capacity of the
FR-XCL reactor is appropriate for
the capacity of the converter.

Earth (ground)

Devices on the inverter's output side
Do not install a power factor correction capacitor or surge
suppressor or capacitor type filter on the inverter's output
side.
When installing a molded case circuit breaker (MCCB) on
the inverter's output side, contact the manufacturer of
MCCB for MCCB selection.
Earth (ground)
Always earth (ground) the converter, the dedicated reactor
FR-XCL or FR-XCB, the inverter, and the motor.

R2 S2PNT2

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

Inverter

Select an inverter according to
the capacity of the converter.
The control logic (sink
logic/source logic) of the
converter and the inverter must
be matched.

Earth (ground)

Motor

Earth (ground)

16

Earth (ground)

OUTLINE

Precautions for selecting peripheral devices

Noise propagated
through power supply
cable

…Path (c)

…Path (b)

…Path (a)

Noise directly radiated
from converter

…Path (d), (e)

Air propagated
noise

…Path (f)

Electrical path
propagated noise

…Path (h)

…Path (g)

Multifunction regeneration
converter generated
electromagnetic noise

Electromagnetic
induction noise

Electrostatic
induction noise

Noise radiated from
power supply cable

Noise radiated from
motor connection cable

Noise from earthing
(grounding) cable
due to leakage current

1.4 Precautions for selecting peripheral devices

1.4.1 Techniques and measures for electromagnetic

compatibility (EMC)

Some electromagnetic noises enter the converter to cause the converter malfunction, and others are radiated by the

converter to cause the peripheral devices to malfunction. (The former is called electromagnetic susceptibility (EMS) problem,

the latter is called electromagnetic interference (EMI) problem, and both is called electromagnetic compatibility (EMC)

problem.) Though the FR-XC series converter is designed to be immune to noises, it requires the following basic measures

and EMS measures as it handles low-level signals. Pay attention to the electromagnetic noises that could be generated by the

FR-XC series converter. If these noises cause peripheral devices to malfunction, EMI measures should be taken to suppress

noises. These techniques differ slightly depending on EMI paths.

Basic measures

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

them.

• Use shielded twisted pair cables for the detector connecting and control signal cables and connect the sheathes of the

shielded cables to terminal SD.

• Ground (earth) the reactor, the converter, the inverter, etc. at one point. (Refer to page 66.)

EMS measures to reduce electromagnetic noises that enter the

When devices that generate many electromagnetic noises (which use magnetic contactors, electromagnetic brakes, many

relays, for example) are installed near the converter and the converter may malfunction due to electromagnetic noises, the

following countermeasures must be taken.

• Provide surge suppressors for devices that generate many electromagnetic noises to suppress electromagnetic noises.

• Install data line filters to signal cables.

• Ground (Earth) the shields of the detector connection and control signal cables with cable clamp metal.



Converter-generated noises are largely classified into those radiated by the converter itself and by the cables (I/O)

connected to its main circuit, those electromagnetically and electrostatically induced to the signal cables of the peripheral

devices close to the power cable connected to the converter main circuit, and those transmitted through the power cables.

converter and cause it to malfunction

EMI measures to reduce electromagnetic noises that are radiated by the
converter to cause the peripheral devices to malfunction

(g)

Instrument Receiver

(b)

(a)

Motor

(e)

Dedicated reactor

or

box-type reactor

Multifunction

regeneration

converter

(c)

Inverter

M

(g)

(d)

(f)

(c)

OUTLINE

Sensor

power supply

(a)

Sensor

Telephone

(h)

1

17

Precautions for selecting peripheral devices

refer to page 66.

Noise

propagation path

(a), (b), (c)

(d), (e), (f)

(g)

(h)

Measure

When devices that handle low-level signals and are liable to malfunction due to electromagnetic noises, e.g.
instruments, receivers and sensors, are contained in the enclosure that contains the converter or when their signal
cables are run near the converter, the devices may malfunction due to by air-propagated electromagnetic noises.
The following measures must be taken:

• Install the easily affected devices as far away from the converter and the inverter as possible.

• Place the easily affected signal cables as far away from the converter and the inverter as possible.

• Do not run signal cables and power cables (converter I/O cables) in parallel with each other and do not bundle
them.

• Install the FR-BLF line noise filter or the FR-BIF radio noise filter on the input side of the converter and install the
FR-BLF on the output side of the inverter to suppress the radiated noise from the cables.

• Use shielded cables as signal cables and power cables, and run them in individual metal conduits, to produce
further effects.

When the signal cables are run in parallel with or bundled with the power cables, magnetic and static induction
noises may be propagated to the signal cables to cause malfunction of the devices. The following measures must
be taken:

• Install the easily affected devices as far away from the converter and the inverter as possible.

• Place the easily affected signal cables as far away from the converter and the inverter as possible.

• Do not run signal cables and power cables (converter I/O cables) in parallel with each other and do not bundle
them.

• Use shielded cables as signal cables and power cables, and run them in individual metal conduits, to produce
further effects.

When the power supplies of the peripheral devices are connected to the power supply of the converter in the same
line, converter-generated noises may flow back through the power supply cables to cause malfunction of the
devices. The following measures must be taken:

• Install the FR-BIF radio noise filter on the input side power cable of the converter.

• Install the FR-BLF line noise filters on the input side power cable of the converter and on the output side power
cable of the inverter.

When a closed loop circuit is formed by connecting the peripheral devices wiring to the converter, leakage currents
may flow through the earthing (grounding) cable of the converter to cause the devices to malfunction. In that case,
disconnecting the earthing (grounding) cables from the devices may stop the malfunction of the devices.

EMI measure example

Power source
for main circuit

For earthing (grounding)
of the converter,

It is preferred that the
inverter, the converter, and
power cables are separated
from sensor circuit by 30 cm
or more (at least 10 cm).

Power source
for control circuit

Decrease the carrier frequency.

Multifunction

regeneration

converter

Inverter

FR­BLF

Enclosure

Dedicated reactor

or

box-type reactor

FR­BIF

Use a twisted pair shielded cable.

Power supply

for sensor

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

Do not connect earthing (grounding) cables of the sensor directly to the enclosure.
Do not use control cables for earthing (grounding).

Install the filter (FR-BLF/FR-BSF01)
on the inverter output side.

FR­BLF

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

Sensor

Motor

M

18

OUTLINE

Precautions for selecting peripheral devices

1.4.2 Peripheral device list

Circuit breaker and magnetic contactor

Check the model of the purchased multifunction regeneration converter. Appropriate peripheral devices must be selected
according to the capacity.

 Common bus regeneration mode

For the converter in common bus regeneration mode, refer to the following table to prepare appropriate peripheral
devices.

• 200 V class

Molded case circuit breaker

(MCCB)∗1/

FR-XC series converter model

earth leakage circuit breaker (ELB)

(NF, NV type)

50°C rating 40°C rating 50°C rating 40°C rating

FR-XC-7.5K 60 A 60 A S-T35 S-T35
FR-XC-11K 75 A 75 A S-T35 S-T35
FR-XC-15K 125 A 125 A S-T50 S-T50

FR-XC-22K
FR-XC-18.5K-PWM

FR-XC-30K
FR-XC-22K-PWM

FR-XC-37K
FR-XC-37K-PWM

FR-XC-55K
FR-XC-55K-PWM

∗1 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 179.)

∗2 The 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 stops during motor driving, the electrical durability is
25 times.
If using an MC for emergency stop during motor driving or using it on the motor side during commercial power supply operation, select an MC
with the class AC-3 rated current for the rated motor current.

Harmonic suppression
disabled

Harmonic suppression
enabled

Harmonic suppression
disabled

Harmonic suppression
enabled

Harmonic suppression
disabled

Harmonic suppression
enabled

Harmonic suppression
disabled

Harmonic suppression
enabled

175 A 175 A S-T65 S-T80

125 A 125 A S-T50 S-T50

225 A 225 A S-T100 S-T100

125 A 125 A S-T65 S-T65

250 A 250 A S-N150 S-N150

200 A 200 A S-T100 S-N150

400 A 400 A S-N180 S-N180

300 A 300 A S-N180 S-N180

Magnetic contactor (MC)∗2

MCCB

MCCB

FR-XC

FR-XC

Inverter

Inverter

M

M

OUTLINE

1

19

Precautions for selecting peripheral devices

• 400 V class

Molded case circuit breaker

(MCCB)∗1/

FR-XC series converter model

earth leakage circuit breaker (ELB)

(NF, NV type)

50°C rating 40°C rating 50°C rating 40°C rating

FR-XC-H7.5K 30 A 30 A S-T21 S-T21
FR-XC-H11K 50 A 50 A S-T21 S-T21
FR-XC-H15K 60 A 60 A S-T35 S-T35

FR-XC-H22K
FR-XC-H18.5K­PWM

FR-XC-H30K
FR-XC-H22K-PWM

FR-XC-H37K
FR-XC-H37K-PWM

FR-XC-H55K
FR-XC-H55K-PWM

Harmonic suppression
disabled

Harmonic suppression
enabled

Harmonic suppression
disabled

Harmonic suppression
enabled

Harmonic suppression
disabled

Harmonic suppression
enabled

Harmonic suppression
disabled

Harmonic suppression
enabled

100 A 100 A S-T35 S-T35

60 A 60 A S-T35 S-T35

125 A 125 A S-T50 S-T50

75 A 75 A S-T35 S-T35

150 A 150 A S-T65 S-T65

100 A 100 A S-T50 S-T65

200 A 200 A S-T100 S-T100

150 A 150 A S-T80 S-T80

Magnetic contactor (MC)∗2

∗1 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 179.)

∗2 The 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 stops during motor driving, the electrical durability is
25 times.
If using an MC for emergency stop during motor driving or using it on the motor side during commercial power supply operation, select an MC
with the class AC-3 rated current for the rated motor current.

MCCB

MCCB

FR-XC

FR-XC

Inverter

Inverter

 Power regeneration mode

To use the converter in power regeneration mode, select a circuit breaker and a magnetic contactor (MC) for the inverter
according to the inverter capacity. For details, refer to the Instruction Manual of each inverter.
Additionally, install a molded case circuit breaker (MCCB) or earth leakage circuit breaker (ELB) with the rating shown in
the following table on the input side of the FR-XCL reactor. For the information of the installation location, refer to page 58.

• 200 V class

FR-XC series

converter model

FR-XC-7.5K 50 A
FR-XC-11K 60 A
FR-XC-15K 75 A
FR-XC-22K

FR-XC-18.5K-PWM
FR-XC-30K

FR-XC-22K-PWM
FR-XC-37K

FR-XC-37K-PWM
FR-XC-55K

FR-XC-55K-PWM

Molded case circuit breaker (MCCB)/

earth leakage circuit breaker (ELB)

125 A

175 A

200 A

250 A

(NF, NV type)

M

M

20

OUTLINE

Precautions for selecting peripheral devices

• 400 V class

FR-XC series

converter model

FR-XC-H7.5K 30 A
FR-XC-H11K 30 A
FR-XC-H15K 40 A
FR-XC-H22K
FR-XC-H18.5K-PWM
FR-XC-H30K
FR-XC-H22K-PWM
FR-XC-H37K
FR-XC-H37K-PWM
FR-XC-H55K
FR-XC-H55K-PWM

Molded case circuit breaker (MCCB)/

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

75 A

100 A

125 A

150 A

NOTE

• If any breaker trips, check for the wiring fault (such as short circuit), damage to internal parts of the multifunction regeneration

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

Fuse

Installation of a fuse between the multifunction regeneration converter and the inverter is recommended.
When using the converter in the common bus regeneration mode, select a fuse according to the capacity of the connected
motor. When using a motor whose 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.
When using the converter in power regeneration mode, select a fuse according to the capacity of the converter.
(Refer to page 60 for wiring between the converter and the inverter.)

 Common bus regeneration mode

• 200 V class

Motor capacity

(kW)

0.1 5 6.900 CP GR 10.38 0005 (FR10GR69V5)

0.2 10 6.900 CP GR 10.38 0010 (FR10GR69V10)

0.4 16 6.900 CP GR 10.38 0016 (FR10GR69V16)

0.75 20 6.900 CP GR 10.38 0020 (FR10GR69V20)

1.5 25 6.900 CP GR 10.38 0025 (FR10GR69V25)

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 —

• 400 V class

Motor capacity

(kW)

0.4 12.5 6.900 CP GR 10.38 0012.5 (FR10GR69V12.5)

0.75 16 6.900 CP GR 10.38 0016 (FR10GR69V16)

1.5 16 6.900 CP GR 10.38 0016 (FR10GR69V16)

2.2 20 6.900 CP GR 10.38 0020 (FR10GR69V20)

3.7 30 6.900 CP GR 10.38 0030 (FR10GR69V30)

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 —

Fuse rating (A) Model∗1 Fuse holder (2 poles)

Fuse rating (A) Model∗1 Fuse holder (2 poles)

US102 (without fuse light melting indicator)
or US102I (with fuse light melting indicator)

1

US102 (without fuse light melting indicator)
or US102I (with fuse light melting indicator)

OUTLINE

21

Precautions for selecting peripheral devices

 Power regeneration mode

• 200 V class

FR-XC series

converter

capacity (kW)

FR-XC-7.5K 125 6.9 URD 30 TTF 0125 —
FR-XC-11K 160 6.9 URD 30 TTF 0160 —
FR-XC-15K 200 6.9 URD 30 TTF 0200 —
FR-XC-22K

FR-XC-18.5K-PWM
FR-XC-30K

FR-XC-22K-PWM
FR-XC-37K

FR-XC-37K-PWM
FR-XC-55K

FR-XC-55K-PWM

• 400 V class

FR-XC series

converter capacity

(kW)

FR-XC-H7.5K 50 6.9 URD 30 TTF 0050 —
FR-XC-H11K 80 6.9 URD 30 TTF 0080 —
FR-XC-H15K 125 6.9 URD 30 TTF 0125 —
FR-XC-H22K

FR-XC-H18.5K-PWM
FR-XC-H30K

FR-XC-H22K-PWM
FR-XC-H37K

FR-XC-H37K-PWM
FR-XC-H55K

FR-XC-H55K-PWM

Fuse rating (A) Model∗1 Fuse holder (2 poles)

315 6.9 URD 30 TTF 0315 —

400 6.9 URD 30 TTF 0400 —

500 6.9 URD 30 TTF 0500 —

700 6.9 URD 31 TTF 0700 —

Fuse rating (A) Model∗1 Fuse holder (2 poles)

160 6.9 URD 30 TTF 0160 —

200 6.9 URD 30 TTF 0200 —

250 6.9 URD 30 TTF 0250 —

350 6.9 URD 30 TTF 0350 —

∗1 Manufacturer: Mersen Japan KK

Contact: Sun-Wa Technos Corporation

NOTE

• Install fuses across terminals P/+ and P/+, and across terminals N/- and N/- of the multifunction regeneration converter and

the inverter.

[Estimated lifespan of fuses]

Components Estimated lifespan∗1 Replacement method

Fuse 10 years Replace by new one

∗1 Estimated lifespan for when the yearly average surrounding air temperature is 50°C. (without corrosive gas, flammable gas, oil mist, dust and

dirt etc.)

NOTE

• If the fuse melts down, wiring failure such as a short circuit may be the cause. Find out the cause and remove it before

replacing the fuse.

22

OUTLINE

Precautions for selecting peripheral devices

Ig1, lg2, lg3: Leakage currents in wire path during

commercial power supply operation

Ign: Leakage current from noise filters on the input side

of the converter

Igm: Leakage current from the motor during

commercial power supply operation

Selection example (diagram shown on the left) (mA)

Breaker

designed for

harmonic and

surge

suppression

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
(≥ Ig × 10) (mA)

30 100

1.4.3 Selecting the rated sensitivity current for the

earth leakage circuit breaker

To install the earth leakage circuit breaker on the inverter circuit, select its rated sensitivity current as follows.

• Breaker designed for harmonic and surge suppression

Rated sensitivity current

I∆n ≥ 10 × (Ig1 + Ign + Ig2 + Ig3 + Igm)

• Standard breaker

Rated sensitivity current

I∆n ≥ 10 × {Ig1 + Ign + Ig2 + 3 × (Ig3 + Igm)}

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

(200 V 60 Hz) (200 V 60 Hz)

120

100

80

60

40

20

[Example]

0

Leakage currents (mA)

2 3.5

8142230386080

5.5

Cable size (mm2)

2

5.5 mm

×5 m

ELB

Noise
filter

FR-XC
converter

Leakage currents (mA)

150

100

5.5 mm2×5 m 5.5 mm2×70 m

lg1 lgn lg2 lg3

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

2. 0

1. 0

0. 7

0. 5

0. 3

0. 2

0. 1

1. 5 3.7

7. 5 152211373055

2. 2

Motor capacity (kW)

Inverter

455.5 18. 5

3φ

IM

200 V 2.2 kW

lgm

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

(Three-phase three-wire delta
connection 400 V 60 Hz)

120

100

80

60

40

20

0

2 3.5

8142230386080

size (mm2)

100

150

Leakage currents (mA)

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

5.5

Cable

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

(Totally-enclosed fan-cooled
type motor 400 V 60 Hz)

2. 0

1. 0

0. 7

0. 5

0. 3

0. 2

0. 1

1. 5 3.7

Leakage currents (mA)

7. 5 152211373055

2. 2

Motor capacity (kW)

455.5 18. 5

5 m

1000 m

5 m

1000 m

70 m

1000 m

• Multifunction regeneration converter leakage current

Input power conditions

: 220 V/60 Hz (200 V class) or 440 V/60 Hz (400 V class), within 3% of power supply unbalance

Voltage

(V)

Leakage

current

Phase
earthing
(grounding)

Earthed-neutral
system

200 2

400 4

400 4

(mA)

OUTLINE

1

23

Precautions for selecting peripheral devices

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 a ground fault in the inverter output side.

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

section 250, IEC 61140 class 1 and other applicable standards)

• Do not install the breaker on the output side of the inverter. Doing so may cause unnecessarily operations by harmonics even

if the effective value is within the rating, since the eddy current and hysteresis loss will increase, leading to temperature rise.

• The following models are included in the standard breakers: the BV-C1, BC-V, NVB, NV-L, NV-G2N, NV-G3NA, and NV-2F

earth leakage relay (except NV-ZHA) and the NV class earth leakage circuit breaker with AA neutral wire open-phase

protection.

The following models are designed for harmonic and surge suppression: NV-C/NV-S/MN series, NV30-FA, NV50-FA, BV-C2,

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

24

OUTLINE

2 INSTALLATION AND

WIRING

Thischapterexplainstheinstallationandthewiringofthisproduct.
Alwaysreadtheinstructionsbeforeuse.

2.1 Removal and reinstallation of the converter covers .............26

2.2 Removal and reinstallation of the FR-XCB reactor cover .....28

2.3 Installation of the converter and enclosure design...............29

2.4 Installation of peripheral devices ............................................36

2.5 Connection of the converter and the inverter ........................38

2.6 Main circuit terminal specification ..........................................41

2.7 Control circuit specification ....................................................50

2.8 Wiring.........................................................................................57

2.9 Earthing (Grounding) precautions ..........................................66

2.10 Connection of the converter and the multiple inverters .......67

2.11 PU installation on converter ....................................................70

2.12 Communication operation .......................................................71

2.13 Before powering and starting operation.................................72

2.14 Digital characters and their corresponding printed

equivalents ................................................................................73

2

INSTALLATION AND WIRING

25

Removal and reinstallation of the converter covers

2.1 Removal and reinstallation of the converter

covers

2.1.1 30K converters or lower

Main circuit terminal block cover

• To remove the cover, hold and pull out the upper part of

the cover.

To reinstall the cover, insert the hooks into the slots on the converter and push the cover to snap it into place.

• The hooks on the lower end of the cover snap out of

position. The cover is detached from the converter.

Slot

Hook

Control circuit terminal block cover

• To remove the cover, loosen the mounting screws of the

cover, and hold and pull out the lower part of the cover.

• The hooks on the upper end of the cover snap out of

position. The cover is detached from the converter.

To reinstall the cover, insert the hooks into the slots on the converter and push the cover to snap it into place.

NOTE

• After installing the cover, check that it is fixed securely in place. Always tighten the mounting screws of the cover.

26

INSTALLATION AND WIRING

Removal and reinstallation of the converter covers

2.1.2 37K converters or higher

Main circuit terminal block cover

• When the mounting screws are removed, the main circuit terminal block cover can be removed.

To reinstall the cover, insert the hooks into the slots on the converter and push the cover to snap it into place.

Control circuit terminal block cover

• To remove the cover, loosen the mounting screws of the

cover, and hold and pull out the lower part of the cover.

To reinstall the cover, insert the hooks into the slots on the converter and push the cover to snap it into place.

NOTE

• After installing the cover, check that it is fixed securely in place. Always tighten the mounting screws of the cover.

• The hooks on the upper end of the cover snap out of

position. The cover is detached from the converter.

2

INSTALLATION AND WIRING

27

Removal and reinstallation of the FR-XCB reactor cover

2.2 Removal and reinstallation of the FR-XCB

reactor cover

 Removal

• Loosen the mounting screws of the cover. • Pull out the cover to remove it.

●FR-XCB-(H)18.5K, 22K

Cover

●FR-XCB-(H)37K or higher

Cover

 Reinstallation

• Align the screw holes on the cover with the holes on the
reactor, and place the cover back into position.

●FR-XCB-(H)18.5K, 22K

Cover

Cover

• Tighten the mounting screws of the cover (tightening

torque: 1.7 Nm).

Cover

●FR-XCB-(H)37K or higher

Cover

Cover

Cover

NOTE

• After installing the front cover, check that it is fixed securely in place. Always tighten the mounting screws of the cover.

• The capacity plate is placed on the cover, and the rating plate is on the remainder of the reactor box. Before reinstalling the

cover, check the serial number on the capacity plate against the one on the rating plate to make sure they are identical with

each other.

28

INSTALLATION AND WIRING

Installation of the converter and enclosure design

2.3 Installation of the converter and enclosure

design

When designing or manufacturing an 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.

The multifunction regeneration converter unit uses many semiconductor devices. To ensure higher reliability and long period

of operation, operate the converter in the ambient environment that completely satisfies the equipment specifications.

2.3.1 Converter installation environment

The following table lists the standard specifications of the installation environment for the multifunction regeneration converter.

Using the converter 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 converter

Item Description

Measurement
position

5 cm

Surrounding air temperature -10 to +50°C∗1 (non-freezing)

5 cm

Converter

5 cm

Ambient 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

∗1 -10 to +40°C (non-freezing) at the 40°C rating.
∗2 Temperature applicable for a short time, for example, in transit.
∗3 For the installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude.

With circuit board coating (conforming to IEC 60721-3-3 3C2/3S2): 95% RH or less (non-condensing)
Without circuit board coating: 90% RH or less (non-condensing)

∗2

∗3

2

5.9 m/s

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

Measurement
position

Temperatur e

The permissible surrounding air temperature of the multifunction regeneration converter is -10 to +50°C (-10 to +40°C at the

40°C rating). Always operate the converter 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 converter within the specified range.
(a) Measures against high temperature

• Use a forced ventilation system or similar cooling system. (Refer to page 31.)

• 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 converter. (Keep the start signal of the inverter OFF.)
(c) Sudden temperature changes

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

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

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

2

INSTALLATION AND WIRING

29