Mitsubishi Electric FR-A802-F Series Instruction Manual
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Mitsubishi Electric FR-A802-F Series Instruction Manual

Mitsubishi Electric FR-A802-F Series Instruction Manual

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INVERTER
A800-F/G
FR-A802-F/G (SEPARATED CONVERTER TYPE)
INSTRUCTION MANUAL (HARDWARE)
High functionality and high performance
FR-A842-07700 to 12120-F/G

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Summary of Contents for Mitsubishi Electric FR-A802-F Series

  • Page 1 INVERTER A800-F/G FR-A802-F/G (SEPARATED CONVERTER TYPE) INSTRUCTION MANUAL (HARDWARE) High functionality and high performance FR-A842-07700 to 12120-F/G...

  • Page 2: Table Of Contents

    Safety instructions..............5 Chapter 1 INTRODUCTION .
  • Page 3 Connection to a motor with encoder (Vector control) ....... . 67 Parameter settings for a motor with encoder .
  • Page 4 Chapter 5 PRECAUTIONS FOR MAINTENANCE AND INSPECTION....... . 108 Inspection item............108 5.1.1 Daily inspection .
  • Page 5 Compliance with the UK certification scheme ........138 7.10 EU Declaration of Conformity.

  • Page 6: Safety Instructions

    • 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.
  • Page 7 Electric shock prevention WARNING • Do not remove the front cover or the wiring cover while the power of this product is ON, and do not run this product with the front cover or the wiring cover removed as the exposed high voltage terminals or the charging part of the circuitry can be touched.
  • Page 8 Additional instructions The following instructions must be also followed. If this product is handled incorrectly, it may cause unexpected fault, an injury, or an electric shock. CAUTION Transportation and installation • To prevent injury, wear cut-resistant gloves when opening packaging with sharp tools. •...
  • Page 9 WARNING Usage • Stay away from the equipment after using the retry function in this product as the equipment will restart suddenly after the output shutoff of this product. • Depending on the function settings of this product, the product does not stop its output even when the STOP/RESET key on the operation panel is pressed.
  • Page 10 CAUTION Usage • The electronic thermal O/L relay function may not be enough for protection of a motor from overheating. It is recommended to install an external thermal relay or a PTC thermistor for overheat protection. • Do not repeatedly start or stop this product with a magnetic contactor on its input side. Doing so may shorten the life of this product.
  • Page 11 Application of caution labels Caution labels are used to ensure safety during use of Mitsubishi Electric inverters. Apply the following labels to the inverter if the "retry function" and/or "automatic restart after instantaneous power failure" have been enabled. • For the retry function...
  • Page 12 CHAPTER 1 INTRODUCTION Product checking and accessories .........................13 Inverter component names .............................15 Compliance with the EU Machinery Directive—Safety sub-functions..............17 Related manuals..............................20...

  • Page 13: Chapter 1 Introduction

    Parameter unit Parameter unit (FR-PU07) Operation panel and parameter unit Inverter Mitsubishi Electric FR-A800 series inverter (separated converter type) Ethernet board Ethernet communication board (FR-A8ETH) Vector control compatible option FR-A8AP/FR-A8AL/FR-A8APA/FR-A8APR/FR-A8APS (plug-in option), FR-A8TP (control terminal option) Parameter number (Number assigned to function)

  • Page 14: Product Checking And Accessories

    Product checking and accessories Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model is as ordered and the product is intact.  Inverter model Symbol Voltage class Symbol Structure, functionality Symbol Description 315K to 500K...
  • Page 15 NOTE • In this Instruction Manual, the inverter model name consists of the applicable motor capacity and the rated current. (Example) FR-A842-07700(315K)  How to read the SERIAL number The SERIAL consists of one symbol, two characters indicating the production year Rating plate example and month, and six characters indicating the control number.

  • Page 16: Inverter Component Names

    Inverter component names Component names are as follows.  RS-485 model Symbol Name Description Refer to page RS-485 terminal Enables RS-485 communication. Plug-in option connector 1 Instruction Plug-in option connector 2 Connects a plug-in option or a communication option. Manual of the option Plug-in option connector 3 Voltage/current input switch...
  • Page 17  Ethernet model Symbol Name Description Refer to page Plug-in option connector 1 Instruction Connects a plug-in option or a communication option. Manual of the Plug-in option connector 3 option The connector 2 cannot be used because the Ethernet board is installed in the initial Plug-in option connector 2 status.

  • Page 18: Compliance With The Eu Machinery Directive-Safety Sub-Functions

    Compliance with the EU Machinery Directive— Safety sub-functions  FR-A800-F/G (with CC-Link IE TSN safety communication option (FR- A8NCG-S) installed) This product with the CC-Link IE TSN safety communication option (FR-A8NCG-S) installed supports safety sub-functions (STO and SS1-t) specified in IEC 61800-5-2. By connecting the inverter with a safety programmable controller with an Ethernet cable, signal input via safety communication is enabled.
  • Page 19  FR-A800-F/G (with PROFIsafe communication option (A8SPRS) installed) This product with the PROFIsafe communication option (A8SPRS) installed supports safety sub-functions (STO, SS1, SS2, SOS, SLS, SDI, SLP, SSM, and SBC) specified in IEC 61800-5-2. By connecting the inverter with a safety programmable controller with an Ethernet cable, signal input via safety communication is enabled.

  • Page 20: Specifications

    1.3.1 Specifications Safety communication option Function Safety level Description FR-A8NCG-S A8SPRS Safety sub- Safe torque off Driving power to the motor is function (IEC (Safe torque off) electronically shut off by responding to 61800-5-2) the input signal from the safety ○...

  • Page 21: Related Manuals

    Related manuals Manuals related to the FR-A800 inverter are shown in the following table. Name Manual number FR-A800 Instruction Manual (Detailed) IB-0600503ENG FR-A800-E Ethernet Function Manual IB-0600628ENG FR-CC2 Instruction Manual IB-0600543ENG FR-A8NCG-S Instruction Manual IB-0600975ENG FR Configurator2 Instruction Manual IB-0600516ENG PLC Function Programming Manual IB-0600492ENG 1.
  • Page 22 CHAPTER 2 INSTALLATION AND WIRING Peripheral devices ..............................22 Removal and reinstallation of the operation panel or the front covers..............25 Installation of the inverter and enclosure design ....................27 Terminal connection diagrams..........................36 Main circuit terminals ..............................42 Control circuit................................48 Communication connectors and terminals......................63 Connection to a motor with encoder (Vector control) .....................67 Parameter settings for a motor with encoder......................73 2.10...

  • Page 23: Chapter 2 Installation And Wiring

    INSTALLATION AND WIRING This chapter explains the installation and the wiring of this product. Always read the instructions before use. Peripheral devices 2.1.1 Inverter and peripheral devices (c) Three-phase AC power supply (d) Molded case (b) Converter unit (a) Inverter (k) USB connector circuit breaker (FR-CC2)
  • Page 24 NOTE • To prevent an electric shock, always earth (ground) the motor, the inverter, and the converter unit. • Do not install a power factor correction capacitor, surge suppressor, or capacitor type filter on the inverter's output side. Doing so will cause the inverter shut off or damage the capacitor or surge suppressor. If any of the above devices is connected, immediately remove it.

  • Page 25: Peripheral Devices

    2000 A 1400 A rated product Assumes the use of a Mitsubishi Electric standard 4-pole motor with the power supply voltage of 400 VAC 50 Hz. Select an MCCB according to the power supply capacity. Install one MCCB per converter unit. For the use in the United States or Canada, refer to page 134, and select the appropriate fuse.

  • Page 26: Removal And Reinstallation Of The Operation Panel Or The Front Covers

    Removal and reinstallation of the operation panel or the front covers  Removal and reinstallation of the operation panel • Loosen the two screws on the operation panel. • Press the upper edge of the operation panel while pulling (These screws cannot be removed.) out the operation panel.
  • Page 27  Removal of the upper front cover Loosen Loosen Loosen (a) With the lower cover removed, loosen the mounting screws on the upper cover. (These screws cannot be removed.) (b) While holding the areas around the installation hooks on the sides of the upper front cover, pull out the cover using its upper side as a support.

  • Page 28: Installation Of The Inverter And Enclosure Design

    Installation of the inverter and enclosure design When designing or manufacturing an inverter enclosure, determine the structure, size, and device layout of the enclosure by fully considering the conditions such as heat generation of the contained devices and the operating environment. An inverter uses many semiconductor devices.
  • Page 29  Humidity Normally operate the inverter within the ambient air humidity of 45% to 90%. Too high humidity will pose problems of reduced insulation and metal corrosion. On the other hand, too low humidity may cause a spatial electrical breakdown. The humidity conditions for the insulation distance defined in JEM 1103 standard "Insulation Distance from Control Equipment"...
  • Page 30  Vibration, impact The vibration resistance of the inverter is up to 2.9 m/s at 10 to 55 Hz frequency and 1 mm amplitude for the directions of X, Y, Z axes. Subjecting the product to vibration and impacts over a long period of time may loosen the structure and cause poor contacts of connectors, even if those vibration and impacts are within the specified values.

  • Page 31: Amount Of Heat Generated By The Inverter

    2.3.2 Amount of heat generated by the inverter  Installing the heat sink inside the enclosure When the heat sink is installed inside the enclosure, the amount of heat generated by the inverter unit and converter unit is shown in the following tables. Converter Amount of heat FR-CC2-H[]...

  • Page 32: Cooling System Types For Inverter Enclosure

    2.3.3 Cooling system types for inverter enclosure From the enclosure that contains the inverter, the heat of the inverter and other equipment (transformers, lamps, resistors, etc.) and the incoming heat such as direct sunlight must be dissipated to keep the in-enclosure temperature lower than the permissible temperatures of the in-enclosure equipment including the inverter.

  • Page 33: Inverter Installation

    2.3.4 Inverter installation  Inverter placement • Install the inverter on a strong surface securely with screws. • Leave enough clearances and take cooling measures. • Avoid places where the inverter is subjected to direct sunlight, high temperature and high humidity. •...
  • Page 34  Encasing multiple inverters and converter units When multiple inverters and converter units are placed in the same enclosure, arrange them horizontally as shown in the figure below. Do not place multiple products vertically. The exhaust air temperature of the inverter and the converter unit may be increased.

  • Page 35: Protruding The Heat Sink Through A Panel

    2.3.5 Protruding the heat sink through a panel When encasing the inverter to an enclosure, the heat generated in the enclosure can be greatly reduced by protruding the heat sink of the inverter. When installing the inverter in a compact enclosure, etc., this installation method is recommended. ...
  • Page 36  Installation of the inverter on the enclosure Push the inverter heat sink part outside the enclosure, and fix the inverter to the panel with upper and lower installation frames. Enclosure Inside the Exhausted air enclosure There are finger guards behind the enclosure. Therefore, the thickness of the panel should be less than 10 mm (∗1) and also do not place anything around finger guards to avoid contact...

  • Page 37: Terminal Connection Diagrams

    Terminal connection diagrams  FM type (RS-485 model) Sink logic Main circuit terminal Brake unit (Option) Control circuit terminal Inverter Converter unit Fuse R/L1 Motor S/L2 T/L3 Jumper Earth (Ground) R1/L11  S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output ...
  • Page 38 A jumper is installed across terminal R1/L11 and terminal P/+, and across terminal S1/L21 and terminal N/-. When using a separate power supply for the control circuit, remove the jumpers connected to terminals R1/L11 and S1/L21. The function of these terminals can be changed using the Input terminal function selection (Pr.178 to Pr.189). Terminal JOG is also used as a pulse train input terminal.
  • Page 39  FM type (Ethernet model) Sink logic Main circuit terminal Brake unit (Option) Control circuit terminal Inverter Converter unit Fuse R/L1 Motor S/L2 T/L3 Jumper Earth (Ground) R1/L11  S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output  (No voltage input allowed) ...
  • Page 40 Terminal input specifications can be changed by analog input specification switchover (Pr.73, Pr.267). To input voltage (0 to 5 V/0 to 10 V), set the voltage/current input switch OFF. To input current (4 to 20 mA), set the voltage/current input switch ON. Terminals 10 and 2 are also used as a PTC input terminal.
  • Page 41  CA type (Ethernet model) Source logic Main circuit terminal Brake unit Control circuit terminal (Option) Inverter Converter unit Fuse R/L1 Motor S/L2 T/L3 Jumper Earth (Ground) R1/L11  S1/L21 Earth Main circuit (Ground) Control circuit Control input signals Relay output  (No voltage input allowed) ...
  • Page 42 The X10 signal (NC contact input specification) is assigned to terminal MRS in the initial setting. Set Pr.599 = "0" to change the input specification of the X10 signal to NO contact. Terminal input specifications can be changed by analog input specification switchover (Pr.73, Pr.267). To input voltage (0 to 5 V/0 to 10 V), set the voltage/current input switch OFF.

  • Page 43: Main Circuit Terminals

    Main circuit terminals 2.5.1 Details on the main circuit terminals of the inverter Refer to Terminal symbol Terminal name Terminal function description page Connect these terminals to a three-phase squirrel cage motor or a PM U, V, W Inverter output —...

  • Page 44: Terminal Layout Of The Main Circuit Terminals, Wiring Of Power Supply And The Motor

    2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor Converter unit Inverter R1/L11 S1/L21 R1/L11 S1/L21 Charge lamp Charge lamp Jumper Jumper R/L1 S/L2 T/L3 To inverter To converter Power supply unit Motor NOTE •...

  • Page 45: Recommended Cables And Wiring Length

    2.5.4 Recommended cables and wiring length Select a recommended size cable to ensure that the voltage drop ratio is within 2%. If the wiring distance is long between the inverter and motor, the voltage drop in the main circuit will cause the motor torque to decrease especially at a low speed.
  • Page 46 • Inverter (HD rating) Cable gauge Crimp AWG/ terminal Inverter Terminal Tightening HIV cables, etc. (mm PVC cables, etc. (mm model screw torque Earthing Earthing FR-A842-[] size (N·m) U, V, W U, V, W P/+, N/- (grounding) U, V, W U, V, W (grounding) cable...
  • Page 47  Total wiring length  With induction motor Connect one or more general-purpose motors within the total wiring length 500 m. (The wiring length should be 100 m or shorter under Vector control.) Total wiring length 300 m 300 m 500 m or less 300 m+300 m=600 m When driving a 400 V class motor by the inverter, surge voltages attributable to the wiring constants may occur at the motor...

  • Page 48: Earthing (Grounding) Precautions

    2.5.5 Earthing (grounding) precautions • Always earth (ground) the motor, the inverter, and the converter unit.  Purpose of earthing (grounding) Generally, an electrical apparatus has an earth (ground) terminal, which must be connected to the ground before use. An electrical circuit is usually insulated by an insulating material and encased. However, it is impossible to manufacture an insulating material that can shut off a leakage current completely, and actually, a slight current flows into the case.

  • Page 49: Control Circuit

    Control circuit 2.6.1 Details on the control circuit terminals of the inverter For the parameter details, refer to the Instruction Manual (Detailed).  Input signal Terminal Type Common Terminal name Terminal function description Rated specification symbol Forward rotation Turn ON the STF signal to start forward When the STF and STR start rotation and turn it OFF to stop.
  • Page 50 Terminal Type Common Terminal name Terminal function description Rated specification symbol 10 ±0.4 VDC, permissible load When connecting the frequency setting potentiometer at an initial current: 10 mA Frequency setting status, connect it to terminal 10. power supply Change the input specifications of terminal 2 using Pr.73 when 5 ±0.5 VDC, connecting it to terminal 10E.
  • Page 51  Output signal Terminal Type Common Terminal name Terminal function description Rated specification symbol 1 changeover contact output that indicates that an inverter's protective function has been activated and the outputs are Relay output 1 — stopped. Contact capacity: 230 (fault output) Fault: discontinuity across B and C (continuity across A and C), VAC 0.3 A...
  • Page 52  Safety stop signal Terminal Common Terminal name Terminal function description symbol Safety stop input (Channel 1) Do not remove the jumpers from terminals S1, S2, and SIC. Do not use terminals S1, S2, and So (SO). Safety stop input (Channel 2) Safety monitor output So (SO)

  • Page 53: Details On The Control Circuit Terminals Of The Converter Unit (Fr-Cc2)

     Communication Terminal Type Terminal name Terminal function description symbol For connecting a safety communication option. For the connection method, refer to the CON8 STO signal connector Instruction Manual of the installed safety communication option. Communication can be made via Ethernet. Category: 100BASE-TX/10BASE-T Data transmission speed: 100 Mbps (100BASE-TX) / 10 Mbps (10BASE-T) Transmission method: Baseband...
  • Page 54  Output signal Terminal Type Common Terminal name Terminal function description Rated specification symbol 1 changeover contact output that indicates that the protective function of the converter unit has been activated and the Contact capacity: 230 Relay output 1 outputs are stopped. VAC 0.3 A —...

  • Page 55: Control Logic (Sink/Source) Change

    2.6.3 Control logic (sink/source) change Switch the control logic of input signals as necessary. To change the control logic, change the jumper connector position on the control circuit board. Connect the jumper connector to the connector pin of the desired control logic. The control logic of input signals is initially set to the sink logic (SINK) for the type FM inverter.
  • Page 56  Sink logic and source logic • In the sink logic, a signal turns ON when a current exits from the corresponding signal input terminal. Terminal SD is common to the contact input signals. Terminal SE is common to the open collector output signals. •...

  • Page 57: Wiring Of Inverter Control Circuit

    2.6.4 Wiring of inverter control circuit  Control circuit terminal layout 1 F/C +24 SD So SOC S1 S2 PC 5 10E 10 SE SE IPF OL FU PC RL RM RH RT AU STP MRS SD SD STF STR JOG (X10)*2 This terminal operates as terminal FM for the type FM inverter.
  • Page 58 • NICHIFU Co., Ltd. Wire gauge Blade terminal part Crimping tool product Insulation cap part No. number 0.3 to 0.75 BT 0.75-11 VC 0.75 NH 69 Insert the wires into a socket. When using single wire or stranded wire without crimp terminal, push an open/close button all the way down with a flathead screwdriver, and insert the wire.

  • Page 59: Wiring Precautions

    • In the sink logic, terminal SD is a common terminal for the contact input terminals (STF, STR, STP (STOP), RH, RM, RL, JOG, RT, MRS, RES, AU, and CS) and the pulse train output terminal (FM ). The open collector circuit is isolated from the internal control circuit by photocoupler.

  • Page 60: When Using Separate Power Supplies For The Control Circuit And The Main Circuit

    • Separate the wiring of the control circuit away from the wiring of the main circuit. Make cuts in rubber bush of the inverter side and lead the wires through. <Wiring example> Rubber bush (viewed from inside) Make cuts along the lines on the inside with a cutter knife 2.6.6 When using separate power supplies for the...
  • Page 61 Power supply terminal block for the control circuit Power supply terminal block for the control circuit R1/L11 S1/L21 (a) Remove the upper screws. (b) Remove the lower screws. (c) Pull the jumper toward you to remove. (d) Connect the separate power supply cable for the control circuit to the upper terminals (R1/L11, S1/L21). NOTE •...

  • Page 62: When Supplying 24 V External Power To The Control Circuit

    2.6.7 When supplying 24 V external power to the control circuit Connect the 24 V external power supply across terminals +24 and SD to turn ON/OFF the I/O terminal, keep the operation panel ON, and carry out communication with other devices even at power-OFF state of inverter's main circuit power supply. When the main circuit power supply is turned ON, the power supply is switched from the 24 V external power supply to the main circuit power supply.
  • Page 63  Operation while the 24 V external power is supplied • Fault records and parameters can be read and parameters can be written (when the parameter write from the operation panel is enabled) using the operation panel keys. • During the 24 V external power supply operation, the monitor items related to inputs to main circuit power supply, such as the output current and converter output voltage, are invalid.

  • Page 64: Communication Connectors And Terminals

    Communication connectors and terminals 2.7.1 PU connector  Mounting the operation panel or the parameter unit on the enclosure surface • Having an operation panel or a parameter unit on the enclosure surface is convenient. With a connection cable, the operation panel or the parameter unit can be mounted to the enclosure surface and connected to the inverter.

  • Page 65: Terminal Block (Rs-485 Model)

    2.7.2 RS-485 terminal block (RS-485 model)  Communication operation Conforming standard EIA-485 (RS-485) Transmission format Multidrop link Communication speed Maximum 115200 bps Overall length 500 m Connection cable Twisted pair cable (4 pairs) The RS-485 terminals enable communication operation from a personal computer, etc. When the inverter is connected with a personal, FA or other computer by a communication cable, a user program can run to monitor the inverter or read and write parameters.

  • Page 66: Usb Connector

     Hubs Use a hub that supports a desired transmission speed of the Ethernet. 2.7.4 USB connector USB host (A connector) USB memory device Communication status Place a flathead screwdriver, indicator (LED) etc. in a slot and push up the USB device cover to open.
  • Page 67 NOTE • Do not connect devices other than a USB memory device to the inverter. • If a USB device is connected to the inverter via a USB hub, the inverter cannot recognize the USB memory device properly. • For details on usage, refer to the Instruction Manual (Detailed). ...

  • Page 68: Connection To A Motor With Encoder (Vector Control)

    Connection to a motor with encoder (Vector control) Using encoder-equipped motors together with a Vector control compatible option enables speed, torque, and positioning control operations under orientation control, encoder feedback control, and full-scale Vector control. This section explains wiring for use of the FR-A8AP. ...
  • Page 69  Switches on the FR-A8AP • Encoder type selection switch (SW3) Selects either the differential line driver or complementary setting. It is initially set to the differential line driver. Switch its position according to the output circuit. Differential line driver (initial status) Complementary •...
  • Page 70  Encoder cable  FR-JCBL FR-A800 F-DPEVSB 12P 0.2 mm D/MS3057-12A (FR-A8AP) Encoder Approx. 140 mm Earth cable 60 mm Positioning keyway D/MS3106B20-29S D/MS3106B20-29S (As viewed from wiring side) 2 mm Model Length L (m) FR-JCBL5 FR-JCBL15 FR-JCBL30  FR-V7CBL FR-A800 (FR-A8AP) Encoder...
  • Page 71 NOTE • Information on crimp terminals Commercially available products (as of October 2020) Phoenix Contact Co., Ltd. Ferrule part No. Terminal screw Wire gauge Crimping tool Without insulation size model No. With insulation sleeve sleeve AI 0,34-6TQ A 0,34-7 CRIMPFOX 6 AI 0,5-6WH A 0,5-6 NICHIFU Co., Ltd.
  • Page 72 • Torque control Vector control dedicated motor, 12 V Standard motor with encoder, 5 V differential line driver complementary Motor with encoder Inverter Vector control dedicated motor To converter unit Inverter Earth Forward rotation start Earth FR-A8AP (Ground) (Ground) Reverse rotation start FR-A8AP Contact input common Encoder...
  • Page 73  Instructions for encoder cable wiring • Use shielded twisted pair cables (0.2 mm or larger) to connect the FR-A8AP. For the wiring to terminals PG and SD, use several cables in parallel or use a thick cable, according to the wiring length. To protect the cables from noise, run them away from any source of noise (such as the main circuit and power supply voltage).

  • Page 74: Parameter Settings For A Motor With Encoder

    Parameter settings for a motor with encoder  Parameter for the encoder (Pr.359, Pr.369, Pr.851, Pr.852) • Set the encoder specifications. Setting Name Initial value Description range Set when using a motor for which Set for the operation forward rotation (encoder) is clockwise at 120 Hz or less.

  • Page 75: Connection Of Stand-Alone Option Units

    2.10 Connection of stand-alone option units The inverter accepts a variety of stand-alone option units as required. Incorrect connection will cause inverter damage or accident. Connect and operate the option unit carefully in accordance with the Instruction Manual of the corresponding option unit. 2.10.1 Connection of the brake unit (FR-BU2) Connect the brake unit (FR-BU2) as follows to improve the braking capability during deceleration.

  • Page 76: Connection Of The High Power Factor Converter (Fr-Hc2)

    NOTE • The warning "oL" of the stall prevention (overvoltage) is disabled while Pr.30 Regenerative function selection = "11 or 111". • For the parameter details, refer to the Instruction Manual (Detailed). 2.10.2 Connection of the high power factor converter (FR- HC2) When connecting the high power factor converter (FR-HC2) to suppress power harmonics, perform wiring securely as follows.
  • Page 77 *12 The number of connected peripheral devices differs according to the capacity. For details, refer to the FR-HC2 Instruction Manual. NOTE • The voltage phases of terminals R/L1, S/L2, and T/L3 and the voltage phases of terminals R4/L14, S4/L24, and T4/L34 must be matched.

  • Page 78: Connection Of The Power Regeneration Converter (Mt-Rc)

    2.10.3 Connection of the power regeneration converter (MT-RC) When connecting the power regeneration converter (MT-RC), perform wiring securely as follows. Incorrect connection will damage the power regeneration converter and the inverter. After making sure that the wiring is correct and secure, set "10 or 110"...

  • Page 79: Connection Of The Earthing (Grounding) Cable (Ethernet Model)

    2.11 Connection of the earthing (grounding) cable (Ethernet model) To use a safety communication option, the enclosed earthing (grounding) cable needs to be installed. Install the cable according to the following procedure. (For how to install the safety communication option, refer to the Instruction Manual of the safety communication option.) Description Insert spacers into the mounting holes that will not be tightened with the option mounting screws.
  • Page 80 CHAPTER 3 PRECAUTIONS FOR USE OF THE INVERTER Electro-magnetic interference (EMI) and leakage currents ..................80 Power supply harmonics............................86 Installation of a reactor ............................89 Power shutdown and magnetic contactor (MC)......................90 Countermeasures against deterioration of the 400 V class motor insulation............92 Checklist before starting operation .........................93 Failsafe system which uses the inverter .........................96...

  • Page 81: Chapter 3 Precautions For Use Of The Inverter

    PRECAUTIONS FOR USE OF THE INVERTER This chapter explains the precautions for use of this product. Always read the instructions before use. Electro-magnetic interference (EMI) and leakage currents 3.1.1 Leakage currents and countermeasures Capacitance exists between the inverter I/O cables, other cables and earth and in the motor, through which a leakage current flows.
  • Page 82  Installation and selection of the molded case circuit breaker Install a molded case circuit breaker (MCCB) on the power receiving side to protect the wiring at the inverter input side. Select an MCCB according to the inverter input side power factor, which depends on the power supply voltage, output frequency and load.

  • Page 83: Techniques And Measures For Electromagnetic Compatibility (Emc)

    NOTE • Install the earth leakage circuit breaker (ELB) on the input side of the converter unit. • 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) •...
  • Page 84  Techniques to reduce electromagnetic noises that are radiated by the inverter or the converter unit to cause the peripheral devices to malfunction (EMI countermeasures) Noises generated from the inverter or the converter unit are largely classified into those radiated by the cables connected to the inverter or the converter unit and its main circuits (I/O), those electromagnetically and electrostatically induced to the signal cables of the peripheral devices close to the main circuit power supply, and those transmitted through the power supply cables.
  • Page 85 • Specification example (ZCAT3035-1330 by TDK) Item Description 10 to 100 MHz Impedance (Ω) 100 to 500 MHz 39 1 Cable fixing band mount 34 1 Outline dimension drawings (mm) Product name Lot number The impedance values above are reference values, and not guaranteed values. ...

  • Page 86: Converter Unit (Fr-Cc2) Built-In Emc Filter

    3.1.3 Converter unit (FR-CC2) built-in EMC filter The converter unit is equipped with a built-in EMC filter (capacitive filter). These filters are effective in reducing air-propagated noise on the input side of the converter unit. To enable the EMC filter, set the EMC filter ON/OFF connector to the ON position. Two female connectors are initially connected to the OFF (disabled) male connectors.

  • Page 87: Power Supply Harmonics

    Power supply harmonics 3.2.1 Power supply harmonics The inverter may generate power supply harmonics from its converter circuit to 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.
  • Page 88 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.
  • Page 89  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 87), harmonics must be calculated by the equation in next subheading.

  • Page 90: Installation Of A Reactor

    Installation of a reactor When the inverter is connected near a large-capacity power transformer (1000 kVA or more) or when a power factor correction capacitor is to be switched over, an excessive peak current may flow in the power input circuit, damaging the converter circuit. To prevent this, always install an AC reactor (FR-HAL), which is available as an option.

  • Page 91: Power Shutdown And Magnetic Contactor (Mc)

    Power shutdown and magnetic contactor (MC)  Converter unit input side magnetic contactor (MC) On the converter unit input side, it is recommended to provide an MC for the following purposes. (Refer to page 24 for selection.) • To disconnect the inverter from the power supply at activation of a protective function or at malfunctioning of the driving system (emergency stop, etc.).
  • Page 92 NOTE • Before wiring or inspection for a PM motor, confirm that the PM motor is stopped. In an application, such as fan and blower, where the motor is driven by the load, a low-voltage manual contactor must be connected at the inverter's output side, and wiring and inspection must be performed while the contactor is open.

  • Page 93: Countermeasures Against Deterioration Of The 400 V Class Motor Insulation

    Countermeasures against deterioration of the 400 V class motor insulation In the PWM type inverter, a surge voltage attributable to wiring constants is generated at the motor terminals. Especially in a 400 V class motor, the surge voltage may deteriorate the insulation. When the 400 V class motor is driven by the inverter, consider the following countermeasures: ...

  • Page 94: Checklist Before Starting Operation

    Checklist before starting operation The FR-A800 series inverter and FR-CC2 converter unit are highly reliable products, but incorrect peripheral circuit making or operation/handling method may shorten the product life or damage the products. Before starting operation, always recheck the following points. Refer to Check by Checkpoint...
  • Page 95 Refer to Check by Checkpoint Countermeasure page user • Make sure that terminal P/+ of the converter unit and terminal P/+ of the inverter, and terminal N/- of the converter unit and terminal N- of the inverter are correctly connected. Connecting the opposite polarity of terminals N/- and P/+ will damage the inverter.
  • Page 96 Refer to Check by Checkpoint Countermeasure page user When performing frequent starts/stops by the inverter, rise/fall in the temperature of the transistor element of the inverter will repeat due to a repeated flow of large current, shortening the life from thermal fatigue. Since thermal fatigue is related to the amount of current, the life can be increased by reducing A countermeasure is provided for current at locked condition, starting current, etc.

  • Page 97: Failsafe System Which Uses The Inverter

    Failsafe system which uses the inverter When a fault is detected by the protective function, the protective function activates and outputs the Fault signal. However, the Fault signal may not be output at an inverter's fault occurrence when the detection circuit or output circuit fails, etc. Although Mitsubishi assures the best quality products, provide an interlock which uses inverter status output signals to prevent accidents such as damage to the machine when the inverter fails for some reason.
  • Page 98  Checking the inverter operating status by using the start signal input to the inverter and the Inverter running signal output from the inverter ... (c) The Inverter running (RUN) signal is output when the inverter is running. (The RUN signal is assigned to terminal RUN in the initial setting.) Check if the RUN signal is output while a start signal (the STF/STR signal for forward/reverse rotation command) is input to the inverter.
  • Page 99  Command speed and actual operation check Check for a gap between the actual speed and commanded speed by comparing the inverter's speed command and the speed detected by the speed detector. Controller System failure Sensor Inverter (speed, temperature, air volume, etc.) To the alarm detection sensor 3.
  • Page 100 CHAPTER 4 PROTECTIVE FUNCTIONS Inverter fault and alarm indications........................100 Reset method for the protective functions ......................101 Check and clear of the fault history ........................102 List of fault displays ..............................104...

  • Page 101: Chapter 4 Protective Functions

    PROTECTIVE FUNCTIONS This chapter explains the "PROTECTIVE FUNCTIONS" that operate in this product. Always read the instructions before use. Inverter fault and alarm indications • When the inverter detects a fault, depending on the nature of the fault, the operation panel displays an error message or warning, or a protective function is activated to shut off the inverter output.

  • Page 102: Reset Method For The Protective Functions

    Reset method for the protective functions Reset the inverter by performing any of the following operations. Note that the accumulated heat value of the electronic thermal relay function and the number of retries are cleared (erased) by resetting the inverter. The inverter recovers about 1 second after the reset is released.

  • Page 103: Check And Clear Of The Fault History

    Check and clear of the fault history The operation panel stores the past eight fault records which appears when a protective function is activated. (Fault history)  Check for the fault history Parameter setting mode Monitor mode Function mode Fault history mode [Operation for displaying fault history] The last eight fault records can be displayed.
  • Page 104  Fault history clearing procedure • Set Err.CL Fault history clear = "1" to clear the fault history. Operating procedure Turning ON the power of the inverter The operation panel is in the monitor mode. Selecting the parameter setting mode Press to choose the parameter setting mode.

  • Page 105: List Of Fault Displays

    List of fault displays For details, refer to the Instruction Manual (Detailed).  Error message  Alarm • A message regarding operational fault and setting fault • The inverter output is not shut off. An Alarm (LF) signal by the operation panel and the parameter unit is can also be output with a parameter setting.
  • Page 106  Others Operation panel indication Name E.PE6 Internal storage device fault • The fault history and the operation status of the inverter are displayed. It is not a fault indication. Parameter storage device fault E.PE (control circuit board) Operation panel indication Name E.PUE PU disconnection...
  • Page 107 MEMO 4. PROTECTIVE FUNCTIONS 4.4 List of fault displays...

  • Page 108: Chapter 5 Precautions For Maintenance And Inspection

    CHAPTER 5 PRECAUTIONS FOR MAINTENANCE AND INSPECTION Inspection item..............................108 Measurement of main circuit voltages, currents, and powers................115...

  • Page 109: Inspection Item

    PRECAUTIONS FOR MAINTENANCE AND INSPECTION This chapter explains the precautions for maintenance and inspection of this product. Always read the instructions before use. Inspection item The inverter is a static unit mainly consisting of semiconductor devices. Daily inspection must be performed to prevent any fault from occurring due to the adverse effects of the operating environment, such as temperature, humidity, dust, dirt and vibration, changes in the parts with time, service life, and other factors.

  • Page 110: Daily And Periodic Inspection

    5.1.3 Daily and periodic inspection Inspection Area of Corrective action at fault Check interval Inspection item Description inspection occurrence by user Daily Periodic Surrounding Check the surrounding air temperature, humidity, ○ Improve the environment. environment dirt, corrosive gas, oil mist, etc. Check fault location and Check for unusual vibration and noise.

  • Page 111: Checking The Inverter And Converter Semiconductor Devices

    NOTE • Continuous use of a leaked, deformed, or degraded smoothing aluminum electrolytic capacitor (as shown in the table above) may lead to a burst, breakage, or fire. Replace such capacitor without delay. • For details on Pr.257 Control circuit capacitor life display, refer to the Instruction Manual (Detailed). 5.1.4 Checking the inverter and converter semiconductor devices...

  • Page 112: Cleaning

    Output current: 80% of the inverter rating NOTE • For parts replacement, contact the nearest Mitsubishi Electric FA center.  Inverter parts life display The inverter diagnoses the control circuit capacitor and the cooling fan by itself, and estimates their lives.
  • Page 113  Replacement procedure of the cooling fan The replacement interval of the cooling fan used for cooling the parts generating heat such as the main circuit semiconductor is greatly affected by the surrounding air temperature. When unusual noise and/or vibration are noticed during inspection, the cooling fan must be replaced immediately.

  • Page 114: Removal And Reinstallation Of The Control Circuit Terminal Block

     Smoothing capacitors A large-capacity aluminum electrolytic capacitor is used for smoothing in the DC section of the main circuit, and an aluminum electrolytic capacitor is used for stabilizing the control power in the control circuit. Adverse effects from ripple currents deteriorate capacitors.
  • Page 115 NOTE • Before starting the replacement, power OFF the inverter, wait for at least 10 minutes, and then check that the charge lamp is OFF to ensure safety.  Removal and reinstallation precautions The following are the precautions to remove or reinstall the control circuit terminal block. Observe the following precautions and handle the inverter properly to avoid malfunctions or failures.

  • Page 116: Measurement Of Main Circuit Voltages, Currents, And Powers

    Measurement of main circuit voltages, currents, and powers Since the voltages and currents on the inverter power supply and output sides include harmonics, measurement data depends on the instruments used and circuits measured. When instruments for commercial frequency are used for measurement, measure the following circuits with the instruments given on the next page.
  • Page 117  Measuring points and instruments Item Measuring point Measuring instrument Remarks (reference measured value) Between R/L1 and S/L2, Commercial power Power supply voltage S/L2 and T/L3, and T/L3 Within permissible AC voltage fluctuation. (Refer and R/L1 page 122.) Input current Line current at R/L1, S/L2, Digital power meter and T/L3...

  • Page 118: Measurement Of Powers

    Item Measuring point Measuring instrument Remarks (reference measured value) Digital power meter Output voltage Between U and V, V and Difference between the phases must be within 1% W, and W and U of the maximum output voltage. (designed for inverter) Output current Line current at U, V, and Difference between the phases must be within...

  • Page 119: Measurement Of Voltages

    5.2.2 Measurement of voltages  Converter unit (FR-CC2) input side Use a digital power meter for inverters for the input side voltage.  Inverter output side Always use a digital power meter for inverter for measurement as the output side voltage has a PWM-controlled rectangular wave.

  • Page 120: Insulation Resistance Test Using Megger

    5.2.7 Insulation resistance test using megger • For the inverter and the converter unit (FR-CC2), conduct the insulation resistance test on the main circuit only as follows and do not perform the test on the control circuit. (Use a 500 VDC megger.) NOTE •...
  • Page 121 MEMO 5. PRECAUTIONS FOR MAINTENANCE AND INSPECTION 5.2 Measurement of main circuit voltages, currents, and powers...
  • Page 122 CHAPTER 6 SPECIFICATIONS Inverter rating................................122 Common specifications............................123 Outline dimension drawings..........................125...

  • Page 123: Chapter 6 Specifications

    Forced air Approx. mass (kg) The applicable motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi Electric standard 4-pole motor. The rated output capacity is the value with respect to 440 V output voltage. The percentage of the overload current rating is the ratio of the overload current to the inverter's rated output current. For repeated duty, allow time for the inverter and motor to return to or below the temperatures under 100% load.

  • Page 124: Common Specifications

    Common specifications Soft-PWM control, high carrier frequency PWM control (selectable among V/F control, Advanced magnetic flux vector control, Real sensorless vector control), Optimum excitation control, Vector Control method control , and PM sensorless vector control 0.2 to 590 Hz (The upper-limit frequency is 400 Hz under Advanced magnetic flux vector control, Real Output frequency range sensorless vector control, Vector control , and PM sensorless vector control.)
  • Page 125 Pulse train Max. 2.4 kHz via one terminal (for the indication of inverter output frequency). output (FM type The item for monitoring can be changed using Pr.54 FM/CA terminal function selection. inverter) For indication Current output Max. 20 mADC via one terminal (for the indication of inverter output frequency). on external (CA type meters...

  • Page 126: Outline Dimension Drawings

    Outline dimension drawings FR-A842-07700(315K), FR-A842-08660(355K) 3×I12 hole 8×I25 hole (70) (Unit: mm) FR-A842-09620(400K), FR-A842-10940(450K), FR-A842-12120(500K) 3×I12 hole 8×I25 hole (100) (Unit: mm) 6. SPECIFICATIONS 6.3 Outline dimension drawings...
  • Page 127 Operation panel (FR-DU08, FR-LU08) Outline drawing Panel cutting dimension drawing 120 or more Panel 3.2max 27.8 Operation panel Parameter unit connection cable Air- (FR-CB2[ ]) bleeding (option) hole 2×M3 screw Operation panel connection connector (FR-ADP option) Denotes the space required to connect an optional parameter unit connection cable (FR-CB2[ ]).

  • Page 128: Chapter 7 Appendix

    CHAPTER 7 APPENDIX Comparison with FR-A840............................128 Comparison with FR-A800............................129 Compatible plug-in option .............................130 Instructions for compliance with the EU Directives....................131 Instructions for UL and cUL ..........................134 Instructions for EAC..............................136 Restricted Use of Hazardous Substances in Electronic and Electrical Products..........137 Referenced Standard (Requirement of Chinese standardized law) ..............137 Compliance with the UK certification scheme.......................138 7.10 EU Declaration of Conformity ..........................138...

  • Page 129: Comparison With Fr-A840

    APPENDIX APPENDIX provides the reference information for use of this product. Refer to APPENDIX as required. Comparison with FR-A840 The following table shows the function differences between FR-A840 (standard model) and FR-A842 (separated converter type). Item FR-A840 FR-A842 Setting ranges: "0 to 2, 10, 11, 20, 21, 100 to 102, Pr.30 Regenerative function Setting ranges: "2, 10, 11, 102, 110, 111"...

  • Page 130: Comparison With Fr-A800

    Comparison with FR-A800 The following table shows the function differences between FR-A800 and FR-A800-F/G (safety communication model). FR-A800-F/G (with safety communication option installed) Item FR-A800/FR-A800-E FR-A8NCG-S A8SPRS Safety communication CC-Link IE TSN PROFIsafe Not supported Safety performance PLe SIL3 (PLd SIL2 without the option installed) PLe SIL3 / PLd SIL2 (depending on the SERIAL) Refer to the specifications of the safety sub- Functional safety...

  • Page 131: Compatible Plug-In Option

    Compatible plug-in option The following plug-in options are available in this product with the safety communication option is installed. • When used with FR-A8NCG-S Model Specification/function FR-A8AX 16-bit digital input FR-A8AY Analog output / digital output FR-A8AR Relay output FR-A8AP Orientation control / encoder feedback control / Vector control FR-A8TP Vector control terminal block...

  • Page 132: Instructions For Compliance With The Eu Directives

    CE marking. • The authorized representative in the EU The authorized representative in the EU is shown below. Name: Mitsubishi Electric Europe B.V. Address: Mitsubishi-Electric-Platz 1, 40882 Ratingen, Germany  EMC Directive We declare that this inverter conforms with the EMC Directive and affix the CE marking on the inverter.
  • Page 133 • Use the cable sizes on page 44 under the following conditions. · Surrounding air temperature: 40°C maximum If conditions are different from the above, select appropriate wire according to EN 60204-1 or IEC 60364-5-52. • Use a tinned (plating should not include zinc) crimping terminal to connect the earth (ground) cable. When tightening the screw, be careful not to damage the threads.
  • Page 134 The % value denotes the percentage to the inverter rated current. It is not the percentage to the rated motor current. When the electronic thermal relay function dedicated to the Mitsubishi Electric constant-torque motor is set, this characteristic curve applies to operation at 6 Hz or higher.

  • Page 135: Instructions For Ul And Cul

    Instructions for UL and cUL (Standard to comply with: UL 508C, CSA C22.2 No.274-13)  Installation The below types of inverter have been approved as products for use in enclosure. Design the enclosure so that the surrounding air temperature, humidity and ambience of the inverter will satisfy the specifications.
  • Page 136 The % value denotes the percentage to the inverter rated current. It is not the percentage to the rated motor current. When the electronic thermal relay function dedicated to the Mitsubishi Electric constant-torque motor is set, this characteristic curve applies to operation at 6 Hz or higher.

  • Page 137: Instructions For Eac

    • Authorized sales representative (importer) in the CU area The authorized sales representative (importer) in the CU area is shown below. Name: Mitsubishi Electric Turkey A.S. Head Office Address: Serifali Mahallesi Kale Sokak. No:41 34775 Umraniye, Istanbul, Turkey Phone: +90-216-969-25-00 FAX: +90-216-661-44-47 7.

  • Page 138: Restricted Use Of Hazardous Substances In Electronic And Electrical Products

    Restricted Use of Hazardous Substances in Electronic and Electrical Products The mark of restricted use of hazardous substances in electronic and electrical products is described as follows based on the "Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products" of the People's Republic of China.

  • Page 139: Compliance With The Uk Certification Scheme

    Compliance with the UK certification scheme We declare that this product conforms with the related technical requirements under UK legislation, and affix the UKCA (UK Conformity Assessed) marking on the product. Approval conditions are the same as those for the EU Directives. (Refer to page 131.) UKCA marking:...
  • Page 140 MEMO 7. APPENDIX 7.10 EU Declaration of Conformity...
  • Page 141 (1) Damages caused by any cause found not to be the responsibility of Mitsubishi Electric. (2) Loss in opportunity, lost profits incurred to the user by Failures of Mitsubishi Electric products. (3) Special damages and secondary damages whether foreseeable or not, compensation for accidents, and compensation for damages to products other than Mitsubishi Electric products.
  • Page 142 • The copyright and other rights of the enclosed CD-ROM all belong to Mitsubishi Electric Corporation. • No part of the enclosed CD-ROM may be copied or reproduced without the permission of Mitsubishi Electric Corporation. • Specifications of the enclosed CD-ROM are subject to change for modification without notice.
  • Page 143 REVISIONS *The manual number is given on the bottom left of the back cover. Revision date Manual number Revision Sep. 2023 IB(NA)-0600978ENG-A First edition IB-0600978ENG-A...
  • Page 144 (Instruction Manual (HARDWARE) et Instruction Manual (Detailed)) destinés à être utilisés avec ce produit. Veuillez transmettre les manuels correspondants à l’utilisateur final. Les manuels peuvent également être téléchargés au format PDF sur Mitsubishi Electric FA Global Website. Pour commander des manuels, veuillez contacter votre représentant commercial.
  • Page 145  Fuse selection Fuses are selected based on IEC/EN/UL 61800-5-1 and CSA C22.2 No. 274. For installation in the United States, the following semi-conductor fuses must be provided, in accordance with the National Electrical Code and any applicable local codes. For installation in Canada, the following semi-conductor fuses must be provided, in accordance with the Canada Electrical Code and any applicable provincial codes.
  • Page 146 (The operation characteristic is shown on the Pr. 9 = 50% setting of Pr. 9 = 100% setting left.) inverter rating* of inverter rating* • When using the Mitsubishi Electric constant-torque motor 30Hz or more* 30Hz or more* 20Hz Operation range (1) Set one of "1, 13 to 16"...
  • Page 147 MEMO BCN-C22005-1010...
  • Page 148 HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN IB(NA)-0600978ENG-A(2309)MEE Printed in Japan Specifications subject to change without notice.

This manual is also suitable for:

Fr-a802-g seriesFr-a842-07700 315kFr-a842-08660 355kFr-a842-09620 400kFr-a842-10940 450kFr-a842 12120 500k

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