Mitsubishi Electric FR-A842-07700 Instruction Manual Download Page 1

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INVERTER

VERTER

800 Plus

FR-A802-R2R

IN
STRUCTION MA

NUAL

(HA

RDW

AR
E)

INTRODUCTION

INSTALLATION AND WIRING

PRECAUTIONS FOR USE OF

THE INVERTER

PROTECTIVE FUNCTIONS

IB(NA)-0600607ENG-C(1905)MEE Printed in Japan

Specifications subject to change without notice.

FR-A802-R2R (SEPARATED CONVERTER TYPE)

INSTRUCTION MANUAL (HARDWARE)

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

Roll to Roll Function

HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

Summary of Contents for FR-A842-07700

Page 1: ...NCTIONS 4 PRECAUTIONS FOR MAINTENANCE AND INSPECTION 5 SPECIFICATIONS 6 IB NA 0600607ENG C 1905 MEE Printed in Japan Specifications subject to change without notice FR A802 R2R SEPARATED CONVERTER TYPE INSTRUCTION MANUAL HARDWARE FR A842 07700 315K to 12120 500K R2R Roll to Roll Function HEAD OFFICE TOKYO BUILDING 2 7 3 MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN ...

Page 2: ...st conform to the requirements of national and local safety regulations and electrical code NEC section 250 IEC 61140 class 1 and other applicable standards A neutral point earthed grounded power supply must be used for 400 V class of this product to be compliant with EN standard Any person who is involved in wiring or inspection of this product shall be fully competent to do the work This product...

Page 3: ... or damage of this product CAUTION Usage The electronic thermal O L relay function may not be enough for protection of the motor from overheating It is recommended to install an external thermal relay or a PTC thermistor for overheat protection Do not repeatedly start or stop this product with a magnetic contactor on its input side Doing so may shorten the life of this product Use a noise filter o...

Page 4: ...ral instruction For clarity illustrations in this Instruction Manual may be drawn with covers or safety guards removed Ensure all covers and safety guards are properly installed prior to starting operation Stay away from the motor and machine They will start suddenly after given time has elapsed when alarm occurs CAUTION Retry Function Has Been Selected Stay away from the motor and machine They wi...

Page 5: ...licable cables and wiring length 38 2 5 5 Earthing grounding precautions 40 2 6 Control circuit 41 2 6 1 Details on the control circuit terminals of the inverter 41 2 6 2 Details on the control circuit terminals of the converter unit FR CC2 45 2 6 3 Control logic sink source change 46 2 6 4 Wiring of inverter control circuit 48 2 6 5 Wiring precautions 50 2 6 6 When using separate power supplies f...

Page 6: ...r 88 4 PROTECTIVE FUNCTIONS 91 4 1 Inverter fault and indications 92 4 2 Reset method for the protective functions 92 4 3 Check and clear of the fault history 93 4 4 List of fault displays 95 5 PRECAUTIONS FOR MAINTENANCE AND INSPECTION 97 5 1 Inspection item 98 5 1 1 Daily inspection 98 5 1 2 Periodic inspection 98 5 1 3 Daily and periodic inspection 99 5 1 4 Checking the inverter and converter s...

Page 7: ...ion drawings 113 6 3 1 Inverter outline dimension drawings 113 APPENDIX 115 Appendix 1 Comparison with FR A840 R2R 116 Appendix 2 Instructions for compliance with the EU Directives 117 Appendix 3 Instructions for UL and cUL 120 Appendix 4 Instructions for EAC 122 Appendix 5 Restricted Use of Hazardous Substances in Electronic and Electrical Products 123 Appendix 6 Referenced Standard Requirement o...

Page 8: ...l option Pr Parameter number Number assigned to function PU operation Operation using the PU operation panel parameter unit External operation Operation using the control circuit signals Combined operation Combined operation using the PU operation panel parameter unit and External operation Trademarks Ethernet is a registered trademark of Fuji Xerox Corporation in Japan Other company and product n...

Page 9: ...oltage output 0 to 10 VDC OFF Sink logic 60 Hz 9999 same as the power supply voltage CA terminal CA equipped model Terminal CA analog current output 0 to 20 mA DC Terminal AM analog voltage output 0 to 10 VDC ON Source logic 50 Hz 8888 95 of the power supply voltage Rating plate Input rating Output rating SERIAL Inverter model 1387 02 5 5 5 287387 6 5 0 1 F R A 8 4 2 07700 1 400 V class Symbol Vol...

Page 10: ... 1 Including the Instruction Manual Detailed and other documents Rating plate example 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 Symbol Year Month Control number SERIAL ...

Page 11: ...ion 56 h USB A connector Connects a USB memory device 57 i USB mini B connector Connects a personal computer and enables communication with FR Configurator 2 57 j Front cover Remove this cover for the installation of the product installation of a plug in communication option RS 485 terminal wiring switching of the voltage current input switch etc 18 k Power lamp Stays ON while the power is supplie...

Page 12: ... Connects the operation panel or the parameter unit This connector also enables the RS 485 communication 56 h USB A connector Connects a USB memory device 57 i USB mini B connector Connects a personal computer and enables communication with FR Configurator2 57 j Upper front cover Remove this cover for the installation of the product installation of a plug in communication option RS 485 terminal wi...

Page 13: ...A800 Instruction Manual Detailed IB 0600503ENG Roll to Roll Function Manual IB 0600622ENG FR A800 E R2R Ethernet Function Manual IB 0600813ENG FR CC2 Instruction Manual IB 0600543ENG FR Configurator2 Instruction Manual IB 0600516ENG FR A800 PLC Function Programming Manual IB 0600492ENG FR A800 Safety stop function instruction manual BCN A23228 001 ...

Page 14: ... reinstallation of the front cover 18 2 3 Installation of the inverter and enclosure design 20 2 4 Terminal connection diagrams 27 2 5 Main circuit terminals 36 2 6 Control circuit 41 2 7 Communication connectors and terminals 56 2 8 Connection of motor with encoder vector control 60 2 9 Parameter settings for a motor with encoder 65 2 10 Connection of stand alone option units 66 2 11 Installing a...

Page 15: ...t includes high frequency components which may interfere with the communication devices such as AM radios used near the inverter or the converter unit In this case activating the EMC filter of the converter unit may minimize interference Refer to page 78 For details of options and peripheral devices refer to the respective Instruction Manual Earth Ground R L1 S L2 T L3 N N P P N P P P PR PR Instal...

Page 16: ...rten the life of the inverter and the converter unit 83 f AC reactor FR HAL Install this to suppress harmonics and to improve the power factor An AC reactor FR HAL option is required when installing the inverter near a large power supply system 1000 kVA or more Under such condition the inverter and the converter unit may be damaged if you do not use a reactor Select a reactor according to the appl...

Page 17: ...842 Rated current A 280 H315 315 H315K 355 H355K 315K 07700 683 315K 07700 683 400 H400K 315K 07700 770 355K 08660 770 355K 08660 770 450 H450K 355K 08660 866 400K 09620 866 400K 09620 866 500 H500K 400K 09620 962 450K 10940 962 450K 10940 962 560 H560K 450K 10940 1094 500K 12120 1094 500K 12120 1094 630 H630K 500K 12120 1212 Motor capacity kW 1 Converter unit FR CC2 Inverter ND normal duty initia...

Page 18: ...uit breaker ELB NF NV type Input side magnetic contactor 3 315 FR CC2 H315K 700 A S N600 355 FR CC2 H355K 800 A S N600 400 FR CC2 H400K 900 A S N800 450 FR CC2 H450K 1000 A 1000 A rated product 500 FR CC2 H500K 1200 A 1000 A rated product 560 FR CC2 H560K 1500 A 1200 A rated product 630 FR CC2 H630K 2000 A 1400 A rated product 1 Assumes the use of a Mitsubishi Electric 4 pole standard motor with t...

Page 19: ...iffers by the capacity b With the terminal block cover removed the main circuit terminals can be wired Loosen the two screws on the operation panel These screws cannot be removed Press the upper edge of the operation panel while pulling out the operation panel To reinstall the operation panel align its connector on the back with the PU connector of the inverter and insert the operation panel After...

Page 20: ...ls can be wired and the plug in option can be installed Reinstallation of the front cover and the terminal block cover a Clip on the front cover as illustrated Check that it is properly secured b Tighten the screws on the lower part of the front cover c Attach the terminal block cover using the screws The number of screws differs depending on the capacity of the inverter NOTE Fully make sure that ...

Page 21: ...thin the specified range a Measures against high temperature Use a forced ventilation system or similar cooling system Refer to page 22 Install the enclosure in an air conditioned electric chamber Block direct sunlight Provide a shield or similar plate to avoid direct exposure to the radiated heat and wind of a heat source Ventilate the area around the enclosure well b Measures against low tempera...

Page 22: ...to make the in enclosure air pressure higher than the outside air pressure Corrosive gas salt damage If the inverter is exposed to corrosive gas or to salt near a beach the printed board patterns and parts will corrode or the relays and switches will result in poor contact In such places take the measures given above Explosive flammable gases As the inverter is non explosion proof it must be conta...

Page 23: ... Cooling by heat exchanger or cooler heat pipe cooler etc Cooling system Enclosure structure Comment Natural Natural ventilation enclosed type open type This system is low in cost and generally used but the enclosure size increases as the inverter capacity increases This system is for relatively small capacities Natural ventilation totally enclosed type Being a totally enclosed type this system is...

Page 24: ...wiring space and the clearance above the inverter is required as a heat dissipation space When designing or building an enclosure for the inverter carefully consider influencing factors such as heat generation of the contained devices and the operating environment 1 There needs to be a space of at least 30 cm in front of the inverter to replace the cooling fan Refer to page 102 for fan replacement...

Page 25: ...ounding air temperature of the inverter and the converter unit higher than the permissible value by providing ventilation and increasing the enclosure size Arrangement of multiple inverters and converter units Heat generated in the inverter is blown up from the bottom of the unit as warm air by the cooling fan When installing a ventilation fan for that heat determine the place of ventilation fan i...

Page 26: ...ced by protruding the heat sink of the inverter When installing the inverter in a compact enclosure etc this installation method is recommended Panel cutting Cut the panel of the enclosure according to the inverter capacity FR A842 07700 315K FR A842 08660 355K Unit mm FR A842 09620 400K FR A842 10940 450K FR A842 12120 500K Unit mm 6 M10 screw 520 Hole 200 15 15 1270 1300 200 660 Hole 240 240 6 M...

Page 27: ... inverter and cooling fan section Two installation frames are attached to each of the upper and lower parts of the inverter Remove the rear side installation frame on the top and bottom of the inverter as shown on the right Upper installation frame rear side Lower installation frame rear side 185 mm Exhausted air There are finger guards behind the enclosure Therefore the thickness of the panel sho...

Page 28: ...RT MRS X10 RES AU CS SD RUN SU IPF OL FU SE Data reception 5 VCC 5V Sink logic 6 Earth Ground N P Initial value ON OFF 4 2 Safety stop signal Safety monitor output Safety monitor output common So SO SOC Safety stop input Channel 1 Shorting wire Safety stop input common Safety stop input Channel 2 S1 S2 PC SD SIC 24 SD Brake unit Option Jumper 1 Permissible load current 100mA connector 1 connector ...

Page 29: ... 561 6 It is recommended to use 2 W 1 kΩ when the frequency setting signal is changed frequently 7 The function of these terminals can be changed with the output terminal assignment Pr 195 Pr 196 8 The function of these terminals can be changed with the output terminal assignment Pr 190 to Pr 194 9 No function is assigned in the initial setting Use Pr 192 for function assignment 10 The terminal FM...

Page 30: ... Safety stop signal Safety monitor output Safety monitor output common So SO SOC Safety stop input Channel 1 Shorting wire Safety stop input common Safety stop input Channel 2 S1 S2 PC SD SIC 24 SD Brake unit Option Jumper 1 Permissible load current 100mA connector 1 connector 2 connector 3 24V external power supply input Common terminal 24VDC power supply Forward rotation start Reverse rotation s...

Page 31: ...rrent input switch ON Terminals 10 and 2 are also used as a PTC input terminal Pr 561 6 It is recommended to use 2 W 1 kΩ when the frequency setting signal is changed frequently 7 The function of these terminals can be changed with the output terminal assignment Pr 195 Pr 196 8 The function of these terminals can be changed with the output terminal assignment Pr 190 to Pr 194 9 No function is assi...

Page 32: ...D RUN SU IPF OL FU SE 5 Sink logic 6 Earth Ground N P Initial value ON OFF 4 2 Safety stop signal Safety monitor output Safety monitor output common So SO SOC Safety stop input Channel 1 Shorting wire Safety stop input common Safety stop input Channel 2 S1 S2 PC SD SIC 24 SD Brake unit Option Jumper 1 connector 1 connector 2 12 connector 3 24V external power supply input Common terminal 24VDC powe...

Page 33: ...minals can be changed with the output terminal assignment Pr 195 Pr 196 8 The function of these terminals can be changed with the output terminal assignment Pr 190 to Pr 194 9 No function is assigned in the initial setting Use Pr 192 for function assignment 10 Terminal FM can be used to output pulse trains as open collector output by setting Pr 291 11 Not required when calibrating the scale with t...

Page 34: ...onitor output Safety monitor output common So SO SOC Safety stop input Channel 1 Shorting wire Safety stop input common Safety stop input Channel 2 S1 S2 PC SD SIC 24 SD Brake unit Option Jumper 1 connector 1 connector 2 10 connector 3 24V external power supply input Common terminal 24VDC power supply Forward rotation start Reverse rotation start Start self holding selection Middle speed High spee...

Page 35: ...en the frequency setting signal is changed frequently 7 The function of these terminals can be changed with the output terminal assignment Pr 195 Pr 196 8 The function of these terminals can be changed with the output terminal assignment Pr 190 to Pr 194 9 No function is assigned in the initial setting Use Pr 192 for function assignment 10 The option connector 2 cannot be used because the Ethernet...

Page 36: ...e initial setting For the X10 signal NC contact input specification is selected in the initial setting Set Pr 599 0 to change the input specification to NO contact 3 For the terminal used for the X11 signal input set 11 in any of Pr 178 to Pr 189 input terminal function selection to assign the function For RS 485 or any other form of communication where the start command is only transmitted once u...

Page 37: ...unit FR CC2 brake unit FR BU2 or high power factor converter FR HC2 27 66 Earth ground For earthing grounding the inverter chassis This must be earthed grounded 40 Terminal symbol Terminal name Terminal function description Refer to page R L1 S L2 T L3 AC power input Connect these terminals to the commercial power supply When the converter unit is connected to the 12 phase rectifier power transfor...

Page 38: ... tighten a nut from the right side of the conductor When wiring two wires place wires on both sides of the conductor Refer to the diagram below For wiring use bolts nuts provided with the inverter When wiring the main circuit conductor R L1 S L2 T L3 of the converter unit FR CC2 use the bolts nuts for main circuit wiring which are provided on the front side of the conductor FR CC2 H315K to FR CC2 ...

Page 39: ...y the following formula Line voltage drop V Use a larger diameter cable when the wiring distance is long or when it is desired to decrease the voltage drop torque reduction in the low speed range NOTE Tighten the terminal screw to the specified torque A screw that has been tightened too loosely can cause a short circuit or malfunction A screw that has been tightened too tightly can cause a short c...

Page 40: ... the inverter may be affected by a charging current caused by the stray capacitances of the wiring leading to a malfunction of the overcurrent protective function or fast response current limit function or a malfunction or fault of the equipment connected on the inverter output side If the fast response current limit function malfunctions disable this function For the details of Pr 156 Stall preve...

Page 41: ...ing in the figure below where the inverter is connected with the other equipment at an earthing grounding point Do not use the other equipment s earthing grounding cable to earth ground the inverter as shown in III A leakage current containing many high frequency components flows into the earthing grounding cables of the inverter and peripheral devices Because of this the inverter must be earthed ...

Page 42: ...tion enable Connect to terminal RDA of the converter unit FR CC2 When the RDA signal is turned OFF the inverter output is shut off The X10 signal NC contact is assigned to terminal MRS in the initial setting Use Pr 599 to change the specification to NO contact RES Reset Use this signal to reset a fault output provided when a protective function is activated Turn ON the RES signal for 0 1s or longe...

Page 43: ...ut is invalid Use Pr 267 to switch among input 4 to 20 mA initial setting 0 to 5 VDC and 0 to 10 VDC Set the voltage current input switch in the OFF position to select voltage input 0 to 5 V 0 to 10 V 1 Use Pr 858 to switch terminal functions 1 Frequency setting auxiliary Inputting 0 to 5 VDC or 0 to 10 VDC adds this signal to terminal 2 or 4 frequency setting signal Use Pr 73 to switch between in...

Page 44: ...r 192 FU Frequency detection Switched to LOW when the inverter output frequency is equal to or higher than the preset detection frequency and to HIGH when it is less than the preset detection frequency SE Open collector output common Common terminal for terminals RUN SU OL IPF FU Pulse FM 1 For meter Outputs a selected monitored item such as output frequency among several monitored items The signa...

Page 45: ...rsonal computer via USB to enable setting monitoring test operations of the inverter by FR Configurator2 Terminal Symbol Terminal name Terminal function description Rated specification S1 Safety stop input Channel 1 Terminals S1 and S2 are used for the safety stop input signal for the safety relay module Terminals S1 and S2 are used at the same time dual channel Inverter output is shutoff by short...

Page 46: ...erter trips by the external thermal relay operation E OHT RDI Contact input The function can be assigned by setting Pr 178 SD Contact input common sink Common terminal for contact input terminal sink logic and terminal FM External transistor common source Connect this terminal to the power supply common terminal of a transistor output open collector output device such as a programmable controller ...

Page 47: ...LOW when the converter unit operation is ready Assign the signal to terminal MRS X10 of the inverter The inverter can be started when the RDA status is LOW Permissible load 24 VDC maximum 27 VDC 0 1 A The voltage drop is 2 8 V at maximum while the signal is ON LOW is when the open collector output transistor is ON conducted HIGH is when the transistor is OFF not conducted RDB Inverter operation en...

Page 48: ...e inverter due to undesirable currents Source logic Use terminal SD as a common terminal and perform wiring as shown below Do not connect terminal PC of the inverter with terminal 24 V of the external power supply When using terminals PC SD as a 24 VDC power supply do not install an external power supply in parallel with the inverter Doing so may cause a malfunction in the inverter due to undesira...

Page 49: ...rimp terminal and check that the wires come out for about 0 to 0 5 mm from a sleeve Check the condition of the crimp terminals after crimping Do not use the crimp terminals of which the crimping is inappropriate or the face is damaged Crimp terminals commercially available as of January 2017 Phoenix Contact Co Ltd Wire strip length Wire gauge mm2 Ferrule part No Crimping tool model No With insulat...

Page 50: ... the analog output terminals AM CA 2 It should be protected from external noise using a shielded or twisted cable Terminal SE is a common terminal for the open collector output terminals RUN SU OL IPF FU The contact input circuit is isolated from the internal control circuit by photocoupler 1 Terminal FM is provided in the FM type inverter 2 Terminal CA is provided in the CA type inverter Wire gau...

Page 51: ...uding the 200V relay sequence circuit For the cables connected to the control circuit terminals connect their shields to the common terminal of the connected control circuit terminal When connecting an external power supply to terminal PC however connect the shield of the power supply cable to the negative side of the external power supply Do not directly earth ground the shield to the enclosure e...

Page 52: ...ct terminals Doing so may damage the inverter Connection diagram 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 When using separate power supplies always remove the jumpers from terminals R1 L11 and S1 L21 The inverter may be damaged if the jumpers...

Page 53: ...hen the main power supply is turned ON during the 24 V external power supply operation a reset is performed in the inverter then the power supply changes to the main circuit power supply The reset can be disabled using Pr 30 Confirming the 24 V external power supply input During 24 V external power supply operation EV flashes on the operation panel The alarm LED also flashes Thus the 24 V external...

Page 54: ...age drop caused by it Depending on the power supply the inrush current protection may be activated to disable the power supply Select the power supply and capacity carefully When the wiring length between the external power supply and the inverter is long the voltage often drops Select the appropriate wiring size and length to keep the voltage in the rated input voltage range In a serial connectio...

Page 55: ...ction diagram To prevent restart at fault occurrence connect terminals So SO and SOC to the reset button which are the feedback input terminals of the safety relay module Terminal symbol Terminal function description S1 1 For input of the safety stop channel 1 Between S1 and SIC S2 and SIC Open In safety stop mode Short Other than the safety stop mode S2 1 For input of the safety stop channel 2 SI...

Page 56: ...ual Find a PDF file of the manual in the CD ROM enclosed with the product Input power Internal safety circuit status Input terminal 1 2 Output terminal Output signal 8 9 10 Inverter running status Operation panel indication S1 S2 So SO SAFE E SAF 6 SA 7 OFF OFF OFF Output shutoff Safe state Not displayed Not displayed ON Normal ON ON ON 3 OFF Drive enabled Not displayed Not displayed Normal ON OFF...

Page 57: ...r to the following table when fabricating the cable on the user side Keep the total cable length within 20 m Commercially available products as of February 2015 Communication operation Using the PU connector enables communication operation from a personal computer etc When the PU connector is connected with a personal FA or other computer by a communication cable a user program can run to monitor ...

Page 58: ...mode of the trace function Encryption function Not available Function Description Parameter copy Copies the parameter setting from the inverter to the USB memory device A maximum of 99 parameter setting files can be saved in a USB memory device The parameter setting data copied in the USB memory device can be copied to other inverters This function is useful in backing up the parameter setting or ...

Page 59: ...link operation and MODBUS RTU protocol For details refer to the FR A800 Instruction Manual Detailed NOTE To avoid malfunction keep the RS 485 terminal wires away from the control circuit board For wiring of the RS 485 terminals used with a plug in option lead the wires on the left side of the plug in option Interface Conforms to USB 1 1 Transmission speed 12 Mbps Wiring length Maximum 5 m Connecto...

Page 60: ...T Data transmission speed 100 Mbps 100BASE TX 10 Mbps 10BASE T Transmission method Baseband Maximum segment length 100 m between the hub and the inverter Number of cascade connection stages Up to 2 100BASE TX up to 4 10BASE T Interface RJ 45 Number of interfaces available 1 IP version IPv4 Communication speed Cable Connector Standard 100 Mbps Category 5 or higher shielded STP straight cable RJ 45 ...

Page 61: ...election switch SW1 Switches ON or OFF the internal terminating resistor 61 f Switch for manufacturer setting SW2 Do not change from the initially set status Switches 1 and 2 are OFF g Connector Connected to the option connector of the inverter 10 h LED for manufacturer check Not used Terminal symbol Terminal name Description PA1 Encoder A phase signal input terminal A B and Z phase signals are in...

Page 62: ...Set the switch OFF when sharing an encoder with another unit NC computerized numerical controller etc having a terminating resistor under the differential line driver setting Prepare an encoder s power supply 5 V 12 V 15 V 24 V according to the encoder s output voltage When the encoder output is the differential line driver type only 5 V can be input The SW2 switch is for manufacturer setting Do n...

Page 63: ...ion type cables need to be treated Refer to the following description Terminal screw size Wire gauge mm2 Ferrule part No Crimping tool model With insulation sleeve Without insulation sleeve M2 0 3 0 5 AI 0 5 6WH A 0 5 6 CRIMPFOX 6 Terminal screw size Wire gauge mm2 Blade terminal part No Insulation cap part No Crimping tool model M2 0 3 to 0 75 BT 0 75 7 VC 0 75 NH 69 F DPEVSB 12P 0 2 mm 2 Earth c...

Page 64: ...n STF STR SD PLG Earth Ground Inverter 10 2 2 3 1 Torque limit command 10V 1 Frequency command Frequency setting potentiometer 1 2W1kΩ 5 5VDC power supply 5 To converter unit P N 4 6 3 PA1 FR A8AP PA2 PB1 PB2 PZ1 PZ2 PG 1 OFF Vector control dedicated motor U V W U V W E A 2 B PG SD SD C D F G S R IM PLG 5 Earth Ground Inverter 12VDC power supply Differential Terminating resistor ON Complementary M...

Page 65: ...V7CBL is provided with a P clip for earthing grounding shielded cables 1 The pin number differs according to the encoder used The control works properly with or without the Z phase being connected 2 Connect the encoder so that there is no looseness between the motor and motor shaft Speed ratio must be 1 1 3 Earth ground the shield of the encoder cable to the enclosure using a tool such as a P clip...

Page 66: ...Set for the operation at a frequency higher than 120 Hz 369 C140 851 C240 Number of encoder pulses 1024 0 to 4096 Set the number of encoder pulses output Set the number of pulses before it is multiplied by 4 The parameters above can be set when a vector control compatible option is installed Item FR A8AP FR A8AL parameter FR A8APR parameter FR A8APS parameter FR A8TP parameter Encoder rotation dir...

Page 67: ...side Incorrect connection will damage the inverter and brake unit 2 For wiring to terminals P and N of the FR A842 08660 355K or lower inverters up to two cables can be connected For wiring to the terminals of the FR A842 09620 400K or higher inverters up to four cables can be connected To use more cables use a bus bar 3 When the power supply is 400 V class install a stepdown transformer 4 The wir...

Page 68: ...ration mode at the time of an instantaneous power failure 6 Assign the IPF signal to an FR HC2 terminal Refer to the Instruction Manual of FR HC2 7 Always connect the FR HC2 terminal RDY to the inverter terminal MRS X10 and the FR HC2 terminal SE to the inverter terminal SD Not connecting these terminals may damage the FR HC2 8 Always connect the R L1 S L2 and T L3 terminals of FR HC2 to the power...

Page 69: ...selection 1 For wiring to terminals P and N of the FR A842 08660 355K or lower inverters up to two cables can be connected For wiring to the terminals of the FR A842 09620 400K or higher inverters up to four cables can be connected To use more cables use a bus bar NOTE When using the inverter with the MT RC install a magnetic contactor MC at the input side of the inverter so that power is supplied...

Page 70: ...rt the option as far as it goes Insert it to the inverter option connector 1 3 Remove the mounting screw lower of the Ethernet board earth plate Fit the one terminal of the earthing grounding cable on the Ethernet board earth plate and fix it securely to the inverter with the mounting screw tightening torque 0 33 N m to 0 40 N m 4 Fix the left part of the communication option securely with the opt...

Page 71: ...MEMO 70 ...

Page 72: ...ns before using the equipment 3 1 Electro magnetic interference EMI and leakage currents 72 3 2 Power supply harmonics 79 3 3 Installation of a reactor 82 3 4 Power OFF and magnetic contactor MC 83 3 5 Countermeasures against deterioration of the 400 V class motor insulation 84 3 6 Checklist before starting operation 85 3 7 Failsafe system which uses the inverter 88 ...

Page 73: ...nd leakage currents Take caution as long wiring will increase the leakage current Decreasing the carrier frequency of the inverter reduces the leakage current Increasing the motor capacity increases the leakage current Line to line leakage currents Harmonics of leakage currents flowing in static capacitances between the inverter output cables may operate the external thermal relay unnecessarily Co...

Page 74: ... current Ig1 mA 1 66 5 m 0 11 3 1000 m Leakage current Ign mA 0 without noise filter Leakage current Igi mA 1 without EMC filter For the leakage current of the inverter refer to the following table Leakage current Ig2 mA 1 66 60 m 1 32 3 1000 m Motor leakage current Igm mA 0 36 Total leakage current mA 2 79 6 15 Rated sensitivity current mA Ig 10 30 100 Inverter converter unit FR A800 Standard mod...

Page 75: ...When the breaker is installed on the output side of the inverter it may be unnecessarily operated by harmonics even if the effective value is within the rating In this case do not install the breaker since the eddy current and hysteresis loss will increase leading to temperature rise The following models are standard breakers BV C1 BC V NVB NV L NV G2N NV G3NA NV 2F earth leakage relay except NV Z...

Page 76: ...agnetic contactors electromagnetic brakes many relays for example are installed near the inverter or the converter unit and it 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 page 76 to signal cables Ground Earth the ...

Page 77: ...gnal 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 and the following countermeasures must be taken Install easily affected devices as far away as possible from the inverter or the converter unit Run easily affected signal cables as far away as possible from the inverte...

Page 78: ... Use a twisted pair shielded cable Enclosure Decrease carrier frequency Motor Inverter power supply Separate inverter converter unit and power line by more than 30 cm at least 10 cm from sensor circuit Control power supply Do not earth ground enclosure directly Do not earth ground control cable Use 4 core cable for motor power cable and use one cable as earth ground cable Do not earth ground shiel...

Page 79: ...ter the power supply has been switched OFF and check that there is no residual voltage using a tester or the like When disconnecting the connector push the fixing tab and pull the connector straight without pulling the cable or forcibly pulling the connector with the tab fixed When installing the connector also engage the fixing tab securely If it is difficult to disconnect the connector use a pai...

Page 80: ...mally 40th to 50th degrees or less 3 kHz or less High frequency several 10 kHz to 1 GHz order Environment To electric channel power impedance To space distance wiring path Quantitative understanding Theoretical calculation possible Random occurrence quantitative grasping difficult Generated amount Nearly proportional to the load capacity Changes with the current variation ratio Gets larger as swit...

Page 81: ...age 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 Application of the specific consumer guidelines Conversion factors for FR A800 series Equivalent Capacity...

Page 82: ...691 2033 1313 782 735 500 469 344 220 355 21515 252 6455 2797 1807 1076 1011 688 645 473 250 403 24424 286 7327 3175 2052 1221 1148 782 733 537 280 450 27273 319 8182 3545 2291 1364 1282 873 818 600 315 506 30667 359 9200 3987 2576 1533 1441 981 920 675 355 571 34606 405 10382 4499 2907 1730 1627 1107 1038 761 400 643 38970 456 11691 5066 3274 1949 1832 1247 1169 857 450 723 43818 512 13146 5696 3...

Page 83: ...o be switched over an excessive peak current may flow in the power input circuit damaging the converter circuit To prevent this always install an optional AC reactor FR HAL MCCB MC Inverter with converter unit R S T Z Y X U V W R L1 S L2 T L3 M 5000 5300 4000 3000 2000 1000 110 165 247 330 420 550 kVA AC reactor FR HAL Power supply Capacities requiring installation of AC reactor Inverter capacity ...

Page 84: ...g terminals STF STR to run stop the inverter Inverter start stop circuit example As shown below always use the start signal ON or OFF of STF STR signal to make a start or stop 1 When the power supply is 400 V class install a stepdown transformer 2 Connect the power supply terminals R1 L11 S1 L21 of the control circuit to the input side of the MC to hold an alarm signal when the inverter s protecti...

Page 85: ...ss motor use an insulation enhanced motor Specifically Order a 400 V class inverter driven insulation enhanced motor For the dedicated motor such as the constant torque motor and low vibration motor use an inverter driven dedicated motor Set Pr 72 PWM frequency selection as indicated below according to the wiring length Suppressing the surge voltage on the inverter side If the motor capacity is 28...

Page 86: ...o minimize interference 78 On the inverter s output side there is no power factor correction capacitor surge suppressor or radio noise filter installed Doing so will cause the inverter to trip or the capacitor and surge suppressor to be damaged If any of the above devices is connected immediately remove it When performing an inspection or rewiring on the product that has been energized the operato...

Page 87: ...t switch remains ON after a power failure the inverter will automatically restart as soon as the power is restored When using vector control the encoder is properly installed The encoder must be directly connected to a motor shaft without any backlash Real sensorless vector control do not require an encoder 60 A magnetic contactor MC is installed on the converter unit s input side On the converter...

Page 88: ...iminate such a condition For an induction motor use the inverter and the converter unit of a higher capacity up to two ranks The specifications and rating match the system requirements Make sure that the specifications and rating match the system requirements Countermeasures are taken against electrical corrosion on the motor bearing When a motor is driven by the inverter axial voltage is generate...

Page 89: ...ction Y12 signal a Checking by the output of the inverter fault signal When the inverter s protective function is activated and the inverter trips the Fault signal is output The ALM signal is assigned to terminal A1B1C1 in the initial setting With this signal check that the inverter operates properly In addition negative logic can be set ON when the inverter is normal OFF when the fault occurs b C...

Page 90: ... logic check configure a sequence considering the inverter s deceleration time In addition it is recommended to check the three phase current when using the current detector b 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 d Checking the motor operating stat...

Page 91: ...MEMO 90 ...

Page 92: ... the PROTECTIVE FUNCTIONS that operates in this product Always read the instructions before using the equipment 4 1 Inverter fault and indications 92 4 2 Reset method for the protective functions 92 4 3 Check and clear of the fault history 93 4 4 List of fault displays 95 ...

Page 93: ...setting an inverter fault with the start signal ON restarts the motor suddenly Item Description Fault output signal Opening the magnetic contactor MC provided on the input side of the inverter at a fault occurrence shuts off the control power to the inverter therefore the fault output will not be retained Fault or alarm indication When a protective function is activated the operation panel display...

Page 94: ...ated from 0 to 65535 hours then cleared and accumulated again from 0 Fault history mode Monitor mode Parameter setting mode Function mode Operation for displaying fault history The last eight fault records can be displayed On the display of the last fault record fault record 1 a decimal point LED is ON When the fault history is empty E0 is displayed Latest fault Second latest fault Eighth latest f...

Page 95: ...ing mode Press to choose the parameter setting mode The parameter number read previously appears 3 Selecting the parameter number Turn until fault history clear appears Press to read the present set value initial value appears 4 Fault history clear Turn to change the set value to Press to start clear and are displayed alternately after the fault history is cleared Turn to read another parameter Pr...

Page 96: ... electronic thermal relay function E FIN Heat sink overheat E OLT Stall prevention stop E LUP Upper limit fault detection E LDN Lower limit fault detection E GF Output side earth ground fault overcurrent Fault E LF Output phase loss E OHT External thermal relay operation E PTC PTC thermistor operation E OPT Option fault E OP1 Communication option fault to E 16 to E 20 User definition error by the ...

Page 97: ...TIONS If faults other than the above appear contact your sales representative Others E Fault history E 0 No fault records EV 24 V external power supply operation RD Backup in progress WR Restoration in progress Operation panel indication Name ...

Page 98: ...S FOR MAINTENANCE AND INSPECTION This chapter explains the PRECAUTIONS FOR MAINTENANCE AND INSPECTION for this product Always read the instructions before using the equipment 5 1 Inspection item 98 5 2 Measurement of main circuit voltages currents and powers 105 ...

Page 99: ...ults during operation Motor operation fault Improper installation environment Cooling system fault Abnormal vibration abnormal noise Abnormal overheat discoloration 5 1 2 Periodic inspection Check the areas inaccessible during operation and requiring periodic inspection Consult us for periodic inspection Check and clean the cooling system Clean the air filter etc Check the tightening and retighten...

Page 100: ...crack discoloration etc Contact the manufacturer Contact the manufacturer Transformer reactor Check for unusual odor and abnormal increase of whining sound Stop the equipment and contact the manufacturer Terminal block Check for a damage Stop the equipment and contact the manufacturer Smoothing aluminum electrolytic capacitor 1 Check for liquid leakage Contact the manufacturer 2 Check for safety v...

Page 101: ...nuity the measured value is almost When there is an instantaneous electric continuity due to the smoothing capacitor the tester may not indicate At the time of electric continuity the measured value is several Ω to several tens of Ω When all measured values are almost the same although values may not be constant depending on the tester type it shows that there are no electrical paths with problems...

Page 102: ...ollows 1 Estimated lifespan for when the yearly average surrounding air temperature is 40 C without corrosive gas flammable gas oil mist dust and dirt etc 2 Output current 80 of the inverter rating NOTE For parts replacement contact the nearest Mitsubishi FA center Inverter parts life display The inverter diagnoses the control circuit capacitor and the cooling fan by itself and estimates their liv...

Page 103: ... cooling fans differs according to the inverter capacity Reinstallation 1 Before installing the new fan check the orientation of the fan to be sure that the AIR FLOW arrow printed on the side of the fan points upward 2 For reconnection of the fan refer to the above figure The tightening torque of the fan fixing screws is 0 73 N m NOTE Installing the fan in the opposite direction of air flow can ca...

Page 104: ...he capacitor has reached the end of its life when its capacity has dropped below 80 of its rated capacity NOTE The inverter diagnoses the control circuit capacitor by itself and can judge its life Refer to the FR A800 Instruction Manual Detailed Relay output terminals The contacts of relays deteriorate over time To prevent faults from occurring relays must be replaced when they have reached the ma...

Page 105: ...e the inverter properly to avoid malfunctions or failures To remove or reinstall the control circuit terminal block keep it upright so that it is parallel with the inverter To install the control circuit terminal block slide it upward so that the tongues on the inverter slot into the grooves on the terminal block Check that the terminal block is parallel to the inverter and the pins on the inverte...

Page 106: ...he next page NOTE When installing meters etc on the inverter output side When the wiring length between the inverter and the motor is large the meters and CTs may generate heat due to line to line leakage current Therefore choose equipment which has enough capacity for the current rating To measure and display the output voltage and output current of the inverter it is recommended that the termina...

Page 107: ... W and W and U Digital power meter designed for inverter 1 Difference between the phases is within 1 of the maximum output voltage Output side current I2 U V and W line currents Digital power meter designed for inverter Difference between the phases is 10 or lower of the inverter rated current Output side power P2 U V W and across U and V V and W P2 W21 W22 2 wattmeter method or 3 wattmeter method...

Page 108: ... meter for inverter for the input side of the converter unit FR CC2 and the output side of the inverter Since the converter unit input current tends to be unbalanced measurement of three phases is recommended The correct value cannot be obtained by measuring only one or two phases On the other hand the unbalanced ratio of each phase of the output current should be within 10 The inverter output cur...

Page 109: ...rrent output terminals CA and 5 of the inverter Measure the current using a digital multimeter For detailed specifications of the analog current output terminal CA refer to the FR A800 Instruction Manual Detailed 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 shown below and do not perf...

Page 110: ...9 6 SPECIFICATIONS This chapter explains the SPECIFICATIONS of this product Always read the instructions before using the equipment 6 1 Inverter rating 110 6 2 Common specifications 111 6 3 Outline dimension drawings 113 ...

Page 111: ...0 630 LD 355 400 450 500 560 SND 2 355 400 450 500 560 ND initial setting 315 355 400 450 500 HD 280 315 355 400 450 Output Rated capacity kVA 3 SLD 587 660 733 834 924 LD 521 587 660 733 834 SND 2 521 587 660 733 834 ND initial setting 465 521 587 660 733 HD 417 465 521 587 660 Rated current A SLD 770 866 962 1094 1212 LD 683 770 866 962 1094 SND 2 683 770 866 962 1094 ND initial setting 610 683 ...

Page 112: ...election Forward rotation command Reverse rotation command Inverter reset The input signal can be changed using Pr 178 to Pr 189 input terminal function selection Pulse train input 100k pulses s Operational functions Dancer feedback speed control tension sensor feedback speed control tension sensorless torque control tension sensor feedback torque control winding diameter calculation initial windi...

Page 113: ...peration panel power supply short circuit RS 485 terminals power supply short circuit 24 VDC power fault Abnormal output current detection 5 Communication fault inverter Analog input fault USB communication fault Safety circuit fault Overspeed occurrence 5 Speed deviation excess detection 1 5 Signal loss detection 1 5 Encoder phase fault 1 5 4 mA input fault 5 PID signal fault 5 Option fault Oppos...

Page 114: ...rawings FR A842 07700 315K FR A842 08660 355K R2R FR A842 09620 400K FR A842 10940 450K FR A842 12120 500K R2R Unit mm Unit mm 185 185 23 12 70 200 540 440 4 5 4 5 200 70 15 1300 17 17 1296 15 1330 3 φ12 hole 8 φ25 hole 185 185 23 12 100 240 680 440 4 5 4 5 240 100 15 1550 17 17 1546 15 1580 3 φ12 hole 8 φ25 hole ...

Page 115: ... 3 3 3 3 72 16 17 3 2max 1 Denotes the space required to connect an optional parameter unit connection cable FR CB2 When using another cable leave the space required for the cable specification Outline drawing Panel cutting dimension drawing 66 72 5 21 5 22 20 Parameter unit connection cable FR CB2 option 2 M3 screw Panel Air bleeding hole 120 or more 1 ...

Page 116: ...rison with FR A840 R2R 116 Appendix 2 Instructions for compliance with the EU Directives 117 Appendix 3 Instructions for UL and cUL 120 Appendix 4 Instructions for EAC 122 Appendix 5 Restricted Use of Hazardous Substances in Electronic and Electrical Products 123 Appendix 6 Referenced Standard Requirement of Chinese standardized law 123 ...

Page 117: ...eding Y85 Main circuit capacitor life Y87 Inrush current limit circuit life Y89 With Acceptable Instantaneous power failure undervoltage IPF During deceleration at occurrence of power failure retained until release Y46 Regenerative brake pre alarm RBP DC current feeding Y85 Main circuit capacitor life Y87 Inrush current limit circuit life Y89 Without Unacceptable Pr 192 IPF terminal function selec...

Page 118: ...en using the inverter in a residential area take appropriate measures and ensure the conformity of the inverter used in the residential area The installer shall provide a guide for installation and use including recommended mitigation devices Note First environment Environment including buildings facilities which are directly connected to a low voltage main supply which also supplies residential b...

Page 119: ...ion of the power supply overvoltage category III usable with the earthed neutral system power supply 400 V class only and pollution degree 2 or lower specified in IEC 60664 To use the inverter under the conditions of pollution degree 2 install it in the enclosure of IP2X or higher To use the inverter under the conditions of pollution degree 3 install it in the enclosure of IP54 or higher On the in...

Page 120: ...ects the overload of the motor and trips the inverter by stopping the operation of the transistor at the inverter output side The operation characteristic is shown on the left Mitsubishi Electric constant torque motor 1 Set one of 1 13 to 16 in Pr 71 This setting will enable the 100 constant torque characteristic in the low speed range 2 Set the rated current of the motor in Pr 9 1 When a value 50...

Page 121: ...ation in the United States Class T Class J Class CC or Class L fuses must be provided in accordance with the National Electrical Code and any applicable local codes For installation in Canada Class T Class J Class CC or Class L fuses must be provided in accordance with the Canadian Electrical Code and any applicable local codes Wiring to the power supply and the motor Refer to the National Electri...

Page 122: ...nd trips the inverter by stopping the operation of the transistor at the inverter output side The operation characteristic is shown on the left Mitsubishi Electric constant torque motor 1 Set one of 1 13 to 16 in Pr 71 This setting will enable the 100 constant torque characteristic in the low speed range 2 Set the rated current of the motor in Pr 9 1 When a value 50 of the inverter rated output cu...

Page 123: ...al Regulations CU TR and the EAC marking must be affixed to the products For information on the country of origin manufacture year and month and authorized sales representative importer in the CU area of this product refer to the following Country of origin indication Check the rating plate of the product Refer to page 8 Example MADE IN JAPAN Manufactured year and month Check the SERIAL number ind...

Page 124: ...名称含量含有部件如下表所示产品中所含有害物质的名称及含量上表依据 SJ T11364 的规定编制表示该有害物质在该部件所有均质材料中的含量均在 GB T26572 规定的限量要求以下表示该有害物质在该部件的至少一种均质材料中的含量超出 GB T26572 规定的限量要求 1 即使表中记载为根据产品型号也可能会有有害物质的含量为限制值以下的情况 2 根据产品型号一部分部件可能不包含在产品中 Appendix 6 Referenced Standard Requirement of Chinese standardized law This Product is designed and manufactured accordance with following Chinese standards Machinery safety GB T 16855 1 GB T 126...

Page 125: ...chnology that was not available at the time of the shipment of the Product from our company any other failures which we are not responsible for or which you acknowledge we are not responsible for 2 Term of warranty after the stop of production 1 We may accept the repair at charge for another seven 7 years after the production of the product is discontinued The announcement of the stop of productio...

Page 126: ...ted documents NOTE This is a personal computer dedicated CD ROM Do not attempt to play it on ordinary audio devices The loud volume may damage hearing and speakers System requirements for the enclosed CD ROM The following system is required to read instruction manuals contained in the enclosed CD ROM Operating method of the enclosed CD ROM How to read instruction manuals Step 1 Start the personal ...

Page 127: ... First edition Aug 2018 IB NA 0600607ENG B Addition Ethernet model Restricted Use of Hazardous Substances in Electronic and Electrical Products Referenced Standard Requirement of Chinese standardized law May 2019 IB NA 0600607ENG C Modification Numbers of referenced standards Requirement of Chinese standardized law updated IB NA 0600607ENG C ...

Page 128: ...NCTIONS 4 PRECAUTIONS FOR MAINTENANCE AND INSPECTION 5 SPECIFICATIONS 6 IB NA 0600607ENG C 1905 MEE Printed in Japan Specifications subject to change without notice FR A802 R2R SEPARATED CONVERTER TYPE INSTRUCTION MANUAL HARDWARE FR A842 07700 315K to 12120 500K R2R Roll to Roll Function HEAD OFFICE TOKYO BUILDING 2 7 3 MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN ...

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