Mitsubishi Electric FR-A806-E Inverter Instruction Manual (Hardware)

2.1 Peripheral devices

2.1.1 Inverter and peripheral devices

The following diagram illustrates the typical setup of the inverter with its peripheral devices:

[Diagram showing connections between AC power supply, MCCB/ELB/fuse, Magnetic Contactor (MC), AC Reactor, Brake Unit, High Power Factor Converter, Multifunction Regeneration Converter, Power Regeneration Common Converter, Power Regeneration Converter, Resistor Unit, Induction Motor, PM Motor, EMC filter, USB connector, and Personal Computer (FR Configurator 2).]

Notes:

• To prevent electric shock, always earth (ground) the motor and inverter.
• Do not install a power factor correction capacitor or surge suppressor or capacitor type filter on the inverter's output side. Doing so will cause the inverter to trip or the capacitor and surge suppressor to be damaged. If any of the above devices is connected, immediately remove it.
• When installing a molded case circuit breaker on the output side of the inverter, contact the manufacturer of the molded case circuit breaker.
• Electromagnetic wave interference: The input/output (main circuit) of the inverter includes high frequency components, which may interfere with communication devices (such as AM radios) used near the inverter. In this case, activating the EMC filter may minimize interference. (Refer to page 80.)
• For details of options and peripheral devices, refer to the respective Instruction Manual.
• A PM motor cannot be driven by the commercial power supply.
• A PM motor is a motor with permanent magnets embedded inside. High voltage is generated at the motor terminals while the motor is running. Before closing the contactor at the output side, make sure that the inverter power is ON and the motor is stopped.

Peripheral Device Overview

2.1.2 Peripheral devices

Check the model of the inverter you purchased. Appropriate peripheral devices must be selected according to the capacity. Refer to the table below to prepare appropriate peripheral devices.

Assumes the use of a Mitsubishi Electric 4-pole standard motor with the power supply voltage of 400 VAC, 50 Hz.

Select an MCCB according to the power supply capacity.

Install one MCCB per inverter.

[Diagram: MCCB INV M]

For the use in the United States or Canada, refer to page 141, and select an appropriate fuse or molded case circuit breaker (MCCB).

Magnetic contactor is selected based on the AC-1 class. The electrical durability of magnetic contactor is 500,000 times. When the magnetic contactor is used for emergency stops during motor driving, the electrical durability is 25 times.

If using an MC for emergency stop during motor driving, select an MC regarding the inverter input side current as JEM1038-AC-3 class rated current. When providing an MC on the inverter output side for switching to commercial power supply during general-purpose motor operation, select an MC regarding the rated motor current as JEM1038-AC-3 class rated current.

Notes:

• When the inverter capacity is larger than the motor capacity, select an MCCB and a magnetic contactor according to the inverter model, and select cables and reactors according to the motor output.
• When the breaker on the inverter's input side trips, check for the wiring fault (short circuit), damage to internal parts of the inverter etc. The cause of the trip must be identified and removed before turning ON the power of the breaker.

2.2 Removal and reinstallation of the front cover

Procedures for removing and reinstalling the front cover are detailed below, depending on the inverter model.

Removal of the front cover

• Remove the front cover installation screws to remove the front cover. (For the FR-A846-00620(22K) to 01160(45K), remove the operation panel before removing the front cover.)

[Diagram showing screw loosening]

Reinstallation of the front cover

• Fix the front cover with the front cover installation screws. (For the FR-A846-00620(22K) to 01160(45K), install the front cover while the operation panel is removed.)

Tighten the front cover installation screws in the numerical order shown in the figures below.

[Diagrams showing tightening order for different inverter series]

Removal and installation of front covers for control circuit and main circuit inspection (FR-A846-01800(55K) or higher)

• Remove the installation screws to remove the front cover for control circuit inspection and/or the front cover for main circuit inspection.

[Diagram showing screw loosening]

Installation of the front covers

• Fix the covers with the installation screws.

Tighten the installation screws in the numerical order shown in the figures below.

[Diagrams showing tightening order for front covers]

Notes:

• When installing the front cover for the FR-A846-00470(18.5K) or lower, fit the connector of the operation panel securely along the guides of the PU connector. Otherwise, the operation panel connection connector or the PU connector may be damaged.
• For the FR-A846-00620(22K) to 03610(132K), before removing/installing the front cover, always remove the operation panel. Otherwise, the operation panel connection connector or the PU connector may be damaged.
• When removing/installing the front cover of the FR-A846-00620(22K) to 01160(45K), always hold the front cover at the flange sections. Otherwise, the front cover may fall off, resulting in damage or injuries.
• Before installing the front cover, check the waterproof gasket to make sure that it is not damaged. If it is damaged, contact the nearest Mitsubishi Electric FA center.
• Securely install the front cover to fit the waterproof gasket closely. Do not let the waterproof gasket get stuck between the front cover edge and the inverter. Otherwise, water may get into the inverter. Also, do not let any foreign matter get stuck between the waterproof gasket and the front cover.
• Keep the waterproof gasket of the inverter clean. Otherwise, water may get into the inverter. If there is any dirt on the gasket, make sure to remove it.
• Fully make sure that the front cover is installed securely. Always tighten the mounting screws of the front cover.

2.3 Installation of the inverter

An inverter unit uses many semiconductor devices. To ensure higher reliability and long period of operation, operate the inverter in the ambient environment that completely satisfies the equipment specifications.

2.3.1 Inverter installation environment

The following table lists the standard specifications of the inverter installation environment. Using the inverter in an environment that does not satisfy the conditions deteriorates the performance, shortens the life, and causes a failure. Refer to the following points, and take adequate measures.

Standard environmental specifications of the inverter

* For installation at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude.

* 2.9 m/s² or less for the FR-A846-01800(55K) or higher.

Temperature

The permissible ambient temperature of the inverter is between -10°C and +40°C. Always operate the inverter within this temperature range. Operation outside this range will considerably shorten the service lives of the semiconductors, parts, capacitors and others. Take the following measures to keep the ambient temperature of the inverter within the specified range.

• (a) Measures against high temperature
• Ventilate the room.
• Install the inverter 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 inverter well.
• (b) Measures against low temperature
• Provide a heater around the inverter.
• Do not power OFF the inverter. (Keep the start signal of the inverter OFF.)
• (c) Sudden temperature changes
• Select an installation place where temperature does not change suddenly.
• Avoid installing the inverter near the air outlet of an air conditioner.
• If temperature changes are caused by opening/closing of a door, install the inverter away from the door.

Note:

• For the amount of heat generated by the inverter unit, refer to page 20.

Humidity

Operate the inverter within the ambient air humidity of usually 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 insulation distance defined in JEM1103 "Control Equipment Insulator" is humidity of 45 to 85%.

• (a) Measures against high humidity
• Provide dry air into the room from outside.
• Use a dehumidifier.
• (b) Measures against low humidity
• Air with proper humidity can be blown into the room from outside. Also when installing or inspecting the unit, discharge your body (static electricity) beforehand, and keep your body away from the parts and patterns.
• (c) Measures against condensation
• Condensation may occur if frequent operation stops change the in-room temperature suddenly or if the outside air temperature changes suddenly. Condensation causes such faults as reduced insulation and corrosion.
• Take the measures against high humidity in (a).
• Do not power OFF the inverter. (Keep the start signal of the inverter OFF.)

Dust, dirt, oil mist

Dust and dirt will cause faults such as poor contacts, reduction in insulation and cooling effect due to accumulation of moisture-absorbed dust and dirt, and equipment internal temperature rise due to a clogged ventilation filter in the room where the equipment is installed. In an atmosphere where conductive powder floats, dust and dirt will cause such faults as malfunction, deteriorated insulation and short circuit in a short time. Since oil mist will cause similar conditions, it is necessary to take adequate measures.

Countermeasure

• Purge air. Pump clean air from outside to make the in-enclosure air pressure higher than the outside air pressure.

Corrosive gas, salt damage

If the inverter is exposed to corrosive gas or to salt near a beach, the printed board patterns and parts will corrode or the relays and switches will result in poor contact. In such a place, take the countermeasures described in "Dust, dirt, oil mist" above.

Explosive, flammable gases

As the inverter is non-explosion proof, it must be contained in an explosion-proof enclosure. In places where explosion may be caused by explosive gas, dust or dirt, an enclosure cannot be used unless it structurally complies with the guidelines and has passed the specified tests. This makes the enclosure itself expensive (including the test charges). The best way is to avoid installation in such places and install the inverter in a non-hazardous place.

High altitude

Use the inverter at an altitude of within 2500 m. For use at an altitude above 1000 m, consider a 3% reduction in the rated current per 500 m increase in altitude. If it is used at a higher place, it is likely that thin air will reduce the cooling effect and low air pressure will deteriorate dielectric strength.

Vibration, impact

The vibration resistance of the inverter is up to 5.9 m/s² (2.9 m/s² or less for the FR-A846-01800(55K) or higher) at 10 to 55 Hz frequency and 1 mm amplitude in X, Y, and Z directions. Applying vibration and impacts for a long time may loosen the structures and cause poor contacts of connectors, even if those vibration and impacts are within the specified values. Especially when impacts are applied repeatedly, caution must be taken because such impacts may break the installation feet.

Countermeasure

• Strengthen the structure to prevent the installation surface from resonance.
• Install the inverter away from the sources of the vibration.

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 is shown in the following tables.

Note:

• The amount of heat generated shown assumes that the output current is the inverter rated current, and the carrier frequency is 2 kHz.

2.3.3 Inverter installation

Inverter placement

• Install the inverter on a strong flat surface securely with screws.
• Fix six positions for the FR-A846-01800(55K) or higher.
• Leave enough clearances and take cooling measures.
• Avoid places where the inverter is subjected to direct sunlight, high temperature and high humidity.
• Install the inverter on a nonflammable wall surface.
• For heat dissipation and maintenance, keep clearance between the inverter and the other devices. The clearance below the inverter is required as a wiring space, and the clearance above the inverter is required as a heat dissipation space.
• When designing or building an enclosure for the inverter, carefully consider influencing factors such as heat generation of the contained devices and the operating environment.

For the FR-A846-00126(3.7K) or lower, allow 1 cm or more clearance.

Installation orientation of the inverter

Install the inverter on a wall as specified. Do not install it horizontally or in any other way.

Above the inverter

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

2.4 Terminal connection diagrams

The following diagrams illustrate the terminal connections for the FM type (Sink logic) and CA type (Source logic) inverters.

FM type (Sink logic)

[Diagram showing FM type terminal connections for Main circuit and Control circuit, including power supply, motor, MCCB, MC, reactor, brake unit, EMC filter, PU connector, USB connectors, Ethernet connector, and various control input/output signals like STF, STR, STP, etc.]

Notes for FM type:

• The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). (Refer to the FR-A800 Instruction Manual (Detailed).)
• Terminal JOG is also used as a pulse train input terminal. Use Pr.291 to choose JOG or pulse.
• Terminal input specifications can be changed by analog input specification switchover (Pr.73, Pr.267). To input a voltage, set the voltage/current input switch OFF. To input a current, set the voltage/current input switch ON.
• Terminals 10 and 2 are also used as a PTC input terminal. (Pr.561) (Refer to the FR-A800 Instruction Manual (Detailed).)
• It is recommended to use 2 W 1 kΩ when the frequency setting signal is changed frequently.
• The function of these terminals can be changed with the output terminal assignment (Pr.195, Pr.196). (Refer to the FR-A800 Instruction Manual (Detailed).)
• The function of these terminals can be changed with the output terminal assignment (Pr.190 to Pr.194). (Refer to the FR-A800 Instruction Manual (Detailed).)
• Terminal FM can be used to output pulse trains as open collector output by setting Pr.291.
• Not required when calibrating the scale with the operation panel.
• Do not change the initially set ON (enabled) position of the EMC filter ON/OFF connector in the case of the inverter with a built-in C2 filter. The Class C2 compatibility condition is not satisfied with the EMC filter OFF. The FR-A846-00250(7.5K)-L2 to FR-A846-00470(18.5K)-L2 are not provided with the EMC filter ON/OFF connector. The EMC filter is always ON.
• The option connector 2 cannot be used because the Ethernet board is installed in the initial status. The Ethernet board must be removed to install a plug-in option to the option connector 2. (However, Ethernet communication is disabled in that case.)
• To prevent a malfunction due to noise, keep the signal cables 10 cm or more away from the power cables. Also, separate the main circuit cables at the input side from the main circuit cables at the output side.
• After wiring, wire offcuts must not be left in the inverter. Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter clean. When drilling mounting holes in a wall or the side of the enclosure etc., take caution not to allow chips and other foreign matters to enter the inverter.
• Set the voltage/current input switch correctly. Incorrect setting may cause a fault, failure or malfunction.

CA type (Source logic)

[Diagram showing CA type terminal connections for Main circuit and Control circuit, including power supply, motor, MCCB, MC, reactor, brake unit, EMC filter, PU connector, USB connectors, Ethernet connector, and various control input/output signals like STF, STR, STP, etc.]

Notes for CA type:

• The function of these terminals can be changed with the input terminal assignment (Pr.178 to Pr.189). (Refer to the FR-A800 Instruction Manual (Detailed).)
• Terminal JOG is also used as a pulse train input terminal. Use Pr.291 to choose JOG or pulse.
• Terminal input specifications can be changed by analog input specification switchover (Pr.73, Pr.267). To input a voltage, set the voltage/current input switch OFF. To input a current, set the voltage/current input switch ON.
• Terminals 10 and 2 are also used as a PTC input terminal. (Pr.561) (Refer to the FR-A800 Instruction Manual (Detailed).)
• It is recommended to use 2 W 1 kΩ when the frequency setting signal is changed frequently.
• The function of these terminals can be changed with the output terminal assignment (Pr.195, Pr.196). (Refer to the FR-A800 Instruction Manual (Detailed).)
• The function of these terminals can be changed with the output terminal assignment (Pr.190 to Pr.194). (Refer to the FR-A800 Instruction Manual (Detailed).)
• Do not change the initially set ON (enabled) position of the EMC filter ON/OFF connector in the case of the inverter with a built-in C2 filter. The Class C2 compatibility condition is not satisfied with the EMC filter OFF. The FR-A846-00250(7.5K)-L2 to FR-A846-00470(18.5K)-L2 are not provided with the EMC filter ON/OFF connector. The EMC filter is always ON.
• The option connector 2 cannot be used because the Ethernet board is installed in the initial status. The Ethernet board must be removed to install a plug-in option to the option connector 2. (However, Ethernet communication is disabled in that case.)
• To prevent a malfunction due to noise, keep the signal cables 10 cm or more away from the power cables. Also, separate the main circuit cables at the input side from the main circuit cables at the output side.
• After wiring, wire offcuts must not be left in the inverter. Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter clean. When drilling mounting holes in a wall or the side of the enclosure etc., take caution not to allow chips and other foreign matters to enter the inverter.
• Set the voltage/current input switch correctly. Incorrect setting may cause a fault, failure or malfunction.

2.5 Main circuit terminals

2.5.1 Details on the main circuit terminals

Available when used in the common bus regeneration mode.

2.5.2 Terminal layout of the main circuit terminals, wiring of power supply and the motor

[Diagrams showing terminal layouts for different inverter capacity ranges, illustrating connections for power supply and motor.]

Notes:

• Make sure the power cables are connected to the R/L1, S/L2, and T/L3. (Phase need not be matched.) Never connect the power cable to the U, V, and W of the inverter. Doing so will damage the inverter.
• Connect the motor to U, V, and W. The phase need to be matched.

2.5.3 Wiring method

1. Remove the front cover of the inverter. (Refer to page 15)
2. For the FR-A846-00470(18.5K) or lower, remove the wiring cover installation screws (hexalobular screws, screw size: M5, screwdriver size: T25, tightening torque: 2.8 to 3.6 N·m) to remove the wiring cover.
3. For the FR-A846-00470(18.5K) or lower, remove the protective bushes from the wiring cover. For the FR-A846-00620(22K) to FR-A846-01160(45K), remove the protective bushes from the bottom of the inverter. For the FR-A846-01800(55K) or higher, remove the protective bushes from the bottom and the side of the inverter. (Do not remove the protective bushes from the holes that are not used for wiring of cables.)
4. Fix the cables using a cable gland and a nut, according to the diameter of the holes. For the details such as hole diameters and recommended cable glands, refer to the following table.

(a) EMC-compliant cable gland, (b) General-purpose cable gland

5. For the FR-A846-00470(18.5K) or lower, install the wiring cover.
6. Connect cables to the terminals of the inverter.
7. Install the front cover to the inverter. (Refer to page 15)

CAUTION

• Always use a waterproof cable gland (IP55 or higher) for the hole from which the protective bush is removed because water may get into the inverter.

2.5.4 Applicable cables and the wiring length

Select a recommended cable size to ensure that the voltage drop will be 2% or less. If the wiring distance is long between the inverter and motor, the voltage drop in the main circuit wires will cause the motor torque to decrease especially at a low speed. The following table shows inverter/cable combinations for a wiring length of 20 m.

• 400 V class (440 V input power supply (with 150% rated current for one minute))

Notes on cable gauge:

• For the FR-A846-01800(55K) or lower, it is the gauge of a cable with the continuous maximum permissible temperature of 75°C (HIV cable (600 V grade heat-resistant PVC insulated wire), etc.). It assumes a surrounding air temperature of 50°C or lower and the wiring distance of 20 m or shorter. For the FR-A846-02160(75K) or higher, it is the gauge of the cable with the continuous maximum permissible temperature of 90°C or higher. (LMFC (heat resistant flexible cross-linked polyethylene insulated cable), etc.). It assumes a surrounding air temperature of 50°C or lower.
• For the FR-A846-01160(45K) or lower, it is the gauge of a cable with the continuous maximum permissible temperature of 75°C (THHW cable). It assumes a surrounding air temperature of 40°C or lower and the wiring distance of 20 m or shorter. For the FR-A846-01800(55K) or higher, it is the gauge of a cable with the continuous maximum permissible temperature of 90°C (THHN cable). It assumes a surrounding air temperature of 40°C or lower. (For the use in the United States or Canada, refer to page 141.)
• For the FR-A846-01160(45K) or lower, it is the gauge of a cable with the continuous maximum permissible temperature of 70°C (PVC cable). It assumes a surrounding air temperature of 40°C or lower and the wiring distance of 20 m or shorter. For the FR-A846-01800(55K) or higher, it is the gauge of a cable with the continuous maximum permissible temperature of 90°C (XLPE cable). It assumes a surrounding air temperature of 40°C or lower. (Selection example for use mainly in Europe.)
• The terminal screw size indicates the size of terminal screw for R/L1, S/L2, T/L3, U, V, W, P/+, N/-, P1, and a screw for earthing (grounding).

The line voltage drop can be calculated by the following formula:

Line voltage drop [V] = · wire resistance[m/Ωm] · wiring distance[m] · current[A] / 1000

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.

Notes:

• 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 circuit or malfunction due to the unit breakage.
• Use crimp terminals with insulation sleeves to wire the power supply and motor.

Total wiring length

With induction motor

Connect one or more general-purpose motors within the total wiring length shown in the following table. (The wiring length should be 100 m or less under vector control.)

Total wiring length (FR-A846-00052(1.5K) or higher)

When driving a 400 V class motor by the inverter, surge voltages attributable to the wiring constants may occur at the motor terminals, deteriorating the insulation of the motor. In this case, take one of the following measures.

• Use a "400 V class inverter-driven insulation-enhanced motor" and set Pr.72 PWM frequency selection according to the wiring length.

• For the FR-A846-01800(55K) or lower, connect a surge voltage suppression filter (FR-ASF-H/FR-BMF-H) at the output side of the inverter. For the FR-A846-02160(75K) or higher, connect a sine wave filter (MT-BSL/BSC) at the output side of the inverter.

With PM motor

The wiring length should be 100 m or shorter when connecting a PM motor. Use one PM motor for one inverter. Multiple PM motors cannot be connected to an inverter. When the wiring length exceeds 50 m for a 400 V class motor driven by an inverter under PM sensorless vector control, set "9" (6 kHz) or less in Pr.72 PWM frequency selection.

Notes:

• Especially for long-distance wiring or wiring with shielded cables, the inverter may be affected by a charging current caused by stray capacitances of the wiring, leading to an activation of the overcurrent protection, malfunction of the fast-response current limit operation, or even to an inverter failure. It may also cause a malfunction or fault of the equipment connected ON the inverter output side. Stray capacitances of the wiring differ by the installation condition, use the total wiring length in the table above as reference values. If the fast-response current limit function malfunctions, disable this function. (Refer to Pr.156 Stall prevention operation selection on the FR-A800 Instruction Manual (Detailed).)
• A surge voltage suppression filter (FR-ASF-H/FR-BMF-H) can be used under V/F control and Advanced magnetic flux vector control. A sine wave filter (MT-BSL/BSC) can be used under V/F control. Do not use the filters under different control methods.
• For the details of Pr.72 PWM frequency selection, refer to the FR-A800 Instruction Manual (Detailed).
• Refer to page 87 to drive a 400 V class motor by an inverter.
• The carrier frequency is limited during PM sensorless vector control. (Refer to the FR-A800 Instruction Manual (Detailed).)

2.5.5 Earthing (grounding) precautions

Always earth (ground) the motor and inverter.

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. The purpose of earthing (grounding) the case of an electrical apparatus is to prevent operators from getting an electric shock from this leakage current when touching it. To avoid the influence of external noises, this earthing (grounding) is important to audio equipment, sensors, computers and other apparatuses that handle low-level signals or operate very fast.

Earthing (grounding) methods and earthing (grounding) work

As described previously, earthing (grounding) is roughly classified into an electrical shock prevention type and a noise-influenced malfunction prevention type. Therefore, these two types should be clearly distinguished, and the following work must be done to prevent the leakage current having the inverter's high frequency components from entering the malfunction prevention type earthing (grounding):

• Whenever possible, use the independent earthing (grounding) for the inverter. If independent earthing (grounding) (I) is not available, use (II) common earthing (grounding) 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 (grounded) separately from EMI-sensitive devices. In a high building, it may be effective to use the EMI prevention type earthing (grounding) connecting to an iron structure frame, and electric shock prevention type earthing (grounding) with the independent earthing (grounding) together.
• This inverter must be earthed (grounded). 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). A neutral-point earthed (grounded) power supply in compliance with EN standard must be used.
• Use the thickest possible earthing (grounding) cable. The earthing (grounding) cable should be the size indicated in the table on page 30.
• The earthing (grounding) point should be as close as possible to the inverter, and the earth (ground) wire length should be as short as possible.
• Run the earthing (grounding) cable as far away as possible from the I/O wiring of equipment sensitive to noises and run them in parallel in the minimum distance.

[Diagram showing three earthing (grounding) methods: (I) Independent, (II) Common, (III) Common earthing (grounding) cable (Not allowed)]

Notes:

• To be compliant with the EU Directive (Low Voltage Directive), refer to page 137.

2.6 Control circuit

2.6.1 Details on the control circuit terminals

Input signal function of the terminals can be selected by setting Pr.178 to Pr.196 (I/O terminal function selection). For the details of the control circuit terminal function selection, refer to the FR-A800 Instruction Manual (Detailed).

Input signal

Frequency setting

[Diagram showing voltage/current input switch settings]

+24 V external power supply input

For connecting a 24 V external power supply. If a 24 V external power supply is connected, power is supplied to the control circuit while the main power circuit is OFF. (Refer to page 42.)

Output signal

Terminal FM is provided in the FM-type inverter. Terminal CA is provided in the CA-type inverter.

Communication

Safety stop signal

For the safety stop function, refer to page 44.

Notes:

• Use the terminal So (SO) to output a fault and to prevent restarting of the inverter. The signal cannot be used as safety stop input terminal to other devices.

Connection diagram

[Diagram showing connection for safety stop function, including emergency stop button, safety relay module/controller, and inverter terminals.]

Safety stop function operation

ON: The transistor is conducted. OFF: The transistor is not conducted.

When not using the safety stop function, short across terminals S1 and PC, S2 and PC, and SIC and SD to use the inverter. (In the initial status, terminals S1 and PC, S2 and PC, and SIC and SD are respectively shorted with shorting wires.)

If any of the faults shown in the following table occurs, terminal So (SO) and the SAFE signal turns OFF.

When the internal safety circuit is operated normally (no faults occurs), terminal So (SO) and the SAFE signal remain ON until "E.SAF" is displayed. Terminal So (SO) and the SAFE signal turn OFF when "E.SAF" is displayed.

SA is displayed when the terminals S1 and S2 are identified as OFF due to the internal safety circuit failure.

If another fault occurs at the same time as E.SAF, the other fault can be displayed. If another warning occurs at the same time as SA, the other warning can be displayed.

The ON/OFF state of the output signal is the one for the positive logic. The ON and OFF are reversed for the negative logic.

To assign the function of the SAFE signal to an output terminal, set either value shown in the following table in any parameter from Pr.190 to Pr.196 (Output terminal function selection).

The use of SAFE signal has not been certified for compliance with safety standards.

For more details, refer to the Safety stop function instruction manual. (A PDF copy can be found in the enclosed CD-ROM. For how to use this CD-ROM, refer to page 146.)

2.7 Operation panel (FR-LU08-01)

2.7.1 Components of the operation panel

The operation panel (FR-LU08-01) is an IP55 compatible model that can only be installed on the FR-A806-L2/L3 series. (It cannot be installed on the standard model or the separated converter type of the FR-A800 series.)

[Diagram showing front and rear views of the operation panel with labeled components.]

Notes:

• Do not operate the keys with sharp tools.
• Do not press the LCD part.
• Do not peel off the waterproof seal affixed to the operation panel. If the seal is peeled off, the operation panel does not conform to IP55.

2.7.2 Outline of the Main monitor indicator

[Diagram showing the operation panel display with various indicators and their meanings.]

2.7.3 Basic operation of the operation panel

For the details of operating procedures for the operation panel, refer to the Instruction Manual of the FR-LU08(-01).

[Diagrams illustrating operation modes, frequency setting, fault history, and parameter setting.]

2.8 Communication connectors and terminals

2.8.1 PU connector

Connecting the operation panel or parameter unit

• With a connection cable, the operation panel or the parameter unit can be connected to the inverter. (A connection connector is also required for connecting the operation panel.) Use the option FR-CB2[] cable (and FR-ADP connector), or a cable and connector available on the market. Securely insert both ends of the connection cable until the stoppers are fixed.
• The inverter does not conform to IP55 when the operation panel is removed.

[Diagram showing connection of parameter unit/operation panel via cables and connectors.]

Notes:

• Refer 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):
  • Connection cable: Mitsubishi Cable Industries, Ltd. SGLPEV-T (Cat5e/300 m), 24AWG • 4P
  • Connector: Tyco Electronics 5-554720-3

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 the inverter or read and write parameters.
• Communication can be performed with the Mitsubishi inverter protocol (computer link operation).
• For the details, refer to the FR-A800 Instruction Manual (Detailed).
• The inverter does not conform to IP55 when the operation panel is removed.

Removal and reinstallation of the operation panel

• Loosen the four fixing screws on the operation panel and pull out the operation panel. (These screws cannot be removed.)
• To reinstall the operation panel, align its connector on the back with the PU connector of the inverter, and insert the operation panel. After confirming that the operation panel is fit securely, tighten the screws in the diagonal order. (Tightening torque: 0.39 to 0.49 N·m)

2.8.2 Ethernet connector

Ethernet communication specifications

Connection cable

Use Ethernet cables compliant with the following standards.

Hub

Use a hub that supports transmission speed of the Ethernet.

2.8.3 USB connector

Connection to the USB connectors

1. Before removing a front cover, check to make sure that the indication of the inverter operation panel is OFF, wait for at least 10 minutes after the power supply has been switched OFF, and check that there is no residual voltage using a tester or the like.
2. Connect a USB memory device to the USB A connector, and a USB cable to the USB mini B connector. Refer to the following for the clearance required for the USB memory device and USB cable. They must fit in the space between each connector and the front cover.

[Diagram showing USB A and mini B connectors on the inverter front panel, with space requirements indicated.]

USB host communication

• Interface: Conforms to USB1.1
• Transmission speed: 12 Mbps
• Wiring length: Maximum 5 m
• Connector: USB A connector (receptacle)
• Compatible USB memory: Format FAT32, Capacity 1 GB or more (used in the recorder mode of the trace function). Encryption function: Not available.

The USB host communication enables the following functions:

• 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 for sharing the parameter setting among multiple inverters.
  • The parameter setting file can be copied onto a personal computer from the USB memory device and edited using FR Configurator 2.
• Trace
• The monitored data and output status of the signals can be saved in a USB memory device.
• The saved data can be imported to FR Configurator 2 to diagnose the operating status of the inverter.
• PLC function data copy
• This function copies the PLC function project data to a USB memory device when the PLC function is used.
• The PLC function project data copied in the USB memory device can be copied to other inverters.
• This function is useful in backing up the parameter setting and for allowing multiple inverters to operate by the same sequence programs.

The operating status of the USB host can be checked on the operation panel. Refer to page 47 for details. The operating status of the USB host can be also checked on the LED display of the inverter.

When a device such as a USB battery charger is connected to the USB connector and an excessive current (500 mA or more) flows, USB host error (UF warning) is displayed on the operation panel. When the UF warning appears, the USB error can be canceled by removing the USB device and setting Pr.1049 = "1". (The UF warning can also be canceled by resetting the inverter power or resetting with the RES signal.)

Notes:

• 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 the details of the usage of the USB connector, refer to the FR-A800 Instruction Manual (Detailed).

USB device communication

The inverter can be connected to a personal computer with a USB (Ver. 1.1) cable. Parameter setting and monitoring can be performed by FR Configurator 2.

• Interface: Conforms to USB1.1
• Transmission speed: 12 Mbps
• Wiring length: Maximum 5 m
• Connector: USB mini B connector (receptacle)
• Power supply: Self-powered

Note:

• For the details of FR Configurator 2, refer to the Instruction Manual of FR Configurator 2.

WARNING

• While power is ON or when the inverter is running, do not open the front cover. Otherwise you may get an electric shock.

2.9 Connection of 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.

Appearance and parts name of the FR-A8AP

[Diagram showing the FR-A8AP option unit, its terminals, and switches.]

Terminals of the FR-A8AP

Notes:

• When the encoder's output voltage differs from its input power supply voltage, the signal loss detection (E.ECT) may occur.
• Incorrect wiring or faulty setting to the encoder will cause a fault such as an overcurrent (E.OC[]) and an inverter overload (E.THT). Correctly perform the encoder wiring and setting.

Switches of 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.
• Terminating resistor selection switch (SW1): Selects ON/OFF of the internal terminating resistor. Set the switch to ON (initial status) when an encoder output type is differential line driver, and set to OFF when complementary.

Notes:

• Set all switches to the same setting (ON/OFF).
• 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.

Motor and switch setting

Notes:

• Set according to the motor (encoder).
• Prepare an encoder's power supply (5 V/12 V/15 V/24 V) according to the encoder's output voltage. When the control terminal option FR-A8TP is installed, 24 V power supply can be provided from the FR-A8TP.
• When the encoder output is the differential line driver type, only 5 V can be input.

Notes:

• The SW2 switch is for manufacturer setting. Do not change the setting.
• When the power supply of the inverter is turned OFF, also turn off the power supply of the encoder. Otherwise, the plug-in option may be damaged.

Encoder specification

Encoder cable

[Diagrams showing encoder cable wiring examples for different motor types and connection terminals.]

Notes:

• As the terminal block of the FR-A8AP is an insertion type, cables need to be treated. (Refer to the following description.)
• When using an encoder cable (FR-JCBL, FR-V5CBL, etc.) dedicated to the conventional motor, cut the crimp terminal of the encoder cable and strip its sheath to make its cable wires loose. Also, treat the shielding wires of the shielded twisted pair cable to ensure that they will not contact conductive areas. Wire the stripped cable after twisting it to prevent it from becoming loose. In addition, do not solder it.

[Diagram showing cable stripping size.]

Notes on blade terminals:

• Commercially available products (as of January 2017):
  • Phoenix Contact Co., Ltd.: Terminal screw size M2, Cable gauge (mm²) 0.3, Ferrule terminal model AI 0,34-6TQ, AI 0,5-6WH, Crimping tool model CRIMPFOX 6.
  • NICHIFU Co., Ltd.: Terminal screw size M2, Cable gauge (mm²) 0.3 to 0.75, Blade terminal product number BT 0.75-7, Insulation cap product number VC 0.75, Crimping tool product number NH 69.
• When using a blade terminal (without insulation sleeve), take caution that the twisted wires do not come out.

Connection terminal compatibility table

[Table showing compatibility between motor encoder cables and FR-A8AP terminals.]

Wiring example

[Diagrams showing wiring examples for Speed control, Torque control, and Position control.]

Notes:

• The pin number differs according to the encoder used. Speed, control, torque control, and position control by pulse train input are available with or without the Z-phase being connected.
• Connect the encoder so that there is no looseness between the motor and motor shaft. Speed ratio must be 1:1.
• Earth (ground) the shield of the encoder cable to the enclosure using a tool such as a P-clip. (Refer to page 58.)
• For the complementary, set the terminating resistor selection switch to OFF position. (Refer to page 54.)
• A separate power supply of 5 V/12 V/15 V/24 V is necessary according to the encoder power specification. When the encoder output is the differential line driver type, only 5 V can be input. Make the voltage of the external power supply the same as the encoder output voltage, and connect the external power supply across PG and SD.
• For terminal compatibility of the FR-JCBL, FR-V7CBL, and FR-A8AP, refer to page 56.
• For the fan of the 7.5 kW or lower dedicated motor, the power supply is single phase. (200 V/50 Hz, 200 to 230 V/60 Hz)
• Connect the recommended 2W1k resistor between the terminal PC and OH. (Recommended product: MOS2C102J 2W1k by KOA Corporation) Insert the input line and the resistor to a 2-wire blade terminal, and connect the blade terminal to the terminal OH. (For the recommended 2-wire blade terminals, refer to page 39.) Insulate the lead wire of the resistor, for example by applying a contraction tube, and shape the wires so that the resistor and its lead wire will not touch other cables. Caulk the lead wire securely together with the thermal protector input line using a 2-wire blade terminal. (Do not subject the lead wire's bottom area to an excessive pressure.) To use a terminal as the terminal OH, assign the OH (external thermal O/L relay input) signal to an input terminal. (Set "7" in any parameter from Pr.178 to Pr.189. For details, refer to the FR-A800 Instruction Manual (Detailed).)
• Assign the function using Pr.178 to Pr.184, Pr.187 to Pr.189 (input terminal function selection).
• When position control is selected, terminal JOG function is invalid and simple position pulse train input terminal becomes valid.
• Assign the function using Pr.190 to Pr.194 (output terminal function selection).

Instructions for encoder cable wiring

• Use shielded twisted pair cables (0.2 mm² or larger) to connect the FR-A8AP. For the wiring to the 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).

[Diagram showing parallel connection with two cables.]

• To reduce noise of the encoder cable, earth (ground) the encoder's shielded cable to the metal fitting for earthing (grounding) with a metal P-clip or U-clip. Refer to the following figure.

[Diagram showing earthing (grounding) example using a P-clip.]

• When one encoder is shared between FR-A8AP and CNC (computerized numerical controller), its output signal should be connected as shown below. In this case, the wiring length between FR-A8AP and CNC should be as short as possible, within 5 m.

[Diagram showing shared encoder connection.]

Notes:

• For the details of the optional encoder dedicated cable (FR-JCBL/FR-V7CBL), refer to page 55.
• The FR-V7CBL is provided with a P-clip for earthing (grounding) shielded cables.

2.10 Parameter settings for a motor with encoder

Parameter for the encoder (Pr.359, Pr.369, Pr.851, Pr.852)

• Set the encoder specifications.

The parameters above can be set when a vector control compatible option is installed.

Parameter settings for the motor under vector control

Values in [ ] indicate initial values.

Notes:

• Offline auto tuning is required. (Refer to the FR-A800 Instruction Manual (Detailed).)
• Set this parameter according to the motor.
• Use the thermal protector input provided with the motor.

When using the inverter with the SF-V5RU (1500 r/min series), refer to the table below to set Pr.83 Rated motor voltage and Pr.84 Rated motor frequency.

When using the inverter with the SF-V5RU1, SF-V5RU3, or SF-V5RU4, refer to the table below to set Pr.83 Rated motor voltage and Pr.84 Rated motor frequency.

Combination with the vector control dedicated motor

When using the inverter with a vector control dedicated motor, refer to the table below.

Combination with the SF-V5RU and SF-THY (ND rating)

Notes:

• The maximum speed is 2400 r/min.
• 80% output in the high-speed range. (The output is reduced when the speed is 2400 r/min or faster.)

Notes:

• The SF-V5RU1 (speed ratio 1:1), SF-V5RU3 (speed ratio 1:3), and SF-V5RU4 (speed ratio 1:4) will be manufactured per order.

2.11 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 corresponding option unit manual.

2.11.1 Connection of the brake unit (FR-BU2)

Connect the brake unit (FR-BU2(H)) as shown below to improve the braking capability during deceleration.

[Diagram showing connection example with GRZG type discharging resistor.]

Notes:

• When wiring, make sure to match the terminal symbol (P/+, N/-) at the inverter side and at the brake unit (FR-BU2) side. (Incorrect connection will damage the inverter and brake unit.)
• Install a stepdown transformer.
• The wiring distance between the inverter and brake unit (FR-BU2), and between the brake unit (FR-BU2) and discharging resistor must be within 5 m. Even when the wires are twisted, the cable length must be within 10 m.
• It is recommended to install an external thermal relay to prevent overheat of the discharging resistor.
• For the connection method of the discharging resistor, refer to the Instruction Manual of the FR-BU2.

Notes:

• Set "1" in Pr.0 Brake mode selection of the FR-BU2 to use a GRZG type discharging resistor.
• Do not remove the jumper across terminals P/+ and P1.

Connection example with the FR-BR-(H) resistor unit

[Diagram showing connection example with FR-BR resistor unit.]

Notes:

• When wiring, make sure to match the terminal symbol (P/+, N/-) at the inverter side and at the brake unit (FR-BU) side. (Incorrect connection will damage the inverter.)
• Install a stepdown transformer.
• The wiring distance between the inverter and brake unit (FR-BU), and between the brake unit (FR-BU) and resistor unit (FR-BR) must be within 5 m. Even when the cable is twisted, the wiring length must be within 10 m.
• The contact between TH1 and TH2 is closed in the normal status and is open at a fault.

Notes:

• Do not remove the jumper across terminals P/+ and P1.

Connection example with the MT-BR5 type resistor unit

After wiring securely, set Pr.30 Regenerative function selection = "1" and Pr.70 Special regenerative brake duty = "0 (initial value)". Set Pr.0 Brake mode selection = "2" in the brake unit FR-BU2.

[Diagram showing connection example with MT-BR5 resistor unit.]

Notes:

• When wiring, make sure to match the terminal symbol (P/+, N/-) at the inverter side and at the brake unit (FR-BU2) side. (Incorrect connection will damage the inverter and brake unit.)
• Install a stepdown transformer.
• The wiring distance between the inverter and brake unit (FR-BU2), and between the brake unit (FR-BU2) and resistor unit (MT-BR5) must be within 5 m. Even when the wire is twisted, the wiring length must be within 10 m.
• The contact between TH1 and TH2 is open in the normal status and is closed at a fault.
• The CN8 connector used with the MT-BU5 type brake unit is not used.

Notes:

• The stall prevention (overvoltage), oL, does not occur while Pr.30 Regenerative function selection = "1 or 101" and Pr.70 Special regenerative brake duty = "0% (initial value)". (Refer to the FR-A800 Instruction Manual (Detailed).)

2.11.2 Connection of the brake unit (FR-BU)

Connect the brake unit (FR-BU(H)) as shown below to improve the braking capability during deceleration. The FR-BU is compatible with the FR-A846-01800(55K) or lower.

[Diagram showing connection example with FR-BR resistor unit.]

Notes:

• When wiring, make sure to match the terminal symbol (P/+, N/-) at the inverter side and at the brake unit (FR-BU(H)) side. (Incorrect connection will damage the inverter.)
• Install a stepdown transformer.
• The wiring distance between the inverter and brake unit (FR-BU), and between the brake unit (FR-BU) and resistor unit (FR-BR) must be within 5 m. Even when the cable is twisted, the wiring length must be within 10 m.

Notes:

• If the transistors in the brake unit should become faulty, the resistor will overheat. Install a magnetic contactor on the inverter's input side and configure a circuit that shut off the current in case of a fault.
• Do not remove the jumper across terminals P/+ and P1.

2.11.3 Connection of the brake unit (BU type)

Connect the brake unit (BU type) correctly as shown below. Incorrect connection will damage the inverter. Remove the jumpers across terminals HB and PC and terminals TB and HC of the brake unit and fit one across terminals PC and TB. The BU type is compatible with the FR-A846-01800(55K) or lower.

[Diagram showing connection example with discharging resistor.]

Notes:

• The wiring distance between the inverter and brake unit (BU type), and between the brake unit (BU type) and discharging resistor must be within 2 m. Even when the cable is twisted, the wiring length must be within 5 m.
• If the transistors in the brake unit should become faulty, the resistor will overheat and result in a fire. Install a magnetic contactor on the inverter's input side and configure a circuit that shut off the current in case of a fault.
• Remove the jumper across terminals P/+ and P1.

2.11.4 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 shown below. Incorrect connection will damage the high power factor converter and the inverter. After making sure that the wiring is correct and secure, set the rated motor voltage in Pr.19 Base frequency voltage (under V/F control) or Pr.83 Rated motor voltage (under other than V/F control) and "2 or 102" in Pr.30 Regenerative function selection.

[Diagram showing connection of FR-HC2 converter.]

Notes:

• Do not connect anything to power input terminals (R/L1, S/L2, T/L3). Incorrect connection will damage the inverter. (E.OPT (option fault) will occur.)
• Remove the jumper across terminals P/+ and P1.
• Do not install an MCCB across the terminals P/+ and N/- (across terminals P and P/+ or across N and N/-). Connecting the opposite polarity of terminals N/- and P/+ will damage the inverter.
• Use Pr.178 to Pr.189 (input terminal function selection) to assign the terminals used for the X10 (X11) signal. For RS-485 or any other communication where the start command is only transmitted once, use the X11 signal to save the operation mode at the time of an instantaneous power failure.
• Assign the IPF signal to an FR-HC2 terminal. (Refer to the Instruction Manual of the FR-HC2.)
• Always connect the FR-HC2 terminal RDY to a terminal where the X10 signal or MRS signal is assigned in the inverter. Always connect the FR-HC2 terminal SE to the inverter terminal SD. Not connecting these terminals may damage the FR-HC2.
• Always connect the R/L1, S/L2, and T/L3 terminals of FR-HC2 to the power supply. Operating the inverter without connecting them will damage the FR-HC2.
• Do not install an MCCB or MC between the reactor 1 terminals (R/L1, S/L2, T/L3) and the FR-HC2 terminals (R4/L14, S4/L24, T4/L34). It will not operate properly.
• Securely perform grounding (earthing) by using the grounding (earthing) terminal.
• Installation of a fuse is recommended. (Refer to the Instruction Manual of the FR-HC2.)

Notes:

• 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.
• The control logic (sink logic/source logic) of the high power factor converter and the inverter must be matched. (Refer to page 37 for the switching of the control logic.)
• For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

2.11.5 Connection of the multifunction regeneration converter (FR-XC)

Common bus regeneration mode with harmonic suppression disabled (Pr.416 = "0")

When connecting the multifunction regeneration converter (FR-XC) to suppress power harmonics, perform wiring securely as follows. Incorrect connection will damage the multifunction regeneration converter and the inverter. Turn ON switch 1 (connection mode setting switch) in the function selection switch assembly (SW2). If the switch setting does not match the actual wiring, the connection mode fault "E.T" occurs. After making sure that the wiring is correct and secure, set "2 or 102" in Pr.30 Regenerative function selection. (Refer to the Instruction Manual (Detailed) of the FR-A800 inverter.)

[Diagram showing connection for FR-XC converter in common bus regeneration mode.]

Notes:

• Never connect the power supply to terminals R/L1, S/L2, and T/L3 on the inverter. Incorrect connection will damage the inverter and the converter.
• Remove the jumper across terminals P/+ and P1.
• Connect between the inverter terminal P/+ and the converter terminal P/+ and between the inverter terminal N/- and the converter terminal N/- for polarity consistency. Connecting opposite polarity of terminals P/+ and N/- will damage the converter and the inverter.
• Confirm the correct phase sequence of three-phase current to connect between the reactor and the converter, and between the power supply and terminals R/L1, S/L2, and T/L3. Incorrect connection will damage the converter.
• Be sure to connect the power supply and terminals R/L1, S/L2, and T/L3 of the converter. Operating the inverter without connecting them will damage the converter.
• Assign the X10 signal to any of the input terminals.
• To use separate power supply for the control circuit, remove each jumper at terminal R1/L11 and terminal S1/L21.
• Install UL listed fuses on the input side of the reactor to meet the UL/cUL standards (refer to the FR-XC Instruction Manual for information about the fuse).
• Do not install an MCCB or MC between the reactor and the converter. Doing so disrupts proper operation.

CAUTION

• In the common bus regeneration mode, always connect between the converter terminal RYB and the inverter terminal to which the X10 (MRS) signal is assigned and between the converter terminal SE and the inverter terminal SD. If the terminals are not connected, the converter may be damaged.

Common bus regeneration mode with harmonic suppression enabled (Pr.416 = "1")

When connecting the multifunction regeneration converter (FR-XC) to suppress power harmonics, perform wiring securely as follows. Incorrect connection will damage the multifunction regeneration converter and the inverter. Turn ON switch 1 (connection mode setting switch) in the function selection switch assembly (SW2). If the switch setting does not match the actual wiring, the connection mode fault "E.T" occurs. After making sure that the wiring is correct and secure, set the rated motor voltage in Pr.19 Base frequency voltage (under V/F control) or Pr.83 Rated motor voltage (under other than V/F control) and "2 or 102" in Pr.30 Regenerative function selection. (Refer to the Instruction Manual (Detailed) of the FR-A800 inverter.)

[Diagram showing connection for FR-XC converter in common bus regeneration mode with harmonic suppression enabled.]

Notes:

• Never connect the power supply to terminals R/L1, S/L2, and T/L3 on the inverter. Incorrect connection will damage the inverter and the converter.
• Connect between the inverter terminal P/+ and the converter terminal P/+ and between the inverter terminal N/- and the converter terminal N/- for polarity consistency. Connecting opposite polarity of terminals P/+ and N/- will damage the converter and the inverter.
• Remove the jumper across terminals P/+ and P1.
• Confirm the correct phase sequence of three-phase current to connect between the FR-XCB reactor and the converter, and between the power supply and terminals R/L1, S/L2, and T/L3. Incorrect connection will damage the converter.
• Be sure to connect the power supply and terminals R/L1, S/L2, and T/L3 of the converter. Operating the inverter without connecting them will damage the converter.
• Assign the X10 signal to any of the input terminals.
• Install UL listed fuses on the input side of the FR-XCB reactor to meet the UL/cUL standards (refer to the FR-XC Instruction Manual for information about the fuse).
• Do not install an MCCB or MC between the reactor and the converter. Doing so disrupts proper operation.

CAUTION

• In the common bus regeneration mode, always connect between the converter terminal RYB and the inverter terminal to which the X10 (MRS) signal is assigned and between the converter terminal SE and the inverter terminal SD. If the terminals are not connected, the converter may be damaged.

Notes:

• The control logic (sink logic/source logic) of the converter and the inverter must be matched. The converter does not operate properly if the control logic is not consistent with each other. (Refer to page 38 for the switching of the control logic. Refer to the FR-XC Instruction Manual for the switching of the control logic of the converter.)
• Keep the wiring length between terminals as short as possible.
• When the power is distorted or falls off sharply, the reactors may generate abnormal acoustic noise. This acoustic noise is caused by the power supply fault and not by the damage of the converter.

Power regeneration mode

When connecting the multifunction regeneration converter (FR-XC) to suppress power harmonics, perform wiring securely as follows. Incorrect connection will damage the multifunction regeneration converter and the inverter. Turn OFF switch 1 (connection mode setting switch) in the function selection switch assembly (SW2). If the switch setting does not match the actual wiring, the connection mode fault "E.T" occurs. After making sure that the wiring is correct and secure, set "0 or 100" in Pr.30 Regenerative function selection. (Refer to the Instruction Manual (Detailed) of the FR-A800 inverter.)

[Diagram showing connection for FR-XC converter in power regeneration mode.]

Notes:

• Connect between the inverter terminal P/+ and the converter terminal P4 and between the inverter terminal N/- and the converter terminal N/- for polarity consistency. Connecting opposite polarity of terminals P/+ and N/- will damage the converter and the inverter.
• Confirm the correct phase sequence of three-phase current to connect between the reactor and the converter, and between the power supply and the reactor. Incorrect connection will damage the converter.
• Be sure to connect the power supply and terminals R/L1, S/L2, and T/L3 of the converter. Operating the inverter without connecting them will damage the converter. A branch point to each of these terminals must be placed between the power supply and the AC reactor.
• Install the AC reactor between the node points joined to the converter terminals R/L1, S/L2, and T/L3 and the node points joined to the FR-XCL reactor. To select an appropriate model, refer to the FR-XC Instruction Manual.
• To use separate power supply for the control circuit, remove each jumper at terminal R1/L11 and terminal S1/L21.
• To select an appropriate MCCB, refer to the FR-XC Instruction Manual.
• Install UL listed fuses on the input side of the reactor to meet the UL/cUL standards (refer to the FR-XC Instruction Manual for information about the fuse).
• Do not install an MCCB or MC between the reactor and the converter. Doing so disrupts proper operation.

2.11.6 Connection of the power regeneration common converter (FR-CV)

When connecting the power regeneration common converter (FR-CV), connect the inverter terminals (P/+, N/-) and the power regeneration common converter (FR-CV) terminals as shown below so that their symbols match with each other. The FR-CV is applicable to FR-A846-01800(55K) or lower. After making sure that the wiring is correct, set "2" in Pr.30 Regenerative function selection.

[Diagram showing connection of FR-CV converter.]

Notes:

• Do not connect anything to power input terminals (R/L1, S/L2, T/L3). Incorrect connection will damage the inverter. (E.OPT (option fault) will occur.)
• Remove the jumper across terminals P/+ and P1.
• Do not insert an MCCB between terminals P/+ and N/- (between terminals P/L+ and P/+ or between N/L- and N/-). Connecting the opposite polarity of terminals N/- and P/+ will damage the inverter.
• Use Pr.178 to Pr.189 (input terminal function selection) to assign the terminals used for the X10 signal.
• Be sure to connect the power supply and terminals R/L11, S/L21, and T/MC1. Operating the inverter without connecting them will damage the power regeneration common converter.
• Always connect terminal RDYB of the FR-CV to the inverter terminal where the X10 signal or the MRS signal is assigned to. Always connect terminal SE of the FR-CV to the inverter terminal SD. Not connecting these terminals may damage the FR-CV.

Notes:

• The voltage phases of terminals R/L11, S/L21, and T/MC1 and the voltage phases of terminals R2/L1, S2/L2, and T2/L3 must be matched.
• Use the sink logic (initial setting for the FM type) when the FR-CV is connected. It cannot be connected when the source logic is selected.
• For the parameter details, refer to the FR-A800 Instruction Manual (Detailed).

2.11.7 Connection of the power regeneration converter (MT-RC)

When connecting the power regeneration converter (MT-RC), perform wiring securely as shown below. Incorrect connection will damage the power regeneration converter and the inverter. The MT-RC is applicable to FR-A846-02160(75K) or higher. After making sure that the wiring is correct, set "1" in Pr.30 Regenerative function selection and "0" in Pr.70 Special regenerative brake duty.

[Diagram showing connection of MT-RC converter.]

Notes:

• 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 to the inverter after 1 s or more has elapsed after powering ON the MT-RC. When power is supplied to the inverter prior to the MT-RC, the inverter and the MT-RC may be damaged or the MCCB may trip or be damaged.
• When connecting the power coordination reactor and others, refer to Instruction Manual of the MT-RC for precautions.

2.12 Installing a communication option

To use a communication option, the enclosed earthing (grounding) cable needs to be installed. Install the cable according to the following procedure.

1. Insert spacers into the mounting holes that will not be tightened with the option mounting screws.
2. Fit the connector of the communication option to the guide of the connector of the inverter, and insert 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 option mounting screw, and place another terminal of the earthing (grounding) cable on the right part of the option and fix the cable terminal and the option with the option mounting screw (tightening torque 0.33 N·m to 0.40 N·m). If the screws are not tightened properly, the connector may not be inserted deep enough. Check the connector.

[Diagram showing installation of communication option and earthing cable.]

Notes:

• The number and shape of the spacers used differ depending on the communication option type. Refer to the Instruction Manual of each communication option for details.
• The earth plate enclosed with a communication option is not used.

Precautions for Use of the Inverter

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

• 3.1 Electro-magnetic interference (EMI) and leakage currents ..76
• 3.2 Power supply harmonics .........................................................82
• 3.3 Installation of a reactor ............................................................85
• 3.4 Power-OFF and magnetic contactor (MC) ..............................86
• 3.5 Countermeasures against deterioration of the 400 V class motor insulation ....................................... 87
• 3.6 Checklist before starting operation ........................................88
• 3.7 Failsafe system which uses the inverter ................................91