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Mitsubishi Electric FR-A800 Instruction Manual

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INVERTER
FR-A800
FR-A806 (IP55/UL Type 12 SPECIFICATIONS)
INSTRUCTION MANUAL (HARDWARE)
High functionality and high performance
FR-A846-00023(0.4K) to 03610(132K)
INTRODUCTION
INSTALLATION AND WIRING
PRECAUTIONS FOR USE OF
THE INVERTER
PROTECTIVE FUNCTIONS
PRECAUTIONS FOR
MAINTENANCE AND
INSPECTION
SPECIFICATIONS
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2
3
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5
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Table of Contents
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Summary of Contents for Mitsubishi Electric FR-A800

  • Page 1 INVERTER FR-A800 FR-A806 (IP55/UL Type 12 SPECIFICATIONS) INSTRUCTION MANUAL (HARDWARE) High functionality and high performance FR-A846-00023(0.4K) to 03610(132K) INTRODUCTION INSTALLATION AND WIRING PRECAUTIONS FOR USE OF THE INVERTER PROTECTIVE FUNCTIONS PRECAUTIONS FOR MAINTENANCE AND INSPECTION SPECIFICATIONS...

  • Page 2: Safety Instructions

    This Instruction Manual describes handling and cautions about the hardware, such as installation and wiring, for the FR-A806(IP55/ UL Type12 specification product) that are different from the FR-A800. Information about the software, such as basic operations and parameters, is described in the FR-A800 Instruction Manual (Detailed) in the CD-ROM enclosed with the product.
  • Page 3  Additional Instructions The following instructions must be also followed. If the product Warning is handled incorrectly, it may cause unexpected fault, an injury, Usage or an electric shock.  Everyone must stay away from the equipment when the retry function is set as it will restart suddenly after a trip. Caution Transportation and Mounting ...

  • Page 4: The Inverter

    Caution Caution Usage Waterproof and dustproof performances  The electronic thermal relay function does not guarantee  The inverter is rated with an IPX5 waterproof rating and an  protection of the motor from overheating. It is IP5X dustproof rating when the operation panel (FR-DU08- ...

  • Page 5: Table Of Contents

    CONTENTS 1 INTRODUCTION Product checking and accessories Component names About the related manuals 2 INSTALLATION AND WIRING Peripheral devices 2.1.1 Inverter and peripheral devices ........................12 2.1.2 Peripheral devices............................14 Removal and reinstallation of the front cover Installation of the inverter 2.3.1 Inverter installation environment ........................
  • Page 6 2.10.5 Connection of the power regeneration common converter (FR-CV) ..............64 2.10.6 Connection of the power regeneration converter (MT-RC)................65 3 PRECAUTIONS FOR USE OF THE INVERTER Electro-magnetic interference (EMI) and leakage currents 3.1.1 Leakage currents and countermeasures ......................68 3.1.2 Countermeasures against inverter-generated EMI..................70 3.1.3 Built-in EMC filter ............................72 Power supply harmonics...
  • Page 7 5.2.7 Measurement of inverter output frequency....................118 5.2.8 Insulation resistance test using megger ....................... 118 5.2.9 Pressure test ..............................118 6 SPECIFICATIONS Inverter rating Common specifications Inverter outline dimension drawings APPENDIX Appendix 1 Differences and compatibility with the FR-A840 ............... 128 Appendix 2 Instructions for compliance with the EU Directives..............

  • Page 8: Introduction

    DU ..........Operation panel (FR-DU08-01) PU ..........Operation panel (FR-DU08-01) and parameter unit (FR-PU07) Inverter ........... Mitsubishi inverter FR-A800 series (IP55 compatible model) Pr........... Parameter number (Number assigned to function) PU operation ........Operation using the PU (operation panel / parameter unit) External operation ......

  • Page 9: Product Checking And Accessories

    Product checking and accessories Product checking and accessories Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model agrees with the order and the product is intact.  Inverter model ∗1 Symbol Voltage class Symbol Structure, functionality...

  • Page 10: Component Names

    Cooling fan Cools the inverter. (FR-A846-00250(7.5K) or higher) Internal fan Cools the inverter. Bracket Fixes the internal fan. Protects the fan to avoid contacting the wiring. (FR-A846-00250(7.5K) to Protective cover 00470(18.5K))  Refer to the FR-A800 Instruction Manual (Detailed) INTRODUCTION...

  • Page 11: About The Related Manuals

    About the related manuals About the related manuals The manuals related to FR-A806 are shown below. Related manuals Manual name Manual number FR-A800 Instruction Manual (Detailed) IB-0600503ENG FR Configurator 2 Instruction Manual IB-0600516ENG PLC function programming manual IB-0600492ENG Safety stop function instruction manual...

  • Page 12: Installation And Wiring

    INSTALLATION AND WIRING This chapter explains the "INSTALLATION" and the "WIRING" of this product. Always read the instructions before using the equipment. 2.1 Peripheral devices ..............12 2.2 Removal and reinstallation of the front cover......15 2.3 Installation of the inverter ............18 2.4 Terminal connection diagrams ..........21 2.5 Main circuit terminals...

  • Page 13: Peripheral Devices

    Peripheral devices Peripheral devices 2.1.1 Inverter and peripheral devices (a) Inverter (b) Three-phase AC power supply ∗1 (k) USB connector USB host (A connector) Communication status indicator (LED)(USB host) (c) Moulded case circuit breaker USB device (MCCB) or earth leakage current (Mini B connector) breaker (ELB), fuse Personal computer...
  • Page 14 Peripheral devices Refer Symbol Name Overview to page The life of the inverter is influenced by the ambient temperature. The ambient temperature should be as low as possible within the permissible range. Incorrect wiring may lead to damage of the inverter. The control signal Inverter (FR-A806) lines must be kept fully away from the main circuit lines to protect them from noise.

  • Page 15: Peripheral Devices

    Peripheral devices 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. Molded case circuit breaker (MCCB)  Motor output Input-side magnetic Applicable inverter model or earth leakage circuit breaker (ELB)

  • Page 16: Removal And Reinstallation Of The Front

    Removal and reinstallation of the front cover Removal and reinstallation of the front cover 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.) Inverter Screw type Screw size...
  • Page 17 Removal and reinstallation of the front cover Removal of the front cover for control circuit inspection and the front cover for 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.
  • Page 18 Removal and reinstallation of the front cover NOTE • 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. •...

  • Page 19: Installation Of The Inverter

    Installation of the inverter 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.
  • Page 20 Installation of the inverter 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"...

  • Page 21: Inverter Installation

    Installation of the inverter 2.3.2 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. •...

  • Page 22: Terminal Connection Diagrams

    Terminal connection diagrams Terminal connection diagrams FM type Sink logic Brake unit (Option) Main circuit terminal Control circuit terminal Jumper Reactor MCCB Motor R/L1 Inrush current Three-phase S/L2 limit circuit AC power T/L3 supply EMC filter Earth (Ground) ON/OFF ∗9 connecter Main circuit Earth...
  • Page 23 Terminal connection diagrams  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.

  • Page 24: Main Circuit

    Terminal connection diagrams CA type Source logic Brake unit (Option) Main circuit terminal Control circuit terminal Jumper Reactor MCCB Motor R/L1 Inrush current Three-phase S/L2 limit circuit AC power T/L3 supply EMC filter Earth (Ground) ON/OFF ∗7 connecter Main circuit Earth (Ground) Control circuit...
  • Page 25 Terminal connection diagrams  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.

  • Page 26: Main Circuit Terminals

    Main circuit terminals Main circuit terminals 2.5.1 Details on the main circuit terminals Terminal Refer to Terminal name Terminal function description symbol page R/L1, Connect these terminals to the commercial power supply. S/L2, AC power input Do not connect anything to these terminals when using the high power factor —...

  • Page 27: Wiring Method

    Main circuit terminals NOTE • 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. •...
  • Page 28 Main circuit terminals (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. FR-A846-00023(0.4K) to 00170(5.5K) FR-A846-00250(7.5K) to 00470(18.5K) FR-A846-00620(22K) to 01160(45K) FR-A846-01800(55K) to 03610(132K)

  • Page 29: Applicable Cables And The Wiring Length

    Main circuit terminals 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.
  • Page 30 • For the details of Pr.72 PWM frequency selection, refer to the FR-A800 Instruction Manual (Detailed). • Refer to page 79 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).) INSTALLATION AND WIRING...

  • Page 31: Earthing (Grounding) Precautions

    Main circuit terminals 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.

  • Page 32: Control Circuit

    Details on the control circuit terminals Input signal function of the terminals in 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 Terminal...
  • Page 33 Applying a voltage with the voltage/current input switch ON (current input is selected) or a current with the switch OFF (voltage input is selected) could cause component damage of the inverter or analog circuits of output devices. (For the details, refer to the FR-A800 Instruction Manual (Detailed).)
  • Page 34 (load impedance 10 k or Output item: frequency, output current, and torque. more) Resolution 8 bits Output frequency (initial (Refer to the FR-A800 Instruction setting) Load impedance 200  to Manual (Detailed).) 450  Analog current output Output signal 0 to 20 ...
  • Page 35 Control circuit Communication Terminal Terminal name Terminal function description Symbol With the PU connector, communication can be made through RS-485. (For connection on a 1:1 basis only) Conforming standard: EIA-485 (RS-485) — PU connector Transmission format: Multidrop link Communication speed: 4800 to 115200 bps Wiring length: 500 m TXD+ Inverter transmission terminal...

  • Page 36: Control Logic (Sink/Source) Change

    Control circuit 2.6.2 Control logic (sink/source) change Change the control logic of input signals as necessary. To change the control logic, change the jumper connector position on the control circuit board. Connect the jumper connector to the connector pin of the desired control logic. The control logic of input signals is initially set to the sink logic (SINK) for the FM type.
  • Page 37 Control circuit Sink logic and source logic • In the sink logic, a signal switches ON when a current flows from the corresponding signal input terminal. Terminal SD is common to the contact input signals. Terminal SE is common to the open collector output signals. •...

  • Page 38: Wiring Of Control Circuit

    Control circuit 2.6.3 Wiring of control circuit Control circuit terminal layout • Recommended cable gauge: 0.3 to 0.75 mm ∗1 1 F/C +24 SD So SOC S1 S2 PC 5 10E 10 SE SE IPF OL FU PC RL RM RH RT AU STP MRS RES SD SD STF STR JOG...
  • Page 39 Control circuit NICHIFU Co.,Ltd. Cable gauge Blade terminal Insulation product Crimping tool product number number product number 0.3 to 0.75 BT 0.75-11 VC 0.75 NH 69 (3) Insert the wires into a socket. When using a single wire or stranded wires without a blade terminal, push the open/close button all the way down with a flathead screwdriver, and insert the wire.

  • Page 40: Wiring Precautions

    Control circuit Common terminals of the control circuit (SD, PC, 5, SE) • Terminals SD (sink logic), PC (source logic), 5, and SE are common terminals (0V) for I/O signals. (All common terminals are isolated from each other.) Do not earth (ground) these terminals. Avoid connecting the terminal SD (sink logic) with 5, the terminal PC (source logic) with 5, and the terminal SE with 5.

  • Page 41: When Supplying 24 V External Power To The Control Circuit

    (The reset can be disabled using Pr.30. (For the details of Pr.30, refer to the FR-A800 Instruction Manual (Detailed).)) Confirming the 24 V external power supply input •...
  • Page 42 Control circuit Operation while the 24 V external power is supplied • Faults history and parameters can be read and parameters can be written (when the parameter write from the operation panel is enabled) using the operation panel keys. • The safety stop function is invalid during the 24 V external power supply operation. •...

  • Page 43: Safety Stop Function

    Control circuit 2.6.6 Safety stop function Function description The terminals related to the safety stop function are shown below. Terminal Terminal function description symbol Between S1 and SIC, S2 and SIC For input of the safety stop channel 1.  Open: In safety stop mode For input of the safety stop channel 2.
  • Page 44 Control circuit Safety stop function operation Output Operation panel Input Internal safety Input terminal   terminal indication Inverter running status power circuit status E.SAF   ― ― ― Output shutoff (Safe state) Not displayed Not displayed Normal Drive enabled Not displayed Not displayed ...

  • Page 45: Operation Panel (Fr-Du08-01)

    Operation panel (FR-DU08-01) Operation panel (FR-DU08-01) 2.7.1 Differences with the FR-DU08 Item FR-DU08 FR-DU08-01 Applicable model FR-A800 FR-A806 Protective structure IP40 (except for the PU connector) IP55 (except for the PU connector) Outline dimension (WHD [mm]) 7278.517 809619 Number of fixing screws...

  • Page 46: Components Of The Operation Panel (Fr-Du08-01)

    2.7.2 Components of the operation panel (FR-DU08-01) The operation panel (FR-DU08-01) is an IP55 compatible model that can only be mounted to the FR-A806 series. (It cannot be mounted on the standard model of FR-A800 series.) Component Name Description HAND: Lit to indicate the PU operation mode.

  • Page 47: Basic Operation Of The Operation Panel

    Operation panel (FR-DU08-01) 2.7.3 Basic operation of the operation panel For the details of each function, refer to the FR-A800 Instruction Manual (Detailed). Operation mode switchover/Frequency setting External operation mode At power-ON) PU Jog operation mode PU operation mode Flicker...

  • Page 48: Communication Connectors And Terminals

    Communication can be performed with the Mitsubishi inverter protocol (computer link operation). For the details, refer to the FR-A800 Instruction Manual (Detailed). • If the operation panel is removed from the inverter, the inverter does not conform to IP55.

  • Page 49: Usb Connector

    Communication connectors and terminals 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.
  • Page 50 • 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).

  • Page 51: Rs-485 Terminal Block

    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) and Modbus-RTU protocol. For the details, refer to the FR-A800 Instruction Manual (Detailed). Terminating resistor switch Initially-set to "OPEN".

  • Page 52: Connection Of Motor With Encoder (Vector Control)

    Connection of motor with encoder (vector control) Connection of motor with encoder (vector control) Using an encoder-equipped motor together with the plug-in option FR-A8AP enables speed, torque, and positioning control operations under orientation control, encoder feedback control, and full-scale vector control. Appearance and parts name of FR-A8AP Front view Rear view...
  • Page 53 Connection of motor with encoder (vector control) Switches of the FR-A8AP Differential line driver (initial status) • 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.
  • Page 54 Length L (m) Model Length L (m) (grounding) a shielded FR-JCBL5 FR-V7CBL5 FR-JCBL15 cable is provided. FR-V7CBL15 FR-JCBL30 FR-V7CBL30 FR-A800 FR-A800 (FR-A8AP) (FR-A8AP) Positioning keyway Positioning keyway D/MS3106B20-29S D/MS3106B20-29S (As viewed from wiring side) (As viewed from wiring side) 2 mm 2 mm ...

  • Page 55: Wiring Example

    Connection of motor with encoder (vector control) • Connection terminal compatibility table Motor SF-V5RU, SF-THY SF-JR/HR/JRCA/HRCA (with encoder) Encoder cable FR-V7CBL FR-JCBL Do not connect anything to this. Do not connect anything to this. FR-A8AP terminal Do not connect anything to this. Wiring example •...
  • Page 56 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 of Pr.178 to Pr.189. For details, refer to the FR-A800 Instruction Manual (Detailed).) When OH signal is assigned to terminal RH (Pr.182 = “7”)
  • Page 57 To protect the cables from noise, run them away from any source of noise (such as the main circuit and power supply voltage). Example of parallel connection with two cables (with complementary encoder output) FR-A800 (FR-A8AP) 2 mm Wiring length Parallel connection...

  • Page 58: Parameter Settings For The Motor Under Vector Control

     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. INSTALLATION AND WIRING...
  • Page 59 Connection of motor with encoder (vector control) • 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. SF-V5RU SF-V5RU Motor Motor capacity capacity Pr.83 (V) Pr.84 (Hz) Pr.83 (V)

  • Page 60: Connection Of Stand-Alone Option Units

    Connection of stand-alone option units 2.10 Connection of stand-alone option units The inverter accepts a variety of stand-alone option units as required. Incorrect connection will cause inverter damage or accident. Connect and operate the option unit carefully in accordance with the corresponding option unit manual.
  • Page 61 The CN8 connector used with the MT-BU5 type brake unit is not used. NOTE • The stall prevention (overvoltage), oL, does not occur while Pr.30 Regenerative function selection = "1" and Pr.70 Special regenerative brake duty = "0% (initial value)". (Refer to the FR-A800 Instruction Manual (Detailed).) INSTALLATION AND WIRING...

  • Page 62: Connection Of The Brake Unit (Fr-Bu)

    Connection of stand-alone option units 2.10.2 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. ∗2 FR-BR MCCB Motor R/L1 Three-phase AC S/L2...

  • Page 63: Connection Of The Brake Unit (Bu Type)

    Connection of stand-alone option units 2.10.3 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.

  • Page 64: Connection Of The High Power Factor Converter (Fr-Hc2)

    • The control logic (sink logic/source logic) of the high power factor converter and the inverter must be matched. (Refer to page 35.) • For the parameter details, refer to the FR-A800 Instruction Manual (Detailed). INSTALLATION AND WIRING...

  • Page 65: Connection Of The Power Regeneration Common Converter (Fr

    • 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). INSTALLATION AND WIRING...

  • Page 66: Connection Of The Power Regeneration Converter (Mt-Rc)

    Connection of stand-alone option units 2.10.6 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"...
  • Page 67 MEMO...

  • Page 68: Precautions For Use Of The Inverter

    PRECAUTIONS FOR USE OF THE INVERTER This chapter explains the precautions for use of this product. Always read the instructions before using the equipment. 3.1 Electro-magnetic interference (EMI) and leakage currents ..68 3.2 Power supply harmonics ............74 3.3 Installation of a reactor ............77 3.4 Power-OFF and magnetic contactor (MC) ......78...

  • Page 69: Electro-Magnetic Interference (Emi) And Leakage Currents

    Electro-magnetic interference (EMI) and leakage currents Electro-magnetic interference (EMI) and leakage currents 3.1.1 Leakage currents and countermeasures Capacitances exist between the inverter I/O cables, other cables and earth and in the motor, through which a leakage current flows. Since its value depends on the static capacitances, carrier frequency, etc., low acoustic noise operation at the increased carrier frequency of the inverter will increase the leakage current.
  • Page 70 Electro-magnetic interference (EMI) and leakage currents Installation and selection of the molded case circuit breaker Install a molded case circuit breaker (MCCB) on the power receiving side to protect the wiring at the inverter input side. Select an MCCB according to the inverter input side power factor, which depends on the power supply voltage, output frequency and load.

  • Page 71: Countermeasures Against Inverter-Generated Emi

    Electro-magnetic interference (EMI) and leakage currents NOTE • Install the earth leakage circuit breaker (ELB) on the input side of the inverter. • In the connection earthed-neutral system, the sensitivity current is blunt against a ground fault in the inverter output side. Earthing (Grounding) must conform to the requirements of national and local safety regulations and electrical codes.
  • Page 72 Electro-magnetic interference (EMI) and leakage currents Noise propagation Countermeasure path When devices that handle low-level signals and are liable to malfunction due to electromagnetic noises, e.g. instruments, receivers and sensors, are near the inverter or when the signal cables are run near the inverter, the devices may malfunction due to by air-propagated electromagnetic noises.

  • Page 73: Built-In Emc Filter

    Electro-magnetic interference (EMI) and leakage currents 3.1.3 Built-in EMC filter This inverter is equipped with a built-in EMC filter (capacitive filter) and a common mode choke. These filters are effective in reducing air-propagated noise on the input side of the inverter. To enable the EMC filter, fit the EMC filter ON/OFF connector to the ON position.
  • Page 74 Electro-magnetic interference (EMI) and leakage currents • Switching ON/OFF the filter (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.

  • Page 75: Power Supply Harmonics

    Power supply harmonics Power supply harmonics 3.2.1 Power supply harmonics The inverter may generate power supply harmonics from its converter circuit to affect the power generator, power factor correction capacitor etc. Power supply harmonics are different from noise and leakage currents in source, frequency band and transmission path.

  • Page 76: Harmonic Suppression Guidelines In Japan

    Power supply harmonics 3.2.2 Harmonic suppression guidelines in Japan Harmonic currents flow from the inverter to a power receiving point via a power transformer. The Harmonic Suppression Guidelines was established to protect other consumers from these outgoing harmonic currents. The three-phase 200 V input specifications 3.7 kW or lower were previously covered by "the Harmonic Suppression Guidelines for Household Appliances and General-purpose Products"...
  • Page 77 Power supply harmonics • Harmonic content (Values of the fundamental current is 100%) Reactor 11th 13th 17th 19th 23rd 25th Used (DC side) Used (AC, DC sides) • Calculation of equivalent capacity P0 of harmonic generating equipment "Equivalent capacity" is the capacity of a 6-pulse converter converted from the capacity of consumer's harmonic generating equipment and is calculated by the following equation: If the sum of equivalent capacities is higher than the limit (Refer to page 75), harmonics must be calculated with the following procedure:...

  • Page 78: Installation Of A Reactor

    Installation of a reactor • Determining if a countermeasure is required A countermeasure for harmonics is required if the following condition is satisfied: outgoing harmonic current > maximum value per 1 kW contract power  contract power • Harmonic suppression techniques Item Description Because a DC reactor is built in on the DC side of this product, outgoing harmonic current can be...

  • Page 79: Power-Off And Magnetic Contactor (Mc)

    When an MC is provided to switch to a commercial power supply, for example, it is recommended to use the commercial power supply-inverter switchover function Pr.135 to Pr.139 (Refer to the FR-A800 Instruction Manual (Detailed)). (The commercial power supply operation is not available with vector control dedicated motors (SF-V5RU, SF-THY) nor with PM motors.)

  • Page 80: Countermeasures Against Deterioration Of The 400 V Class Motor Insulation

    A sine wave filter (MT-BSL/BSC) can be used under V/F control. Do not use the filters under different control modes. • The carrier frequency is limited during PM sensorless vector control. (Refer to the FR-A800 Instruction Manual (Detailed).) PRECAUTIONS FOR USE OF THE INVERTER...

  • Page 81: Checklist Before Starting Operation

    Checklist before starting operation Checklist before starting operation The FR-A800 series inverter is a highly reliable product, but incorrect peripheral circuit making or operation/handling method may shorten the product life or damage the product. Before starting operation, always recheck the following points.
  • Page 82 Checklist before starting operation Refer Check Checkpoint Countermeasure page user When using a switching circuit as shown below, chattering due to mis- configured sequence or arc generated at switching may allow undesirable current to flow in and damage the inverter. Mis-wiring may also damage the inverter.

  • Page 83: Failsafe System Which Uses The Inverter

    Failsafe system which uses the inverter Failsafe system which uses the inverter When a fault is detected by the protective function, the protective function activates and outputs a fault signal. However, a fault signal may not be output at an inverter's fault occurrence when the detection circuit or output circuit fails, etc. Although Mitsubishi assures the best quality products, provide an interlock which uses inverter status output signals to prevent accidents such as damage to the machine when the inverter fails for some reason.
  • Page 84 • Changing the terminal assignment using Pr.190 and Pr.196 (output terminal function selection) may affect the other functions. Set parameters after confirming the function of each terminal. • For the details of the parameters and signals, refer to the FR-A800 Instruction Manual (Detailed). Backup method outside the inverter Even if the interlock is provided by the inverter status signal, enough failsafe is not ensured depending on the failure status of the inverter itself.
  • Page 85 MEMO...

  • Page 86: Protective Functions

    PROTECTIVE FUNCTIONS This chapter explains the "PROTECTIVE FUNCTIONS" that operates in this product. Always read the instructions before using the equipment. 4.1 Inverter fault and alarm indications ........86 4.2 Reset method for the protective functions......86 4.3 Faults history and the list of fault displays ......87 PROTECTIVE FUNCTIONS...

  • Page 87: Inverter Fault And Alarm Indications

    A protective function activates to trip the inverter and output a Fault (ALM) signal. NOTE • For the details of fault displays and other malfunctions, also refer to the FR-A800 Instruction Manual (Detailed). • The past eight faults can be displayed using the setting dial. (Refer to...

  • Page 88: Faults History And The List Of Fault Displays

    Faults history and the list of fault displays Faults history and the list of fault displays For details, refer to the FR-A800 Instruction Manual (Detailed). Operation panel Operation panel Name Name indication indication E. SOT Loss of synchronism detection E---- Faults history E.LF...
  • Page 89 MEMO...

  • Page 90: Precautions For Maintenance And Inspection

    PRECAUTIONS 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................90 Measurement of main circuit voltages, currents and powers...114 PRECAUTIONS FOR MAINTENANCE AND INSPECTION...

  • Page 91: Inspection Item

    Inspection item The inverter is a static unit mainly consisting of semiconductor devices. Daily inspection must be performed to prevent any fault from occurring due to the adverse effects of the operating environment, such as temperature, humidity, dust, dirt and vibration, changes in the parts with time, service life, and other factors.

  • Page 92: Daily And Periodic Inspection

    Inspection item 5.1.3 Daily and periodic inspection Inspection Corrective action Check Area of Inspection interval Description at fault by the inspection item Periodic occurrence user Daily  Surrounding Check the ambient temperature, humidity, dirt, Improve the  environment corrosive gas, oil mist, etc. environment.
  • Page 93 Inspection item Inspection Corrective action Check Area of Inspection interval Description at fault by the inspection item Periodic occurrence user Daily  Contact the (1)Check that display is normal.  manufacturer. Indication (2)Check for stain.  Clean. Display Stop the equipment Meter Check that reading is normal.

  • Page 94: Checking The Inverter And Converter Modules

    Inspection item 5.1.4 Checking the inverter and converter modules Preparation • Disconnect the external power supply cables (R/L1, S/L2, T/L3) and motor cables (U, V, W). • Prepare a tester. (For the resistance measurement, use the 100 Ω range.) Checking method Change the polarity of the tester alternately at the inverter terminals R/L1, S/L2, T/L3, U, V, W, P/+, and N/- and check the electric continuity.

  • Page 95: Replacement Of Parts

    Estimated remaining life 10% (Power ON: 100,000 times left) Cooling fan Less than 50% of the specified speed. NOTE • Refer to the FR-A800 Instruction Manual (Detailed) to perform the life check of the inverter parts. PRECAUTIONS FOR MAINTENANCE AND INSPECTION...
  • Page 96 Inspection item Replacement procedure of the fan The replacement interval of the cooling fan used for cooling the parts generating heat such as the main circuit semiconductor is greatly affected by the ambient temperature. When unusual noise and/or vibration are noticed during inspection, the cooling fan must be replaced immediately.
  • Page 97 Inspection item  Removal of the cooling fan (FR-A846-00620(22K) to 01160(45K)) (1) Remove the installation screws, and then remove the fan cover. Fan cover Installation screw (2) Disconnect the fan connectors. Fan connector (3) Remove the installation screws, and then remove the fan. Installation screw PRECAUTIONS FOR MAINTENANCE AND INSPECTION...
  • Page 98 Inspection item  Removal of the cooling fan (FR-A846-01800(55K) to 03610(132K)) (1) Remove the installation screws, and then remove the fan cover. Fan cover Installation screw (2) Disconnect the fan connectors. Fan connector (3) Remove the installation screws, and then remove the fan. Installation screw PRECAUTIONS FOR MAINTENANCE AND INSPECTION...
  • Page 99 Inspection item  Reinstallation of the cooling fan (FR-A846-00250(7.5K) to 00470(18.5K)) (1) After confirming the orientation of the fan, reinstall the fan so that the "AIR FLOW" faces up. Then, fix the fan with the installation screws. (tightening torque 1.4 to 1.9 N•m) AIR FLOW ...
  • Page 100 Inspection item  Reinstallation of the cooling fan (FR-A846-00620(22K) to 01160(45K)) (1) After confirming the orientation of the fan, reinstall the fan so that the "AIR FLOW" faces up. Then, fix the fan with the installation screws. (tightening torque 1.4 to 1.9 N•m) AIR FLOW ...
  • Page 101 Inspection item  Reinstallation of the cooling fan (FR-A846-01800(55K) to 03610(132K)) (1) After confirming the orientation of the fan, reinstall the fan so that the "AIR FLOW" faces up. Then, fix the fan with the installation screws. (tightening torque 1.4 to 1.9 N•m) AIR FLOW ...
  • Page 102 Inspection item  Removal of the internal fan (FR-A846-00170(5.5K) or lower) (1) Remove the inverter front cover. (Refer to page (2) Move the fan connector case, and then remove the fan connector. Fan connector Connector case (3) Remove the installation screws, and then remove the bracket. Bracket Installation screw (4) Remove the installation screws, and then remove the fan.
  • Page 103 Inspection item  Removal of the internal fan (FR-A846-00250(7.5K) to 00470(18.5K)) (1) Remove the inverter front cover. (Refer to page (2) Remove the installation screws, and then remove the protective cover. Protective cover Installation screw (3) Move the fan connector case, and then remove the fan connector. Fan connector Connector case (4) Remove the bracket.
  • Page 104 Inspection item  Removal of the internal fan (FR-A846-00620(22K) to 01160(45K)) (1) Remove the inverter front cover. (Refer to page (2) Move the fan connector case, and then remove the fan connector. Fan connector Connector case (3) Remove the installation screws and the bracket, and then remove the fan. Installation screw Bracket PRECAUTIONS FOR MAINTENANCE AND INSPECTION...
  • Page 105 Inspection item  Removal of the internal fan (upper) (FR-A846-01800(55K) to 02600(90K)) (1) Remove the inverter front cover. (Refer to page (2) Move the fan connector case, and then remove the fan connector. Fan connector Connector case (3) Remove the installation screws, and then remove the fan. Installation screw ...
  • Page 106 Inspection item  Removal of the internal fan (upper) (FR-A846-03250(110K) or higher) (1) Remove the inverter front cover. (Refer to page (2) Move the fan connector case, and then remove the fan connector. Connector case Fan connector (3) Remove the installation screws, and then remove the bracket. Installation screw Bracket (4) Remove the installation screws, and then remove the fan.
  • Page 107 Inspection item  Reinstallation of the internal fan (FR-A846-00170(5.5K) or lower) (1) After confirming the orientation of the fan, fix the fan to the bracket with the installation screws so that the "AIR FLOW" arrow on the fan side faces up when the fan is installed to the inverter. (tightening torque 1.4 to 1.9 N•m) Bracket AIR FLOW ...
  • Page 108 Inspection item  Reinstallation of the internal fan (FR-A846-00250(7.5K) to 00470(18.5K)) (1) After confirming the orientation of the fan, fix the fan to the bracket with the installation screws so that the "AIR FLOW" arrow on the fan side faces up when the fan is installed to the inverter. (tightening torque 1.4 to 1.9 N•m) Bracket AIR FLOW ...
  • Page 109 Inspection item  Reinstallation of the internal fan (FR-A846-00620(22K) to 01160(45K)) (1) Fix the fan to the inverter with the bracket and the installation screws. (tightening torque 1.4 to 1.9 N•m) After confirming the orientation of the fan, reinstall the fan so that air flows as shown below. (The "AIR FLOW"...
  • Page 110 Inspection item  Reinstallation of the internal fan (upper) (FR-A846-01800(55K) to 02600(90K)) (1) Fix the fan to the inverter with the installation screws. (tightening torque 1.4 to 1.9 N•m) After confirming the orientation of the fan, reinstall the fan so that air flows as shown below. (The "AIR FLOW"...
  • Page 111 Inspection item  Reinstallation of the internal fan (lower) (FR-A846-01800(55K) to 02600(90K)) (1) Fix the fan to the bracket with the installation screws. (tightening torque 1.4 to 1.9 N•m) After confirming the orientation of the fan, reinstall the fan so that air flows as shown below. (The "AIR FLOW"...
  • Page 112 Inspection item  Reinstallation of the internal fan (upper) (FR-A846-03250(110K) or higher) (1) Fix the fan to the bracket with the installation screws. (tightening torque 1.4 to 1.9 N•m) After confirming the orientation of the fan, reinstall the fan so that air flows as shown below. (The "AIR FLOW"...
  • Page 113 Inspection item  Reinstallation of the internal fan (lower) (FR-A846-03250(110K) or higher) (1) Fix the fan to the bracket with the installation screws. (tightening torque 1.4 to 1.9 N•m) After confirming the orientation of the fan, reinstall the fan so that air flows as shown below. (The "AIR FLOW"...

  • Page 114: Inverter Replacement

    NOTE • The inverter diagnoses the main circuit capacitor and control circuit capacitor by itself and can judge their lives. (Refer to the FR-A800 Instruction manual (Detailed).) Relays To prevent a contact fault, etc., relays must be replaced according to the cumulative number of switching times (switching life).

  • Page 115: Measurement Of Main Circuit Voltages, Currents And Powers

    Measurement of main circuit voltages, currents and powers Measurement of main circuit voltages, currents and powers Since the voltages and currents on the inverter power supply and output sides include harmonics, measurement data depends on the instruments used and circuits measured. When instruments for commercial frequency are used for measurement, measure the following circuits with the instruments given on the next page.
  • Page 116 Measurement of main circuit voltages, currents and powers Measuring points and instruments Item Measuring point Measuring instrument Remarks (reference measured value) Across R/L1 and S/L2, Commercial power supply Power supply voltage S/L2 and T/L3, Moving-iron type AC voltmeter Within permissible AC voltage fluctuation ...

  • Page 117: Measurement Of Powers

    Measurement of main circuit voltages, currents and powers 5.2.1 Measurement of powers Use digital power meters (for inverter) for the both of inverter input and output side. Alternatively, measure using electrodynamic type single-phase wattmeters for the both of inverter input and output side in two-wattmeter or three- wattmeter method.

  • Page 118: Measurement Of Currents

    Measurement of main circuit voltages, currents and powers 5.2.3 Measurement of currents Use moving-iron type meters on both the input and output sides of the inverter. However, if the carrier frequency exceeds 5 kHz, do not use that meter since an overcurrent losses produced in the internal metal parts of the meter will increase and the meter may burn out.

  • Page 119: Measurement Of Inverter Output Frequency

    5 VDC is indicated at the maximum frequency. For detailed specifications of the pulse train output terminal FM, refer to the FR-A800 Instruction Manual (Detailed). In the initial setting of the CA-type inverter, a pulse train proportional to the output frequency is output across the analog current output terminals CA and 5 of the inverter.

  • Page 120: Specifications

    SPECIFICATIONS This chapter explains the "SPECIFICATIONS" of this product. Always read the instructions before using the equipment. 6.1 Inverter rating................120 6.2 Common specifications ............121 6.3 Inverter outline dimension drawings ........123 SPECIFICATIONS...

  • Page 121: Inverter Rating

    The power supply capacity is the value when at the rated output current. It varies by the impedance at the power supply side (including those of the input reactor and cables).  For the power voltage exceeding 480 V, set Pr.977 Input voltage mode selection. (For the details, refer to the FR-A800 Instruction Manual (Detailed).) ...

  • Page 122: Common Specifications

    Common specifications Common specifications Soft-PWM control, high carrier frequency PWM control (selectable among V/F control, Advanced magnetic flux vector Control method control, Real sensorless vector control), Optimum excitation control, vector control , and PM sensorless vector control  0.2 to 590 Hz (The upper-limit frequency is 400 Hz under Advanced magnetic flux vector control, Real sensorless vector Output frequency range control, vector control , and PM sensorless vector control.)
  • Page 123 Common specifications Overcurrent trip during acceleration, Overcurrent trip during constant speed, Overcurrent trip during deceleration or stop, Regenerative overvoltage trip during acceleration, Regenerative overvoltage trip during constant speed, Regenerative overvoltage trip during deceleration or stop, Inverter overload trip, Motor overload trip, Heatsink overheat, Instantaneous power failure, Undervoltage, Input phase loss , Stall prevention stop, Loss of synchronism detection ...

  • Page 124: Inverter Outline Dimension Drawings

    Inverter outline dimension drawings Inverter outline dimension drawings FR-A846-00023(0.4K) to 00170(5.5K) 2-8 hole (18.5) 18.5 (Unit: mm) FR-A846-00250(7.5K) to 00470(18.5K) 2-φ10 hole 4-φ20 hole 18.5 (18.5) (Unit: mm) SPECIFICATIONS...
  • Page 125 Inverter outline dimension drawings FR-A846-00620(22K) to 01160(45K) 4-φ25 hole 2-φ12 hole 22.5 (22.5) (Unit: mm) FR-A846-01800(55K) to 03610(132K) 4-φ25 hole 3-φ15 hole (35) 456.6 Inverter Model FR-A846-01800(55K) to 02600(90K) 1360 1334 1314 FR-A846-03250(110K), 03610(132K) 1510 1482 1464 (Unit: mm) SPECIFICATIONS...
  • Page 126 Inverter outline dimension drawings Operation panel (FR-DU08-01) 80±0.5 68±0.5 5±0.3 -0.5 (Unit: mm) NOTE • For the outline dimensions of the dedicated motors, refer to the FR-A800 Instruction Manual (Detailed). SPECIFICATIONS...
  • Page 127 MEMO...

  • Page 128: Appendix

    APPENDIX APPENDIX provides the reference information for use of this product. Refer to APPENDIX as required. Appendix 1 Differences and compatibility with the FR-A840 ..128 Appendix 2 Instructions for compliance with the EU Directives..129 Appendix 3 Instructions for UL and cUL ........132 APPENDIX...

  • Page 129: Appendix 1 Differences And Compatibility With The Fr-A840

    Appendix 1 Differences and compatibility with the FR-A840 Item FR-A840 FR-A846 Enclose type (IP20): FR-A840-00620(22K) or Protective structure lower Dust- and water-proof type (IP55): all capacities Open type (IP00): FR-A840-00770(30K) or higher Multiple rating SLD, LD, ND (initial setting), HD rating LD, ND rating (initial setting) (Pr.570 Multiple rating (Setting range “0 to 3”)

  • Page 130: Appendix 2 Instructions For Compliance With The Eu Directives

    CE marking. • The authorized representative in the EU The authorized representative in the EU is shown below. Name: Mitsubishi Electric Europe B.V. Address: Gothaer Strasse 8, 40880 Ratingen, Germany • Note We declare that this inverter conforms with the EMC Directive in industrial environments and affix the CE marking on the inverter.
  • Page 131  Note Set the EMC filter valid and install the inverter and perform wiring according to the following instructions.  This inverter is equipped with an EMC filter. Enable the EMC filter. (For details, refer to page 72.)  Connect the inverter to an earthed power supply. ...

  • Page 132: Low Voltage Directive

    Low Voltage Directive We have self-confirmed our inverters as products compliant to the Low Voltage Directive (Conforming standard EN 61800-5- 1) and affix the CE marking on the inverters.  Outline of instructions  Do not use an earth leakage current breaker as an electric shock protector without connecting the equipment to the earth. Connect the equipment to the earth securely.

  • Page 133: Appendix 3 Instructions For Ul And Cul

    Appendix 3 Instructions for UL and cUL (Standard to comply with: UL 508C, CSA C22.2 No.14) General precaution CAUTION - Risk of Electric Shock - The bus capacitor discharge time is 10 minutes. Before starting wiring or inspection, switch power off, wait for more than 10 minutes.

  • Page 134: Motor Overload Protection

    Motor overload protection When using the electronic thermal relay function as motor overload protection, set the rated motor current in Pr.9 Electronic thermal O/L relay. This function detects the overload (overheat) of the motor, stops the operation of the inverter's Operation characteristics of electronic thermal relay function output transistor, and stops the output.

  • Page 135: Operating Environment

    • The copyright and other rights of the enclosed CD-ROM all belong to Mitsubishi Electric Corporation. • No part of the enclosed CD-ROM may be copied or reproduced without the permission of Mitsubishi Electric Corporation. • Specifications of the enclosed CD-ROM are subject to change for modification without notice.
  • Page 136 WARRANTY When using this product, make sure to understand the warranty described below. 1. Warranty period and coverage We will repair any failure or defect (hereinafter referred to as "failure") in our FA equipment (hereinafter referred to as the "Product") arisen during warranty period at no charge due to causes for which we are responsible through the distributor from which you purchased the Product or our service provider.
  • Page 137 REVISIONS *The manual number is given on the bottom left of the back cover. Print Date *Manual Number Revision Feb. 2014 IB(NA)-0600531ENG-A First edition Apr. 2014 IB(NA)-0600531ENG-B Addition • FR-A846-00023(0.4K) to 00170(5.5K) Oct. 2014 IB(NA)-0600531ENG-C Addition • FR-A846-00620(22K) to 01160(45K) Dec.
  • Page 138 HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN FR-A806 MODEL INSTRUCTION MANUAL (HARDWARE) MODEL 1A2-P56 CODE IB(NA)-0600531ENG-D(1412)MEE Printed in Japan Specifications subject to change without notice.
  • Page 140 Phone: +371 (0)6 / 784 2280 Fax: +371 (0)6 / 784 2281 Mitsubishi Electric Europe B.V. / FA - European Business Group / Gothaer Straße 8 / D-40880 Ratingen / Germany / Tel.: +49(0)2102-4860 / Fax: +49(0)2102-4861120 / [email protected] / https://eu3a.mitsubishielectric.com...

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