Mitsubishi Electric FR-A8AL User manual

FR-A8AL INSTRUCTION MANUAL

D

INVERTER

PRE-OPERATION INSTRUCTIONS 1

INSTALLATION 2

ENCODER SPECIFICATIONS AND

PARAMETER SETTINGS 3

ORIENTATION CONTROL 4

ENCODER FEEDBACK CONTROL 5

VECTOR CONTROL 6

POSITION CONTROL FUNCTION 7

ENCODER PULSE DIVIDING OUTPUT 8

INVERTER

Plug-in option

INSTRUCTION MANUAL

INVERTER

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

FR-A8AL

Orientation control

Encoder feedback control

Vector control

Position control

Encoder pulse dividing output

IB(NA)-0600597ENG-D(2308) MEE Printed in Japan Specifications subject to change without notice.

1

Safety instructions

Thank you for choosing this Mitsubishi Electric inverter plug-in option.

This Instruction Manual provides handling information and precautions for use of this product. Incorrect handling might cause an unexpected fault. Before

using this product, read all relevant instruction manuals carefully to ensure proper use.

Please forward this Instruction Manual to the end user.

Electric shock prevention

WARNING

Do not remove the front cover or the wiring cover of the inverter while the inverter power is ON. Do not operate the inverter with any cover or

wiring cover removed, as accidental contact with exposed high-voltage terminals and internal components may occur, resulting in an

electrical shock.

Even if power is OFF, do not remove the front cover of the inverter except for wiring or periodic inspection as you may accidentally touch the

charged circuits and get an electric shock.

Before wiring or inspection, check that the display of the inverter operation panel is OFF. Any person who is involved in wiring or inspection

shall wait for 10 minutes or longer after power OFF and check that there are no residual voltage using a tester or the like. The capacitor is

charged with high voltage for some time after power OFF, and it is dangerous.

Any person who is involved in wiring or inspection of this product shall be fully competent to do the work.

This product must be installed before wiring. Otherwise you may get an electric shock or be injured.

Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Doing so may cause an electric shock.

Do not touch this product or handle the cables with wet hands. Doing so may cause an electric shock.

Do not attempt to install, operate, maintain or inspect this product until you have read this Instruction Manual and supplementary documents

carefully. Do not use this product until you have a full knowledge of this product mechanism, safety information and instructions. In this

Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION".

Incorrect handling may cause hazardous conditions, resulting in death or severe injury.

Incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause only material

damage.

Note that even the level may lead to a serious consequence depending on conditions. Be sure to follow the instructions

of both levels as they are critical to personnel safety.

WARNING

CAUTION

2

Injury prevention

Additional instructions

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

CAUTION

The voltage applied to each terminal must be as specified in the Instruction Manual. Otherwise an explosion or damage may occur.

The cables must be connected to the correct terminals. Otherwise an explosion or damage may occur.

The polarity (+ and -) must be correct. Otherwise an explosion or damage may occur.

While power is ON or for some time after power OFF, do not touch the inverter as it will be extremely hot. Doing so may cause burns.

CAUTION

Transportation and installation

Do not stand or place heavy objects on this product.

Ensure the mounting orientation of this product is correct.

Do not install or operate this product if it is damaged or has parts missing.

Foreign conductive objects must be prevented from entering the inverter. That includes screws and metal fragments or other flammable

substance such as oil.

If halogens (including fluorine, chlorine, bromine, and iodine) contained in fumigants for wood packages enter this product, the product may

be damaged. Prevent the entry of fumigant residuals or use an alternative method such as heat disinfection. Note that sterilization or

disinfection of wood packages should be performed before packing the product.

Test operation

Before starting operation, confirm or adjust the parameter settings. Failure to do so may cause some machines to make unexpected

motions.

WARNING

Usage

Do not modify this product.

Do not remove any part which is not instructed to be removed in the Instruction Manuals. Doing so may lead to a failure or damage of this

product.

3

CAUTION

Usage

As all parameters return to their initial values after Parameter clear or All parameter clear is performed, the needed parameters for operation

of the inverter and this product must be set again before the operation is started.

To avoid damage to this product due to static electricity, static electricity in your body must be discharged before you touch this product.

Maintenance, inspection and parts replacement

Do not carry out a megger (insulation resistance) test.

Disposal

This product must be treated as industrial waste.

General instruction

For clarity, illustrations in this Instruction Manual may be drawn with covers or safety guards removed. Ensure all covers and safety guards

are properly installed prior to starting operation.

4

— CONTENTS —

Safety instructions 1

1 PRE-OPERATION INSTRUCTIONS 7

1.1 Unpacking and product confirmation............................................................................................................................7

1.1.1 Product confirmation ............................................................................................................................................................. 7

1.1.2 SERIAL number check.......................................................................................................................................................... 8

1.2 Component names ..........................................................................................................................................................9

2 INSTALLATION 11

2.1 Pre-installation instructions .........................................................................................................................................11

2.2 Installation procedure ...................................................................................................................................................12

2.3 Encoder specification / terminating resistor switch setting......................................................................................16

2.4 Wiring..............................................................................................................................................................................20

2.5 Encoder cables dedicated to Mitsubishi Electric motors ..........................................................................................25

2.6 Terminals........................................................................................................................................................................28

3 ENCODER SPECIFICATIONS AND PARAMETER SETTINGS 34

3.1 Encoder ..........................................................................................................................................................................34

3.2 Parameter setting ..........................................................................................................................................................36

3.2.1 Parameter for encoder ........................................................................................................................................................ 36

3.2.2 Parameter settings for the motor under vector control........................................................................................................ 38

3.3 Function differences between induction motors and PM motors.............................................................................39

4 ORIENTATION CONTROL 41

4.1 Wiring example ..............................................................................................................................................................42

4.2 Terminals........................................................................................................................................................................44

5

4.3 Machine end simple orientation control......................................................................................................................45

4.4 Specifications ................................................................................................................................................................46

5 ENCODER FEEDBACK CONTROL 47

5.1 Wiring examples ............................................................................................................................................................48

5.2 Specifications ................................................................................................................................................................49

6 VECTOR CONTROL 50

6.1 Wiring examples (Vector control) ................................................................................................................................51

6.2 Setting procedure of Vector control for motor with encoder ....................................................................................55

6.3 Pulse train torque command ........................................................................................................................................57

6.3.1 Parameter list...................................................................................................................................................................... 57

6.3.2 Pulse train torque command ............................................................................................................................................... 58

6.4 Specifications ................................................................................................................................................................59

7 POSITION CONTROL FUNCTION 60

7.1 Position control .............................................................................................................................................................60

7.2 Wiring example ..............................................................................................................................................................63

7.3 Operation........................................................................................................................................................................64

7.4 Interface of the positioning module and inverter .......................................................................................................67

7.5 Parameter setting and details.......................................................................................................................................68

7.5.1 Block diagram ..................................................................................................................................................................... 68

7.5.2 Selection of control method (Pr.800) .................................................................................................................................. 69

7.5.3 Position control ................................................................................................................................................................... 70

7.5.4 Troubleshooting .................................................................................................................................................................. 72

7.6 Specifications ................................................................................................................................................................73

8 ENCODER PULSE DIVIDING OUTPUT 74

8.1 Wiring example ..............................................................................................................................................................74

6

8.2 Parameter related to encoder pulse dividing output..................................................................................................76

APPENDIX 77

Appendix 1 Instructions for compliance with the EU Directives ....................................................................................77

Appendix 2 Instructions for EAC .......................................................................................................................................78

Appendix 3 Restricted Use of Hazardous Substances in Electronic and Electrical Products .....................................79

Appendix 4 Referenced Standard (Requirement of Chinese standardized law) ...........................................................80

Appendix 5 Regarding Directive on Waste Electrical and Electronic Equipment .........................................................81

Appendix 6 Compliance with the UK certification scheme .............................................................................................82

REVISIONS 84

PRE-OPERATION INSTRUCTIONS 7

1

1PRE-OPERATION INSTRUCTIONS

1.1 Unpacking and product confirmation

Take the plug-in option out of the package, check the product name, and confirm that the product is as you ordered and intact.

This product is a plug-in option made for the FR-A800 series.

1.1.1 Product confirmation

Product confirmation

Check the enclosed items.

NOTE

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

otherwise specified. (For the control logic, refer to the Instruction Manual (Detailed) of the inverter.)

Plug-in option.............................1

Mounting screw (M3 × 8 mm).....3

(Refer to page 12.)

Spacer........................................3

(Refer to page 12.)

1

2

3

4

O

N

8PRE-OPERATION INSTRUCTIONS

1.1.2 SERIAL number check

The FR-A8AL can be used for the inverter models listed below with the following SERIAL number. Check the SERIAL number

indicated on the inverter rating plate or package. For the location of the rating plate, refer to the Instruction Manual (Detailed) of

the inverter.

Rating plate example

• FR-A800 series

The SERIAL consists of one symbol, two characters indicating

the production year and month, and six characters indicating

the control number.

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

and the Month is indicated by 1 to 9, X (October), Y

(November), or Z (December).

Model Country of

origin indication SERIAL number

FR-A820-00046(0.4K) to 04750(90K)

FR-A840-00023(0.4K) to 06830(280K)

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

FR-A846-00023(0.4K) to 00470(18.5K)

MADE in Japan 58 or later

MADE in China 59 or later

SERIAL

number

Country

of origin

,1387;;;;;

02'(/)5$

287387;;;;;

6(5,$/;;;;;;;;;

0$'(,1;;;;;

 { { {{{{{{

Symbol Year Month Control number

SERIAL

PRE-OPERATION INSTRUCTIONS 9

1

1.2 Component names

FPA

FPAR

FPB

FPBR

FPZ

FPZR

FPA2

FPB2

OPC

VDD

RDY

CR

PA

PAR

PB

PBR

PZ

PZR

PGP

PP

PGN

NP

PG24

PG

PGV

SD

FPZ2

SD

Front view Rear view

Terminal layout

1

2

3

4

O

N

(a) (f)

(b) (a)

(a)

(e)

(d)

(g)

(c)

(a)

10 PRE-OPERATION INSTRUCTIONS

Symbol Name Description

Refer

to

page

a Mounting hole Used to fix this product to the inverter by inserting a mounting screw or a

spacer. 12

b Terminal block Connected with the encoder. 20

c Encoder type selection switch (SW3) Used to switch the encoder type (differential line driver/ complementary). 16

d CON2 connector Connector for the FR-A8NS (SSCNET III) connection ―

e

Terminating resistor selection switches

(SW2-1 to SW2-3) Used to switch ON or OFF the internal terminating resistor.

16

Encoder power supply selection switch

(SW2-4) Used to switch the voltage supplied to the encoder from terminal PGV.

f Board mounted option connector Used to connect this product to the option connector on the inverter. 12

g Switch for manufacturer setting (SW1) Do not change the switch setting from the initial setting ( ). ―

INSTALLATION 11

2

2INSTALLATION

2.1 Pre-installation instructions

Check that the inverter's input power and the control circuit power are both OFF.

CAUTION

• Do not install or remove this product while the inverter power is ON. Doing so may damage the inverter or this product.

• To avoid damage due to static electricity, static electricity in your body must be discharged before you touch this product.

12 INSTALLATION

2.2 Installation procedure

1. Remove the inverter front cover. (Refer to Chapter 2 of the Instruction Manual (Detailed) of the inverter for instructions for

removing the front cover.)

2. As shown in the next page, when the plug-in option is installed to the connector 1, insert spacers in the three mounting

holes that will not be tightened with mounting screws. (When the plug-in option is installed to the connector 2, insert

spacers in the two mounting holes.)

3. Fit the board mounted option connector on this product to the guide of the option connector on the inverter and insert the

plug-in option as far as it goes.

4. When the plug-in option is installed to the connector 1, fit the two locations, the left and right, of the product securely to

the inverter unit by screwing in the supplied mounting screws. (When the plug-in option is installed to the connector 2, fit

the three locations.) (Tightening torque 0.33 N∙m to 0.40 N∙m) If the screw holes do not line up, the connector may not be

inserted deep enough. Check the connector.

INSTALLATION 13

2

• Example of installation to connector 1

Spacer

Inverter side

option connector

14 INSTALLATION

Insertion positions for screws and spacers

Mounting screw

Mounting screw Mounting screw

Connector 1Connector 2

Spacer

Spacer Spacer

INSTALLATION 15

2

NOTE

• When installing/removing the plug-in option, hold the sides of the option. Do not press on the parts on the option circuit

board. Stress applied to the parts by pressing, etc. may cause a failure.

• Be careful not to drop mounting screws during the installation or removal of the plug-in option.

• The priorities of vector control compatible plug-in options are defined as follows: FR-A8AL > FR-A8APS > FR-A8APA > FR-

A8APR > FR-A8AP. The vector control compatible plug-in options with lower priority do not function.

• Only one option can be used. When multiple options are mounted, priority is given to option connectors 1, 2 and 3 on the

inverter in this order, and options having a lower priority do not function.

• When the inverter cannot recognize the option due to improper installation or any reason, the protective function (E.1 to E.3)

is activated and the inverter cannot be operated. The indication shown (when a fault occurs) depends on the connector used

(option connector 1 to 3).

• When removing the plug-in option, remove the two screws on either side, and then pull it straight out. Pressure applied to

the option connector and to the option board may break the option.

Mounted position Fault indication

Option connector 1

Option connector 2

Option connector 3

16 INSTALLATION

2.3 Encoder specification / terminating resistor switch setting

Encoder specification selection switch (SW3)

Select either differential line driver or complementary.

It is initially set to the complementary. Switch its position according to output circuit.

Complementary

(initial status)

Differential line driver

INSTALLATION 17

2

Terminating resistor selection switches (SW2-1 to SW2-3)

Select "ON"/"OFF" of the internal terminating resistor. Set the SW2-1 to SW2-3 switches to "ON" when an encoder output type

is differential line driver and set to "OFF" when complementary (initial status).

ON : with internal terminating resistor

OFF : without internal terminating resistor (initial status)

Encoder power supply selection switch (SW2-4)

Select 5 V or 12 V power to be supplied to the encoder from terminal PGV.

Set SW2-4 to the ON position for the 12 V power supply, or set SW2-4 to the OFF position (initial status) for the 5 V power

supply.

1

2

3

4

O

N

Internal terminating

resistor-OFF

(initial status)

Internal terminating

resistor-ON

(initial status)

18 INSTALLATION

When power is supplied to the encoder from terminal PGV, connect terminal PGV and terminal PG.

NOTE

• If the encoder output type is differential line driver, set the terminating resistor switch to the "OFF" position when sharing the

same encoder with other unit (CNC (computerized numerical controller), etc.) or a terminating resistor is connected to other

unit.

• Terminals PGV and PG24 cannot be used simultaneously.

• When using terminal PGV to supply power to the encoder, check that the voltage setting meets the encoder specification.

Applying a voltage exceeding the encoder specification may damage the encoder.

When terminal PGV is used

PG

SD

PGV

To encoder

INSTALLATION 19

2

Motor used and switch setting

*1 Set according to the motor encoder used.

*2 Depending on the encoder to be used, prepare an external power supply (15 V) for the encoder. When the 24 V power supply of the FR-

A8AL is used, the power is supplied to the encoder through terminal PG24. When the 5 V/12 V power supply of the FR-A8AL is used, the

power is supplied to the encoder through terminal PGV.

*3 When the encoder output is the differential line driver type, only 5 V can be input.

NOTE

• Switch "SW1" is for manufacturer setting. Do not change the setting.

• When an external power supply is used for the encoder, turn OFF the encoder's power supply while power is not supplied to

the control circuit of the inverter. Otherwise, the plug-in option may be damaged.

Motor Encoder specification

selection switch (SW3)

Terminating resistor selection

switches (SW2-1 to SW2-3)

Power

specifications*2

Mitsubishi Electric standard

motor with encoder

Mitsubishi Electric high-

efficiency motor with encoder

SF-JR Differential ON 5 V

SF-HR Differential ON 5 V

Others *1 *1 *1*3

Mitsubishi Electric constant-

torque motor with encoder

SF-JRCA Differential ON 5 V

SF-HRCA Differential ON 5 V

Others *1 *1 *1*3

Mitsubishi Electric high-

performance energy-saving

motor with encoder

SF-PR-SC Complementary OFF 12 to 24 V

Vector control dedicated motor SF-V5RU Complementary OFF 12 to 24 V

SF-THY Complementary OFF 12 to 24 V

Other manufacturer's motor with encoder *1 *1 *1*3

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Mitsubishi Electric FR-A8AL User manual

Mitsubishi Electric FR-A8AL User manual

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