Mitsubishi Electric FR-A860 (600V CLASS Owner's manual

INVERTER

INVERTER FR-A800

FR-A860 INSTRUCTION MANUAL (DETAILED)

D

INTRODUCTION

1

INSTALLATION AND WIRING

2

PRECAUTIONS FOR USE OF

THE INVERTER

3

BASIC OPERATION

4

PARAMETERS

5

PROTECTIVE FUNCTIONS

6

PRECAUTIONS FOR

MAINTENANCE AND

INSPECTION

7

SPECIFICATIONS

8

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

IB(NA)-0600563ENG-D(1903)MEE Printed in Japan Specifications subject to change without notice.

FR-A800

FR-A860 (600V CLASS SPECIFICATION INVERTER)

INSTRUCTION MANUAL (DETAILED)

FR-A860-00027 to 00450-N6

FR-A860-00680 to 04420

High functionality and high performance

MODEL

FR-A800

INSTRUCTION MANUAL

MODEL

CODE

XXX-XXX

Safety Instructions

1

Thank you for choosing this Mitsubishi Electric inverter.

This Instruction Manual provides instructions for advanced use of the FR-A860 series inverters.

Incorrect handling might cause an unexpected fault. Before using this inverter, always carefully read this Instruction Manual and

the Instruction Manual (Startup) [IB-0600562ENG] packed with the product to use the equipment to its optimum performance.

 Electric Shock Prevention

 Fire Prevention

 Injury Prevention

 Additional Instructions

The following instructions must be also followed. If the product

is handled incorrectly, it may cause unexpected fault, an injury,

or an electric shock.

Safety Instructions

Do not attempt to install, operate, maintain or inspect the

product until you have read through this Instruction Manual

and appended documents carefully and can use the

equipment correctly. Do not use this product until you have a

full knowledge of the equipment, safety information and

instructions.

Installation, operation, maintenance and inspection must be

performed by qualified personnel. Here, an expert means a

person who meets all the conditions below.

• A person who took a proper engineering training. Such

training may be available at your local Mitsubishi Electric

office. Contact your local sales office for schedules and

locations.

• A person who can access operating manuals for the

protective devices (e.g. light curtain) connected to the safety

control system. A person who has read and familiarized

himself/herself with the manuals.

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

 While the inverter power is ON, do not remove the front cover or

the wiring cover. Do not run the inverter with the front cover or

the 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 except for

wiring or periodic inspection. You may accidentally touch the

charged inverter circuits and get an electric shock.

 Before wiring or inspection, the power lamp must be switched

OFF. Any person who is involved in wiring or inspection shall

wait for at least 10 minutes after the power supply has been

switched 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.

 This inverter must be earthed (grounded). Earthing (grounding)

must conform to the requirements of national and local safety

regulations and electrical code (NEC section 250, IEC 61140

class 1 and other applicable standards).

 Any person who is involved in wiring or inspection of this

equipment shall be fully competent to do the work.

 The inverter must be installed before wiring. Otherwise you may

get an electric shock or be injured.

 Setting dial and key operations must be performed with dry

hands to prevent an electric shock. Otherwise you may get an

electric shock.

 Do not subject the cables to scratches, excessive stress, heavy

loads or pinching. Doing so may cause an electric shock.

 Do not change the cooling fan while power is ON. It is dangerous

to change the cooling fan while power is ON.

 Do not touch the printed circuit board or handle the cables with

wet hands. Doing so may cause an electric shock.

 When measuring the main circuit capacitor capacity, the DC

voltage is applied to the motor for 1s at powering OFF. Never

touch the motor terminal, etc. right after powering OFF to

prevent an electric shock.

 A PM motor is a synchronous motor with high-performance

magnets embedded in the rotor. Motor terminals holds high-

voltage while the motor is running even after the inverter power

is turned OFF. Before wiring or inspection, the motor must be

confirmed to be stopped. In an application, such as fan and

blower, where the motor is driven by the load, a low-voltage

manual motor starter must be connected at the inverter's output

side, and wiring and inspection must be performed while the

motor starter is open. Otherwise you may get an electric shock.

WARNING

CAUTION

 Inverter must be installed on a nonflammable wall without holes

(so that nobody touches the inverter heat sink on the rear side,

etc.). Mounting it to or near flammable material may cause a fire.

 If the inverter has become faulty, the inverter power must be

switched OFF. A continuous flow of large current may cause a

fire.

 When using a brake resistor, a sequence that will turn OFF

power when a fault signal is output must be configured.

Otherwise the brake resistor may excessively overheat due to

damage of the brake transistor and such, causing a fire.

 Do not connect a resistor directly to the DC terminals P/+ and N/

-. Doing so could cause a fire.

 Be sure to perform daily and periodic inspections as specified in

the Instruction Manual. If a product is used without any

inspection, a burst, breakage, or a fire may occur.

CAUTION

 The voltage applied to each terminal must be the ones 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 burst, damage,

etc. may occur.

 While power is ON or for some time after power-OFF, do not

touch the inverter as it will be extremely hot. Touching these

devices may cause a burn.

CAUTION

Transportation and installation

 Any person who is opening a package using a sharp object,

such as a knife and cutter, must wear gloves to prevent injuries

caused by the edge of the sharp object.

 The product must be transported in correct method that

corresponds to the weight. Failure to do so may lead to injuries.

 Do not stand or rest heavy objects on the product.

 Do not stack the boxes containing inverters higher than the

number recommended.

 When carrying the inverter, do not hold it by the front cover; it

may fall off or fail.

 During installation, caution must be taken not to drop the inverter

as doing so may cause injuries.

 The product must be installed on the surface that withstands the

weight of the inverter.

 Do not install the product on a hot surface.

 The mounting orientation of the inverter must be correct.

 The inverter must be installed on a strong surface securely with

screws so that it will not drop.

 Do not install or operate the inverter 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.

 As the inverter is a precision instrument, do not drop or subject it

to impact.

 For the FR-A860-00090 or lower, the surrounding air temperature

must be -10 to +40°C for the LD, ND, or HD rating (-10 to +30°C

for the SLD rating) (non-freezing). Otherwise the inverter may be

damaged.

 For the FR-A860-00170 to 01080, the surrounding air

temperature must be -10 to +40°C (non-freezing). Otherwise the

inverter may be damaged.

 For the FR-A860-01440 or higher, the surrounding air

temperature must be -10 to +50°C for the LD or ND rating (-10 to

+40°C for the SLD or HD rating) (non-freezing). Otherwise the

inverter may be damaged.

 The ambient humidity must be 95%RH or less (non-

condensing). Otherwise the inverter may be damaged. (Refer to

page 24 for details.)

2

Safety Instructions

 2.9 m/s

2

or less for the FR-A860-02890 or higher.

CAUTION

Transportation and Mounting

 The storage temperature (applicable for a short time, e.g. during

transit) must be between -20 and +65°C. Otherwise the inverter

may be damaged.

 The inverter must be used indoors (without corrosive gas,

flammable gas, oil mist, dust and dirt etc.) Otherwise the inverter

may be damaged.

 The inverter must be used at an altitude of 2500 m or less, with

5.9 m/s

2

or less vibration at 10 to 55 Hz (directions of X, Y, Z

axes). Otherwise the inverter may be damaged. (For the

installation at an altitude above 1000 m, consider a 3% reduction

in the rated current per 500 m increase in altitude.)

 If halogen-based materials (fluorine, chlorine, bromine, iodine,

etc.) infiltrate into a Mitsubishi Electric product, the product will

be damaged. Halogen-based materials are often included in

fumigant, which is used to sterilize or disinfest wooden

packages. When packaging, prevent residual fumigant

components from being infiltrated into Mitsubishi Electric

products, or use an alternative sterilization or disinfection

method (heat disinfection, etc.) for packaging. Sterilization of

disinfection of wooden package should also be performed before

packaging the product.

Wiring

 Do not install a power factor correction capacitor or surge

suppressor/capacitor type filter on the inverter output side.

These devices on the inverter output side may be overheated or

burn out.

 The output side terminals (terminals U, V, and W) must be

connected correctly. Otherwise the motor will rotate inversely.

 PM motor terminals (U, V, W) hold high-voltage while the PM

motor is running even after the power is turned OFF. Before

wiring, the PM motor must be confirmed to be stopped.

Otherwise you may get an electric shock.

 Never connect an PM motor to the commercial power supply.

Applying the commercial power supply to input terminals (U, V,

W) of an PM motor will burn the PM motor. The PM motor must

be connected with the output terminals (U, V, W) of the inverter.

Trial run

 Before starting operation, each parameter must be confirmed

and adjusted. A failure to do so may cause some machines to

make unexpected motions.

WARNING

Usage

 Stay away from the equipment after using the retry function in

this product as the equipment will restart suddenly after the

output shutoff of this product.

 Since pressing the STOP/RESET key may not stop output

depending on the function setting status, separate circuit and

switch that make an emergency stop (power OFF, mechanical

brake operation for emergency stop, etc.) must be provided.

 OFF status of the start signal must be confirmed before resetting

the inverter fault. Resetting inverter fault with the start signal ON

restarts the motor suddenly.

 Do not use an PM motor for an application where the PM motor

is driven by its load and runs at a speed higher than the

maximum motor speed.

 Use this inverter only with three-phase induction motors or with

an PM motor. Connection of any other electrical equipment to

the inverter output may damage the equipment.

 Performing pre-excitation (LX signal and X13 signal) under

torque control (Real sensorless vector control) may start the

motor running at a low speed even when the start command

(STF or STR) is not input The motor may run also at a low speed

when the speed limit value = 0 with a start command input. It

must be confirmed that the motor running will not cause any

safety problem before performing pre-excitation.

 Do not modify the equipment.

 Do not perform parts removal which is not instructed in this

manual. Doing so may lead to fault or damage of the product.

CAUTION

Usage

 The electronic thermal relay function does not guarantee

protection of the motor from overheating. It is recommended to

install both an external thermal and PTC thermistor for overheat

protection.

 Do not use a magnetic contactor on the inverter input for

frequent starting/stopping of the inverter. Doing so may shorten

the life of this product.

 The effect of electromagnetic interference must be reduced by

using a noise filter or by other means. Otherwise nearby

electronic equipment may be affected.

 Appropriate measures must be taken to suppress harmonics.

Otherwise power supply harmonics from the inverter may heat/

damage the power factor correction capacitor and generator.

 When driving a 600 V class motor by the inverter, the motor must

be an insulation-enhanced motor or measures must be taken to

suppress surge voltage. Surge voltage attributable to the wiring

constants may occur at the motor terminals, deteriorating the

insulation of the motor.

 When parameter clear or all parameter clear is performed, the

required parameters must be set again before starting

operations. because all parameters return to their initial values.

 The inverter can be easily set for high-speed operation. Before

changing its setting, the performances of the motor and machine

must be fully examined.

 Stop status cannot be hold by the inverter's brake function. In

addition to the inverter’s brake function, a holding device must

be installed to ensure safety.

 Before running an inverter which had been stored for a long

period, inspection and test operation must be performed.

 Static electricity in your body must be discharged before you

touch the product.

 Only one PM motor can be connected to an inverter.

 An PM motor must be used under PM sensorless vector control.

Do not use a synchronous motor, induction motor, or

synchronous induction motor.

 Do not connect an PM motor in the induction motor control

settings (initial settings). Do not use an induction motor in the

PM sensorless vector control settings. It will cause a failure.

 In the system with an PM motor, the inverter power must be

turned ON before closing the contacts of the contactor at the

output side.

Emergency stop

 A safety backup such as an emergency brake must be provided

for devices or equipment in a system to prevent hazardous

conditions in case of failure of this product or an external device

controlling this product.

 When the breaker on the inverter input side trips, the wiring must

be checked for fault (short circuit), and internal parts of the

inverter for a damage, etc. The cause of the trip must be

identified and removed before turning ON the power of the

breaker.

 When a protective function is activated, take an appropriate

corrective action, then reset the inverter, and resume the

operation.

Maintenance, inspection and parts replacement

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

control circuit of the inverter. It will cause a failure.

Disposal

 The inverter 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.

For details on the PM motor, refer to the Instruction Manual of

the PM motor.

CONTENTS

3

1 INTRODUCTION 11

1.1 Product checking and accessories 12

1.2 Component names 13

1.3 Operation steps 14

1.4 About the related manuals 15

2 INSTALLATION AND WIRING 17

2.1 Peripheral devices 18

2.1.1 Inverter and peripheral devices ......................................................................................................................18

2.1.2 Peripheral devices ..........................................................................................................................................20

2.2 Removal and reinstallation of the front covers 21

2.3 Installation of the inverter and enclosure design 24

2.3.1 Inverter installation environment.....................................................................................................................24

2.3.2 Amount of heat generated by the inverter ......................................................................................................26

2.3.3 Cooling system types for inverter enclosure...................................................................................................27

2.3.4 Inverter installation..........................................................................................................................................28

2.3.5 Protruding the heat sink through a panel........................................................................................................30

2.4 Terminal connection diagrams 32

2.5 Main circuit terminals 34

2.5.1 Details on the main circuit terminals ...............................................................................................................34

2.5.2 Terminal layout of the main circuit terminals, wiring of power supply and the motor......................................35

2.5.3 Applicable cables and the wiring length..........................................................................................................40

2.5.4 Earthing (grounding) precautions ...................................................................................................................42

2.6 Control circuit 43

2.6.1 Details on the control circuit terminals............................................................................................................43

2.6.2 Control logic (sink/source) change .................................................................................................................47

2.6.3 Wiring of control circuit ...................................................................................................................................49

2.6.4 Wiring precautions..........................................................................................................................................51

2.6.5 When using separate power supplies for the control circuit and the main circuit ...........................................52

2.6.6 When supplying 24 V external power to the control circuit .............................................................................54

2.7 Communication connectors and terminals 56

2.7.1 PU connector..................................................................................................................................................56

2.7.2 USB connector................................................................................................................................................58

2.7.3 RS-485 terminal block ....................................................................................................................................59

2.8 Connection of motor with encoder (vector control) 60

2.9 Parameter settings for a motor with encoder 64

2.10 Connection of stand-alone option units 65

2.10.1 Connection of the brake resistor other than the provided brake resistor........................................................65

2.10.2 Connection of the DC reactor .........................................................................................................................66

CONTENTS

4

CONTENTS

3 PRECAUTIONS FOR USE OF THE INVERTER 67

3.1 Electro-magnetic interference (EMI) and leakage currents 68

3.1.1 Leakage currents and countermeasures........................................................................................................ 68

3.1.2 Countermeasures against inverter-generated EMI ........................................................................................ 69

3.2 Power supply harmonics 71

3.3 Installation of a reactor 71

3.4 Power-OFF and magnetic contactor (MC) 72

3.5 Countermeasures against deterioration of the 600 V class motor insulation 73

3.6 Checklist before starting operation 74

3.7 Failsafe system which uses the inverter 76

4 BASIC OPERATION 79

4.1 Frequently-used parameters (simple mode parameters) 80

4.1.1 Simple mode parameter list............................................................................................................................ 80

4.2 Basic operation procedure (PU operation) 82

4.2.1 Operating at a set frequency (example: operating at 30 Hz).......................................................................... 82

4.2.2 Setting the frequency by switches (multi-speed setting) ................................................................................ 83

4.2.3 Setting the frequency with analog signals (voltage input) .............................................................................. 84

4.2.4 Using an analog signal (current input) to give a frequency command ........................................................... 85

4.3 Basic operation procedure (External operation) 86

4.3.1 Using the frequency set by the operation panel ............................................................................................. 86

4.3.2 Setting the frequency by switches (multi-speed setting) (Pr.4 to Pr.6)........................................................... 87

4.3.3 Setting the frequency with analog signals (voltage input) .............................................................................. 88

4.3.4 Changing the frequency (60 Hz, initial value) at the maximum voltage input (5 V, initial value) .................... 89

4.3.5 Using an analog signal (current input) to give a frequency command ........................................................... 90

4.3.6 Changing the frequency (60 Hz, initial value) at the maximum current input (at 20 mA, initial value) ........... 91

4.4 Basic operation procedure (JOG operation) 92

4.4.1 Performing JOG operation using external signals.......................................................................................... 92

4.4.2 JOG operation from the operation panel........................................................................................................ 93

5 PARAMETERS 95

5.1 Parameter List 96

5.1.1 Parameter list (by parameter number) ........................................................................................................... 96

5.1.2 Parameter list (by function group) ................................................................................................................ 122

5.2 Control method 131

5.2.1 Vector control and Real sensorless vector control ....................................................................................... 134

5.2.2 Changing the control method ....................................................................................................................... 137

5.2.3 Selecting the Advanced magnetic flux vector control .................................................................................. 143

5.2.4 Selecting the PM sensorless vector control ................................................................................................ 145

CONTENTS

5

5.3 Speed control under Real sensorless vector control, vector control, PM sensorless vector

control 147

5.3.1 Setting procedure of Real sensorless vector control (speed control) ..........................................................150

5.3.2 Setting procedure of vector control (speed control) .....................................................................................152

5.3.3 Setting procedure of PM sensorless vector control (speed control) ............................................................153

5.3.4 Setting the torque limit level .........................................................................................................................154

5.3.5 Performing high-accuracy, fast-response control (gain adjustment for Real sensorless vector control, vector

control and PM sensorless vector control) ...................................................................................................164

5.3.6 Troubleshooting in the speed control ...........................................................................................................171

5.3.7 Speed feed forward control and model adaptive speed control ...................................................................173

5.3.8 Torque bias ..................................................................................................................................................175

5.3.9 Avoiding motor overrunning .........................................................................................................................179

5.3.10 Notch filter ....................................................................................................................................................181

5.4 Torque control under Real sensorless vector control and vector control 182

5.4.1 Torque control...............................................................................................................................................182

5.4.2 Setting procedure of Real sensorless vector control (torque control) ..........................................................187

5.4.3 Setting procedure for vector control (torque control) ...................................................................................189

5.4.4 Torque command .........................................................................................................................................190

5.4.5 Speed limit ...................................................................................................................................................195

5.4.6 Torque control gain adjustment ...................................................................................................................201

5.4.7 Troubleshooting in torque control ................................................................................................................202

5.4.8 Torque control by variable-current limiter control ........................................................................................203

5.5 Position control under vector control 204

5.5.1 About position control ..................................................................................................................................204

5.5.2 Setting procedure of vector control (position control) ..................................................................................206

5.5.3 Simple positioning function by parameters ..................................................................................................207

5.5.4 Position control by the FR-A8AL pulse train input .......................................................................................222

5.5.5 Position control by inverter pulse train input ................................................................................................225

5.5.6 Clear signal selection....................................................................................................................................226

5.5.7 Pulse monitor ...............................................................................................................................................227

5.5.8 Electronic gear setting .................................................................................................................................232

5.5.9 Position adjustment parameter settings .......................................................................................................234

5.5.10 Position control gain adjustment ..................................................................................................................236

5.5.11 Troubleshooting in position control ..............................................................................................................237

5.6 Real sensorless vector control, vector control, PM sensorless vector control adjustment 239

5.6.1 Speed detection filter and torque detection filter .........................................................................................239

5.6.2 Excitation ratio .............................................................................................................................................240

5.6.3 Gain adjustment of current controllers for the d axis and the q axis ............................................................240

5.7 (E) Environment setting parameters 241

5.7.1 Real time clock function................................................................................................................................242

5.7.2 Reset selection/disconnected PU detection/PU stop selection ....................................................................244

5.7.3 PU display language selection......................................................................................................................247

5.7.4 Buzzer control...............................................................................................................................................247

5.7.5 PU contrast adjustment ................................................................................................................................248

5.7.6 Extended direct setting .................................................................................................................................248

5.7.7 Resetting USB host errors ............................................................................................................................249

5.7.8 Multiple rating setting....................................................................................................................................249

5.7.9 Parameter write selection .............................................................................................................................251

5.7.10 Password function ........................................................................................................................................253

5.7.11 Free parameter .............................................................................................................................................255

5.7.12 Setting multiple parameters as a batch ........................................................................................................255

5.7.13 Extended parameter display and user group function ..................................................................................259

5.7.14 Parameter copy alarm release......................................................................................................................260

5.7.15 PWM carrier frequency and Soft-PWM control.............................................................................................261

5.7.16 Inverter parts life display...............................................................................................................................262

6

CONTENTS

5.7.17 Maintenance timer alarm.............................................................................................................................. 266

5.7.18 Current average value monitor signal .......................................................................................................... 267

5.8 (F) Setting of acceleration/deceleration time and acceleration/deceleration pattern 269

5.8.1 Setting the acceleration and deceleration time ............................................................................................ 269

5.8.2 Acceleration/deceleration pattern................................................................................................................. 274

5.8.3 Remote setting function................................................................................................................................ 279

5.8.4 Starting frequency and start-time hold function ........................................................................................... 283

5.8.5 Minimum motor speed frequency ................................................................................................................ 284

5.8.6 Shortest acceleration/deceleration and optimum acceleration/deceleration (automatic acceleration/

deceleration)................................................................................................................................................. 285

5.8.7 Lift operation (automatic acceleration/deceleration) .................................................................................... 288

5.9 (D) Operation command and frequency command 290

5.9.1 Operation mode selection ............................................................................................................................ 291

5.9.2 Startup in Network operation mode at power-ON ........................................................................................ 300

5.9.3 Start command source and frequency command source during communication operation......................... 301

5.9.4 Reverse rotation prevention selection .......................................................................................................... 308

5.9.5 Frequency setting via pulse train input......................................................................................................... 308

5.9.6 JOG operation.............................................................................................................................................. 312

5.9.7 Operation by multi-speed setting.................................................................................................................. 314

5.10 (H) Protective function parameter 316

5.10.1 Motor overheat protection (electronic thermal O/L relay) ............................................................................. 317

5.10.2 Fault definition .............................................................................................................................................. 323

5.10.3 Cooling fan operation selection .................................................................................................................... 324

5.10.4 Earth (ground) fault detection at start .......................................................................................................... 325

5.10.5 Initiating a protective function....................................................................................................................... 325

5.10.6 I/O phase loss protection selection .............................................................................................................. 326

5.10.7 Retry function ............................................................................................................................................... 327

5.10.8 Limiting the output frequency (maximum/minimum frequency).................................................................... 329

5.10.9 Avoiding the mechanical resonance points (frequency jump) ...................................................................... 330

5.10.10 Stall prevention operation ............................................................................................................................ 332

5.10.11 Load characteristics fault detection .............................................................................................................. 339

5.10.12 Motor overspeeding detection ...................................................................................................................... 343

5.11 (M) Monitor display and monitor output signal 344

5.11.1 Speed display and rotations per minute setting ........................................................................................... 345

5.11.2 Monitor indicator selection using operation panel or via communication ..................................................... 347

5.11.3 Monitor display selection for terminals FM and AM...................................................................................... 357

5.11.4 Adjustment of terminal FM and terminal AM ................................................................................................ 362

5.11.5 Energy saving monitor.................................................................................................................................. 365

5.11.6 Output terminal function selection ................................................................................................................ 370

5.11.7 Output frequency detection .......................................................................................................................... 379

5.11.8 Output current detection function ................................................................................................................. 382

5.11.9 Output torque detection ............................................................................................................................ 384

5.11.10 Remote output function ................................................................................................................................ 385

5.11.11 Analog remote output function ..................................................................................................................... 386

5.11.12 Fault code output selection .......................................................................................................................... 388

5.11.13 Pulse train output of output power................................................................................................................ 389

5.11.14 Detection of control circuit temperature........................................................................................................ 390

5.11.15 Encoder pulse dividing output ...................................................................................................................... 391

5.12 (T) Multi-Function Input Terminal Parameters 392

5.12.1 Analog input selection .................................................................................................................................. 393

5.12.2 Analog input terminal (terminal 1, 4) function assignment ........................................................................... 397

5.12.3 Analog input compensation.......................................................................................................................... 398

5.12.4 Analog input responsiveness and noise elimination..................................................................................... 400

5.12.5 Frequency setting voltage (current) bias and gain ....................................................................................... 402

5.12.6 Bias and gain for torque (magnetic flux) and set voltage (current)............................................................... 407

CONTENTS

7

5.12.7 Checking of current input on analog input terminal ......................................................................................411

5.12.8 Input terminal function selection ...................................................................................................................415

5.12.9 Inverter output shutoff signal ........................................................................................................................418

5.12.10 External fault input signal..............................................................................................................................419

5.12.11 Selecting operation condition of the second function selection signal (RT) and the third function selection

signal (X9).....................................................................................................................................................419

5.12.12 Start signal operation selection.....................................................................................................................421

5.13 (C) Motor constant parameters 423

5.13.1 Applied motor................................................................................................................................................423

5.13.2 Offline auto tuning ......................................................................................................................................426

5.13.3 Offline auto tuning for a PM motor (motor constants tuning) .......................................................................436

5.13.4 Online auto tuning ........................................................................................................................................444

5.13.5 Signal loss detection of encoder signals ......................................................................................................446

5.14 (A) Application parameters 447

5.14.1 Electronic bypass function ...........................................................................................................................448

5.14.2 Self power management ..............................................................................................................................454

5.14.3 Brake sequence function .............................................................................................................................457

5.14.4 Start count monitor .......................................................................................................................................462

5.14.5 Stop-on-contact control ................................................................................................................................463

5.14.6 Load torque high speed frequency control ...................................................................................................466

5.14.7 Traverse function..........................................................................................................................................469

5.14.8 Anti-sway control ..........................................................................................................................................471

5.14.9 Orientation control ........................................................................................................................................473

5.14.10 PID control....................................................................................................................................................488

5.14.11 Changing the display increment of the numerical values used in PID control ..............................................501

5.14.12 PID pre-charge function................................................................................................................................504

5.14.13 Dancer control ..............................................................................................................................................508

5.14.14 Automatic restart after instantaneous power failure/flying start with an induction motor .............................515

5.14.15 Offline auto tuning for a frequency search ...................................................................................................522

5.14.16 Power failure time deceleration-to-stop function...........................................................................................526

5.14.17 PLC function .................................................................................................................................................531

5.14.18 Trace function...............................................................................................................................................533

5.15 (N) Operation via communication and its settings 541

5.15.1 Wiring and configuration of PU connector ....................................................................................................541

5.15.2 Wiring and configuration of RS-485 terminals ..............................................................................................543

5.15.3 Initial setting of operation via communication...............................................................................................546

5.15.4 Initial settings and specifications of RS-485 communication........................................................................553

5.15.5 Mitsubishi inverter protocol (computer link communication) .........................................................................555

5.15.6 MODBUS RTU communication specification................................................................................................569

5.15.7 USB device communication..........................................................................................................................584

5.15.8 Automatic connection with GOT ...................................................................................................................585

5.15.9 Backup/restore..............................................................................................................................................586

5.16 (G) Control parameters 588

5.16.1 Manual torque boost ....................................................................................................................................589

5.16.2 Base frequency, voltage ..............................................................................................................................591

5.16.3 Load pattern selection .................................................................................................................................593

5.16.4 Excitation current low-speed scaling factor ..................................................................................................595

5.16.5 Energy saving control ..................................................................................................................................597

5.16.6 Adjustable 5 points V/F ................................................................................................................................598

5.16.7 DC injection brake, zero speed control, and servo lock................................................................................599

5.16.8 Output stop function......................................................................................................................................605

5.16.9 Stop selection ...............................................................................................................................................607

5.16.10 Regenerative brake selection and DC feeding mode ...................................................................................608

5.16.11 Regeneration avoidance function .................................................................................................................614

5.16.12 Increased magnetic excitation deceleration .................................................................................................617

5.16.13 Slip compensation .......................................................................................................................................618

8

CONTENTS

5.16.14 Encoder feedback control ............................................................................................................................ 619

5.16.15 Droop control ............................................................................................................................................... 621

5.16.16 Speed smoothing control ............................................................................................................................. 624

6 PROTECTIVE FUNCTIONS 625

6.1 Inverter fault and alarm indications 626

6.2 Reset method for the protective functions 626

6.3 The list of fault displays 627

6.4 Causes and corrective actions 629

6.5 Check first when you have a trouble 648

6.5.1 Motor does not start ..................................................................................................................................... 648

6.5.2 Motor or machine is making abnormal acoustic noise ................................................................................. 650

6.5.3 Inverter generates abnormal noise............................................................................................................... 650

6.5.4 Motor generates heat abnormally................................................................................................................. 651

6.5.5 Motor rotates in the opposite direction ......................................................................................................... 651

6.5.6 Speed greatly differs from the setting........................................................................................................... 651

6.5.7 Acceleration/deceleration is not smooth....................................................................................................... 652

6.5.8 Speed varies during operation ..................................................................................................................... 652

6.5.9 Operation mode is not changed properly ..................................................................................................... 653

6.5.10 Operation panel display is not operating ...................................................................................................... 653

6.5.11 Motor current is too large ............................................................................................................................. 653

6.5.12 Speed does not accelerate........................................................................................................................... 654

6.5.13 Unable to write parameter setting ................................................................................................................ 654

6.5.14 Power lamp is not lit ..................................................................................................................................... 654

7 PRECAUTIONS FOR MAINTENANCE AND

INSPECTION 655

7.1 Inspection item 656

7.1.1 Daily inspection ............................................................................................................................................ 656

7.1.2 Periodic inspection ....................................................................................................................................... 656

7.1.3 Daily and periodic inspection........................................................................................................................ 657

7.1.4 Checking the inverter module and the converter module............................................................................. 659

7.1.5 Cleaning ....................................................................................................................................................... 659

7.1.6 Replacement of parts ................................................................................................................................... 660

7.1.7 Removal and reinstallation of the control circuit terminal block.................................................................... 665

7.2 Measurement of main circuit voltages, currents and powers 666

7.2.1 Measurement of powers............................................................................................................................... 668

7.2.2 Measurement of voltages ............................................................................................................................. 668

7.2.3 Measurement of currents ............................................................................................................................. 668

7.2.4 Measurement of inverter input power factor................................................................................................. 668

7.2.5 Measurement of converter output voltage (across terminals P and N) ........................................................668

7.2.6 Measurement of inverter output frequency................................................................................................... 669

7.2.7 Insulation resistance test using megger ....................................................................................................... 669

7.2.8 Pressure test ................................................................................................................................................ 669

CONTENTS

9

8 SPECIFICATIONS 671

8.1 Inverter rating 672

8.2 Common specifications 674

8.3 Outline dimension drawings 676

8.3.1 Inverter outline dimension drawings .............................................................................................................676

APPENDIX 681

Appendix 1 For customers replacing the conventional model with this inverter................................. 682

Appendix 2 International standards.......................................................................................................... 683

Appendix 3 Specification comparison between PM sensorless vector control and induction motor

control ..................................................................................................................................... 684

Appendix 4 Parameters (functions) and instruction codes under different control methods ............ 685

Appendix 5 For customers using HMS network options ........................................................................ 704

MEMO

10

INTRODUCTION

11

1

1 INTRODUCTION

The contents described in this chapter must be read before using this

product.

Always read the instructions before using the equipment.

For the "INTRODUCTION" of the separated converter type, refer to the

FR-A862 (Separated Converter Type) Instruction Manual (Hardware) [IB-

0600571ENG]

1.1 Product checking and accessories.........................................12

1.2 Component names....................................................................13

1.3 Operation steps.........................................................................14

1.4 About the related manuals.......................................................15

DU ..................................................Operation panel (FR-LU08)

Operation panel .............................Operation panel (FR-LU08)

Parameter unit ...............................Parameter unit (FR-PU07)

PU ..................................................Operation panel and parameter unit

Inverter ...........................................Mitsubishi Electric inverter FR-A860 series

Vector control compatible option..... FR-A8AP/FR-A8AL/FR-A8APA/FR-A8APR/FR-A8APS (plug-in option), FR-

A8TP (control terminal option)

Pr. ..................................................Parameter number (Number assigned to function)

PU operation ..................................Operation using the PU (operation panel/parameter unit)

External operation ..........................Operation using the control circuit signals

Combined operation ......................Combined operation using the PU (operation panel/parameter unit) and

External operation

• Microsoft and Visual C++ are registered trademarks of Microsoft Corporation in the United States and other

countries.

• MODBUS is a registered trademark of SCHNEIDER ELECTRIC USA, INC.

• Other company and product names herein are the trademarks and registered trademarks of their respective

owners.

• 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 page 47.)

Product checking and accessories

12

INTRODUCTION

1.1 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

• FR-A860-00450 or lower

• FR-A860-00680 or higher

 Applicable for the FR-A860-00170 or higher.

 Accessory

• Eyebolt for hanging the inverter

• Brake resistor (FR-A860-00090 or lower)

• Protective bush (FR-A860-00090 or lower)

 How to read the SERIAL number

Capacity Eyebolt Size Quantity

FR-A860-02890, 03360 M10 2

FR-A860-04420 M12 2

Rating plate example

The SERIAL consists of one symbol, two characters indicating the production

year and month, and six characters indicating the control number. The last digit

of the production year is indicated as the Year, and the Month is indicated by 1

to 9, X (October), Y (November), or Z (December).

   

Symbol Year Month Control number

SERIAL

FR --A8 06 -1- N600320

Symbol Voltage class

600 V class6

Symbol Description

00027 to 00450 Inverter SLD rated current (A)

Symbol

Circuit board coating

(conforming to IEC60721-3-3 3C2/3S2)

UL Type 1

certification

Plated conductor

With WithWithoutN6

FR --A8 06 -1-00680

Symbol Voltage class

600 V class6

Symbol Description

00680 to 04420 Inverter SLD rated current (A)

Symbol

Circuit board coating

(conforming to IEC60721-3-3 3C2/3S2)

With

Plated conductor

With

Without

06∗1

60

,1387;;;;;

02'(/)5$1

287387;;;;;

6(5,$/;;;;;;;;;

0$'(,1;;;;;

Rating plate

Input rating

Output rating

SERIAL

Inverter model

Country of origin

Component names

INTRODUCTION

13

1

1.2 Component names

Component names are shown below.

Symbol Name Description

Refer to

page

(a) PU connector

Connects the operation panel or the parameter unit. This connector also

enables the RS-485 communication.

56

(b) USB A connector Connects a USB memory device. 58

(c) USB mini B connector

Connects a personal computer and enables communication with FR

Configurator2.

58

(d) RS-485 terminals Enables RS-485, MODBUS RTU communication. 59

(e)

Terminating resistor switch

(SW1)

Select whether or not to use the terminating resistor for RS-485 communication. 59

(f) Plug-in option connector 1

Connects a plug-in option or a communication option.

Instruction

Manual of

the option

(g) Plug-in option connector 2

(h) Plug-in option connector 3

(i)

Voltage/current input switch

(SW2)

Selects between voltage and current for the terminal 2 and 4 inputs. 393

(j) Control circuit terminal block Connects cables for the control circuit. 43

(k) Main circuit terminal block Connects cables for the main circuit. 34

(l) Charge lamp Stays ON while the power is supplied to the main circuit. 35

(m) Wiring cover

When conduits are installed in the knockout holes of this cover, wiring can be

passed through the conduits. (FR-A860-00450 or lower)

37

(n) Alarm lamp Turns ON when the protective function of the inverter is activated. 35

(o) Power lamp Stays ON while the power is supplied to the control circuit (R1/L11, S1/L21). 35

(p) Front cover (upper side)

Remove this cover for the installation of the product, installation of a plug-in

(communication) option, RS-485 terminal wiring, switching of the voltage/

current input switch, etc.

21

(q) Front cover (lower side) Remove this cover for wiring. 21

(r) Accessory cover Remove this cover for using the PU connector. 56

(s) Cooling fan Cools the inverter. (FR-A860-00061 or higher) 661

(t)

Switches for manufacturer

setting (SW3 and SW4)

Do not change the initial setting (OFF ).



(r)

(i)

(l)

(o)

(s)

(k)

(p)

(a)

(n)

(h)

(d)

(q)

(j)

(f)

(g)

(b)

(c)

(m)

(t)

(e)

Operation steps

14

INTRODUCTION

1.3 Operation steps

Symbol Overview Refer to page

(a) Install the inverter. 24

(b) Perform wiring for the power supply and the motor. 35

(c)

Select the control method (V/F control, Advanced magnetic flux vector control, vector control, or PM

sensorless vector control).

137

(d) Input the start command via communication. 541

(e) The PU gives both start and frequency commands. (PU operation mode) 82

(f)

The PU gives a start command, and inputs to terminal RH, RM, and RL give a frequency command.

(External/PU combined operation mode 2)

83

(g)

The PU gives a start command, and voltage input to terminal 2 gives a frequency command.

(External/PU combined operation mode 2)

84

(h)

The PU gives a start command, and current input to terminal 4 gives a frequency command.

(External/PU combined operation mode 2)

85

(i)

Inputs to terminal STF and STR give a start command, and the PU gives a frequency command.

(External/PU combined operation mode 1)

86

(j)

Inputs to terminal STF and STR give a start command, and inputs to terminal RH, RM, and RL give a

frequency command. (External operation mode)

87

(k)

Inputs to terminal STF and STR give a start command, and voltage input to terminal 2 gives a frequency

command. (External operation mode)

88

(l)

Inputs to terminal STF and STR give a start command, and current input to terminal 4 gives a frequency

command. (External operation mode)

90

ON

Frequency

Time

(S)

(Hz)

Start command

Frequency command

Inverter

output

frequency

Step of operation

Installation/mounting

Control method selection

Wiring of the power

supply and motor

Connect a switch, relay, etc.

to the control circuit

terminal block of the inverter

to give a start command. (External)

Start command via the PU

connector and RS-485 terminal of

the inverter and plug-in option

(Communication)

Set from the

PU (operation panel/

parameter unit).

(PU)

Set from the

PU (operation panel/

parameter unit).

Change of frequency

with ON/OFF switches

connected to terminals

(multi-speed setting)

(External) (External)

(PU) (External) (External) (External)

How

o

to give a start

e

command?

m

How

to give a start

command?

How to

w

give a frequency

re

command?

m

How to

give a frequency

command?

(a)

(b)

(c)

(d)

(e) (f) (g) (h)

(i) (j) (k) (l)

Perform frequency

setting by a current

output device

(Connection across

terminals 4 and 5)

Perform frequency

setting by a voltage

output device

(Connection across

terminals 2 and 5)

Perform frequency

setting by a current

output device

(Connection across

terminals 4 and 5)

Perform frequency

setting by a voltage

output device

(Connection across

terminals 2 and 5)

How to

w

give a frequency

re

command?

m

How to

give a frequency

command?

Change frequency

with ON/OFF switches

connected to terminals

(multi-speed setting)

(External)

Start command with

on the operation panel (PU)

: Initial setting

About the related manuals

INTRODUCTION

15

1

1.4 About the related manuals

The manuals related to FR-A860 are shown below.

Manual name Manual number

FR-A860 Instruction Manual (Startup) IB-0600562ENG

FR-A862 (Separated Converter Type) Instruction Manual (Hardware) IB-0600571ENG

FR-CC2-C (Converter unit) Instruction Manual IB-0600572ENG

PLC function programming manual IB-0600492ENG

FR Configurator2 Instruction Manual IB-0600516ENG

MEMO

16

INSTALLATION AND WIRING

17

2

2 INSTALLATION AND

WIRING

This chapter explains the installation and the wiring of this product.

Always read the instructions before using the equipment.

For the "INSTALLATION AND WIRING" of the separated converter type,

refer to the FR-A862 (Separated Converter Type) Instruction Manual

(Hardware) [IB-0600571ENG].

2.1 Peripheral devices ....................................................................18

2.2 Removal and reinstallation of the front covers......................21

2.3 Installation of the inverter and enclosure design ..................24

2.4 Terminal connection diagrams ................................................32

2.5 Main circuit terminals ...............................................................34

2.6 Control circuit ...........................................................................43

2.7 Communication connectors and terminals............................56

2.8 Connection of motor with encoder (vector control) ..............60

2.9 Parameter settings for a motor with encoder ........................64

2.10 Connection of stand-alone option units.................................65

Peripheral devices

18

INSTALLATION AND WIRING

2.1 Peripheral devices

2.1.1 Inverter and peripheral devices

NOTE

• To prevent an 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 the

communication devices (such as AM radios) used near the inverter. Refer to page 69 for countermeasures.

• 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.

Earth (Ground)

R/L1 S/L2 T/L3

P1P/+

: Install these options as required.

U

Earth (Ground)

VW

IM connection

PM connection

(c) Molded case circuit breaker

(MCCB) or earth leakage current

breaker (ELB), fuse

(e) AC reactor (f) DC reactor

(k) Noise filter

UVW

Earth (Ground)

(l) Induction

motor

(m) Contactor

Example) No-fuse

switch

(DSN type)

(n) PM motor

(g) Noise filter

(d) Magnetic contactor (MC)

(a) Inverter

(b) Three-phase AC power supply

(h) USB connector

USB host

(A connector)

USB device

(Mini B connector)

Communication

status indicator

(LED)(USB host)

Earth

(Ground)

Earth

(Ground)

USB

Personal computer

PR

(j) Brake resistor

(i) Provided brake resistor

PR

P3

(P/+)

Peripheral devices

INSTALLATION AND WIRING

19

2

 Compatible with the FR-A860-01080 or lower.

Symbol Name Overview

Refer

to page

(a) Inverter (FR-A860)

The life of the inverter is influenced by the surrounding air temperature.

The surrounding air temperature should be as low as possible within the

permissible range. This must be noted especially when the inverter is

installed in an enclosure.

Incorrect wiring may lead to damage of the inverter. The control signal

lines must be kept fully away from the main circuit lines to protect them

from noise.

24

32

(b) Three-phase AC power supply Must be within the permissible power supply specifications of the inverter. 672

(c)

Molded case circuit breaker (MCCB),

earth leakage circuit breaker (ELB), or

fuse

Must be selected carefully since an inrush current flows in the inverter at

power ON.

20

(d) Magnetic contactor (MC)

Install this to ensure safety.

Do not use this to start and stop the inverter. Doing so will shorten the life

of the inverter.

72

(e) AC reactor

Install this to suppress harmonics and to improve the power factor.

An AC reactor is required when installing the inverter near a large power

supply system (1000 kVA or more). Under such condition, the inverter

may be damaged if you do not use a reactor.

Select a reactor according to the applied motor capacity.

71

(f) DC reactor

Install this to suppress harmonics and to improve the power factor.

Select a reactor according to the applicable motor capacity.

For the FR-A860-01440 or higher, or a motor with a capacity of 75 kW or

higher, always connect a DC reactor.

When using the DC reactor with the FR-A860-01080 or lower, remove the

jumper across terminals P/+ and P1 before connecting the DC reactor to

the inverter.

71

(g) Noise filter Suppresses the noise radiated from the power supply side of the inverter. 69

(h) USB connection

A USB (Ver. 1.1) cable connects the inverter with a personal computer.

A USB memory device enables parameter copies and the trace function.

58

(i) Provided brake resistor

Improves the braking capability.

This brake resistor is provided with the FR-A860-00090 or lower.

39

(j) Brake resistor



Improves the braking capability.

Install a thermal relay to prevent an overheat and burnout of the brake

resistor.

65

(k) Noise filter

Install this to reduce the electromagnetic noise generated from the

inverter. The noise filter is effective in the range from about 0.5 MHz to 5

MHz.

A wire should be wound four turns at maximum.

69

(l) Induction motor Connect a squirrel-cage induction motor. 

(m)

Contactor

Example) No-fuse switch (DSN type)

Connect this for an application where a PM motor is driven by the load

even while the inverter power is OFF. Do not open or close the contactor

while the inverter is running (outputting).



(n) PM motor

A PM motor can be used. A PM motor cannot be driven by the

commercial power supply.



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Mitsubishi Electric FR-A860 (600V CLASS Owner's manual

Mitsubishi Electric FR-A860 (600V CLASS Owner's manual

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