Contents

FR-A800 INSTRUCTION MANUAL (DETAILED)
CONTENTS
Safety instructions
1 INTRODUCTION
- 1.1 Product checking and accessories
- 1.2 Component names
- 1.3 Operation steps
- 1.4 Related manuals
2 INSTALLATION AND WIRING
- 2.1 Peripheral devices
  - 2.1.1 Inverter and peripheral devices
  - 2.1.2 Peripheral devices
- 2.2 Removal and reinstallation of the operation panel or the front covers
- 2.3 Installation of the inverter and enclosure design
  - 2.3.1 Inverter installation environment
  - 2.3.2 Amount of heat generated by the inverter
  - 2.3.3 Cooling system types for inverter enclosure
  - 2.3.4 Inverter installation
  - 2.3.5 Protruding the heat sink through a panel
- 2.4 Terminal connection diagrams
- 2.5 Main circuit terminals
  - 2.5.1 Details on the main circuit terminals
  - 2.5.2 Main circuit terminal layout and wiring to power supply and motor
  - 2.5.3 Recommended cables and wiring length
  - 2.5.4 Earthing (grounding) precautions
- 2.6 Control circuit
  - 2.6.1 Details on the control circuit terminals
  - 2.6.2 Control logic (sink/source) change
  - 2.6.3 Wiring of control circuit
  - 2.6.4 Wiring precautions
  - 2.6.5 When using separate power supplies for the control circuit and the main circuit
  - 2.6.6 When supplying 24 V external power to the control circuit
  - 2.6.7 Safety stop function
- 2.7 Communication connectors and terminals
  - 2.7.1 PU connector
  - 2.7.2 USB connector
  - 2.7.3 RS-485 terminal block
- 2.8 Connection to a motor with encoder (Vector control)
- 2.9 Parameter settings for a motor with encoder
- 2.10 Connection of stand-alone option units
  - 2.10.1 Connection of the brake resistor
  - 2.10.2 Connection of the brake unit (FR-BU2)
  - 2.10.3 Connection of the brake unit (FR-BU)
  - 2.10.4 Connection of the brake unit (BU type)
  - 2.10.5 Connection of the high power factor converter (FR- HC2)
  - 2.10.6 Connection of the multifunction regeneration converter (FR-XC)
  - 2.10.7 Connection of the power regeneration common converter (FR-CV)
  - 2.10.8 Connection of the power regeneration converter (MT-RC)
  - 2.10.9 Connection of the DC reactor (FR-HEL)
- 2.11 Wiring for use of the CC-Link IE Field Network (FR- A800-GF)
  - 2.11.1 System configuration example
  - 2.11.2 Network configuration
  - 2.11.3 Network components
  - 2.11.4 Component names of the CC-Link IE Field Network communication circuit board
  - 2.11.5 Wiring method
  - 2.11.6 Operation status LEDs
3 PRECAUTIONS FOR USE OF THE INVERTER
- 3.1 Electro-magnetic interference (EMI) and leakage currents
  - 3.1.1 Leakage currents and countermeasures
  - 3.1.2 Techniques and measures for electromagnetic compatibility (EMC)
  - 3.1.3 Built-in EMC filter
- 3.2 Power supply harmonics
  - 3.2.1 Power supply harmonics
  - 3.2.2 Harmonic suppression guidelines in Japan
- 3.3 Installation of a reactor
- 3.4 Power shutdown and magnetic contactor (MC)
- 3.5 Countermeasures against deterioration of the 400 V class motor insulation
- 3.6 Checklist before starting operation
- 3.7 Failsafe system which uses the inverter
4 BASIC OPERATION
- 4.1 Operation panel (FR-DU08)
  - 4.1.1 Components of the operation panel (FR-DU08)
  - 4.1.2 Basic operation of the operation panel
  - 4.1.3 Digital characters and their corresponding printed equivalents
  - 4.1.4 Changing the parameter setting value
- 4.2 Monitoring the inverter
  - 4.2.1 Monitoring of output current and output voltage
  - 4.2.2 First priority monitor screen
  - 4.2.3 Displaying the set frequency
- 4.3 Easy setting of the inverter operation mode
- 4.4 Frequently-used parameters (simple mode parameters)
  - 4.4.1 Simple mode parameter list
- 4.5 Basic operation procedure (PU operation)
  - 4.5.1 Setting the frequency on the operation panel (example: operating at 30 Hz)
  - 4.5.2 Perform PU operation using the setting dial like a potentiometer
  - 4.5.3 Setting the frequency with switches (multi-speed setting)
  - 4.5.4 Setting the frequency using an analog signal (voltage input)
  - 4.5.5 Setting the frequency using an analog signal (current input)
- 4.6 Basic operation procedure (External operation)
  - 4.6.1 Setting the frequency on the operation panel
  - 4.6.2 Setting the frequency and giving a start command with switches (multi-speed setting) (Pr.4 to Pr.6)
  - 4.6.3 Setting the frequency using an analog signal (voltage input)
  - 4.6.4 Changing the frequency (60 Hz, initial value) at the maximum voltage input (5 V, initial value)
  - 4.6.5 Setting the frequency using an analog signal (current input)
  - 4.6.6 Changing the frequency (60 Hz, initial value) at the maximum current input (at 20 mA, initial value)
- 4.7 Basic operation procedure (JOG operation)
  - 4.7.1 Giving a start command by using external signals for JOG operation
  - 4.7.2 Giving a start command from the operation panel for JOG operation
5 PARAMETERS
- 5.1 Parameter list
  - 5.1.1 Parameter list (by parameter number)
  - 5.1.2 Use of a function group number for the identification of parameters
  - 5.1.3 Parameter list (by function group number)
- 5.2 Control method
  - 5.2.1 Vector control and Real sensorless vector control
  - 5.2.2 Changing the control method and mode
  - 5.2.3 Selecting the Advanced magnetic flux vector control
  - 5.2.4 Selecting the PM sensorless vector control
  - 5.2.5 Low-speed range torque characteristics
- 5.3 Speed control under Real sensorless vector control, vector control, PM sensorless vector control
  - 5.3.1 Setting procedure of Real sensorless vector control (speed control)
  - 5.3.2 Setting procedure of Vector control (speed control)
  - 5.3.3 Setting procedure of PM sensorless vector control (speed control)
  - 5.3.4 Setting the torque limit level
  - 5.3.5 Performing high-accuracy, fast-response control (gain adjustment for Real sensorless vector control, Vector control, and PM sensorless vector control)
  - 5.3.6 Troubleshooting in the speed control
  - 5.3.7 Speed feed forward control, model adaptive speed control
  - 5.3.8 Torque bias
  - 5.3.9 Avoiding motor overrunning
  - 5.3.10 Notch filter
- 5.4 Torque control under Real sensorless vector control and Vector control
  - 5.4.1 Torque control
  - 5.4.2 Setting procedure of Real sensorless vector control (torque control)
  - 5.4.3 Setting procedure for Vector control (torque control)
  - 5.4.4 Torque command
  - 5.4.5 Speed limit
  - 5.4.6 Torque control gain adjustment
  - 5.4.7 Troubleshooting in torque control
  - 5.4.8 Torque control by variable-current limiter control
- 5.5 Position control under vector control and PM sensorless vector control
  - 5.5.1 About position control
  - 5.5.2 Setting procedure of Vector control (position control)
  - 5.5.3 Setting procedure of PM sensorless vector control (position control)
  - 5.5.4 Simple positioning function by parameters
  - 5.5.5 Position control by the FR-A8AL pulse train input
  - 5.5.6 Position control by pulse train input to the inverter
  - 5.5.7 Clear signal selection
  - 5.5.8 Pulse monitor
  - 5.5.9 Electronic gear settings
  - 5.5.10 Position adjustment parameter settings
  - 5.5.11 Position control gain adjustment
  - 5.5.12 Troubleshooting in position control
- 5.6 Adjustment during Real sensorless vector control, Vector control, PM sensorless vector control
  - 5.6.1 Speed detection filter and torque detection filter
  - 5.6.2 Excitation ratio
  - 5.6.3 Gain adjustment of current controllers for the d axis and the q axis
- 5.7 (E) Environment setting parameters
  - 5.7.1 Real time clock function
  - 5.7.2 Reset selection / disconnected PU detection / PU stop selection
  - 5.7.3 PU display language selection
  - 5.7.4 Buzzer control
  - 5.7.5 PU contrast adjustment
  - 5.7.6 Display-off setting
  - 5.7.7 Direct setting
  - 5.7.8 Resetting USB host errors
  - 5.7.9 Easy frequency setting (Volume-knob-like setting) and key lock function selection
  - 5.7.10 Frequency change increment amount setting
  - 5.7.11 Multiple rating setting
  - 5.7.12 Using the power supply exceeding 480 VAC
  - 5.7.13 Parameter write selection
  - 5.7.14 Password
  - 5.7.15 Free parameter
  - 5.7.16 Setting multiple parameters by batch
  - 5.7.17 Extended parameter display and user group function
  - 5.7.18 PWM carrier frequency and Soft-PWM control
  - 5.7.19 Inverter parts life display
  - 5.7.20 Maintenance timer alarm
  - 5.7.21 Current average value monitor signal
- 5.8 (F) Setting of acceleration/deceleration time and acceleration/deceleration pattern
  - 5.8.1 Setting the acceleration and deceleration time
  - 5.8.2 Acceleration/deceleration pattern
  - 5.8.3 Remote setting function
  - 5.8.4 Starting frequency and start-time hold function
  - 5.8.5 Minimum motor speed frequency and hold function at the motor start up
  - 5.8.6 Shortest acceleration/deceleration and optimum acceleration/deceleration (automatic acceleration/ deceleration)
  - 5.8.7 Lift operation (automatic acceleration/ deceleration)
- 5.9 (D) Operation command and frequency command
  - 5.9.1 Operation mode selection
  - 5.9.2 Startup of the inverter in Network operation mode at power-ON
  - 5.9.3 Start command source and frequency command source during communication operation
  - 5.9.4 Reverse rotation prevention selection
  - 5.9.5 Frequency setting using pulse train input
  - 5.9.6 JOG operation
  - 5.9.7 Operation by multi-speed setting
- 5.10 (H) Protective function parameter
  - 5.10.1 Motor overheat protection (electronic thermal O/L relay)
  - 5.10.2 Fault definition
  - 5.10.3 Cooling fan operation selection
  - 5.10.4 Earth (ground) fault detection at start
  - 5.10.5 Varying the activation level of the undervoltage protective function
  - 5.10.6 Initiating a protective function
  - 5.10.7 I/O phase loss protection selection
  - 5.10.8 Retry function
  - 5.10.9 Limiting the output frequency (maximum/minimum frequency)
  - 5.10.10 Avoiding machine resonance points (frequency jump)
  - 5.10.11 Stall prevention operation
  - 5.10.12 Load characteristics fault detection
  - 5.10.13 Motor overspeeding detection
- 5.11 (M) Item and output signal for monitoring
  - 5.11.1 Speed indication and its setting change to rotations per minute
  - 5.11.2 Monitor item selection on operation panel or via communication
  - 5.11.3 Monitor display selection for terminals FM/CA and AM
  - 5.11.4 Adjustment of terminal FM/CA and terminal AM
  - 5.11.5 Energy saving monitoring
  - 5.11.6 Output terminal function selection
  - 5.11.7 Output frequency detection
  - 5.11.8 Output current detection function
  - 5.11.9 Output torque detection function
  - 5.11.10 Remote output function
  - 5.11.11 Analog remote output function
  - 5.11.12 Fault code output selection
  - 5.11.13 Pulse train output to announce cumulative output energy
  - 5.11.14 Detection of control circuit temperature
  - 5.11.15 Encoder pulse dividing output
- 5.12 (T) Multi-function input terminal parameters
  - 5.12.1 Analog input selection
  - 5.12.2 Analog input terminal (terminal 1, 4) function assignment
  - 5.12.3 Analog input compensation
  - 5.12.4 Response level of analog input and noise elimination
  - 5.12.5 Frequency setting voltage (current) bias and gain
  - 5.12.6 Torque (magnetic flux) setting voltage (current) bias and gain
  - 5.12.7 Checking of current input on analog input terminal
  - 5.12.8 Input terminal function selection
  - 5.12.9 Inverter output shutoff
  - 5.12.10 External fault input signal
  - 5.12.11 Selecting the condition to activate the Second function selection (RT) signal or the Third function selection (X9) signal
- 5.13 (C) Motor constant parameters
  - 5.13.1 Applied motor
  - 5.13.2 Offline auto tuning for an induction motor
  - 5.13.3 Offline auto tuning for a PM motor (under Vector control)
  - 5.13.4 Offline auto tuning for a PM motor (motor constant tuning)
  - 5.13.5 Online auto tuning
  - 5.13.6 Signal loss detection of encoder signals
- 5.14 (A) Application parameters
  - 5.14.1 Electronic bypass function
  - 5.14.2 Self power management
  - 5.14.3 Brake sequence function
  - 5.14.4 Start count monitor
  - 5.14.5 Stop-on-contact control
  - 5.14.6 Load torque high-speed frequency control
  - 5.14.7 Traverse function
  - 5.14.8 Anti-sway control
  - 5.14.9 Orientation control
  - 5.14.10 PID control
  - 5.14.11 Changing the display increment of numerical values used in PID control
  - 5.14.12 PID Pre-charge function
  - 5.14.13 Dancer control
  - 5.14.14 Automatic restart after instantaneous power failure/flying start with an induction motor
  - 5.14.15 Automatic restart after instantaneous power failure/flying start with a PM motor
  - 5.14.16 Offline auto tuning for a frequency search
  - 5.14.17 Power failure time deceleration-to-stop function
  - 5.14.18 PLC function
  - 5.14.19 Trace function
- 5.15 (N) Communication operation parameters
  - 5.15.1 Wiring and configuration of PU connector
  - 5.15.2 Wiring and configuration of RS-485 terminals
  - 5.15.3 Initial setting of operation via communication
  - 5.15.4 Initial settings and specifications of RS-485 communication
  - 5.15.5 Mitsubishi inverter protocol (computer link communication)
  - 5.15.6 MODBUS RTU communication specification
  - 5.15.7 CC-Link IE Field Network function setting (FR- A800-GF)
  - 5.15.8 USB device communication
  - 5.15.9 Automatic connection with GOT
  - 5.15.10 Backup/restore
- 5.16 (G) Control parameters
  - 5.16.1 Manual torque boost
  - 5.16.2 Base frequency voltage
  - 5.16.3 Load pattern selection
  - 5.16.4 Excitation current low-speed scaling factor
  - 5.16.5 Energy saving control
  - 5.16.6 Adjustable 5 points V/F
  - 5.16.7 SF-PR slip amount adjustment mode
  - 5.16.8 DC injection brake, zero speed control, and servo lock
  - 5.16.9 Output stop function
  - 5.16.10 Start signal operation selection / stop selection
  - 5.16.11 Regenerative brake selection and DC feeding mode
  - 5.16.12 Regeneration avoidance function
  - 5.16.13 Increased magnetic excitation deceleration
  - 5.16.14 Slip compensation
  - 5.16.15 Encoder feedback control
  - 5.16.16 Droop control
  - 5.16.17 Speed smoothing control
- 5.17 Parameter clear / All parameter clear
- 5.18 Copying and verifying parameters on the operation panel
  - 5.18.1 Parameter copy
  - 5.18.2 Parameter verification
- 5.19 Copying and verifying parameters using a USB memory
- 5.20 Checking parameters changed from their initial values (initial value change list)
- 5.21 CC-Link IE Field Network (FR-A800-GF)
  - 5.21.1 Cyclic transmission
  - 5.21.2 I/O signal list
  - 5.21.3 Details of the remote input and output signals
  - 5.21.4 Details of the remote register
  - 5.21.5 Programming examples
  - 5.21.6 Instructions
  - 5.21.7 Troubleshooting
6 PROTECTIVE FUNCTIONS
- 6.1 Inverter fault and alarm indications
- 6.2 Reset method for the protective functions
- 6.3 Check and clear of the fault history
- 6.4 List of fault displays
- 6.5 Causes and corrective actions
- 6.6 Check first when you have a trouble
  - 6.6.1 Motor does not start
  - 6.6.2 Motor or machine is making abnormal acoustic noise
  - 6.6.3 Inverter generates abnormal noise
  - 6.6.4 Motor generates heat abnormally
  - 6.6.5 Motor rotates in the opposite direction
  - 6.6.6 Speed greatly differs from the setting
  - 6.6.7 Acceleration/deceleration is not smooth
  - 6.6.8 Speed varies during operation
  - 6.6.9 Operation mode is not changed properly
  - 6.6.10 Operation panel (FR-DU08) display is not operating
  - 6.6.11 The motor current is too large
  - 6.6.12 Speed does not accelerate
  - 6.6.13 Unable to write parameter setting
  - 6.6.14 Power lamp is not lit
7 PRECAUTIONS FOR MAINTENANCE AND INSPECTION
- 7.1 Inspection item
  - 7.1.1 Daily inspection
  - 7.1.2 Periodic inspection
  - 7.1.3 Daily and periodic inspection
  - 7.1.4 Checking the inverter and converter modules
  - 7.1.5 Cleaning
  - 7.1.6 Replacement of parts
  - 7.1.7 Removal and reinstallation of the control circuit terminal block
- 7.2 Measurement of main circuit voltages, currents, and powers
  - 7.2.1 Measurement of powers
  - 7.2.2 Measurement of voltages
  - 7.2.3 Measurement of currents
  - 7.2.4 Measurement of inverter input power factor
  - 7.2.5 Measurement of converter output voltage (between terminals P and N)
  - 7.2.6 Measurement of inverter output frequency
  - 7.2.7 Insulation resistance test using megger
  - 7.2.8 Withstand voltage test
8 SPECIFICATIONS
- 8.1 Inverter rating
- 8.2 Motor rating
  - 8.2.1 Vector control dedicated motor SF-V5RU (1500 r/ min series)
  - 8.2.2 Vector control dedicated motor SF-THY
  - 8.2.3 IPM motor MM-CF (2000 r/min series)
- 8.3 Common specifications
- 8.4 Outline dimension drawings
  - 8.4.1 Inverter outline dimension drawings
  - 8.4.2 Dedicated motor outline dimension drawings
9 APPENDIX
- 9.1 For customers replacing the conventional model with this inverter
  - 9.1.1 Replacement of the FR-A700 series
  - 9.1.2 Replacement of the FR-A500(L) series
- 9.2 International standards
- 9.3 Acquisition of type certification for ship classification standards (400 V class)
  - 9.3.1 Applicable models
  - 9.3.2 Details of type certification for standard model / Separated converter type
  - 9.3.3 Details of type certification for IP55 compatible model
  - 9.3.4 Wiring for compliance with EMC standards
- 9.4 Specification comparison between PM sensorless vector control and induction motor control
- 9.5 Parameters (functions) and instruction codes under different control methods
- 9.6 For customers using HMS network options
- 9.7 Ready bit status selection (Pr.349, N240)
REVISIONS
Instruction Supplement (BCN-C22005-957)
- 1 Emergency drive
- 2 Forward rotation output (Y30) signal and Reverserotation output (Y31) signal
Instruction Supplement (BCN-C22005-969)
- 1 Internal storage device fault (E.PE6)
- 2 Note for terminal P3 (200/400 V class only)

Mitsubishi Electric FR A800 Instruction Manual

Mitsubishi Electric FR A800 manual cover

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Mitsubishi Electric FR A800 Specification

The Mitsubishi Electric FR-A800 is an advanced frequency inverter designed for high-performance industrial applications. It features a robust design suitable for a wide range of demanding environments, delivering superior motor control and energy efficiency. The FR-A800 supports a power range from 0.4 kW to 1 MW, making it versatile for various industrial needs. Its advanced vector control technology ensures precise speed and torque control, even at low speeds, enhancing operational accuracy and reliability.

The inverter is equipped with a built-in PLC functionality, which allows for the implementation of complex control systems without the need for additional hardware. This is complemented by a user-friendly interface, featuring an easy-to-read LCD display and straightforward programming capabilities. Connectivity is a strong suit of the FR-A800, with support for a variety of communication protocols including Ethernet, Modbus TCP, and CC-Link, facilitating seamless integration into existing industrial networks.

Safety and reliability are prioritized with features such as advanced fault diagnostics, overload protection, and an emergency stop function. The FR-A800 also includes energy-saving functions such as an automatic energy optimization mode, which adjusts motor performance to minimize power consumption. The inverter's design ensures efficient heat dissipation and includes an intelligent cooling fan system that operates only when necessary, prolonging the lifespan of the device.

Additionally, the FR-A800 is engineered for easy maintenance with a detachable cooling fan and replaceable components, reducing downtime and maintenance costs. Its compact size and adaptable mounting options make it suitable for installations with space constraints. Overall, the Mitsubishi Electric FR-A800 combines advanced technology with user-centric features, offering a reliable and efficient solution for modern industrial motor control applications.

Mitsubishi Electric FR A800 F.A.Q.

How do I perform a factory reset on the Mitsubishi Electric FR A800?

To perform a factory reset on the FR A800, navigate to the parameter menu and set parameter Pr. 79 to "1". This will reset all parameters to their factory default settings. Ensure that you have recorded any custom settings before performing the reset, as these will be lost.

What are the common causes of an over-voltage fault in the FR A800?

Common causes of over-voltage faults include sudden deceleration, a power supply issue, or incorrect parameter settings. Check the power supply for stability, ensure that the deceleration time is adequate, and verify parameter settings related to voltage thresholds.

How can I connect the FR A800 to a PLC for remote control?

To connect the FR A800 to a PLC, use the built-in RS-485 or Ethernet communication ports. Configure the communication parameters (such as baud rate, parity, and stop bits) to match those of the PLC. Use the appropriate communication protocol, such as Modbus, to establish a connection.

What maintenance practices should be followed to ensure optimal performance of the FR A800?

Regularly inspect and clean the cooling fans, heat sinks, and air filters to prevent overheating. Check electrical connections for tightness and signs of wear. Periodically update firmware and backup parameter settings. Conduct visual inspections for signs of damage or wear.

How do I troubleshoot a communication error on the FR A800?

Check the communication cable connections and ensure they are secure. Verify that the communication settings, such as baud rate and parity, match those of the connected device. Inspect the cable for damage and replace if necessary. Review error codes in the manual for additional guidance.

Can the FR A800 operate multiple motors simultaneously?

Yes, the FR A800 can control multiple motors through the use of a multi-motor control configuration. You need to set up the appropriate parameters for each motor and ensure that the total current does not exceed the drive's rating.

What should I do if the FR A800 drive does not start?

First, check that the power supply is connected and the main circuit breaker is on. Verify that all safety interlocks and external devices are in the correct state. Check for any active alarm or fault codes displayed on the drive and refer to the manual for troubleshooting steps.

How do I set up the PID control on the FR A800?

To set up PID control, access the parameter settings and configure the parameters related to PID (such as Pr.128, Pr.129, and Pr.130 for PID gain settings). Input the desired setpoint and feedback source, and adjust the parameters for optimal control. Refer to the manual for detailed instructions.

What is the recommended environment for installing the FR A800 drive?

Install the FR A800 in a clean, dry, and well-ventilated area. Avoid locations with excessive dust, corrosive gases, or extreme temperatures. Ensure there is adequate clearance around the drive for cooling and maintenance access.

How can I extend the lifespan of the FR A800?

To extend the lifespan of the FR A800, ensure regular maintenance, such as cleaning and inspection. Operate the drive within specified environmental and electrical conditions. Avoid frequent start/stop cycles and ensure proper cooling. Use surge protection to prevent electrical damage.