Contents

FR-A860 (600V CLASS SPECIFICATION INVERTER) INSTRUCTION MANUAL (DETAILED)
Safety Instructions
CONTENTS
1 INTRODUCTION
- 1.1 Product checking and accessories
- 1.2 Component names
- 1.3 Operation steps
- 1.4 About the 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 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 Terminal layout of the main circuit terminals, wiring of power supply and the motor
  - 2.5.3 Applicable cables and the 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
- 2.7 Communication connectors and terminals
  - 2.7.1 PU connector
  - 2.7.2 USB connector
  - 2.7.3 RS-485 terminal block
- 2.8 Connection of 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 other than the provided brake resistor
  - 2.10.2 Connection of the DC reactor
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 Countermeasures against inverter-generated EMI
- 3.2 Power supply harmonics
- 3.3 Installation of a reactor
- 3.4 Power-OFF and magnetic contactor (MC)
- 3.5 Countermeasures against deterioration of the 600 V class motor insulation
- 3.6 Checklist before starting operation
- 3.7 Failsafe system which uses the inverter
4 BASIC OPERATION
- 4.1 Frequently-used parameters (simple mode parameters)
  - 4.1.1 Simple mode parameter list
- 4.2 Basic operation procedure (PU operation)
  - 4.2.1 Operating at a set frequency (example: operating at 30 Hz)
  - 4.2.2 Setting the frequency by switches (multi-speed setting)
  - 4.2.3 Setting the frequency with analog signals (voltage input)
  - 4.2.4 Using an analog signal (current input) to give a frequency command
- 4.3 Basic operation procedure (External operation)
  - 4.3.1 Using the frequency set by the operation panel
  - 4.3.2 Setting the frequency by switches (multi-speed setting) (Pr.4 to Pr.6)
  - 4.3.3 Setting the frequency with analog signals (voltage input)
  - 4.3.4 Changing the frequency (60 Hz, initial value) at the maximum voltage input (5 V, initial value)
  - 4.3.5 Using an analog signal (current input) to give a frequency command
  - 4.3.6 Changing the frequency (60 Hz, initial value) at the maximum current input (at 20 mA, initial value)
- 4.4 Basic operation procedure (JOG operation)
  - 4.4.1 Performing JOG operation using external signals
  - 4.4.2 JOG operation from the operation panel
5 PARAMETERS
- 5.1 Parameter List
  - 5.1.1 Parameter list (by parameter number)
  - 5.1.2 Parameter list (by function group)
- 5.2 Control method
  - 5.2.1 Vector control and Real sensorless vector control
  - 5.2.2 Changing the control method
  - 5.2.3 Selecting the Advanced magnetic flux vector control
  - 5.2.4 Selecting the PM sensorless vector control
- 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 and 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
  - 5.5.1 About position control
  - 5.5.2 Setting procedure of vector control (position control)
  - 5.5.3 Simple positioning function by parameters
  - 5.5.4 Position control by the FR-A8AL pulse train input
  - 5.5.5 Position control by inverter pulse train input
  - 5.5.6 Clear signal selection
  - 5.5.7 Pulse monitor
  - 5.5.8 Electronic gear setting
  - 5.5.9 Position adjustment parameter settings
  - 5.5.10 Position control gain adjustment
  - 5.5.11 Troubleshooting in position control
- 5.6 Real sensorless vector control, vector control, PM sensorless vector control adjustment
  - 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 Extended direct setting
  - 5.7.7 Resetting USB host errors
  - 5.7.8 Multiple rating setting
  - 5.7.9 Parameter write selection
  - 5.7.10 Password function
  - 5.7.11 Free parameter
  - 5.7.12 Setting multiple parameters as a batch
  - 5.7.13 Extended parameter display and user group function
  - 5.7.14 Parameter copy alarm release
  - 5.7.15 PWM carrier frequency and Soft-PWM control
  - 5.7.16 Inverter parts life display
  - 5.7.17 Maintenance timer alarm
  - 5.7.18 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
  - 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 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 via 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 Initiating a protective function
  - 5.10.6 I/O phase loss protection selection
  - 5.10.7 Retry function
  - 5.10.8 Emergency drive
  - 5.10.9 Limiting the output frequency (maximum/ minimum frequency)
  - 5.10.10 Avoiding the mechanical 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) Monitor display and monitor output signal
  - 5.11.1 Speed display and rotations per minute setting
  - 5.11.2 Monitor indicator selection using operation panel or via communication
  - 5.11.3 Monitor display selection for terminals FM and AM
  - 5.11.4 Adjustment of terminal FM and terminal AM
  - 5.11.5 Energy saving monitor
  - 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
  - 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 of output power
  - 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 Analog input responsiveness and noise elimination
  - 5.12.5 Frequency setting voltage (current) bias and gain
  - 5.12.6 Bias and gain for torque (magnetic flux) and set voltage (current)
  - 5.12.7 Checking of current input on analog input terminal
  - 5.12.8 Input terminal function selection
  - 5.12.9 Inverter output shutoff signal
  - 5.12.10 External fault input signal
  - 5.12.11 Selecting operation condition of the second function selection signal (RT) and the third function selection signal (X9)
- 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 constants 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 the 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 Offline auto tuning for a frequency search
  - 5.14.16 Power failure time deceleration-to-stop function
  - 5.14.17 PLC function
  - 5.14.18 Trace function
- 5.15 (N) Operation via communication and its settings
  - 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 USB device communication
  - 5.15.8 Automatic connection with GOT
  - 5.15.9 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 DC injection brake, zero speed control, and servo lock
  - 5.16.8 Output stop function
  - 5.16.9 Start signal operation selection / stop selection
  - 5.16.10 Regenerative brake selection and DC feeding mode
  - 5.16.11 Regeneration avoidance function
  - 5.16.12 Increased magnetic excitation deceleration
  - 5.16.13 Slip compensation
  - 5.16.14 Encoder feedback control
  - 5.16.15 Droop control
  - 5.16.16 Speed smoothing control
6 PROTECTIVE FUNCTIONS
- 6.1 Inverter fault and alarm indications
- 6.2 Reset method for the protective functions
- 6.3 The list of fault displays
- 6.4 Causes and corrective actions
- 6.5 Check first when you have a trouble
  - 6.5.1 Motor does not start
  - 6.5.2 Motor or machine is making abnormal acoustic noise
  - 6.5.3 Inverter generates abnormal noise
  - 6.5.4 Motor generates heat abnormally
  - 6.5.5 Motor rotates in the opposite direction
  - 6.5.6 Speed greatly differs from the setting
  - 6.5.7 Acceleration/deceleration is not smooth
  - 6.5.8 Speed varies during operation
  - 6.5.9 Operation mode is not changed properly
  - 6.5.10 Operation panel display is not operating
  - 6.5.11 Motor current is too large
  - 6.5.12 Speed does not accelerate
  - 6.5.13 Unable to write parameter setting
  - 6.5.14 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 module and the converter module
  - 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 (across terminals P and N)
  - 7.2.6 Measurement of inverter output frequency
  - 7.2.7 Insulation resistance test using megger
  - 7.2.8 Pressure test
8 SPECIFICATIONS
- 8.1 Inverter rating
- 8.2 Common specifications
- 8.3 Outline dimension drawings
  - 8.3.1 Inverter outline dimension drawings
APPENDIX
- Appendix 1 For customers replacing the conventional model with this inverter
  - Appendix 1.1 Replacement of the FR-A700 series
- Appendix 2 International standards
- Appendix 3 Specification comparison between PM sensorless vector control and induction motor control
- Appendix 4 Parameters (functions) and instruction codes under different control methods
- Appendix 5 For customers using HMS network options
- Appendix 6 Ready bit status selection (Pr.349, N240)
REVISIONS
Instruction Supplement (BCN-C22005-971)
- 1 Internal storage device fault (E.PE6)

Mitsubishi Electric FR A800, FR A860 Instruction Manual

Mitsubishi Electric FR A800, FR A860 manual cover

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Mitsubishi Electric FR A800, FR A860 Specification

The Mitsubishi Electric FR-A800 and FR-A860 series are advanced frequency inverters designed for optimized motor control and energy efficiency in industrial applications. Both series are engineered to deliver high performance, reliability, and flexibility, catering to a wide range of industrial needs.

The FR-A800 series is characterized by its powerful and versatile capabilities, supporting a wide voltage range and offering motor control options for both induction and permanent magnet motors. It features an integrated PLC function, allowing for customizable automation solutions, and provides a high starting torque to ensure efficient operation even under demanding conditions. The series incorporates advanced auto-tuning functions and offers various communication options, including Ethernet and RS485, to facilitate easy integration into existing systems. The FR-A800 also emphasizes energy efficiency with its built-in energy-saving functions and regenerative braking capabilities.

The FR-A860 series, on the other hand, is designed for specialized applications requiring higher precision and performance. This series is equipped with a high-speed processor, enabling rapid response and superior control for demanding tasks. It supports advanced vector control and delivers exceptional torque accuracy, making it suitable for applications such as elevators and cranes. The FR-A860 also includes enhanced safety features, such as safe torque off (STO) and other safety protocols, to ensure secure operation in critical environments.

Both the FR-A800 and FR-A860 series are built with user-friendly interfaces and robust construction to withstand harsh industrial environments. They offer extensive diagnostic and monitoring capabilities to aid in maintenance and troubleshooting. Overall, these inverters represent Mitsubishi Electric's commitment to innovation and quality in industrial motor control solutions.

Mitsubishi Electric FR A800, FR A860 F.A.Q.

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

To perform a factory reset on the FR A800 inverter, navigate to the parameter reset settings and set the appropriate reset parameter (typically Pr. 99) to reset the device to its default factory settings.

What is the procedure to connect the FR A800 inverter to a PLC using Modbus RTU?

To connect the FR A800 to a PLC using Modbus RTU, configure the communication parameters such as baud rate and parity, and set the inverter as a Modbus slave. Connect the RS485 communication cable from the PLC to the inverter's communication terminal.

How can I troubleshoot an overcurrent fault on the FR A860 inverter?

Check the motor connections and ensure they are secure. Verify that the motor and inverter ratings match and inspect for any short circuits in the motor windings. Adjust the acceleration and deceleration times if needed.

What maintenance steps should be regularly performed on the FR A800 inverter?

Regularly inspect and clean the cooling fan and heat sink for dust accumulation. Check for loose connections and ensure the environmental conditions around the inverter remain within specified limits. Perform routine checks on parameter settings.

How can I change the frequency setting on the FR A800 inverter?

Access the operation panel, navigate to the frequency setting parameter (usually Pr. 1), and adjust the frequency value as required. Ensure that the inverter is in the correct mode to accept frequency changes.

What should I do if the FR A860 inverter is not starting the motor?

Check that the run command is correctly issued and that the control circuit connections are intact. Verify that the motor is not in a fault state and that all protective devices are reset.

How do I configure PID control on the FR A800 inverter?

Enable the PID function by setting the appropriate parameter and configure the PID setpoint and feedback source. Adjust the PID gain values to achieve the desired control response.

Can the FR A860 inverter be used with a remote keypad?

Yes, the FR A860 inverter can be used with a remote keypad. Connect the keypad to the inverter's communication port and configure the inverter to accept commands from the remote keypad.

How do I update the firmware on a Mitsubishi Electric FR A800 inverter?

Obtain the latest firmware version from Mitsubishi Electric's official website. Use the manufacturer's recommended software and follow the instructions to upload the firmware to the inverter via a USB or communication interface.

What are the common causes of overheating in the FR A860 inverter?

Common causes include inadequate ventilation, excessive ambient temperature, and blocked cooling paths. Ensure the cooling fan is operational and clear any obstructions around the heat sink.