FR A700 INSTRUCTION MANUAL (BASIC) FR A700 INSTRUCTION MANUAL (BASIC) FR A720 0 4K to 90K FR A740 0 4K to 500K INVERTER IB(NA) 0600225ENG C(0509)MEE Printed in Japan Specifications subject to change w[.]
Peripheral devices
Check the motor capacity of the inverter you purchased Appropriate peripheral devices must be selected according to the capacity Refer to the following list and prepare appropriate peripheral devices:
Breaker Selection *2,4 Input Side Magnetic Contactor *3
Reactor connection Reactor connection without with without with
*1 Selections for use of the Mitsubishi 4-pole standard motor with power supply voltage of 200VAC 50Hz.
*2 Select the MCCB according to the inverter power supply capacity
Install one MCCB per inverter.
For installations in the United States or Canada, use the fuse certified by the UL and cUL.
A magnetic contactor is selected based on the AC-1 classification, ensuring suitability for standard motor control applications It boasts an impressive electrical durability of up to 500,000 operating cycles, highlighting its long-term reliability When used specifically for emergency stop functions during motor operation, the magnetic contactor's electrical durability is rated at 25,000 cycles, underscoring its robustness in safety-critical scenarios.
When performing an emergency stop with the motor controller (MC) during motor operation or operating on the motor side during commercial power supply, it is essential to choose an MC rated for class AC-3 current corresponding to the motor's rated current, ensuring safe and reliable system performance.
When the breaker on the inverter's primary side trips, it is essential to check for wiring faults such as short circuits and inspect the internal components of the inverter for damage Identifying the root cause of the trip allows for targeted troubleshooting; once the issue is resolved, the breaker can be reset and powered on safely Regular maintenance and prompt diagnosis help prevent inverter failures and ensure reliable energy conversion.
Breaker Selection *2,4 Input Side Magnetic Contactor *3
Reactor connection Reactor connection without with without with
*1 Selections for use of the Mitsubishi 4-pole standard motor with power supply voltage of 400VAC 50Hz.
*2 Select the MCCB according to the inverter power supply capacity
Install one MCCB per inverter.
For installations in the United States or Canada, use the fuse certified by the UL and cUL.
The magnetic contactor is selected based on the AC-1 electrical contactor class, ensuring reliable operation for standard switching applications It boasts an impressive electrical durability of up to 500,000 switching cycles, highlighting its long-lasting performance In emergency stop scenarios during motor operation, the magnetic contactor can endure up to 25 switching cycles, providing essential safety and reliability This durable and dependable component is ideal for controlling motors in various industrial applications.
For emergency stop situations during motor operation or when using the motor side during commercial power supply, select an MC with a class AC-3 rated current matching the motor's rated current to ensure safe and reliable performance.
When the breaker on the inverter primary side trips, it’s essential to inspect for wiring faults such as short circuits and internal inverter component damage Identifying the root cause of the trip allows you to effectively eliminate the issue by repairing or replacing faulty parts Once the cause is addressed, reset and power on the breaker to ensure safe and proper inverter operation.
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Method of removal and reinstallation of the front cover
•Removal of the operation panel
1) Loosen the two screws on the operation panel.
(These screws cannot be removed.)
2) Push the left and right hooks of the operation panel and pull the operation panel toward you to remove.
When reinstalling the operation panel, insert it straight to reinstall securely and tighten the fixed screws of the operation panel.
1) Loosen the installation screws of the front cover.
2) Pull the front cover toward you to remove by pushing an installation hook using left fixed hooks as supports.
1) Insert the two fixed hooks on the left side of the front cover into the sockets of the inverter.
2) Using the fixed hooks as supports, securely press the front cover against the inverter.
(Although installation can be done with the operation panel mounted, make sure that a connector is securely fixed.)
3) Tighten the installation screws and fix the front cover.
FR-A720-30K or more, FR-A740-30K or more
1) Remove installation screws on the front cover 1 to remove the front cover 1.
2) Loosen the installation screws of the front cover 2.
3) Pull the front cover 2 toward you to remove by pushing an installation hook on the right side using left fixed hooks as supports.
1) Insert the two fixed hooks on the left side of the front cover 2 into the sockets of the inverter.
Securely press the front cover 2 against the inverter using the fixed hooks as supports to ensure proper installation While installation with the operation panel mounted is possible, it is essential to confirm that the connector is firmly fixed for safe operation.
3) Fix the front cover 2 with the installation screws.
4) Fix the front cover 1 with the installation screws.
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Installation of the inverter and instructions
• Install the inverter under the following conditions.
The inverter is made up of precise mechanical and electronic components, and it is crucial to avoid installing or handling it under certain conditions Improper handling or installation in unsuitable conditions can lead to operational faults or equipment failure Ensuring proper installation and handling according to manufacturer guidelines is essential for optimal performance and safety.
For replacing the cooling fan of the FR-A740-160K or more, 30cm of space is necessary in front of the inverter.
Refer to page 153 for fan replacement.
⋅ When encasing multiple inverters, install them in parallel as a cooling measure
* Refer to the clearances below.
Fix six positions for the FR-A740- * 160K to 355K and fix eight positions for the FR-A740-400K to 500K.
Leave enough clearances and take cooling measures.
10cm or more 10cm or more
*1cm or more for 3.7K or less
Direct sunlight High temperature, high humidity
Oil mist, flammable gas, corrosive gas, fluff, dust, etc.
Transportation by holding the front cover
Vertical mounting (When installing two or more inverters, install them in parallel.)
* 2.9m/s 2 or more for the 160K or more
Wiring
*5 Terminal input specifications can be changed by analog input specifications
STF STR STOP RH RM RL JOG RT MRS RES AU CS SD
RUN SU IPF OL FU SE
*11 FM terminal can be used for pulse train output of open collector output using Pr.291
*9.The FR-A720-0.4K and 0.75K are not provided with the EMC filter ON/OFF connector (Always on)
Remove the jumper across terminal PR-PX when connecting a brake resistor.
(0.4K to 7.5K) Terminal PR is provided for the 0.4K to 22K. Install a thermal relay to prevent an overheat and burnout of the brake resistor.
*3 JOG terminal can be used as pulse train input terminal.
Three-phase AC power supply
EMC filter ON/OFF connecter
24VDC power supply (Common for external power supply transistor) selected
Control input signals (No voltage input allowed)
Forward rotation start Reverse rotation start
Terminal functions vary with the input terminal assignment ( Pr 178 to Pr 189 )
Jog mode Second function selection
Selection of automatic restart after instantaneous power failure Contact input common
(+) (-) (0 to 10VDC) Analog signal output
Moving-coil type 1mA full-scale
Open collector output common Sink/source common Frequency detection
Terminal functions vary with the output terminal assignment ( Pr 190 to Pr 194)
Open collector output Relay output 2
Terminal functions vary with the output terminal assignment ( Pr 195, Pr 196)
*4 AU terminal can be used as PTC input terminal.
*2 To supply power to the control circuit separately, remove the jumper across
*10 It is not necessary when calibrating the indicator from the operation panel.
Be sure to connect the DC reactor supplied with the 75K or more.
When a DC reactor is connected to the 55K or less, remove the jumper across P1-P/+.
*7 A CN8 connector is provided with the 75K or more.
(Refer to the Instruction Manual (applied))
(Refer to the Instruction Manual (applied))
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The inverter is equipped with a built-in EMC filter.
Effective for reduction of air-propagated noise on the input side of the inverter.
The EMC filter is factory-set to disable (OFF).
To enable it, fit the EMC filter ON/OFF connector to the ON position.
The FR-A720-0.4K and 0.75K are not provided with the EMC filter ON/OFF connector (The EMC filter is always valid.)
Before removing the front cover of the inverter, ensure that the operation panel indicator is off and wait at least 10 minutes after turning off the power supply Additionally, verify that there is no residual voltage using a tester or similar device to ensure safety (Refer to page 5 for detailed instructions.)
When disconnecting the connector, it is important to push the fixing tab and pull the connector straight to avoid pulling on the cable or forcing the connector, which could cause damage Similarly, during installation, ensure the fixing tab is securely engaged to maintain a proper connection and prevent loose contacts Proper handling of connectors helps ensure reliable performance and extends component lifespan.
If it is difficult to disconnect the connector, use a pair of long-nose pliers, etc.
⋅ Fit the connector to either ON or OFF.
⋅ Enabling (turning on) the EMC filter increase leakage current (Refer to Instruction Manual (applied))
While power is on or when the inverter is running, do not open the front cover Otherwise you may get an electric shock.
EMC filter OFF EMC filter ON EMC filter OFF EMC filter ON EMC filter OFF EMC filter ON
(initial setting) (initial setting) (initial setting)
EMC filter ON/OFF connector
FR-A720-30K or more FR-A740-30K or more
Disengage connector fixing tab With tab disengaged, pull off connector straight.
2.4.3 Specification of main circuit terminal
2.4.4 Terminal arrangement of the main circuit terminal, power supply and the motor wiring
Connect to the commercial power supply.
Keep these terminals open when using the high power factor converter (FR-HC and MT-HC) or power regeneration common converter (FR-CV).
U, V, W Inverter output Connect a three-phase squirrel-cage motor.
Power supply for control circuit
Connect the device to the AC power supply terminals R/L1 and S/L2 To maintain the alarm display and output, or when using high power factor converters (FR-HC and MT-HC) or the power regeneration converter (FR-CV), remove the jumpers from terminals R/L1-R1/L11 and S/L2-S1/L21 and supply external power to these terminals.
To prevent damage to the inverter, always ensure that the control circuit power supply (R1/L11, S1/L21) is turned off before switching off the main circuit power (R/L1, S/L2, T/L3) It is essential to configure the circuit so that when the control circuit power is disconnected, the main circuit power is also simultaneously turned off, avoiding potential inverter damage.
15K or less : 60VA, 18.5K or more : 80VA
Remove the jumper from terminals PR-PX (7.5K or less) and connect an optional brake resistor (FR-ABR) across terminals P/+-PR.
For the 22K or less, connecting the resistor further provides regenerative braking power.
Connect the brake unit (FR-BU, BU, and MT-BU5) to ensure efficient braking performance; integrate the power regeneration common converter (FR-CV) to optimize energy recovery; utilize high power factor converters (FR-HC and MT-HC) for improved electrical efficiency; and incorporate the power regeneration converter (MT-RC) to enhance overall energy savings and system sustainability.
For the 55K or less, remove the jumper across terminals P/+ - P1 and connect the DC reactor (For the 75K or more, a DC reactor is supplied as standard.)
PR, PX Built-in brake circuit connection
When the jumper is connected across terminals PX-PR (initial status), the built-in brake circuit is valid (Provided for the 7.5K or less.)
Earth (ground) For earthing (grounding) the inverter chassis Must be earthed
CAUTION ã When connecting a dedicated brake resistor (FR-ABR) and brake unit (FR-BU, BU) remove jumpers across terminals PR-PX (7.5K or less) For details, refer to Instruction Manual (applied).
INS TAL LA TION AND WIRING
* Screw size of terminal R1/L11, S1/L21, PR, and PX is M4.
Power supply Screw size (M12) (for option)
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Ensure power supply cables are correctly connected to R/L1, S/L2, and T/L3 outlets; never connect the power cables to the inverter's U, V, W terminals, as this will cause damage The phase sequence does not need to match during connection When wiring the motor, connect it to U, V, W; activating the forward rotation switch will rotate the motor counterclockwise when viewed from the shaft For wiring the main circuit conductor of the FR-F740-220K or higher models, tighten the nut from the right side of the conductor and ensure wires are placed on both sides when using two wires, following the provided wiring diagram; always use the bolts and nuts supplied with the inverter for secure connections.
• Handling of the wiring cover
For the hook of the wiring cover, cut off the necessary parts using a pair of long-nose pliers etc.
Ensure that the same number of lugs are cut off as the wires being connected If any sections without wires are cut off by 10mm or more, the protective structure (JEM1030) becomes an open type, potentially compromising safety and compliance Properly matching the lugs to wires and avoiding unnecessary cuts helps maintain the integrity of the protective structure.
INS TAL LA TION AND WIRING
(1) Cable sizes etc., of the main control circuit terminals and earth (ground) terminals
Select the recommended cable size to ensure that a voltage drop will be 2% max.
Long wiring distances between the inverter and motor can lead to significant voltage drops in the main circuit cable This voltage drop reduces the motor’s torque, particularly at low frequency outputs, potentially impacting overall performance Proper cable sizing and minimizing wiring length are essential to ensure optimal motor operation and maintain consistent torque levels.
The following table indicates a selection example for the wiring length of 20m.
200V class (when input power supply is 220V)
Cable Sizes HIV, etc (mm 2 ) *1 AWG/MCM *2 PVC, etc (mm 2 ) *3
For cable lengths of 55 meters or less, use the same cable size as specified for HIV cables (600V class 2 vinyl-insulated cables), which have a maximum continuous permissible temperature of 75°C This guideline assumes an ambient temperature of 50°C or lower and a wiring distance of 20 meters or less, ensuring safe and effective electrical performance within these parameters.
For electrical installations with loads of 75K or higher, it is recommended to use cables such as LMFC (heat-resistant flexible cross-linked polyethylene insulated cable) that can handle a maximum continuous temperature of 90°C This recommendation assumes an ambient temperature of 50°C or lower and that the wiring is installed within an enclosure to ensure safety and optimal performance.
The recommended cable size should be based on the THHW cable, which has a continuous maximum permissible temperature of 75°C This recommendation assumes an ambient temperature of 40°C or below and a wiring distance of 20 meters or less Proper cable sizing under these conditions ensures safety and optimal electrical performance.
(Selection example for use mainly in the United States.)
*3 For the 15K or less, the recommended cable size is that of the cable (PVC cable) with continuous maximum permissible temperature of 70°C.
Assumes that the ambient temperature is 40°C or less and the wiring distance is 20m or less.
For the 18.5K or more, the recommended cable size is that of the cable (XLPE cable) with continuous maximum permissible temperature of 90°C.
Assumes that the ambient temperature is 40°C or less and wiring is performed in an enclosure
(Selection example for use mainly in Europe.)
The terminal screw size indicates the appropriate size for connections to R/L1, S/L2, T/L3, U, V, W, and the grounding screw For models with 4.0K ratings, the screw sizes are standardized, while for 5.5K and 7.5K models, the screw sizes differ (R1/L11, S1/L21, PR, PX) Additionally, for capacities of 18.5K and above, the screw sizes are adjusted accordingly, with specific sizes for each terminal and grounding connection Proper selection of screw sizes ensures reliable and secure electrical connections across different inverter ratings.
400V class (when input power supply is 440V)
Cable Sizes HIV, etc (mm 2 ) *1 AWG/MCM *2 PVC, etc (mm 2 ) *3
FR-A740-220K M12/M10 24.5 100-12 100-12 2×100 2×100 2×100 60 2×4/0 2×4/0 2×95 2×95 95 FR-A740-250K M12/M10 24.5 100-12 100-12 2×100 2×100 2×125 60 2×4/0 2×4/0 2×95 2×95 95 FR-A740-280K M12/M10 24.5 150-12 150-12 2×125 2×125 2×125 60 2×250 2×250 2×120 2×120 120 FR-A740-315K M12/M10 24.5 150-12 150-12 2×150 2×150 2×150 100 2×300 2×300 2×150 2×150 150 FR-A740-355K M12/M10 24.5 C2-200 C2-200 2×200 2×200 2×200 100 2×350 2×350 2×185 2×185 2×95 FR-A740-400K M12/M10 24.5 C2-200 C2-200 2×200 2×200 2×200 100 2×400 2×400 2×185 2×185 2×95 FR-A740-450K M12/M10 24.5 C2-250 C2-200 2×250 2×250 2×250 100 2×500 2×500 2×240 2×240 2×120 FR-A740-500K M12/M10 24.5 C2-200 C2-250 3×200 2×250 3×200 2×100 2×500 2×500 2×240 2×240 2×120
For electrical installations supporting loads of 55K or less, the appropriate cable size corresponds to the specifications of the chosen cable, such as HIV cable (600V class 2 vinyl-insulated cable), which has a maximum continuous permissible temperature of 75°C It is important to assume that the ambient temperature does not exceed 50°C and that the wiring distance is 20 meters or less to ensure safe and compliant electrical connections Proper cable selection under these conditions guarantees reliable performance and adherence to safety standards.
For electrical installations with loads of 75K or more, it is recommended to use cables such as LMFC (heat-resistant flexible cross-linked polyethylene insulated cable) that have a continuous maximum permissible temperature of 90°C This guideline assumes an ambient temperature of 50°C or less and that the wiring is installed within an enclosure to ensure safety and optimal performance Proper cable sizing according to these specifications helps maintain system reliability and compliance with safety standards.
For electrical installations involving loads of 45K or less, it is recommended to use THHW cables with a maximum permissible temperature of 75°C This guideline assumes an ambient temperature of 40°C or lower and a wiring distance of 20 meters or less, ensuring safe and efficient electrical performance.
Power-off and magnetic contactor (MC)
(1) Inverter input side magnetic contactor (MC)
On the inverter input side, it is recommended to provide an MC for the following purposes.
( Refer to page 3 for selection.)
1) To release the inverter from the power supply when the inverter's protective function is activated or when the drive is not functioning (e.g emergency stop operation)
To prevent overheating and burnout of the electrical-discharge resistor during cycle or heavy-duty operations with an optional brake resistor, it is essential to ensure that the regenerative brake transistor is not damaged This can occur if the electrical-discharge resistor lacks sufficient heat capacity or if there is an excessive regenerative brake duty Proper management of regenerative braking and adequate resistor specifications are crucial for maintaining system reliability and avoiding component failure.
2) To prevent any accident due to an automatic restart at restoration of power after an inverter stop made by a power failure
3) To reset the inverter for an extended period of time
The inverter's control power supply is always active, consuming minimal power during operation To save energy during extended periods of inactivity, turning off the inverter completely is recommended, as this helps reduce unnecessary power consumption Properly powering down the inverter ensures efficient energy use and prolongs device lifespan.
4) To separate the inverter from the power supply to ensure safe maintenance and inspection work
For emergency stopping during normal operation, select the JEM1038-AC3MC class MC for the inverter's input side current The inverter's input side MC is specifically designed for this purpose, ensuring reliable and safe operation when halting machinery quickly Proper selection of the inverter input side MC enhances safety and performance during emergency stop scenarios.
(2) Handling of the inverter output side magnetic contactor
Switch the magnetic contactor between the inverter and motor only when both the inverter and motor are at a stop.
Turning on the magnetic contactor (MC) while the inverter is operational can trigger overcurrent protection and other safety features To switch to a commercial power supply using an MC, it is recommended to follow the inverter's specific procedures, such as performing the power supply switch-over operation (Pr 135 to Pr 139) outlined in the Instruction Manual Properly managing the transition between inverter and commercial power supply ensures safe and reliable operation of the system.
Repeated inrush currents during power on can significantly shorten the lifespan of the converter circuit, which typically has a switching life of approximately 1,000,000 cycles; for 200V class models such as 37K or higher, the switching life is around 500,000 cycles To prevent this, frequent starting and stopping of the motor controller (MC) should be avoided Instead, control the inverter’s start/stop function by turning the inverter's start control terminals (STF, STR) on or off to ensure smooth operation and extend the lifespan of the inverter.
• Inverter start/stop circuit example
As shown on the left, always use the start signal (ON or OFF across terminals STF or STR-SD) to make a start or stop.
*1 When the power supply is 400V class, install a step-down transformer.
Connect the power supply terminals R1/L11 and S1/L21 of the control circuit to the primary side of the motor controller (MC) to activate an alarm signal when the inverter's protective circuit is triggered Ensure that jumpers across the terminals are removed during this process for proper alarm operation.
L1-R1/L11 and S/L2-S1/L21 (Refer to page 18 for removal of the jumper.)
Precautions for use of the inverter
The FR-A700 series is a highly reliable product, but incorrect peripheral circuit making or operation/handling method may shorten the product life or damage the product.
Before starting operation, always recheck the following items.
(1) Use crimping terminals with insulation sleeve to wire the power supply and motor.
(2) Application of power to the output terminals (U, V, W) of the inverter will damage the inverter Never perform such wiring.
(3) After wiring, wire offcuts must not be left in the inverter.
Wire offcuts can lead to alarms, malfunctions, or failures in your inverter To prevent this, always keep the inverter clean and free of debris When drilling mounting holes in enclosures or other components, ensure that chips and foreign matter do not enter the inverter, maintaining optimal performance and longevity.
(4) Use cables of the size to make a voltage drop 2% maximum.
Long wiring distances between the inverter and motor can lead to significant voltage drops along the main circuit cable This voltage drop reduces the effective voltage supplied to the motor, especially at low frequencies, resulting in decreased motor torque Properly managing cable length and selecting suitable wiring can help maintain optimal motor performance and prevent torque loss.
Refer to page 15 for the recommended cable sizes.
(5) The overall wiring length should be 500m maximum.
(The wiring length should be 100m maximum for vector control.)
For long-distance wiring, the fast-response current limit function may be diminished, increasing the risk of equipment connected to the inverter output malfunctioning or becoming faulty due to charging current caused by wiring stray capacitance It is essential to consider the total wiring length to ensure system stability and optimal performance (Refer to page 17.)
The main circuit of the inverter contains high-frequency components that can interfere with nearby communication devices like AM radios To reduce this interference, it is essential to enable the EMC filter, which helps minimize electromagnetic disturbances and ensure smooth operation of surrounding electronic equipment.
Avoid installing power factor correction capacitors, surge suppressors, or radio noise filters on the inverter output side, as this can lead to inverter trips or damage to these devices If such equipment is present, it must be removed immediately to ensure proper inverter operation and prevent equipment failure.
Before beginning any wiring or maintenance work after the inverter has been operated, ensure safety by waiting at least 10 minutes after switching off the power supply Use a tester to verify that there is no residual voltage, as the capacitor remains charged with high voltage for a period after power removal, posing a significant electrical hazard.
A short circuit or earth (ground) fault on the inverter output side can damage inverter modules It is essential to thoroughly check the insulation resistance of the circuit before operating the inverter, as repeated short circuits caused by peripheral circuit issues or ground faults due to wiring problems or degraded motor insulation may lead to inverter damage Prior to power-on, ensure the insulation between the inverter output to earth (ground) and between phases is properly tested Special care should be taken when using older motors or operating in harsh environments; verifying motor insulation resistance is particularly important to prevent inverter damage.
(10) Do not use the inverter input side magnetic contactor to start/stop the inverter.
Always use the start signal (ON/OFF of STF and STR signals) to start/stop the inverter
(11) Across P/+ and PR terminals, connect only an external regenerative brake discharge resistor.
Do not connect a mechanical brake.
INST ALLA TION AND WIRING
To prevent the machine from restarting automatically after a power failure, install a magnetic contactor on the inverter's input side Additionally, establish a control sequence that ensures the start signal is not activated immediately following power restoration, maintaining safe and controlled operation.
If the start signal (start switch) remains on after a power failure, the inverter will automatically restart as soon as the power is restored.
Frequent start/stop operations with an inverter cause repeated temperature fluctuations in the transistor elements due to continuous high current flow, leading to thermal fatigue and shortened component lifespan To enhance inverter durability, it is essential to reduce current during locked conditions and startup, as thermal fatigue is directly related to current levels While decreasing current can prolong the inverter’s life, it may also result in insufficient torque and startup issues Therefore, selecting an inverter with sufficient current capacity—preferably up to two sizes larger—is recommended to ensure reliable operation and extended lifespan.
(16) Make sure that the specifications and rating match the system requirements.
A motor equipped with an encoder is essential for effective vector control, as it allows for precise monitoring of rotor position and speed The encoder should be directly connected to the shaft of a backlash-free motor to ensure accurate feedback and optimal performance Conversely, in real sensorless vector control systems, an encoder is not required, as they rely on advanced algorithms to estimate rotor position without additional sensors.