Mitsubishi Electric 800 Series User manual

INVERTER
FR-E800(-E)
INSTRUCTION MANUAL
(FUNCTIONAL SAFETY)
CONTENTS
1. GENERAL DESCRIPTION ............................................ 3
2. INSTALLATION AND WIRING...................................... 4
3. EXAMPLE OF SAFETY SYSTEM CONFIGURATION .... 8
4. TEST AND CHECKING FAILURE ............................... 11
5. SAFETY PARAMETERS OF FR-E800(-E).................... 12

2
Compliance with the EU Machinery Directive – Functional Safety
To achieve functional safety, any work on the product such as wiring and inspections must be performed according to the
Instruction Manual by technicians who took a safety standard training.
WARNING
Any misuse of safety function could lead to personal injury or death, property damage, or economic
loss. To ensure that the system complies fully with requirement of safety, make a system-level risk
assessment. Mitsubishi Electric cannot assume responsibility for any system to comply with safety
directive.
To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged
before performing any work on the inverter. Measure the DC bus voltage between the terminals P/+
and N/- or at test points (refer to your inverter’s Instruction Manual for locations and discharging
time). The voltage must be zero.
The safety stop function do not isolate electrically between the inverter and the motor. To avoid an
electric shock hazard, verify that the voltage on the bus capacitors has discharged before wiring or
inspection of the motor. Measure the DC bus voltage between the terminals P/+ and N/- or at test
points (refer to your inverter’s Instruction Manual for locations and discharging time). The voltage
must be zero.
CAUTION
The information of this manual is merely a guide for proper installation.

Mitsubishi Electric cannot assume responsibility for the compliance or the noncompliance to any
code, national, local, or otherwise for the proper installation of this equipment.
A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

GENERAL DESCRIPTION 3
1GENERAL DESCRIPTION
Features
The safety stop function of the Mitsubishi Electric FR-E800(-E) inverter can be used to prevent the inverter from supplying
rotational energy to motors. Dual input terminals S1 and S2 can be used to cut off the gate-drive power to the IGBT.
Figure 1 FR-E800(-E) safety stop function diagram
Safety stop function with SIL 2 certification
Mitsubishi Electric FR-E800(-E) series general-purpose inverters have met the SIL 2 requirements of the international
standard IEC 61508 for functional safety.
Table 1 Compliance with SIL 2
FR-E800(-E)
Safety performance
(Standards certified by a third-party certification body)
ISO 13849-1:2015 Category 3/PLd
IEC 62061:2015 / IEC 61800-5-2:2016 / IEC 61508 SIL2
IEC 60204-1:2016 / IEC 61800-5-2:2016 Stop category 0
WARNING
Disconnecting the power to the gate driver by the safety stop function does not isolate electrically
between the inverter and the motor. To avoid an electric shock hazard, disconnect power to the
inverter and verify that the main circuit capacitor voltage is zero (across terminals P/+ and N/-)
before performing any work on the motor (refer to your inverter’s Instruction Manual for discharging
time).
The misuse of safety function leads to personal injury or death, property damage, or economic loss.
To ensure that the system complies fully with requirement of safety, make a system-level risk
assessment. Mitsubishi Electric cannot assume responsibility for any system to comply with safety
standards.
Safety relay module/
Safety programmable controller
PC
RESET
Emergency
stop button
R/L1 S/L2 T/L3
UVW
SO
SOC
S2
S1
CPU
FR-E800(-E)
Logic
M
+24V
Fuse
Gate
Driver
Gate
Driver
CPU
IGBTs

4INSTALLATION AND WIRING
2INSTALLATION AND WIRING
Installation
The safety stop function of the Mitsubishi Electric FR-E800(-E) inverter should be used under the following conditions and
environment.
Table 2 Conditions and environment for using the safety stop function
 Derate the rated current when using the inverter in a temperature of 50°C or higher.
 Temperature applicable for a short time, e.g. in transit.
 For the installation at an altitude above 1,000 m, derate the rated current 3% per 500 m.
CAUTION
The following information is merely a guide for proper installation.
Mitsubishi Electric cannot assume responsibility for the compliance or the noncompliance to any
code, national, local, or otherwise for the proper installation of this equipment.
A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.
Ensure the safety relay unit and the FR-A800/F800 inverter are mounted closely in an enclosure
meeting IP54 and all interconnection wiring is short and protected against open and short circuit
faults. Refer ISO/IEC 13849-2.
Item Condition
Surrounding air
temperature LD, ND -20 to +60ºC (non-freezing)
Ambient humidity With circuit board coating (conforming to IEC 60721-3-3 3C2/3S2): 95% RH or less (non-condensing),
Without circuit board coating: 90% RH or less (non-condensing)
Storage temperature -40 to +70ºC
Vibration 5.9 m/s2or less at 10 to 55 Hz (directions of X, Y, Z axes)
Altitude 200 V/400 V class: Maximum 3000 m.
600 V class: Maximum 2000 m. 
Atmosphere Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)
Overvoltage category III or lower
Pollution degree II or lower
Mounting Wall mounting / vertical orientation
WARNING
To avoid an electric shock hazard, insert the magnetic contactor (MC) between power source and
inverter.
Open the contact of MC and keep away from the inverter for discharging time (refer to your inverter’s
Instruction Manual for information) before performing any work on the inverter. And verify that the
voltage on the bus capacitors has discharged before measuring the DC bus voltage between the
terminals P/+ and N/- or at test points (refer to your inverter’s Instruction Manual for locations). The
voltage must be zero.
CAUTION
In order to meet safety standards, a safety relay module compliant with ISO 13849-1 safety category
3 or higher shall be used in conjunction with the FR-A800/F800 inverter (refer to page 10). In
addition, all other components in the safety stop loop shall be ‘safety approved’ types.
To avoid system faults, check the safety stop function at least once per year.
Also, check the safety stop function at system installation, any software changes, and parameter
setting changes. For details, refer to Chapter 4 TEST AND CHECKING FAILURE.

INSTALLATION AND WIRING 5
Wiring
The safety related terminals are described in Table 3 and Table 4.
Table 3 Safety related terminals
 Specifications for conforming to safety standards.
 ON: The transistor is conducted. OFF: The transistor is not conducted.
Terminal
symbol Terminal name Terminal function description Rating
S1 Safety stop input
(Channel 1)
For input of safety stop channel 1
Between S1 and PC
OFF: In safety stop mode
ON: Other than the safety stop mode Input resistance: 4.7 kΩ
Input current: 4 to 6 mADC
(In case of 24 VDC input)
S2 Safety stop input
(Channel 2)
For input of safety stop channel 2
Between S2 and PC
OFF: In safety stop mode
ON: Other than the safety stop mode
PC 24 VDC power supply - Output voltage: 22 to 26.5 V
Output current: 100 mA max.
SO Inverter running status
Used for internal safety circuit failure detection and
alarm (open collector output).
Between SO and SOC
OFF: Internal safety circuit failure or alarm detected
ON: No internal safety circuit failure
Note: Terminal SO cannot be used for safety signals in a
safety system. Use terminal SO to output a fault
and to prevent restarting of the inverter.
Load: 24 VDC / 0.1 A max.
Voltage drop: 3.4 V max.
(In case of ‘ON’ state)
SOC Safety monitor output
terminal common Common terminal for terminal SO

6INSTALLATION AND WIRING
Table 4 Truth table of safety related signals
 ON: The transistor is conducted. OFF: The transistor is not conducted.
 When not using the safety stop function, short across terminals S1 and PC, and S2 and PC to use the inverter. (In the initial status, terminals S1
and PC, and S2 and PC are respectively shorted with shorting wires.)
 If any of the faults shown in the following table occurs, terminal SO, the SAFE signal, and the SAFE2 signal are turned OFF.
 When the internal safety circuit is operated normally (no fault occurs), terminal SO, the SAFE signal, and the SAFE2 signal remain ON until
"E.SAF" is displayed. Terminal SO, the SAFE signal, and the SAFE2 signal are turned OFF when "E.SAF" is displayed.
 SA is displayed when the terminals S1 and S2 are identified as OFF due to the internal safety circuit failure.
 If another fault occurs at the same time as E.SAF, the other fault can be displayed.
 If another warning occurs at the same time as SA, the other warning can be displayed.
 The ON/OFF state of the output signal is the one for the positive logic. The ON and OFF are reversed for the negative logic.
 To assign the functions of the SAFE signal and SAFE2 signal to output terminals, set values shown in the following table in any two parameters
from Pr.190 to Pr.196 (Output terminal function selection).
 The use of the SAFE signal and SAFE2 signal has not been certified for compliance with safety standards.
NOTE
• The response time from safety stop signal input to drive shutoff (safe state) is faster than 4 ms.
• Hold the ON or OFF status for 2 ms or longer to input signal to terminal S1 or S2.
Signal input shorter than 2 ms is not recognized.
Input
power
Internal
safety
circuit
status
Input terminal
, 
Output
terminal
Output signal
, ,  Inverter
running
status
Operation panel indication
S1 S2 SO SAFE SAFE2 E.SAF SA
OFF OFF OFF OFF Output shutoff
(Safe state) Not displayed Not displayed
ON
Normal ON ON ON OFF ON Drive enabled Not displayed Not displayed
Normal ON OFF OFF OFF OFF Output shutoff
(Safe state) Displayed Displayed
Normal OFF ON OFF OFF OFF Output shutoff
(Safe state) Displayed Displayed
Normal OFF OFF ON ON ON Output shutoff
(Safe state) Not displayed Displayed
FaultONONOFFOFFOFF
Output shutoff
(Safe state) Displayed Not displayed
Fault ON OFF OFF OFF OFF Output shutoff
(Safe state) Displayed Displayed
Fault OFF ON OFF OFF OFF Output shutoff
(Safe state) Displayed Displayed
Fault OFF OFF OFF OFF OFF Output shutoff
(Safe state) Displayed Displayed
Output signal Pr.190 to Pr.196 settings
Positive logic Negative logic
SAFE 80 180
SAFE2 81 181
Error definition Operation panel
indication
Option fault E.OPT
Communication option fault E.OP1
Parameter storage device fault (control
circuit board) E.PE
Retry count excess E.RET
Parameter storage device fault (main circuit
board) E.PE2
Safety circuit fault E.SAF
Overspeed occurrence E.OS
Speed deviation excess detection E.OSD
Brake sequence fault E.MB4 to E.MB7
CPU fault E.CPU
E.5 to E.7
Internal circuit fault E.13
Error definition Operation panel
indication

INSTALLATION AND WIRING 7
Wiring and ferrule terminal specifications
Table 5 Wiring and Ferrule terminal specifications
 Ferrule terminals and the tool are distributed by Phoenix Contact Co., Ltd.
Shorting wire
The shorting wire are installed between terminals S1/S2 and PC in the initial status as shown in Figure 2.
Remove the shorting wires and connect the safety relay module when using the safety stop function.
Figure 2 Shorting wire
Cable gauge (mm2)Ferrule terminal model Crimping tool name
0.3 AI 0,34-10TQ
CRIMPFOX 6
0.5 AI 0,5-10WH
0.75 AI 0,75-10GY
1 AI 1-10RD
1.25 / 1.5 AI1,5-10BK
0.75 (for two wires) AI TWIN 2 X 0,75-10GY
S1 S2 PC RUN FU SE
RL RM RH SD
MRS RES SD STF STR
SO SOC
10 2 5 4
A B C
FR-E800
FM/
AM
SD/
5
S1 S2 PC DI0 DI1 SD
A B C
10 2 5 4
SO SOC
FR-E800-E

8EXAMPLE OF SAFETY SYSTEM CONFIGURATION
3EXAMPLE OF SAFETY SYSTEM
CONFIGURATION
FR-E800(-E) configuration example
 When the control logic is the sink logic, the common terminal is terminal SD.
Figure 3 Safety system example of the FR-E800(-E) inverter
NOTE
• When starting up the system operation, press the RESET switch to reset the safety stop function first.
• In the above configuration, after resetting the emergency stop button, the inverter will be in the safe-state until the RESET
switch is pressed.
CAUTION
To prevent restart of the inverter when the power is restored after a power failure, 3-wire connection
is recommended for the START/STOP control. In case of 2-wire connection and using latching type
switch to short between STF and SD/PC for starting, ensure the compliance with safety standards for
the restarting when the inverter power is restored after a power failure.
Programmable controller
CC-Link IE Field Network
remote I/O module (with safety functions)
NZ2GFSS2 - 32D/NZ2EXSS2 - 8TE
S2
S1
FR-E800(-E)
SO
R/L1 S/L2
T/L3
SOC
T1 X1 T0 X0 X3 X2 Y1 Y0
IO24V IO24G IO24V IO24G
+24V
PC
CPU
CPU
SD
Logic
UVW
COM+ COM+ COM-
Gate
Driver
Gate
Driver
Fuse
Emergency
stop button
RESET
NZ2GFSS2-32D NZ2EXSS2-8TE
∗1
IGBTs
M
STF
STOP
Y2
STOP
START

EXAMPLE OF SAFETY SYSTEM CONFIGURATION 9
Multiple inverter configuration example
Figure 4 When using multiple safety stop function inverters (FR-E800(-E))
NOTE
• Some models cannot be used together because their control logics are different. Refer to the Safety Stop Function Manual of
each model.
Programmable controller
CC-Link IE Field Network
remote I/O module (with safety functions)
NZ2GFSS2 - 32D/NZ2EXSS2 - 8TE
S2
S1
FR-E800(-E)
SO
R/L1 S/L2
T/L3
SOC
T1 X1 T0 X0 X3 X2 Y1 Y0
IO24V IO24G IO24V IO24G
+24V
PC
CPU
CPU
SD
Logic
UVW
COM+ COM+ COM-
Gate
Driver
Gate
Driver
Fuse
IGBTs
Emergency
stop button
RESET
NZ2GFSS2-32D NZ2EXSS2-8TE
S2
S1
FR-E800(-E)
SO
R/L1 S/L2
T/L3
SOC
+24V
PC
CPU
CPU
SD
Logic
UVW
Gate
Driver
Gate
Driver
Fuse
IGBTs
M
M

10 EXAMPLE OF SAFETY SYSTEM CONFIGURATION
Safety controller configuration example
Figure 5 Safety system example of the FR-E800(-E) inverter
NOTE
• When starting up the system operation, press the RESET switch to reset the safety stop function first.
• In the above configuration, after resetting the emergency stop button, the inverter will be in the safe-state until the RESET
switch is pressed.
24VDC
X1
X2
Q4
Q3
Q2
Q1
WS0-CPU0
A1(24V)
A2(0V)
A2(0V)
FLEXBUS+
FLEXBUS+
I8
I7
I6
I5
I4
24V 0V
WS0-XTIO
I1
I2
I3
A1(24V)
RESET
SO
SOC
Emergency
stop button
Application
Application
Mitsubishi Electric safety controller MELSEC-WS series
CPU module WS0-CPU0
Safety I/O combined module WS0-XTIO
S2
S1
FR-E800(-E)
R/L1 S/L2
T/L3
+24V
PC
CPU
CPU
SD
Logic
UVW
Gate
Driver
Gate
Driver
Fuse
IGBTs
M