Mitsubishi Electric FR-A7AP User manual

INVERTER
Plug-in option
INSTRUCTION MANUAL
1
2
3
4
5
FR-A7AP
Orientation control
Encoder feedback control
Vector control
INSTALLATION
ORIENTATION CONTROL
ENCODER FEEDBACK CONTROL
PRE-OPERATION INSTRUCTIONS
VECTOR CONTROL

A-1
Thank you for choosing this Mitsubishi Inverter plug-in option.
This instruction manual gives handling information and
precautions for use of this equipment. Incorrect handling might
cause an unexpected fault. Before using the equipment, please
read this manual carefully to use the equipment to its optimum.
Please forward this manual to the end user.
1. Electric Shock Prevention
This section is specifically about
safety matters
Do not attempt to install, operate, maintain or inspect this
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.
In this instruction manual, the safety instruction levels are
classified into "WARNING" and "CAUTION".
Assumes that incorrect handling may
cause hazardous conditions, resulting
in death or severe injury.
Assumes that incorrect handling may
cause hazardous conditions, resulting
in medium or slight injury, or may
cause physical damage only.
Note that even the level may lead to a serious
consequence according to conditions. Please follow the
instructions of both levels because they are important to
personnel safety.
WARNING
CAUTION
CAUTION
SAFETY INSTRUCTIONS
WARNING
•While power is on or when the inverter is running, do not
open the front cover. You may get an electric shock.
•Do not run the inverter with the front cover or wiring cover
removed. Otherwise, you may access the exposed high-
voltage terminals and charging part and get an electric shock.
•If power is off, do not remove the front cover except for wiring
or periodic inspection. You may access the charged inverter
circuits and get an electric shock.
•Before starting wiring or inspection, check to make sure that
Indication of the inverter operation panel is off, 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.
•Any person who is involved in the wiring or inspection of this
equipment should be fully competent to do the work.
•Always install the plug-in option before wiring. Otherwise,
you may get an electric shock or be injured.
•Do not touch the plug-in option with wet hands. Otherwise
you may get an electric shock.
•Do not subject the cables to scratches, excessive stress,
heavy loads or pinching. Otherwise you may get an electric
shock.

A-2
2. Injury Prevention
3. Additional Instructions
Also note the following points to prevent an accidental failure,
injury, electric shock, etc.
1) Transportation and mounting
2) Trial run
3) Usage
4) Maintenance, inspection and parts replacement
5) Disposal
6) General instruction
CAUTION
•Apply only the voltage specified in the instruction manual to
each terminal. Otherwise, burst, damage, etc. may occur.
•Ensure that the cables are connected to the correct terminals.
Otherwise, burst, damage, etc. may occur.
•Always make sure that polarity is correct to prevent damage, etc.
Otherwise, burst, damage may occur.
•While power is on or for some time after power-off, do not touch
the inverter as it is hot and you may get burnt.
CAUTION
•Do not install or operate the plug-in option if it is damaged or
has parts missing.
•Do not stand or rest heavy objects on the product.
•Check that the mounting orientation is correct.
•Prevent other conductive bodies such as screws and metal
fragments or other flammable substance such as oil from
entering the inverter.
CAUTION
•Before starting operation, confirm and adjust the parameters.
A failure to do so may cause some machines to make
unexpected motions.
WARNING
•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 inverter.
CAUTION
•When parameter clear or all parameter clear is performed,
reset the required parameters before starting operations.
Each parameter returns to the initial value.
•For prevention of damage due to static electricity, touch
nearby metal before touching this product to eliminate static
electricity from your body.
CAUTION
•Do not test the equipment with a megger (measure insulation
resistance).
CAUTION
•Treat as industrial waste.
All illustrations given in this manual may have been drawn with
covers or safety guards removed to provide in-depth
description. Before starting operation of the product, always
return the covers and guards into original positions as specified
and operate the equipment in accordance with the manual.

I
CONTENTS 
1PRE-OPERATION INSTRUCTIONS 1
1.1 Unpacking and Product Confirmation .............................................................................................1
1.1.1 Packing confirmation ...................................................................................................................................... 1
1.1.2 SERIAL number check ...................................................................................................................................2
1.1.3 Parts ...............................................................................................................................................................3
2INSTALLATION 4
2.1 Pre-Installation Instructions .............................................................................................................4
2.2 Installation Procedure .......................................................................................................................5
2.3 Switches .............................................................................................................................................7
2.4 Wiring..................................................................................................................................................9
2.5 Encoder Cable..................................................................................................................................13
2.6 Encoder.............................................................................................................................................15
2.7 Parameter for Encoder ....................................................................................................................16
3ORIENTATION CONTROL 18
3.1 Wiring Example ................................................................................................................................18
3.2 Terminals ..........................................................................................................................................20
3.3 Parameter List for Orientation Control ..........................................................................................22
3.4 Specifications...................................................................................................................................23

II
4ENCODER FEEDBACK CONTROL 24
4.1 Wiring Examples ..............................................................................................................................24
4.2 Terminals ..........................................................................................................................................25
4.3 Encoder Feedback Control Parameter List ...................................................................................26
5VECTOR CONTROL 28
5.1 Wiring Examples ..............................................................................................................................28
5.2 Terminals ..........................................................................................................................................32
5.3 Vector Control Extended Parameter List.......................................................................................33
5.4 Specifications...................................................................................................................................36

1
1
1PRE-OPERATION INSTRUCTIONS
1.1 Unpacking and Product Confirmation
Take the plug-in option out of the package, check the unit name, and confirm that the product is as you
ordered and intact.
This product is a plug-in option dedicated for the FR-A700 series.
1.1.1 Packing confirmation
Check the enclosed items.
Plug-in option
......................................... 1
Mounting screw (M3 ×6mm)
.............. 2 (Refer to page 5.)
Hex-head screw for option
mounting (5.5mm)
............... 1 (Refer to page 5.)
5.5mm

2
PRE-OPERATION INSTRUCTIONS
1.1.2 SERIAL number check
The FR-A7AP can be used with the FR-A700 series having the following serial number or later. Check the
SERIAL number indicated on the inverter rating plate or package.
Model SERIAL (Serial No.) Model SERIAL (Serial No.)
FR-A720-0.4K/0.75K P5{{{{{{{ FR-A740-0.4K L5{{{{{{{
FR-A720-1.5K/2.2K Q5{{{{{{{ FR-A740-0.75K K5{{{{{{{
FR-A720-3.7K N5{{{{{{{ FR-A740-1.5K/2.2K J5{{{{{{{
FR-A720-5.5K to 11K L5{{{{{{{ FR-A740-3.7K H5{{{{{{{
FR-A720-15K to 22K M5{{{{{{{ FR-A740-5.5K/7.5K G5{{{{{{{
FR-A720-30K Q5{{{{{{{ FR-A740-11K to 22K F5{{{{{{{
FR-A720-37K M5{{{{{{{ FR-A740-30K to 55K E5{{{{{{{
FR-A720-45K L5{{{{{{{ FR-A740-75K/90K G5{{{{{{{
FR-A720-55K K5{{{{{{{ FR-A740-110K to 160K E5{{{{{{{
FR-A720-75K/90K E5{{{{{{{ FR-A740-185K to 500K C5{{{{{{{
Rating plate example
5{{{{{{{
Symbol Year Month Control number
SERIAL (Serial No.)
The SERIAL is made up of 1 version symbol, 2 numeric characters
or 1 alphabet letter and 2 numeric characters indicating year and
month, and 6 numeric characters indicating control number.
Month is indicated as 1 to 9, X (October), Y (November), and Z
(December).

3
PRE-OPERATION INSTRUCTIONS
1
1.1.3 Parts
Front view Rear view
Mounting
hole
Mounting
hole
Mounting
hole
Encoder specification selection switch (SW1)
Used to change the specification of encoder
(differential line driver/complementary).
Switch for manufacturer
setting (SW3)
Do not change from initially-
set status (1, 2:OFF ).
Terminating resistor selection
switch (SW2)
Switch ON/OFF of the internal
terminating resistor.
CON2 connector
Not used.
Terminal
block
Connector
Connect to the inverter
option connector.
Terminal layout
PA2
PB2
PZ2
SD
SD
PO
PA1
PB1
PZ1
PG
PG
PIN
1
2
3
4
O
N
1
2
O
N
1
2
O
N
SW2
SW1
LED1
LED2
LED3
SW3
FR-A7AP
PIN and PO are
not used.
(Refer to page 5.)
(Refer to page 7.)
(Refer to page 7.)

4
2INSTALLATION
2.1 Pre-Installation Instructions
Make sure that the input power of the inverter is off.
CAUTION
With input power on, do not install or remove the plug-in option. Otherwise, the inverter and
plug-in option may be damaged.

5
INSTALLATION
2
2.2 Installation Procedure
1) Remove the inverter front cover.
2) Mount the hex-head screw for option
mounting into the inverter screw hole (on
earth plate). (size 5.5mm, tightening
torque 0.56N⋅m to 0.75N⋅m)
3) Securely fit the connector of the plug-in
option to the inverter connector along the
guides.
4) Securely fix the both right and left sides
of the plug-in option to the inverter with
the accessory mounting screws. If the
screw holes do not line-up, the connector
may not have been plugged snugly.
Check for loose plugging.
REMARKS
After removing two screws on the right and left places, remove the plug-in option.
(When the plug-in option is mounted in the connector 3, it is easier to remove the plug-in option after removing a
control circuit terminal block.)
4) Mounting
screws
Inverter side
option
connector
Screw hole for
option mounting
Screw hole for
option mounting
(on earth plate)
Hex-head screw
for option mounting
1)
2)
3)

6
INSTALLATION
CAUTION
•When two or more options are mounted, priority is in order of inverter option connectors 1, 2 and 3, the
options having lower priority are inoperative.
•When the inverter cannot recognize that the option is mounted due to improper
installation, etc., " to " (option alarm) are displayed for the FR-
A700 series.The errors shown differ according to the mounting positions
(connectors 1, 2, 3).
•The FR-F700 series has one connection connector for the plug-in option. When the inverter can not
recognize that the option unit is mounted due to improper installation, etc., " " (option alarm) is
displayed.
•Note that a hex-head screw for option mounting or mounting screw may drop during mounting and removal.
•Pull out the option straight to remove. Otherwise, the connector may be damaged by some applied force.
Mounting
Position
Error
Display
Connector 1
Connector 2
Connector 3

7
INSTALLATION
2
2.3 Switches
(1) Encoder specification selection switch (SW1)
Select either differential line driver or complementary
It is initially set to the differential line driver. Switch its position
according to output circuit.
(2) Terminating resistor selection switch (SW2)
Select ON/OFF of the internal terminating resistor. Set the
switch to ON (initial status) when an encoder output type is
differential line driver and set to OFF when complimentary.
ON : with internal terminating resistor (initial setting status)
OFF : without internal terminating resistor
REMARKS
· Set all swithces to the same setting (ON/OFF).
· If the encoder output type is differential line driver, set the
terminating resistor switch to the "OFF" position when sharing the
same encoder with other unit (NC (numerical controller), etc) or a
terminating resistor is connected to other unit.
CAUTION
SW3 is for manufacturer setting. Do not change from initially-set status (1, 2:OFF).
Complementary
Differential line
driver (initial status)
1
2
3
4
O
N
1
2
O
N
SW2
SW1
SW3
FR-A7AP
Internal terminating
resistor-ON
(initial status)
Internal terminating resistor-OFF
1
2
3
4
O
N
1
2
O
N
SW2
SW1
SW3
FR-A7AP

8
INSTALLATION
(3) Motor used and switch setting
Motor
Encoder Specification
Selection Switch (SW1)
Terminating Resistor
Selection Switch (SW2)
Power
Specifications *2
Mitsubishi standard motor
Mitsubishi high efficiency
motor
SF-JR Differential ON 5V
SF-HR Differential ON 5V
Others *1 *1 *1
Mitsubishi constant-
torque motor
SF-JRCA Differential ON 5V
SF-HRCA Differential ON 5V
Others *1 *1 *1
Dedicated motor SF-V5RU Complimentary OFF 12V
SF-VR Differential ON 5V
Other manufacturer motor – *1 *1 *1
*1 Set according to the motor encoder used.
*2 Choose a power supply for encoder according to the encoder used (5V/12V/15V/24V).

9
INSTALLATION
2
2.4 Wiring
(1) Use twisted pair shield cables (0.2mm2or larger) to connect the FR-A7AP and position detector.
To protect the cables from noise, run them away from any source of noise (e.g. the main circuit
and power voltage).
* When differential driver is set and a wiring length is 30m or more
The wiring length can be extended to 100m by slightly increasing the power by 5V (approx. 5.5V) using six or more cables with
gauge size of 0.2mm2in parallel or a cable with gauge size of 1.25mm2or more. Note that the voltage applied should be within
power supply specifications of encoder.
To reduce noise of the encoder cable, earth (ground) the encoder shielded cable to the enclosure (as near
as the inverter) with a P clip or U clip made of metal.
Wiring Length Paralell Connection Larger-Size Cable
Within 10m At least 2 cables Cable gauge
0.2mm2
0.4mm2 or larger
Within 20m At least 4 cables 0.75mm2 or larger
Within 100m * At least 6 cables 1.25mm2 or larger
REMARKS
· For details of the optional encoder dedicated cable (FR-JCBL/FR-V7CBL), refer to page 13.
· The FR-V7CBL is provided with a P clip for earthing (grounding) shielded cable.
Encoder cable
Shield
P clip
Earthing (grounding) example using a P clip

10
INSTALLATION
(2) Connection with the NC (numerical controller)
When one position detector is shared between the FR-A7AP and NC, its output signal should be
connected as shown on the right. In this case, the wiring length between the FR-A7AP and NC should
be as short as possible, within 5m.
Maximum 5m
(two parallel cables)
NC
Inverter
(FR-A7AP)
Position detecto
r
Encoder

11
INSTALLATION
2
(3) Wire the twisted pair shielded cable after stripping its sheath to make its cables loose.
Also, protect the shielded cable of the twisted pair shielded cable to ensure that it will not make contact
with the conductive area.
(4) Loosen the terminal screw and insert the cable into the terminal.
REMARKS
Information on bar terminals
Introduced products (as of August, 2005): Phoenix Contact Co.,Ltd.
Screw Size Tightening Torque Cable Size Screwdriver
M2 0.22N⋅m to 0.25N⋅m0.3mm2to 0.75mm2Small flat-blade screwdriver
(Tip thickness: 0.4mm/tip width: 2.5mm )
CAUTION
Undertightening can cause cable disconnection or malfunction. Overtightening can cause a short circuit or
malfunction due to damage to the screw or unit.
Cable stripping size Wire the stripped cable after twisting it to prevent it from becoming loose.
In addition, do not solder it.
Use a bar type terminal as required.
5mm
⋅Bar terminal crimping tool: CRIMPFOX ZA3 (Phoenix Contact Co., Ltd.)
Terminal Screw
Size
Bar Terminal Model
(with insulation sleeve)
Bar Terminal Model
(without insulation sleeve) Wire Size (mm2)
M2 Al 0.5-6WH A 0.5-6 0.3 to 0.5
When using the bar terminal (without insulation sleeve),
use care so that the twisted wires do not come out.

12
INSTALLATION
(5) For wiring of 22K or less, remove a hook of the front cover and use a space become available.
For wiring of 30K or more, use the space on the left side of the control circuit terminal block.
REMARKS
When the hook of the inverter front cover is cut off for wiring, the protective structure (JEM1030) changes to open type
(IP00).
Do not use empty terminals as junction terminals because they are used in the option unit. If
they are used as the junction terminals, the option unit may be damaged.
When performing wiring using the space between the inverter front cover and control circuit
terminal block, take care not to subject the cable to stress.
After wiring, wire offcuts must not be left in the inverter. They may cause a fault, failure or
malfunction.
Cut off a hook on the inverter
front cover side surface.
(Cut off so that no portion is left.)
Cut off
with a
nipper,
etc.
Control circuit
terminal block
22K or less 30K or more
C
AUTI
O
N

13
INSTALLATION
2
2.5 Encoder Cable
* As the terminal block of the FR-A7AP is an insertion type, earth cables need to be modified. (Refer to page 11.)
SF-JR Motor with Encoder SF-V5RU
PZ2
PZ1
PB2
PB1
PA2
PA1
PG
SD
P
B
N
A
R
C
H
K
Encoder
2mm2
ABCD
E
K
F
G
H
J
L
M
S
N
R
P
T
MS3106B20-29S
(As viewed from wiring side)
Positioning keyway
FR-A700
(FR-A7AP)
60 L
F-DPEVSB 12P 0.2mm
2
MS3057-12A
Earth cable
MS3106B20-29S
Approx. 140
Type Length L (m)
FR-JCBL5 5
FR-JCBL15 15
FR-JCBL30 30
*
PZ2
PZ1
PB2
PB1
PA2
PA1
SD
PG
G
F
D
C
B
A
R
S
Encoder
2mm2
FR-A700
(FR-A7AP)
ABCD
E
K
F
G
H
J
L
M
S
N
R
P
T
MS3106B20-29S
As viewed from wiring side
Positioning keyway
LMS3106B20-29S
Earth cable F-DPEVSB 12P 0.2mm
2
MS3057-12A
Encoder side
connector
Inverter side
11mm
60mm
Type Length L (m)
FR-V7CBL5 5
FR-V7CBL15 15
FR-V7CBL30 30
⋅A P clip for earthing (grounding)
a shielded cable is provided.

14
INSTALLATION
Connection terminal compatibility table
Motor SF-V5RU SF-JR/HR/JRCA/HRCA (with Encoder)
Encoder cable FR-V7CBL/FR-V5CBL FR-JCBL
FR-A7AP terminal
PA1 PA PA
PA2 Keep this open. PAR
PB1 PB PB
PB2 Keep this open. PBR
PZ1 PZ PZ
PZ2 Keep this open. PZR
PG PG 5E
SD SD AG2

15
INSTALLATION
2
2.6 Encoder
(1) Position detection (pulse encoder)
(2) Power supply
Choose a power supply for encoder according to the encoder used.
When an encoder is used under orientation control, encoder feedback control, and vector control, the power
supply is shared between the inverter and encoder.
CAUTION
⋅When orientation control, encoder feedback control, vector control are used together, the encoder is shared
between these controls.
Use an encoder which has a pulse count of 1000 to 4096ppr (pulse per revolution).
⋅
The encoder should be coupled with the motor shaft or the spindle oriented with a speed ratio of 1 to 1 without any
mechanical looseness.
⋅To ensure correct operation, the encoder must be set in the proper rotation direction and the A and B phases
connected correctly.
P
abcd H
A
A
B
B
Z
Z
L
A/A signal 1000P/R to 4096P/R
B/B signal 1000P/R to 4096P/R
Z/Z signal 1P/R
A signal 1000P/R to 4096P/R
B signal 1000P/R to 4096P/R
Z signal 1P/R
Differential line driver Complimentary
Output pulse specifications
A
Position detector
Encoder
When rotation is clockwise
as viewed from the shaft
end (A) of the encoder.
a, b, c, d should be (1/4
1/8)P
A
B
Z
abcd
P