Mitsubishi Electric FR-A800 User manual

INVERTER
FR-A800/F800
Safety Stop Function Instruction Manual
CONTENTS
1. GENERAL DESCRIPTION ............................................ 3
2. INSTALLATION AND WIRING...................................... 5
3. EXAMPLE OF SAFETY SYSTEM CONFIGURATION .... 9
4. TEST AND CHECKING FAILURE ............................... 12
5. SAFETY PARAMETERS OF FR-A800/F800 ................ 13

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 Corporation. 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, disconnect/isolate power to the inverter and verify to ensure that the voltage
is zero before performing any work on the motor (refer to your inverter’s Instruction Manual for
discharging time).
Caution
The information of this manual is merely a guide for proper installation.

Mitsubishi Electric Corporation. 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-A800/F800 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-A800/F800 safety stop function diagram
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).
R/L1 S/L2 T/L3
UV
W
M
So (SO)
SOC
S1
S2
G G
ASIC
FR-A800/F800
SIC
SD
Logic
RESET
Emergency
stop button
Safety relay module
/ Safety programmable controller
PC Gate
Driver
Gate
Driver
IGBTs
Fuse
CPU
+24V
24VDC

4GENERAL DESCRIPTION
SafetystopfunctionwithSIL3certification
The Mitsubishi Electric FR-A800/F800 inverters now comply with safety integrity level 3 (SIL 3) of the IEC
EC61508:2010 functional safety standard.
• Target models
Mitsubishi Electric FR-A800/F800 inverters
• Change of the compliance
The Mitsubishi Electric FR-A800/F800 inverters now comply with SIL 3.
Table 1 Compliance with SIL 3
• Schedule
Check the SERIAL number indicated on the inverter rating plate or package.
For the products manufactured in Japan, this change has been made sequentially from the June 2018 production.
For the products manufactured in China, this change has been made sequentially from the July 2018 production.
Figure 2 Rating plate example
• Third-party certification body
Safety Integrity Level (SIL) 3:
TÜV SÜD
Safety Integrity Level (SIL) 2:
TUV Rheinland as before, or TÜV SÜD alternatively.
Before change After change
Safety
performance
(Standards
certified by a third-
party certification
body)
ISO13849-1:2008 Category 3/PLd
IEC62061:2005 / IEC61800-5-2:2007 /
IEC61508 SIL2
IEC60204-1:2010 / IEC61800-5-2:2007 Stop category 0
ISO13849-1:2015 Category 3/PLe
IEC62061:2015 / IEC61800-5-2:2016 /
IEC61508:2010 SIL3
IEC60204-1:2016 / IEC61800-5-2:2016 Stop category 0
   
Symbol Year Month Control number
SERIAL
The SERIAL consists of one symbol, two characters indicating the
production year and month, and six characters indicating the
control number.
The last digit of the production year is indicated as the Year, and
the Month is indicated by 1 to 9, X (October), Y (November), or Z
(December).
Warning
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 C
orporation . cannot assume responsibility for any system to
comply with safety standards.
,1387;;;;;
02'(/
287387;;;;;
6(5,$/;;;;;;;;;
0$'(,1;;;;;
SERIAL
number
Country
of origin

INSTALLATION AND WIRING 5
2INSTALLATION AND WIRING
Installation
The safety stop function of the Mitsubishi Electric FR-A800/F800 inverter should be used under the following
conditions and environment.
Table 2 Conditions and environment for using the safety stop function
∗1 The ND and HD ratings can be selected only for the FR-A800 inverter.
∗2 Temperature applicable for a short time, e.g. in transit.
∗3 2.9 m/s2or less for the FR-A840-04320(160K) / FR-F840-04320(185K) or higher.
∗4 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 Corporation. 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/IEC13849-2.
Item Condition
Surrounding air
temperature
LD, ND, HD∗1 -10ºC to +50ºC (non-freezing)
SLD -10ºC to +40ºC (non-freezing)
Storage temperature -20ºC to +65ºC∗2
Ambient humidity
With circuit board coating (conforming to IEC60721-3-3 3C2/3S2): 95% RH or
less (non-condensing),
Without circuit board coating: 90% RH or less (non-condensing)
Vibration 5.9 m/s2∗3 or less at 10 to 55 Hz (directions of X, Y, Z axes)
Altitude Maximum 2500 m ∗4
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

6INSTALLATION AND WIRING
●Wiring
The safety related terminals are described in Table 3 and Table 4.
Table 3 Safety related terminals
∗1 Specifications for conforming to safety standards.
∗2 ON: The transistor is conducted. OFF: The transistor is not conducted.
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 ISO13849-1 safety category 3
or higher shall be used in conjunction with the FR-A800/F800 inverter (refer to page 11). 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.
To comply with SIL 3, the safety stop function must be checked at least once in three months.
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.
Terminal
symbol Terminal name Terminal function description∗2 Rating∗1
S1 Safety stop input
(Channel 1)
For input of safety stop channel 1
Between S1 and SIC
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 SIC
OFF: In safety stop mode
ON: Other than the safety stop mode
SIC Common terminal Common terminal for terminal S1 and terminal S2
So (SO) Open collector output
common
For output for failure detection and alarm
(Open collector output)
Between So (SO) and SOC
OFF: Failure or alarm detected
ON: No failure detected
Note: Terminal SO (SO) cannot be used for safety
signals in a safety system. Use terminal
SO (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 (SO)

INSTALLATION AND WIRING 7
Table 4 Truth table of safety related signals
∗1 ON: The transistor is conducted. OFF: The transistor is not conducted.
∗2 When not using the safety stop function, short across terminals S1 and PC, S2 and PC, and SIC and SD to use the inverter.
(In the initial status, terminals S1 and PC, S2 and PC, and SIC and SD are respectively shorted with shorting wires.)
∗3 If any of the protective functions shown in the following table is activated, the terminal So (SO) and the SAFE output signal
turns OFF.
∗4 When the internal safety circuit is operated normally, the terminal So (SO) and the SAFE output signal remain ON until E.SAF
is displayed, and the terminal So (SO) and the SAFE output signal turn OFF when E.SAF is displayed.
∗5 SA is displayed when the terminals S1 and S2 are identified as OFF due to the internal safety circuit failure.
∗6 If another fault occurs at the same time as E.SAF, the other fault can be displayed.
∗7 If another warning occurs at the same time as SA, the other warning can be displayed.
∗8 For the SAFE signal, refer to the following table and assign the function using Pr.190 to Pr.196 (output terminal function
selection). 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.
∗9 The use of SAFE 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 8ms.
• 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∗1, ∗2 Output
terminal
Output
signal
∗8, ∗9
Inverter
running
status
Operation panel
indication
S1 S2 So (SO) SAFE E.SAF∗6 SA∗7
OFF ⎯⎯⎯OFF OFF Output shutoff
(Safe state)
Not
displayed
Not
displayed
ON
NormalONONON
∗3 OFF Drive enabled Not
displayed
Not
displayed
Normal ON OFF OFF∗4 OFF∗4 Output shutoff
(Safe state) Displayed Displayed
Normal OFF ON OFF∗4 OFF∗4 Output shutoff
(Safe state) Displayed Displayed
Normal OFF OFF ON∗3 ON∗3 Output shutoff
(Safe state)
Not
displayed Displayed
FaultONONOFFOFF
Output shutoff
(Safe state) Displayed Not displayed∗5
Fault ON OFF OFF OFF Output shutoff
(Safe state) Displayed Displayed
Fault OFF ON OFF OFF Output shutoff
(Safe state) Displayed Displayed
Fault 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
Error definition Operation panel indication
Option fault E.OPT
Communication option fault E.OP1 to E.OP3
Parameter storage device fault E.PE
Retry count excess E.RET
Parameter storage device fault E.PE2
Operation panel power supply short circuit/
RS-485 terminals power supply short circuit E.CTE
24 VDC power fault E.P24
Safety circuit fault E.SAF
Overspeed occurrence E.OS
Speed deviation excess detection E.OSD
Signal loss detection E.ECT
Excessive position fault E.OD
Brake sequence fault E.MB1 to E.MB7
Encoder phase fault E.EP
Magnetic pole position unknown E.MP
CPU fault E.CPU
E.5 to E.7
Internal circuit fault E.13
Error definition Operation panel indication

8INSTALLATION AND WIRING
●Wiring and ferrule terminal specifications
Table 5 Wiring and Ferrule terminal specifications
∗1 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 and between terminals SIC and SD in the initial
status as shown in Figure 3.
Figure3 Shorting wire
Before connecting the wires for the safety stop function to terminals S1, S2, and SIC, remove the shorting wires.
Cable gauge (mm2)Ferrule terminal model∗1 Crimping tool name∗1
0.3 AI 0,34-10TQ
CRIMPFOX 6
0.5 AI 0,5-10WH
0.75 AI 0,75-10GY
1AI1-10RD
1.25 / 1.5 AI1,5-10BK
0.75 (for two wires) AI TWIN 2 X 0,75-10GY
AM
2 5 4 1 F/C +24 SD SD S1 S2 PC A1 B1 C1 A2 B2 C2SICSo SOC
510E 10 SE SE SU RUN IPF OL FU PC RL RM RH RT AU SD SD CSSTP MRS RES STF STR JOG

EXAMPLE OF SAFETY SYSTEM CONFIGURATION 9
3EXAMPLE OF SAFETY SYSTEM
CONFIGURATION
●FR-A800/F800 configuration example
∗1 When the control logic is the sink logic, the common terminal is terminal SD.
Figure 4 Safety system example of the FR-A800/F800 inverter
NOTE
• When starting up the system operation, press the RESET switch to reset the safety stop function first,
then turn ON the START switch to run the motor.
• In the above configuration, after resetting the of 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.
S 1
S 2
FR-A800/F800
So (SO)
R/L1 S/L2
T/L3
IGBTs
SOC
RESET
+24V
K1
X0 X1
24G
XS0
XS1 Z10
Z00 Z20
Z11
Z01 Z21
K 2
24V
DC
S a f e t y r e l a y module
M E L S E C Q S 9 0 S R 2 S N-Q
STF
START
STOP
Emergency
stop button
G
+24V
PC
*1
Fuse
SIC
ASIC Gate
Driver
G
Gate
CPU
SD
Logic
UVW
M
STOP
COM0 COM1
Internal
Safety
Circuit
24V
DC
Driver

10 EXAMPLE OF SAFETY SYSTEM CONFIGURATION
●Multiple inverter configuration example
Figure 5 When using multiple safety stop function inverters (FR-A800/F800)
NOTE
• Some models cannot be used together because their control logics are different. Refer to the Safety Stop
Function Manual of each model.
S 1
S 2
PC
FR-A800/F800
So (SO)
R/L1 S/L2
T/L3
IGBTs
SOC
RESET
+24V
K1
X0 X1
24G
XS0
XS1 Z10
Z00 Z20
Z11
Z01 Z21
K 2
24V
DC
S a f e t y r e l a y module
M E L S E C Q S 9 0 S R 2 S N-Q
Emergency
stop button
G
+24V
Fuse
SIC
ASIC
Gate
Drive r
G
Gate
CPU
SD
Logic
UVW
M
COM0 COM1
Internal
Safety
Circuit
24V
DC
S 1
S 2
PC
FR-A800/F800
So (SO)
R/L1 S/L2
T/L3
IGBTs
SOC
G
+24V
Fuse
SIC
ASIC
Gate
Drive r
G
Gate
CPU
SD
Logic
UVW
M
Drive r
Drive r