Mitsubishi Electric FR-A820-00046 (0.4K) User manual

INVERTER
Plug-in option
INSTRUCTION MANUAL
PRE-OPERATION INSTRUCTIONS 1
INSTALLATION AND WIRING 2
INVERTER FUNCTIONS ENABLED
WITH FR-A8APA 3
ORIENTATION CONTROL 4
ENCODER FEEDBACK CONTROL 5
VECTOR CONTROL 6
FR-A8APA
SinCos encoder interface
Orientation control
Encoder feedback control
Vector control

2
Thank you for choosing this Mitsubishi Electric inverter plug-in option.
This Instruction Manual provides handling information and precautions for use of this product. Incorrect handling might cause an unexpected
fault. Before using this product, read all relevant instruction manuals carefully to ensure proper use.
Please forward this Instruction Manual to the end user.
Electric shock prevention
Injury prevention
Safety instructions
Do not attempt to install, operate, maintain or inspect this product until you have read this Instruction Manual and appended documents
carefully. Do not use this product until you have a full knowledge of this product mechanism, safety information and instructions. In this
Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION".
Incorrect handling may cause hazardous conditions, resulting in death or severe injury.
Incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause only
material damage.
Note that even the level may lead to a serious consequence depending on conditions. Be sure to follow the
instructions of both levels as they are critical to personnel safety.
WARNING
Do not remove the front cover or the wiring cover of the inverter while the inverter power is ON. Do not operate the inverter with any cover or wiring cover removed,
as accidental contact with exposed high-voltage terminals and internal components may occur, resulting in an electrical shock.
Even if power is OFF, do not remove the front cover of the inverter except for wiring or periodic inspection as the inside of the inverter is charged. Otherwise you
may get an electric shock.
Before wiring or inspection, check that the display of the inverter operation panel is OFF. Any person who is involved in wiring or inspection shall wait for 10 minutes
or longer after power 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 wiring or inspection of this product shall be fully competent to do the work.
This product must be installed before wiring. Otherwise you may get an electric shock or be injured.
Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Doing so may cause an electric shock.
Do not touch the this product or handle the cables with wet hands. Doing so may cause an electric shock.
CAUTION
The voltage applied to each terminal must be as specified in the Instruction Manual. Otherwise a burst, damage, etc. may occur.
The cables must be connected to the correct terminals. Otherwise a burst, damage, etc. may occur.
The polarity (+ and -) must be correct. Otherwise a burst, damage, etc. may occur.
While power is ON or for some time after power OFF, do not touch the inverter as it will be extremely hot. Doing so may cause a burn.
WARNING
CAUTION
CAUTION

3
Additional instructions
The following instructions must be also followed. If this product is handled incorrectly, it may cause unexpected fault, an injury, or an electric
shock.
CAUTION
Transportation and installation
Do not stand or place heavy objects on this product.
The installing orientation of this product must be correct.
Do not install or operate this product if it is damaged or has parts missing.
Foreign conductive objects must be prevented from entering the inverter. That includes screws and metal fragments or other flammable substance such as oil.
If halogen-based materials (fluorine, chlorine, bromine, iodine, etc.), included in fumigants to sterilize or disinfect wooden packages, infiltrate into this product, the
product may be damaged. Prevent residual fumigant components from being infiltrated into the product when packaging, or use an alternative sterilization or
disinfection method (heat disinfection, etc.). Note that sterilization or disinfection of wooden package should also be performed before packing the product.
Test operation
Before starting operation, confirm or adjust the parameter settings. Failure to do so may cause some machines to make unexpected motions.
WARNING
Usage
Do not modify this product.
Do not remove any part which is not instructed to be removed in the Instruction Manuals. Doing so may lead to a failure or damage of this product.
CAUTION
Usage
As all parameters return to their initial values after Parameter clear or All parameter clear is performed, the needed parameters for operation of the inverter and this
product must be set again before the operation is started.
To avoid damage to this product due to static electricity, static electricity in your body must be discharged before you touch this product.
Maintenance, inspection and parts replacement
Do not carry out a megger (insulation resistance) test.
Disposal
This product must be treated as industrial waste.
General instruction
For clarity purpose, illustrations in this Instruction Manual may be drawn with covers or safety guards removed. Ensure all covers and safety guards are properly
installed prior to starting operation.

4
─CONTENTS ─
1 PRE-OPERATION INSTRUCTIONS 6
1.1 Unpacking and product confirmation.......................................................................................................6
1.1.1 Product confirmation.......................................................................................................................................6
1.1.2 SERIAL number check ...................................................................................................................................7
1.2 Component names .....................................................................................................................................8
2 INSTALLATION AND WIRING 9
2.1 Pre-installation instructions ......................................................................................................................9
2.2 Installation procedure ................................................................................................................................9
2.3 Wiring ........................................................................................................................................................12
2.4 Terminals...................................................................................................................................................14
2.5 Encoder .....................................................................................................................................................15
3 INVERTER FUNCTIONS ENABLED WITH FR-A8APA 16
4 ORIENTATION CONTROL 17
4.1 Wiring example .........................................................................................................................................17
4.2 Terminals...................................................................................................................................................18
4.3 Specifications ...........................................................................................................................................19
5 ENCODER FEEDBACK CONTROL 20
5.1 Wiring examples .......................................................................................................................................20
5.2 Specifications ...........................................................................................................................................21
6 VECTOR CONTROL 22

5
6.1 Wiring examples .......................................................................................................................................22
6.2 Setting procedure of vector control for motor with encoder ...............................................................25
6.3 Vector control for PM motor with encoder.............................................................................................26
6.4 Offline auto tuning....................................................................................................................................27
6.5 Encoder position tuning ..........................................................................................................................29
6.6 Specifications ...........................................................................................................................................32
APPENDIX 33

6PRE-OPERATION INSTRUCTIONS
1PRE-OPERATION INSTRUCTIONS
1.1 Unpacking and product confirmation
Take the product out of the package, check the product name, and confirm that the product is as you ordered and intact.
This product is a plug-in option made for the FR-A800 series inverter.
1.1.1 Product confirmation
Check the enclosed items.
NOTE
• Connection diagrams in this Instruction Manual appear with the control logic of the input terminals as sink logic, unless
otherwise specified. (For the control logic, refer to the Instruction Manual of the inverter.)
Plug-in option
.................................................. 1
Mounting screw (M3  8 mm)
...................... 2 (Refer to
page 9 )
Spacer
......................2 (Refer to page 9 )

PRE-OPERATION INSTRUCTIONS 7
1
1.1.2 SERIAL number check
The FR-A8APA can be used with the models of inverters listed below which have the following SERIAL number. Check the
SERIAL number indicated on the inverter rating plate or package.
Rating plate example
FR-A800 series
   
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).
Model Country of origin
indication SERIAL number
FR-A820-00046(0.4K) to 04750(90K)
FR-A840-00023(0.4K) to 06830(280K)
FR-A842-07700(315K) to 12120(500K)
FR-A846-00023(0.4K) to 03610(132K)
MADE in Japan 83 or later
MADE in China 84 or later
SERIAL
number
Country
of origin

8PRE-OPERATION INSTRUCTIONS
1.2 Component names
Symbol Name Description Refer
to page
a Mounting hole Used to fix this product to the inverter by inserting a mounting screw or a spacer. 9
b Terminal block Used to connect the terminals of this product and an encoder. 14
c CON2 connector Pulse output connector. ―
d Board mounted option connector Used to connect this product to the option connector on the inverter. 9
Front view Rear view
Terminal layout
EC+ ED+EA+ EB+ ER+ UP UN
EC- ED-EA- EB- ER- UP UN
(a) (d)
(a)
(a)
(a)
(a)
(c)
(a)
(b)

INSTALLATION AND WIRING 9
2
2INSTALLATION AND WIRING
2.1 Pre-installation instructions
Check that the inverter's input power and the control circuit power are both OFF.
2.2 Installation procedure
CAUTION
Do not install or remove this product while the inverter power is ON. Doing so may damage the inverter or this product.
To avoid damage due to static electricity, static electricity in your body must be discharged before you touch this product.
(1) Remove the inverter front cover. (Refer to Chapter 2 of
the Instruction Manual (Detailed) of the inverter for
instructions for removing the front cover.)
(2) Insert two spacers into the mounting holes that will not be
filled with mounting screws (see the diagrams on the next
page to identify the holes ).
(3) Fit the board mounted option connector on this product to
the guide of the option connector on the inverter, and
insert the option as far as it goes.
(4) Fasten this product to the inverter using the two mounting
screws through the holes on either side (tightening torque:
0.33 to 0.40 N·m). If the screw holes do not line up, the
connector may not be inserted deep enough. Check the
connector.
Example of installation to connector 1
Spacer
Spacer
Option connector
on the inverter

10 INSTALLATION AND WIRING
• Insertion positions for screws and spacers
FR-A800
Attach the option to connector 1 or 2.
(Do not attach the plug-in option to connector 3.)
FR-A800-E
Attach the option to connector 1 or 3.
Connector 3
Connector 2 Connector 1
Spacer
Spacer
Mounting screw
Mounting screw
Spacer
Spacer
Mounting screw
Spacer
Spacer
Mounting screw
Mounting screw
Connector 1
Connector 3
Ethernet connector

INSTALLATION AND WIRING 11
2
NOTE
• When installing/removing the plug-in option, hold the sides of the option. Do not press on the parts on the option circuit
board. Stress applied to the parts by pressing, etc. may cause a failure.
• Be careful not to drop mounting screws during the installation or removal of the plug-in option.
• The priorities of vector control compatible plug-in options are defined as follows: FR-A8AL > FR-A8APS > FR-A8APA
> FR-A8APR > FR-A8AP. The vector control compatible plug-in options with lower priority do not function.
• Only one option attached to the option connector with high priority can function at once if more than one option of the
same name are installed together on an inverter. Priority is given to option connectors in descending order (1 to 3),
and options having a lower priority do not function.
• When the inverter cannot recognize the option unit due to improper installation, etc., or when a fault occurs in the
option or encoder, the protective function (E.1 to E.3 or E.OP1 to E.OP3) is activated and the inverter cannot be
operated. The indication shown (when a fault occurs) depends on the connector used (option connector 1 to 3).
• When removing the plug-in option, remove the two screws on either side, and then pull it straight out. Pressure applied
to the option connectors and to the option board may break the option.
Mounted position Fault indication
Option connector 1
Option connector 2
Option connector 3

12 INSTALLATION AND WIRING
2.3 Wiring
(1) Strip the signal wires as shown below. If too much of the wire is stripped, a short circuit may occur with neighboring wires.
If not enough of the wire is stripped, wires may become loose and fall out.
Twist the stripped end of wires to prevent them from fraying. Do not solder it.
Use appropriate crimp terminals (ferrules, blade terminals, etc.) for these terminal blocks as necessary.
When using the crimp terminal, make sure that the stranded wire do not come out of the terminal.
NOTE
• Crimp terminals commercially available (as of January 2017. The product may be changed without notice.)
Wire strip length
Terminal
screw size Wire size (mm2)Ferrule part No. Manufacturer Crimping tool model No.With insulation sleeve Without insulation sleeve
M2 0.3 AI 0,34-6TQ A 0,34-7 Phoenix Contact
Co., Ltd. CRIMPFOX 6
0.5 Al 0,5-6WH A 0,5-6
5 mm
Crumpled tip
Wires are not inserted
into the sleeve
Unstranded
wires
Damaged
Wire
Wire
Sleeve
Sleeve
0 to 0.5 mm
0 to 0.5 mm

INSTALLATION AND WIRING 13
2
(2) Loosen the terminal screw and insert the cable into the terminal.
NOTE
• Under-tightening may cause cable disconnection or malfunction. Over-tightening may cause a short circuit or
malfunction due to damage to the screw or unit.
• When wiring the RS-485 terminals on the inverter with the plug-in options installed, be careful not to let RS-485 cables
touch the option circuit boards and the inverter circuit board. This is to prevent a malfunction due to electromagnetic
noises.
Screw size Tightening torque Cable size Screwdriver
M2 0.22 to 0.25 Nm0.3 to 0.75 mm2Small flat-blade screwdriver
(Tip thickness: 0.4 mm, tip width: 2.5 mm)
CAUTION
After wiring, do not leave wire offcuts in the inverter. Doing so may cause a fault, failure, or malfunction.

14 INSTALLATION AND WIRING
2.4 Terminals
Terminal
symbol Terminal name Description
UP Encoder power supply (Up)
For the power supply (5 V) for the encoder
UN Encoder earth (ground) (0V)
EA+ Incremental sine signal: phase A (A+)
For the incremental sine signal output from the sinusoidal encoder
EA- Incremental sine signal: phase A (A-)
EB+ Incremental cosine signal: phase B (B+) For the incremental cosine signal output from the sinusoidal encoder.
The cosine signal has a phase difference of 90 degrees with respect to
the sine signal (phase A).
EB- Incremental cosine signal: phase B (B-)
ER+ Home position signal: phase R (R+)
For the home position signal output from the sinusoidal encoder
ER- Home position signal: phase R (R-)
EC+ Magnetic pole position detection sine signal:
phase C (C+) For the sine signal taken from the Z1 track of the sinusoidal encoder
(one period per revolution)
EC- Magnetic pole position detection sine signal:
phase C (C-)
ED+ Magnetic pole position detection cosine signal:
phase D (D+) For the cosine signal taken from the Z1 track of the sinusoidal encoder
(one period per revolution)
ED- Magnetic pole position detection cosine signal:
phase D (D-)

INSTALLATION AND WIRING 15
2
2.5 Encoder
Required encoder specifications
The following table shows the supported encoder and cables.
(as of January 2018. The product may be changed without notice.)
Interface Sinusoidal voltage signal (1 Vpp)
Signal type
Incremental signal (sine/cosine)
Home position signal
Magnetic pole position detection signal (sine/cosine signal taken from the Z1 track, one period per revolution)
Signal period 2048
Permissible speed
Rotation speed of the SinCos encoder interface encoder-mounted shaft: 5800 r/min
The drive shaft and encoder-mounted shaft must be coupled directly or via a belt (with the speed ratio of 1:1)
without any mechanical looseness or slip. Gear changing shafts cannot be applied.
Applicable encoder ERN 1387
Recommended cable Cables compatible with the encoder above (manufactured by HEIDENHAIN)
Maximum wiring length 100 m
Manufacturer HEIDENHAIN
EA+ UNUPEB+ ER+ EC+ ED+
EA-
UNUP
EB- ER- EC- ED-
UN: White/Green
UP: Brown/Green
ED-: Violet
ED+: Yellow
EC-: Pink
EC+: Gray
ER-: Black
ER+: Red
EB-: Red/Black
EB+: Blue/Black
EA-: Yellow/Black
EA+: Green/Black
SinCos encode
r
FR-A8APA circuit board
Terminals

16 INVERTER FUNCTIONS ENABLED WITH FR-A8APA
3INVERTER FUNCTIONS ENABLED WITH FR-A8APA
Parameter for detector
Maximum setting speed of the inverter
When the FR-A8APA is installed, operate the inverter so that the encoder pulse frequency is kept at 100 kHz or lower. If a
speed higher than the maximum speed is set, the speed is clamped at the maximum speed.
NOTE
• While the motor stops, signal loss may not be detected depending on the motor shaft position. Before starting the
operation, check the wiring.
• The availability of the functions differ according to the specifications of the inverter. Refer to the Instruction Manual of
the Inverter.
• When the motor rotation in the low-speed range (60 r/min or lower) is unstable, check if the encoder cables are
properly connected.
Setting item Parameters for FR-A8APA
Encoder rotation direction Pr.359
Number of detector pulses (Signal period) Pr.369
Encoder signal loss detection enable/disable selection Pr.376

ORIENTATION CONTROL 17
4
4ORIENTATION CONTROL
This function is used with an encoder installed to the spindle of a machine tool, etc. to allow a rotary shaft to be stopped at the
specified position (oriented).
For the details of the parameters used for orientation control, refer to the Instruction Manual (Detailed) of the inverter.
4.1 Wiring example
V/FV/FV/F
Magnetic fluxMagnetic fluxMagnetic flux
VectorVectorVector
Three-phase
AC power
supply
MCCB
Forward rotation start
Reverse rotation start
Orientation command
Contact input common
Earth
(Ground)
Inverter
R/L1
S/L2
T/L3
DY
U
V
W
U
V
W
E
∗5
X0
X1
X14
X15
FR-A8APA
M
STF
STR
SD
SD
X22∗1
ORM
ORA ∗2
SE
∗2
FR-A8AX
MC
∗3
Encoder
ERN 1387
E
∗4
EA+
EA-
EB+
EB-
ER+
ER-
EC+
EC-
ED+
ED-
UP
UN
EA+
EA-
EB+
EB-
ER+
ER-
EC+
EC-
ED+
ED-
UP
EA+
EA-
EB+
EB-
ER+
ER-
EC+
EC-
ED+
ED-
UP
EA+
EA-
EB+
EB-
ER+
ER-
EC+
EC-
ED+
ED-
UP
UN
 Use Pr.178 to Pr.189 (input terminal
function selection) to assign the function
to any of terminal.
Refer to the Instruction Manual (Detailed) of
the inverter for details of Pr.178 to Pr.189
(input terminal function selection).
 Use Pr.190 to Pr.196 (output terminal
function selection) to assign the function
to any of terminal.
Refer to the Instruction Manual (Detailed) of
the inverter for details of Pr.190 to Pr.196
(output terminal function selection).
 Connect the encoder so that there is no
looseness between the motor and motor
shaft. Speed ratio should be 1:1.
 Earth (ground) the shield of the encoder
cable to the enclosure using a tool such as
a P-clip.
 When a stop position command is input
from outside, a plug-in option FR-A8AX is
necessary. Refer to the Instruction Manual
(Detailed) of the inverter for details of
external stop position command.

18 ORIENTATION CONTROL
4.2 Terminals
FR-A8AX terminal
Inverter terminal
 Refer to the Instruction Manual (Detailed) of the inverter for details of Pr.178 to Pr.189 (input terminal function selection) and Pr.190 to
Pr.196 (output terminal function selection).
Terminal
symbol Terminal name Description
X0 to X15 Digital signal input terminal Input the digital signal at the relay contact or open collector terminal.
Using Pr.360, speed or position command is selected as the command signal entered.
DY Data read timing input
signal terminal
Used when a digital signal read timing signal is necessary. Data is read only during the DY
signal is on.
By switching the DY signal off, the X0 to X15 data before signal-off is retained.
Terminal
(signal) Terminal (signal) name Application explanation
Input X22 Orientation command
Used to enter an orientation signal for orientation.
For the terminal used for X22 signal input, set "22" in any of Pr.178 to Pr.189 to assign the
function. 
Output
ORA Orientation complete
Switched LOW if the orientation has stopped within the in-position zone while the start and
X22 signals are input.
For the terminal used for the ORA signal output, assign the function by setting "27 (positive
logic) or 127 (negative logic)" in any of Pr.190 to Pr.196. 
ORM Orientation fault
Switched LOW if the orientation has not completed within the in-position zone while the start
and X22 signals are input.
For the terminal used for the ORM signal output, assign the function by setting "28 (positive
logic) or 128 (negative logic)" in any of Pr.190 to Pr.196. 

ORIENTATION CONTROL 19
4
4.3 Specifications
Repeated positioning
accuracy
1.5°
Depends on the load torque, moment of inertia of the load or orientation, creep speed, position loop switching
position, etc.
Functions
Orientation, creep speed setting, stop position command selection, DC injection brake start position setting,
creep speed and position loop switch position setting, position shift, orientation in-position, position pulse
monitor, etc.
Holding force after
positioning
Under V/F control, Advanced magnetic flux vector control...without servo lock function
Under vector control...with servo lock function
Input signal
(contact input)
Orientation command, forward and reverse rotation commands, stop position command
Binary signal of maximum 16 bits (when used with the FR-A8AX)
Output signal
(open collector output) Orientation completion signal, orientation fault signal

20 ENCODER FEEDBACK CONTROL
5ENCODER FEEDBACK CONTROL
When the FR-A8APA is installed on the FR-A800 series inverter, encoder feedback control can be performed under V/F control
or Advanced magnetic flux vector control.
This controls the inverter output frequency so that the motor speed is constant to the load variation by detecting the motor
speed with the encoder to feed back to the inverter.
For the details of the parameters used for encoder feedback control, refer to the Instruction Manual (Detailed) of the inverter.
5.1 Wiring examples
V/FV/FV/F
Magnetic fluxMagnetic fluxMagnetic flux
Earth
(Ground)
Inverter
Three-phase
AC power supply
MCCB
R/L1
S/L2
T/L3
U
V
W
U
V
W
E
FR-A8APA
M
STF
STR
SD
10
2
5
MC
Forward rotation start
Reverse rotation start
Contact input common
Frequency setting
potentiometer
∗1
Encoder
ERN 1387
E
∗2
EA+
EA-
EB+
EB-
ER+
ER-
EC+
EC-
ED+
ED-
UP
UN
EA+
EA-
EB+
EB-
ER+
ER-
EC+
EC-
ED+
ED-
UP
EA+
EA-
EB+
EB-
ER+
ER-
EC+
EC-
ED+
ED-
UP
EA+
EA-
EB+
EB-
ER+
ER-
EC+
EC-
ED+
ED-
UP
UN
 Connect the encoder so that there is no
looseness between the motor and
motor shaft. Speed ratio should be 1:1.
 Earth (ground) the shield of the
encoder cable to the enclosure using a
tool such as a P-clip.