Mitsubishi Electric FR-A862-05450-E User manual

INVERTER
A800-E INVERTER FR-A862-E INSTRUCTION MANUAL (HARDWARE)
A
INTRODUCTION 1
INSTALLATION AND WIRING 2
PRECAUTIONS FOR USE OF
THE INVERTER 3
PROTECTIVE FUNCTIONS 4
PRECAUTIONS FOR
MAINTENANCE AND
INSPECTION
5
SPECIFICATIONS 6
HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
IB(NA)-0600639ENG-A(1605)MEE Printed in Japan Specifications subject to change without notice.
A800-E
FR-A862-E (SEPARATED CONVERTER TYPE)
INSTRUCTION MANUAL (HARDWARE)
FR-A862-05450 to 08500-E
High functionality and high performance

Safety Instructions 1
Thank you for choosing this Mitsubishi inverter.
This Instruction Manual describes handling and cautions about the hardware, such as installation and wiring, for the FR-A862
(separated converter type) that are different from the FR-A860.
Information about the software, such as basic operations and parameters, is described in the FR-A800 Instruction Manual (Detailed)
in the CD-ROM enclosed with the product. For the details of Ethernet communication, refer to the FR-A800-E Ethernet Function
Manual in the enclosed CD-ROM. In addition to this manual, please read the manuals in the enclosed CD-ROM carefully. Do not use
this product until you have a full knowledge of the equipment, safety information and instructions.
Please forward this Instruction Manual to the end user.
Electric Shock Prevention
Fire Prevention
Injury Prevention
Additional Instructions
The following instructions must be also followed. If the product
is handled incorrectly, it may cause unexpected fault, an injury,
or an electric shock.
Safety Instructions
Do not attempt to install, operate, maintain or inspect the
product until you have read through this Instruction Manual
(Detailed) 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.
Installation, operation, maintenance and inspection must be
performed by qualified personnel. Here, an expert means a
person who meets all the conditions below.
• A person who took a proper engineering training. Such
training may be available at your local Mitsubishi Electric
office. Contact your local sales office for schedules and
locations.
• A person who can access operating manuals for the
protective devices (e.g. light curtain) connected to the safety
control system. A person who has read and familiarized
himself/herself with the manuals.
In this Instruction Manual (Detailed), 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.
The level may even lead to a serious
consequence according to conditions. Both instruction levels
must be followed because these are important to personal
safety.
Warning
While the inverter power is ON, do not remove the front cover or
the wiring cover. Do not run the inverter with the front cover or
the wiring cover removed. Otherwise you may access the
exposed high voltage terminals or the charging part of the
circuitry and get an electric shock.
Even if power is OFF, do not remove the front cover except for
wiring or periodic inspection. You may accidentally touch the
charged inverter circuits and get an electric shock.
Before wiring or inspection, power lamp must be switched OFF.
Any person who is involved in wiring or inspection shall 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.
This inverter must be earthed (grounded). Earthing (grounding)
must conform to the requirements of national and local safety
regulations and electrical code (NEC section 250, IEC 536 class
1 and other applicable standards).
Any person who is involved in wiring or inspection of this
equipment shall be fully competent to do the work.
The inverter must be installed before wiring. Otherwise you may
get an electric shock or be injured.
Setting dial and key operations must be performed with dry
hands to prevent an electric shock. 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.
Do not change the cooling fan while power is ON. It is dangerous
to change the cooling fan while power is ON.
Do not touch the printed circuit board or handle the cables with
wet hands. Otherwise you may get an electric shock.
A PM motor is a synchronous motor with high-performance
magnets embedded in the rotor. Motor terminals holds high-
voltage while the motor is running even after the inverter power
is turned OFF. Before wiring or inspection, the motor must be
confirmed to be stopped. In an application, such as fan and
blower, where the motor is driven by the load, a low-voltage
manual motor starter must be connected at the inverter's output
side, and wiring and inspection must be performed while the
motor starter is open. Otherwise you may get an electric shock.
Warning
Caution
Caution
Caution
Inverter must be installed on a nonflammable wall without holes
(so that nobody touches the inverter heatsink on the rear side,
etc.). Mounting it to or near flammable material may cause a fire.
If the inverter has become faulty, the inverter power must be
switched OFF. A continuous flow of large current may cause a
fire.
Be sure to perform daily and periodic inspections as specified in
the Instruction Manual. If a product is used without any
inspection, a burst, breakage, or a fire may occur.
Caution
The voltage applied to each terminal must be the ones specified
in the Instruction Manual. Otherwise burst, damage, etc. may
occur.
The cables must be connected to the correct terminals.
Otherwise burst, damage, etc. may occur.
The polarity (+ and -) must be correct. Otherwise 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. Touching these
devices may cause a burn.
Caution
Transportation and Mounting
Any person who is opening a package using a sharp object,
such as a knife and cutter, must wear gloves to prevent injuries
caused by the edge of the sharp object.
The product must be transported in correct method that
corresponds to the weight. Failure to do so may lead to injuries.
Do not stand or rest heavy objects on the product.
Do not stack the boxes containing inverters higher than the
number recommended.
When carrying the inverter, do not hold it by the front cover; it
may fall off or fail.
During installation, caution must be taken not to drop the inverter
as doing so may cause injuries.
The product must be installed on the surface that withstands the
weight of the inverter.
Do not install the product on a hot surface.
The mounting orientation of the inverter must be correct.
The inverter must be installed on a strong surface securely with
screws so that it will not drop.
Do not install or operate the inverter 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.
As the inverter is a precision instrument, do not drop or subject it
to impact.
The surrounding air temperature for LD and ND (initial setting)
models must be between -10 and +50°C (non-freezing). The
surrounding air temperature for SLD and HD models must be
between -10 and +40°C (non-freezing). Otherwise the inverter
may be damaged.
The ambient humidity must be 95%RH or less (non-
condensing). Otherwise the inverter may be damaged. (Refer to
page 17 for details.)

2Safety Instructions
Caution
Transportation and Mounting
The storage temperature (applicable for a short time, e.g. during
transit) must be between -20 and +65°C. Otherwise the inverter
may be damaged.
The inverter must be used indoors (without corrosive gas,
flammable gas, oil mist, dust and dirt etc.) Otherwise the inverter
may be damaged.
The inverter must be used at an altitude of 2500 m or less above
sea level, with 2.9 m/s2or less vibration at 10 to 55 Hz
(directions of X, Y, Z axes). Otherwise the inverter may be
damaged. (Refer to page 17 for details.)
If halogen-based materials (fluorine, chlorine, bromine, iodine,
etc.) infiltrate into a Mitsubishi product, the product will be
damaged. Halogen-based materials are often included in
fumigant, which is used to sterilize or disinfest wooden
packages. When packaging, prevent residual fumigant
components from being infiltrated into Mitsubishi products, or
use an alternative sterilization or disinfection method (heat
disinfection, etc.) for packaging. Sterilization of disinfection of
wooden package should also be performed before packaging
the product.
Wiring
Do not install a power factor correction capacitor or surge
suppressor/capacitor type filter on the inverter output side.
These devices on the inverter output side may be overheated or
burn out.
The output side terminals (terminals U, V, and W) must be
connected correctly. Otherwise the motor will rotate inversely.
PM motor terminals (U, V, W) hold high-voltage while the PM
motor is running even after the power is turned OFF. Before
wiring, the PM motor must be confirmed to be stopped.
Otherwise you may get an electric shock.
Never connect a PM motor to the commercial power supply.
Applying the commercial power supply to input terminals (U,V,
W) of a PM motor will burn the PM motor. The PM motor must
be connected with the output terminals (U, V, W) of the inverter.
Trial run
Before starting operation, each parameter must be confirmed
and adjusted. A failure to do so may cause some machines to
make unexpected motions.
Warning
Usage
Everyone must stay away from the equipment when the retry
function is set as it will restart suddenly after a trip.
Since pressing STOP/RESET key may not stop output
depending on the function setting status, separate circuit and
switch that make an emergency stop (power OFF, mechanical
brake operation for emergency stop, etc.) must be provided.
OFF status of the start signal must be confirmed before resetting
the inverter fault. Resetting inverter fault with the start signal ON
restarts the motor suddenly.
Do not use a PM motor for an application where the PM motor is
driven by its load and runs at a speed higher than the maximum
motor speed.
Use this inverter only with three-phase induction motors or with a
PM motor. Connection of any other electrical equipment to the
inverter output may damage the equipment.
Performing pre-excitation (LX signal and X13 signal) under
torque control (Real sensorless vector control) may start the
motor running at a low speed even when the start command
(STF or STR) is not input The motor may run also at a low speed
when the speed limit value = 0 with a start command input. It
must be confirmed that the motor running will not cause any
safety problem before performing pre-excitation.
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 product.
Caution
Usage
The electronic thermal relay function does not guarantee
protection of the motor from overheating. It is recommended to
install both an external thermal and PTC thermistor for overheat
protection.
Do not use a magnetic contactor on the inverter input for
frequent starting/stopping of the inverter. Otherwise the life of the
inverter decreases.
The effect of electromagnetic interference must be reduced by
using a noise filter or by other means. Otherwise nearby
electronic equipment may be affected.
Appropriate measures must be taken to suppress harmonics.
Otherwise power supply harmonics from the inverter may heat/
damage the power factor correction capacitor and generator.
When driving a 600V class motor by the inverter, the motor must
be an insulation-enhanced motor or measures must be taken to
suppress surge voltage. Surge voltage attributable to the wiring
constants may occur at the motor terminals, deteriorating the
insulation of the motor.
When parameter clear or all parameter clear is performed, the
required parameters must be set again before starting
operations because all parameters return to their initial values.
The inverter can be easily set for high-speed operation. Before
changing its setting, the performances of the motor and machine
must be fully examined.
Stop status cannot be hold by the inverter's brake function. In
addition to the inverter’s brake function, a holding device must
be installed to ensure safety.
Before running an inverter which had been stored for a long
period, inspection and test operation must be performed.
Static electricity in your body must be discharged beforeyou
touch the product.
Only one PM motor can be connected to an inverter.
A PM motor must be used under PM sensorless vector control.
Do not use a synchronous motor, induction motor, or
synchronous induction motor.
Do not connect a PM motor in the induction motor control
settings (initial settings). Do not use an induction motor in the
PM sensorless vector control settings. It will cause a failure.
In the system with a PM motor, the inverter power must be
turned ON before closing the contacts of the contactor at the
output side.
In order to protect the inverter and the system against
unauthorized access by external systems via network, take
security measures including firewall settings.
Depending on the network environment, the inverter may not
operate as intended due to delays or disconnection in
communication. Carefully consider the conditions and safety for
the inverter on site.
Emergency stop
A safety backup such as an emergency brake must be provided
to prevent hazardous conditions to the machine and equipment
in case of inverter failure.
When the breaker on the inverter input side trips, the wiring must
be checked for fault (short circuit), and internalparts of the
inverter for a damage, etc. The cause of the trip must be
identified and removed before turning ON the power of the
breaker.
When a protective function activates, take an appropriate
corrective action, then reset the inverter, and resume the
operation.
Maintenance, inspection and parts replacement
Do not carry out a megger (insulation resistance) test on the
control circuit of the inverter. It will cause a failure.
Disposal
The inverter must be treated as industrial waste.
General instruction
Many of the diagrams and drawings in the Instruction Manual
show the product without a cover or partially open for
explanation. Never operate the product in this manner. The
cover must be always reinstalled and the instruction in the
Instruction Manual must be followed when operating the product.
For more details on the PM motor, refer to the Instruction Manual
of the PM motor.

CONTENTS 3
1 INTRODUCTION 7
1.1 Product checking and accessories 8
1.2 Inverter component names 9
1.3 About the related manuals 10
2 INSTALLATION AND WIRING 11
2.1 Peripheral devices 12
2.1.1 Inverter and peripheral devices ......................................................................................................................12
2.1.2 Peripheral devices ..........................................................................................................................................14
2.2 Removal and reinstallation of the front cover 15
2.3 Installation of the inverter and enclosure design 17
2.3.1 Inverter installation environment.....................................................................................................................17
2.3.2 Cooling system types for inverter enclosure...................................................................................................19
2.3.3 Inverter installation..........................................................................................................................................20
2.3.4 Protruding the heatsink...................................................................................................................................22
2.4 Terminal connection diagrams 24
2.5 Main circuit terminals 26
2.5.1 Details on the main circuit terminals of the inverter ........................................................................................26
2.5.2 Details on the main circuit terminals of the converter unit (FR-CC2)..............................................................26
2.5.3 Terminal layout of the main circuit terminals, wiring of power supply and the motor......................................27
2.5.4 Applicable cables and wiring length................................................................................................................28
2.5.5 Earthing (grounding) precautions ...................................................................................................................30
2.6 Control circuit 31
2.6.1 Details on the control circuit terminals of the inverter.....................................................................................31
2.6.2 Details on the control circuit terminals of the converter unit (FR-CC2)...........................................................34
2.6.3 Control logic (sink/source) change .................................................................................................................35
2.6.4 Wiring of inverter control circuit ......................................................................................................................37
2.6.5 Wiring precautions..........................................................................................................................................39
2.6.6 When using separate power supplies for the control circuit and the main circuit ...........................................40
2.6.7 When supplying 24 V external power to the control circuit .............................................................................41
2.7 Communication connectors and terminals 43
2.7.1 PU connector..................................................................................................................................................43
2.7.2 Ethernet connector .........................................................................................................................................44
2.7.3 USB connector................................................................................................................................................45
2.8 Connection of motor with encoder (vector control) 46
2.9 Parameter settings for a motor with encoder 50
2.10 Installing a communication option 51
3 PRECAUTIONS FOR USE OF THE INVERTER 53
CONTENTS

4CONTENTS
3.1 Electro-magnetic interference (EMI) and leakage currents 54
3.1.1 Leakage currents and countermeasures........................................................................................................ 54
3.1.2 Countermeasures against inverter-generated EMI ........................................................................................ 55
3.2 Power supply harmonics 57
3.2.1 Power supply harmonics ................................................................................................................................ 57
3.3 Installation of a reactor 57
3.4 Power-OFF and magnetic contactor (MC) 58
3.5 Countermeasures against deterioration of the 600 V class motor insulation 59
3.6 Checklist before starting operation 60
3.7 Failsafe system which uses the inverter 62
4 PROTECTIVE FUNCTIONS 65
4.1 Inverter fault and alarm indications 66
4.2 Reset method for the protective functions 66
4.3 List of fault displays 67
5 PRECAUTIONS FOR
MAINTENANCE AND INSPECTION 69
5.1 Inspection item 70
5.1.1 Daily inspection .............................................................................................................................................. 70
5.1.2 Periodic inspection ......................................................................................................................................... 70
5.1.3 Daily and periodic inspection.......................................................................................................................... 71
5.1.4 Checking the inverter and converter modules................................................................................................ 72
5.1.5 Cleaning ......................................................................................................................................................... 73
5.1.6 Replacement of parts ..................................................................................................................................... 73
5.1.7 Inverter replacement ...................................................................................................................................... 75
5.2 Measurement of main circuit voltages, currents and powers 76
5.2.1 Measurement of powers................................................................................................................................. 78
5.2.2 Measurement of voltages and use of PT........................................................................................................ 78
5.2.3 Measurement of currents ............................................................................................................................... 79
5.2.4 Use of CT and transducer .............................................................................................................................. 79
5.2.5 Example of measuring converter unit (FR-CC2) input power factor............................................................... 79
5.2.6 Measurement of converter output voltage (across terminals P and N) .......................................................... 79
5.2.7 Measurement of inverter output frequency..................................................................................................... 80
5.2.8 Insulation resistance test using megger ......................................................................................................... 80
5.2.9 Pressure test .................................................................................................................................................. 80
6 SPECIFICATIONS 81

CONTENTS 5
6.1 Inverter rating 82
6.2 Common specifications 83
6.3 Outline dimension drawings 85
6.3.1 Inverter outline dimension drawings ...............................................................................................................85
APPENDIX 87
Appendix 1 For customers replacing the conventional model with this inverter.................................. 88
Appendix 2 Comparison with FR-A860...................................................................................................... 90
Appendix 3 Instructions for UL and cUL ................................................................................................... 91
Appendix 4 Restricted Use of Hazardous Substances in Electronic and Electrical Products............. 92

MEMO
6

1
INTRODUCTION 7
1INTRODUCTION
This chapter contains the descriptions that must be read before
using this product.
Always read the instructions before using the equipment.
1.1 Product checking and accessories.........................................8
1.2 Inverter component names ......................................................9
<Abbreviations>
DU ..................................................Operation panel (FR-DU08)
Operation panel .............................Operation panel (FR-DU08) and LCD operation panel (FR-LU08)
Parameter unit ...............................Parameter unit (FR-PU07)
PU ..................................................Operation panel and parameter unit
Inverter............................................Mitsubishi inverter FR-A800-E series (Separated converter type)
Ethernet board ................................Ethernet communication board (FR-A8ETH)
Vector control compatible option .... FR-A8AP/FR-A8AL/FR-A8APR/FR-A8APS (plug-in option), FR-A8TP
(control terminal option)
Pr. ...................................................Parameter number (Number assigned to function)
PU operation...................................Operation using the PU (operation panel/parameter unit)
External operation........................... Operation using the control circuit signals
Combined operation .......................Combined operation using the PU (operation panel/parameter unit) and
External operation
<Trademarks>
• Ethernet is a registered trademark of Fuji Xerox Co., Ltd.
<Notes on descriptions in this Instruction Manual>
• Connection diagrams in this Instruction Manual suppose that the control logic of the input terminal is the sink
logic, unless otherwise specified. (For the control logic, refer to page 35.)

Product checking and accessories
8INTRODUCTION
1.1 Product checking and accessories
Unpack the product and check the rating plate and the capacity plate of the inverter to ensure that the model agrees with the
order and the product is intact.
Applicable inverter model
How to read the SERIAL number
Accessory
• Earthing (grounding) cable (1): For connection with a communication option. (Refer to page 51.)
• CD-ROM (1): Including the Instruction Manual (Detailed) and other documents.
Rating plate example 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).
   
Symbol Year Month Control number
SERIAL
Rating plate
Input rating
Output rating
SERIAL
Inverter model
FR-A862-05450-E1-60
F R - A 8 6 2 - 05450 - E1 - 60
600 V class
Symbol Voltage class
6
Symbol Circuit board coating
(conforming to IEC60721-3-3 3C2/3S2)
With
With
Plated conductor
With
Without
06
60
Symbol Description
05450 to 08500 SLD rated
inverter current (A)
Symbol Structure, functionality
Separated converter type 2Symbol Communication
type
E1 Ethernet

Inverter component names
INTRODUCTION 9
1
1.2 Inverter component names
Component names are shown below.
 Refer to the FR-A860 Instruction Manual (Detailed)
Symbol Name Description Refer to
page
(a) Plug-in option connector 1
Connects a plug-in option or a communication option.
Instruction
Manual of
the option
(b) Plug-in option connector 3
(c) Plug-in option connector 2
The connector 2 cannot be used because the Ethernet board is installed in
the initial status. The Ethernet board must be removed to install a plug-in
option to the connector 2. (However, Ethernet communication is disabled in
that case.)
44
(d) Voltage/current input switch (SW2) Selects between voltage and current for the terminal 2 and 4 inputs. 
(e)
Ethernet communication connector Connect the Ethernet dedicated cable for connection to the network. 44
(f) Control circuit terminal block Connects cables for the control circuit. 31
(g) PU connector Connects the operation panel or the parameter unit (FR-PU07). This
connector also enables the RS-485 communication. 43
(h) USB A connector Connects a USB memory device. 45
(i) USB mini B connector Connects a personal computer. 45
(j) Front cover (upper side) Remove this cover for the installation of the product, installation of a plug-in
(communication) option, switching of the voltage/current input switch, etc. 15
(k) Power lamp Stays ON while the power is supplied to the control circuit (R1/L11, S1/L21). 27
(l) Alarm lamp Turns ON when the protective function of the inverter is activated. 65
(m) Charge lamp Stays ON while the power is supplied to the main circuit. 27
(n) Accessory cover Remove this cover for using the PU connector. 
(o) Front cover (lower side) Remove this cover for wiring. 15
(p) Main circuit terminal block Connects cables for the main circuit. 26
(q) Cooling fan Cools the inverter. 74
(r) Switches for manufacturer setting
(SW3 and SW4) Do not change the initial setting (OFF ). ─
(p)
(m)
(n)
(k)
(l)
(j)
(o)
(q)
(g)
(f)
(d)
(e)
(b)
(a)
(c)
(h)
(i)
(r)
OFF
ON

About the related manuals
10 INTRODUCTION
1.3 About the related manuals
The manuals related to FR-A862-E are shown below.
Manual name Manual number
FR-A860 Instruction Manual (Detailed) IB-0600563ENG
FR-A800-E Ethernet Function Manual IB-0600628ENG
FR-CC2 (Converter unit) Instruction Manual IB-0600572ENG
FR Configurator 2 Instruction Manual IB-0600516ENG
FR-A800/F800 PLC Function Programming Manual IB-0600492ENG

2
INSTALLATION AND WIRING 11
2INSTALLATION AND
WIRING
This chapter explains the "installation" and the "wiring" of this
product.
Always read the instructions before using the equipment.
2.1 Peripheral devices ....................................................................12
2.2 Removal and reinstallation of the front cover........................15
2.3 Installation of the inverter and enclosure design ..................17
2.4 Terminal connection diagrams ................................................24
2.5 Main circuit terminals ...............................................................26
2.6 Control circuit ...........................................................................31
2.7 Communication connectors and terminals ............................43
2.8 Connection of motor with encoder (vector control) ..............46
2.9 Parameter settings for a motor with encoder ........................50
2.10 Installing a communication option..........................................51

Peripheral devices
12 INSTALLATION AND WIRING
2.1 Peripheral devices
2.1.1 Inverter and peripheral devices
NOTE
• To prevent an electric shock, always earth (ground) the motor, the inverter, and the converter unit.
• Do not install a power factor correction capacitor or surge suppressor or capacitor type filter on the inverter's output side. Doing
so will cause the inverter to trip or the capacitor and surge suppressor to be damaged. If any of the above devices is connected,
immediately remove it. When installing a molded case circuit breaker on the output side of the inverter, contact the manufacturer
of the molded case circuit breaker.
• Electromagnetic wave interference
The input/output (main circuit) of the inverter or the converter unit includes high frequency components, which may interfere
with the communication devices (such as AM radios) used near the inverter or the converter unit. Refer to page 55 for
countermeasures.
• For details of options and peripheral devices, refer to the respective Instruction Manual.
• A PM motor cannot be driven by the commercial power supply.
• A PM motor is a motor with permanent magnets embedded inside. High voltage is generated at the motor terminals while the
motor is running. Before closing the contactor at the output side, make sure that the inverter power is ON and the motor is
stopped.
Earth
(Ground)
R/L1 S/L2 T/L3 N/-N/- P/+P/+
: Install these options as required.
UVW U
Earth (Ground)
VW
(d) Molded case
circuit breaker
(MCCB) or earth
leakage current
breaker (ELB),
fuse
(i) Noise filter
(k) Contactor
Example) No-fuse
switch
(DSN type)
(l) PM motor
(g) Noise filter
(e) Magnetic
contactor
(MC)
(a) Inverter
(FR-A862)
(b) Converter unit
(FR-CC2)
(c) Three-phase AC power supply
(h) USB connector
Personal computer
USB
USB host
(A connector)
USB device
(Mini B connector)
Communication
status indicator
(LED)(USB host)
Earth
(Ground)
(j) Induction
motor
(f) AC reactor
IM connection PM connection
Earth
(Ground)

Peripheral devices
INSTALLATION AND WIRING 13
2
Symbol Name Overview
Refer
to
page
(a) Inverter (FR-A862)
The life of the inverter and the converter unit is influenced by the
surrounding air temperature.
The surrounding air temperature should be as low as possible within the
permissible range. This must be noted especially when the inverter is
installed in an enclosure.
Incorrect wiring may lead to damage of the inverter and the converter unit.
The control signal lines must be kept fully away from the main circuit lines to
protect them from noise.
17
24
(b) Converter unit (FR-CC2)
(c) Three-phase AC power supply Must be within the permissible power supply specifications of the converter
unit. 82
(d)
Molded case circuit breaker (MCCB),
earth leakage circuit breaker (ELB), or
fuse
Must be selected carefully since an inrush current flows in the converter unit
at power ON. 14
(e) Magnetic contactor (MC)
Install this to ensure safety.
Do not use this to start and stop the inverter. Doing so will shorten the life of
the inverter and the converter unit.
58
(f) AC reactor
Install this to suppress harmonics and to improve the power factor.
An AC reactor is required when installing the inverter near a large power
supply system (1000 kVA or more). Under such condition, the inverter and
the converter unit may be damaged if you do not use a reactor.
Select a reactor according to the applied motor capacity.
57
(g) Noise filter Suppresses the noise radiated from the power supply side of the converter
unit. 55
(h) USB connection A USB (Ver. 1.1) cable connects the inverter with a personal computer.
A USB memory device enables parameter copies and the trace function. 45
(i) Noise filter
Install this to reduce the electromagnetic noise generated from the inverter
and the converter unit. The noise filter is effective in the range from about
0.5 MHz to 5 MHz.
55
(j) Induction motor Connect a squirrel-cage induction motor. —
(k) Contactor
Example) No-fuse switch (DSN type)
Connect this for an application where a PM motor is driven by the load even
while the inverter power is OFF. Do not open or close the contactor while
the inverter is running (outputting).
—
(l) PM motor A PM motor can be used. A PM motor cannot be driven by the commercial
power supply. —

Peripheral devices
14 INSTALLATION AND WIRING
2.1.2 Peripheral devices
Selecting the converter unit (FR-CC2)
Select the capacity of the FR-CC2 converter unit according to the connected motor capacity.
 The applicable motor capacity indicated is the maximum capacity applicable for use of the 4-pole standard motor.
Selecting the breaker/magnetic contactor
Check the model of the inverter and the converter unit you purchased. Appropriate peripheral devices must be selected
according to the capacity.
Refer to the table below to prepare appropriate peripheral devices.
NOTE
• When the converter unit capacity is larger than the motor capacity, select an MCCB and a magnetic contactor according to
the converter unit model, and select cables and reactors according to the motor output.
• When the breaker on the converter unit's input side trips, check for the wiring fault (short circuit), damage to internal parts of
the inverter and the converter unit, etc. The cause of the trip must be identified and removed before turning ON the power of
the breaker.
Converter
unit
FR-CC2-[ ]
Inverter
Model
FR-A862-[ ]
Rated current
(A)
Motor capacity
(kW) 
C355K 05450
SLD 545 400
LD 496 355
ND 402 280
HD 304 220
C400K 06470
SLD 647 450
LD 589 400
ND 496 355
HD 402 280
C560K 08500
SLD 850 630
LD 773 560
ND 663 450
HD 589 400
Motor
output
(kW)
Applicable converter
model
Applicable inverter
model
Molded case circuit breaker (MCCB)
or
earth leakage circuit breaker (ELB)
(NF, NV type)
Input-side
magnetic
contactor
280 FR-CC2-C355K FR-A862-05450 600 A 373 A
355 FR-CC2-C400K FR-A862-06470 800 A 469 A
450 FR-CC2-C560K FR-A862-08500 1000 A 617 A
 Assumes the use of a 4-pole standard motor with the power supply voltage of 575 VAC 50 Hz.
 Select an MCCB according to the power supply capacity.
Install one MCCB per converter.
For the use in the United States or Canada, provide the appropriate UL and cUL listed fuse that
is suitable for branch circuit protection. (Refer to page 91.)
 The magnetic contactor is selected based on the AC-1 class. The electrical durability of magnetic contactor is 500,000 times. When the
magnetic contactor is used for emergency stops during motor driving, the electrical durability is 25 times.
If using an MC for emergency stop during driving the motor, select an MC regarding the converter unit input side current as JEM1038-AC-3 class
rated current. When using an MC on the inverter output side for commercial-power supply operation switching using a general-purpose motor,
select an MC regarding the rated motor current as JEM1038-AC-3 class rated current.
MCCB Converter unit
MCCB Converter unit
M
M
INV
INV

Removal and reinstallation of the front cover
INSTALLATION AND WIRING 15
2
2.2 Removal and reinstallation of the front cover
Removal of the front cover (lower side)
(a) Remove the mounting screws to remove the front cover (lower side). (The number of the mounting screws differs by the
capacity.)
(b) With the front cover (lower side) removed, wiring of the main circuit terminals can be performed.
Removal of the front cover (upper side)
(a) With the front cover (lower side) removed, loosen the mounting screws on the front cover (upper side). These screws cannot be
removed.
(b) While holding the areas around the installation hooks on the sides of the front cover (upper side), pull out the front cover (upper
side) using its upper side as a support.
(c) With the front cover (upper side) removed, wiring of the control circuit and the RS-485 terminals, and installation of the plug-in
option can be performed.
(a) (b)
(a) (b) (c)
Loosen
Loosen
Loosen

Removal and reinstallation of the front cover
16 INSTALLATION AND WIRING
Reinstallation of the front covers
(a) Insert the upper hooks of the front cover (upper side) into the sockets of the inverter.
Securely install the front cover (upper side) to the inverter by fixing the hooks on the sides of the cover into place.
(b) Tighten the mounting screw at the lower part of the front cover (upper side).
(c) Fasten the front cover (lower side) with the mounting screws. (The number of the mounting screws differs by the capacity.)
NOTE
• Fully make sure that the front covers are installed securely. Always tighten the mounting screws of the front covers.
(b) (c)
(a)
Fasten
Fasten
Fasten
Fasten
Fasten
Fasten

Installation of the inverter and enclosure design
INSTALLATION AND WIRING 17
2
2.3 Installation of the inverter and enclosure design
When designing or manufacturing an inverter enclosure, determine the structure, size, and device layout of the enclosure by
fully considering the conditions such as heat generation of the contained devices and the operating environment. An inverter
uses many semiconductor devices. To ensure higher reliability and long period of operation, operate the inverter in the
ambient environment that completely satisfies the equipment specifications.
2.3.1 Inverter installation environment
The following table lists the standard specifications of the inverter installation environment. Using the inverter in an
environment that does not satisfy the conditions deteriorates the performance, shortens the life, and causes a failure. Refer to
the following points, and take adequate measures.
Standard environmental specifications of the inverter
 Temperature applicable for a short time, e.g. in transit.
 For the installation at an altitude above 1,000 m (up to 2,500 m), derate the rated current 3% per 500 m.
 Surrounding Air Temperature is a temperature measured at a measurement position in an enclosure.
Ambient Temperature is a temperature outside an enclosure.
Temperature
The permissible surrounding air temperature of the inverter is between -10°C and +50°C (-10°C and +40°C at the SLD and
HD ratings). Always operate the inverter within this temperature range. Operation outside this range will considerably shorten
the service lives of the semiconductors, parts, capacitors and others. Take the following measures to keep the surrounding air
temperature of the inverter within the specified range.
(a) Measures against high temperature
• Use a forced ventilation system or similar cooling system. (Refer to page 19.)
• Install the enclosure in an air-conditioned electric chamber.
• Block direct sunlight.
• Provide a shield or similar plate to avoid direct exposure to the radiated heat and wind of a heat source.
• Ventilate the area around the enclosure well.
(b) Measures against low temperature
• Provide a space heater in the enclosure.
• Do not power OFF the inverter. (Keep the start signal of the inverter OFF.)
(c) Sudden temperature changes
• Select an installation place where temperature does not change suddenly.
• Avoid installing the inverter near the air outlet of an air conditioner.
• If temperature changes are caused by opening/closing of a door, install the inverter away from the door.
Item Description
Surrounding
air
temperature

LD, ND (initial setting) -10 to +50°C (non-freezing)
SLD, HD -10 to +40°C (non-freezing)
Surrounding air humidity 95% RH or less (non-condensing)
Storage temperature -20 to + 65°C
Atmosphere Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)
Altitude Maximum 1,000 m above sea level
Vibration 2.9 m/s2or less at 10 to 55 Hz (directions of X, Y, Z axes)
Measurement
position
Measurement
position
Inverter
5 cm 5 cm
5 cm
Enclosure

Installation of the inverter and enclosure design
18 INSTALLATION AND WIRING
Humidity
Operate the inverter within the ambient air humidity of usually 45 to 95%. Too high humidity will pose problems of reduced
insulation and metal corrosion. On the other hand, too low humidity may cause a spatial electrical breakdown. The insulation
distance defined in JEM1103 "Control Equipment Insulator" is humidity of 45 to 85%.
(a) Measures against high humidity
• Make the enclosure enclosed, and provide it with a hygroscopic agent.
• Provide dry air into the enclosure from outside.
• Provide a space heater in the enclosure.
(b) Measures against low humidity
Air with proper humidity can be blown into the enclosure from outside. Also when installing or inspecting the unit, discharge
your body (static electricity) beforehand, and keep your body away from the parts and patterns.
(c) Measures against condensation
Condensation may occur if frequent operation stops change the in-enclosure temperature suddenly or if the outside air
temperature changes suddenly.
Condensation causes such faults as reduced insulation and corrosion.
• Take the measures against high humidity in (a).
• Do not power OFF the inverter. (Keep the start signal of the inverter OFF.)
Dust, dirt, oil mist
Dust and dirt will cause such faults as poor contacts, reduced insulation and cooling effect due to the moisture-absorbed
accumulated dust and dirt, and in-enclosure temperature rise due to a clogged filter. In an atmosphere where conductive
powder floats, dust and dirt will cause such faults as malfunction, deteriorated insulation and short circuit in a short time.
Since oil mist will cause similar conditions, it is necessary to take adequate measures.
Countermeasure
• Place the inverter in a totally enclosed enclosure.
Take measures if the in-enclosure temperature rises. (Refer to page 19.)
• Purge air.
Pump clean air from outside to make the in-enclosure air pressure higher than the outside air pressure.
Corrosive gas, salt damage
If the inverter is exposed to corrosive gas or to salt near a beach, the printed board patterns and parts will corrode or the
relays and switches will result in poor contact.
In such places, take the measures given above.
Explosive, flammable gases
As the inverter is non-explosion proof, it must be contained in an explosion-proof enclosure. In places where explosion may
be caused by explosive gas, dust or dirt, an enclosure cannot be used unless it structurally complies with the guidelines and
has passed the specified tests. This makes the enclosure itself expensive (including the test charges). The best way is to
avoid installation in such places and install the inverter in a non-hazardous place.
High altitude
Use the inverter at an altitude of within 1000 m. For use at an altitude above 1,000 m (up to 2,500 m), derate the rated current
3% per 500 m.
If it is used at a higher place, it is likely that thin air will reduce the cooling effect and low air pressure will deteriorate dielectric
strength.

Installation of the inverter and enclosure design
INSTALLATION AND WIRING 19
2
Vibration, impact
The vibration resistance of the inverter is up to 2.9 m/s2at 10 to 55 Hz frequency and 1 mm amplitude for the directions of X,
Y, Z axes. Applying vibration and impacts for a long time may loosen the structures and cause poor contacts of connectors,
even if those vibration and impacts are within the specified values.
Especially when impacts are applied repeatedly, caution must be taken because such impacts may break the installation feet.
Countermeasure
• Provide the enclosure with rubber vibration isolators.
• Strengthen the structure to prevent the enclosure from resonance.
• Install the enclosure away from the sources of the vibration.
2.3.2 Cooling system types for inverter enclosure
From the enclosure that contains the inverter, the heat of the inverter and other equipment (transformers, lamps, resistors,
etc.) and the incoming heat such as direct sunlight must be dissipated to keep the in-enclosure temperature lower than the
permissible temperatures of the in-enclosure equipment including the inverter.
The cooling systems are classified as follows in terms of the cooling calculation method.
(a) Cooling by natural heat dissipation from the enclosure surface (totally enclosed type)
(b) Cooling by heatsink (aluminum fin, etc.)
(c) Cooling by ventilation (forced ventilation type, pipe ventilation type)
(d) Cooling by heat exchanger or cooler (heat pipe, cooler, etc.)
Cooling system Enclosure structure Comment
Natural
cooling
Natural ventilation
(enclosed, open type)
This system is low in cost and generally used, but the
enclosure size increases as the inverter capacity increases.
This system is for relatively small capacities.
Natural ventilation (totally
enclosed type)
Being a totally enclosed type, this system is the most
appropriate for hostile environment having dust, dirt, oil mist,
etc. The enclosure size increases depending on the inverter
capacity.
Forced
cooling
Heatsink cooling This system has restrictions on the heatsink mounting position
and area. This system is for relatively small capacities.
Forced ventilation
This system is for general indoor installation. This is
appropriate for enclosure downsizing and cost reduction, and
often used.
Heat pipe This is a totally enclosed for enclosure downsizing.
INV
INV
INV
Heatsink
INV
INV
Heat
pipe