Mitsubishi Electric FR-A8AP User manual

INVERTER
Plug-in option
INSTRUCTION MANUAL PRE-OPERATION INSTRUCTIONS 1
INSTALLATION AND WIRING 2
ENCODER SPECIFICATIONS AND
PARAMETER SETTINGS 3
ORIENTATION CONTROL 4
ENCODER FEEDBACK CONTROL 5
VECTOR CONTROL 6
FR-A8AP
Orientation control
Encoder feedback control
Vector control
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3
Thank you for choosing this Mitsubishi inverter plug-in option.
This Instruction Manual provides handling information and precautions for use of the equipment. Incorrect handling might cause an unexpected
fault. Before using this inverter, always read this Instruction Manual carefully to use the equipment to its optimum performance.
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 the 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".
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 open 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.
Do not remove the inverter front cover even if the power supply is disconnected. The only exception for this would be when performing wiring and periodic
inspection. You may accidentally touch the charged inverter circuits and get an electric shock.
Before wiring or inspection, LED indication of the inverter unit operation panel 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 is no residual voltage using a tester or the like. For a short time after the
power-OFF, a high voltage remains in the smoothing capacitor, and it is dangerous.
Any person who is involved in wiring or inspection of this equipment shall be fully competent to do the work.
The plug-in option must be installed before wiring. Otherwise you may get an electric shock or be injured.
Do not touch the plug-in option or handle the cables 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.
Caution
The voltage applied to each terminal must be the ones 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 or damage 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.
Warning
Caution
Caution
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4
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.
Caution
Transportation and mounting
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.
The mounting orientation must be correct.
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.) 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.
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
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
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.
Static electricity in your body must be discharged before you touch the product.
Maintenance, inspection and parts replacement
Do not carry out a megger (insulation resistance) test.
Disposal
The inverter must be treated as industrial waste.
General instruction
Many of the diagrams and drawings in this Instruction Manual show the inverter without a cover or partially open for explanation. Never operate the inverter in this
manner. The cover must be reinstalled and the instructions in the Instruction Manual must be followed when operating the inverter.
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5
— CONTENTS —
1 PRE-OPERATION INSTRUCTIONS 7
1.1 Unpacking and product confirmation ..............................................................................................7
1.2 Component names.............................................................................................................................8
2 INSTALLATION AND WIRING 9
2.1 Pre-installation instructions .............................................................................................................9
2.2 Installation procedure .......................................................................................................................9
2.3 Encoder specification / terminating resistor switch setting........................................................12
2.4 Wiring................................................................................................................................................14
2.5 Encoder cables dedicated to Mitsubishi motors ..........................................................................17
2.6 Terminals ..........................................................................................................................................18
3 ENCODER SPECIFICATIONS AND PARAMETER SETTINGS 19
3.1 Encoder.............................................................................................................................................19
3.2 Parameter setting.............................................................................................................................21
3.2.1 Parameter for encoder.................................................................................................................................. 21
3.2.2 Parameter settings for the motor under vector control ................................................................................. 22
4 ORIENTATION CONTROL 23
4.1 Wiring example ................................................................................................................................23
4.2 Terminals ..........................................................................................................................................25
4.3 Specifications...................................................................................................................................26
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6
5 ENCODER FEEDBACK CONTROL 27
5.1 Wiring examples ..............................................................................................................................27
5.2 Specifications...................................................................................................................................28
6 VECTOR CONTROL 29
6.1 Wiring examples ..............................................................................................................................29
6.2 Specifications...................................................................................................................................33
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PRE-OPERATION INSTRUCTIONS 7
1
1PRE-OPERATION INSTRUCTIONS
1.1 Unpacking and product confirmation
Take the plug-in option 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 dedicated for the FR-A800 series.
Product confirmation
Check the enclosed items.
Plug-in option
...............................................1
Mounting screw (M3 × 8 mm)
.....................2 (Refer to page 9.)
Spacer
....................2 (Refer to page 9.)
1 2 3 4
O
N
1
2
O
N
SW2
SW3
SW1
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8PRE-OPERATION INSTRUCTIONS
1.2 Component names
Symbol Name Description Refer to
page
a Mounting hole Fixes the option to the inverter with screws, or installs spacers. 9
b Terminal block Connects to the encoder. 14
c
Encoder type selection switch (SW3) Switches the encoder type (differential line driver/ complementary). 12
d CON2 connector Not used. ―
eTerminating resistor selection switch
(SW1) Switches ON or OFF the internal terminating resistor. 12
f
Switch for manufacturer setting (SW2)
D o not change the initially-set status. (Switches 1 and 2 are OFF .)
―
g Connector Connects to the option connector of the inverter. 9
Front view Rear view
Terminal layout
PA2
PB2
PZ2
SD SD
PO
PA1
PB1
PZ1
PG PG
PIN
PIN and PO
are not used.
1
2
O
N
SW2
SW3
SW1
(a) (g)
(a)
(b) (a)
(a)
(a)
(a)
(e)
(d)
(f)
(c)
1 2 3 4
O
N
1
2
O
N
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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
(1) Remove the inverter front cover. (Refer to Chapter 2 of the
Instruction Manual (Detailed) of the inverter for details on how to
remove the front cover.)
(2) For the two mounting holes (as shown in the next page) that will not
be tightened with mounting screws, insert spacers.
(3) Fit the connector of the plug-in option along the guide of the
connector on the inverter, and insert the plug-in option as far as it
goes. (Insert it to the inverter option connector 1 or 2.)
(4) Fit the two locations, the left and right, of the plug-in option securely
to the inverter unit by screwing in the supplied mounting screws
(tightening torque 0.33 N·m to 0.40 N·m). If the screw holes do not
line up, the connector may not be inserted deep enough. Check the
connector.
Caution
Do not mount or remove the plug-in option while the input power is ON. Doing so may damage the inverter or plug-in option.
To avoid damage due to static electricity, static electricity in your body must be discharged before you touch the product.
Spacer
Spacer
Inverter side
option connector
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10 INSTALLATION AND WIRING
Spacer
Spacer
Mounting screw
Do not insert the plug-in option to the connector 3.
Mounting screw
Spacer
Spacer
Mounting screw
Connector 1Connector 2
Connector 3
Insertion positions for screws and spacers
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INSTALLATION AND WIRING 11
2
NOTE
• Caution must be taken of mounting screws falling off when removing and mounting the plug-in option.
• Only one type of option per inverter may be used. When multiple options are mounted, priority is given to option
connectors 1, 2 and 3 on the inverter in this order, and options having a lower priority do not function. (For the
positions of the option connectors 1 to 3, refer to page 10.)
• When the inverter cannot recognize that the option unit is mounted due to improper installation, etc., the protective
function (E.1 to E.3) is displayed. A different indication will appear according to the mounted position (option connector
1 to 3).
• When removing the plug-in option, remove the two screws on the left and right, then pull it straight out. Pressure
applied to the connector and to the option board may break the option.
Mounted position Fault indication
Option connector 1
Option connector 2
Option connector 3
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12 INSTALLATION AND WIRING
2.3 Encoder specification / terminating resistor switch setting
Encoder specification selection switch (SW3)
Select either differential line driver or complementary.
It is initially set to the differential line driver. Switch its position according
to output circuit.
Terminating resistor selection switch (SW1)
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 complementary.
ON : with internal terminating resistor (initial setting status)
OFF : without internal terminating resistor
NOTE
• Set all switches 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 (CNC
(computerized numerical controller), etc) or a terminating
resistor is connected to other unit.
Complementary
Differential line driver
(initial status)
1
2
O
N
SW2
SW3
SW1
1 2 3 4
O
N
Internal terminating
resistor-ON
(initial status)
Internal terminating
resistor-OFF
1
2
O
N
SW2
SW3
SW1
1 2 3 4
O
N
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INSTALLATION AND WIRING 13
2
Motor used and switch setting
 Set according to the motor encoder used.
 Choose a power supply for encoder according to the encoder used (5 V/12 V/15 V/24 V). When the encoder output is the differential line
driver type, only 5 V can be input.
NOTE
• Switch "SW2" is for manufacturer setting. Do not change the setting.
Motor Encoder specification
selection switch (SW3)
Terminating resistor
selection switch (SW1)
Power
specifications
Mitsubishi standard motor with
encoder
Mitsubishi high-efficiency motor
with encoder
SF-JR Differential ON 5 V
SF-HR Differential ON 5 V
Others   
Mitsubishi constant-torque motor
with encoder
SF-JRCA Differential ON 5 V
SF-HRCA Differential ON 5 V
Others   
Vector control dedicated motor SF-V5RU Complementary OFF 12 V
Other manufacturer's motor with encoder   
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14 INSTALLATION AND WIRING
2.4 Wiring
(1) Use twisted pair shield cables (0.2 mm2or larger) to connect the FR-A8AP and position detector.
For the wiring to the terminals PG and SD, use several cables in parallel or use a
thick cable, according to the wiring length. 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 30 m or more
The wiring length can be extended to 100 m by slightly increasing the 5 V power
supply (approx. 5.5 V) and using six or more cables with gauge size of 0.2 mm2in
parallel or a cable with gauge size of 1.25 mm2or 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 close as the inverter) with a P clip or U clip
made of metal.
NOTE
• For details of the optional encoder dedicated cable (FR-JCBL/FR-V7CBL), refer to page 17.
• FR-V7CBL is provided with a P clip for earthing (grounding) shielded cable.
Wiring length Parallel connection
(Cable gauge 0.2 mm2)Larger-size cable
Within 10 m At least two cables in parallel 0.4 mm2or larger
Within 20 m At least four cables in parallel 0.75 mm2or larger
Within 100 m  At least six cables in parallel 1.25 mm2or larger
SD
PG
G
F
D
C
B
A
R
S
Encoder
2mm
2
FR-A800
(FR-A8AP)
PZ2
PZ1
PB2
PB1
PA2
PA1
Example of parallel connection
with two cables
(with complementary encoder output)
Encoder cable
Shield
P clip
Earthing (grounding) example using a P clip
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INSTALLATION AND WIRING 15
2
(2) Wire the shielded twisted pair cable after stripping its sheath to make its cables loose.
Also, protect the shielded cable of the shielded twisted pair cable to ensure that it will
not make contact with the conductive area.
Strip off the sheath for the below length. If the length of the sheath peeled is too long, a
short circuit may occur with neighboring wires. If the length is too short, wires might
come off.
Wire the stripped cable after twisting it to prevent it from becoming loose. In addition,
do not solder it.
Use a blade terminal as necessary.
When using the blade terminal, use care so that the twisted wires do not come
NOTE
• Blade terminals commercially available (as of February 2012. The product may be changed without notice.)
Cable stripping length
Terminal
Screw Size Wire Size (mm2)Blade Terminal Model Manufacturer Blade terminal crimping tool
with insulation sleeve without insulation sleeve
M2 0.3 to 0.5 Al 0,5-6WH A 0,5-6 Phoenix Contact
Co.,Ltd. CRIMPFOX 6
0.75 (for two wires) Al-TWIN 2 0,75-10GY ―
Sheath
Shield
(perform protective treatment)
Twisted pair shielded cable
5 mm
Crumpled tip
Wires are not inserted
into the sleeve
Unstranded
wires
Damaged
Wire
Wire
Sleeve
Sleeve
0 to 0.5mm
0 to 0.5mm
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16 INSTALLATION AND WIRING
(3) Loosen the terminal screw and insert the cable into the terminal.
NOTE
• Undertightening can cause cable disconnection or malfunction. Overtightening can cause a short circuit or malfunction
due to damage to the screw or unit.
• When wiring cables to the inverter's RS-485 terminals while a plug-in option is mounted, take caution not to let the
cables touch the circuit board of the option or of the inverter. Otherwise, electromagnetic noises may cause
malfunctions.
• When one position detector is shared between FR-A8AP and CNC (computerized numerical controller), its output
signal should be connected as shown below. In this case, the wiring length between FR-A8AP and CNC should be as
short as possible, within 5 m.
Screw Size Tightening Torque Cable Size Screwdriver
M2 0.22 Nm to 0.25 Nm0.3 mm2to 0.75 mm2Small flat-blade screwdriver
(Tip thickness: 0.4 mm/tip width: 2.5 mm )
CAUTION
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.
After wiring, wire offcuts must not be left in the inverter. They may cause a fault, failure or malfunction.
Maximum 5 m
(two parallel cables)
CNC
Inverter
(FR-A8AP)
Position detector
Encoder
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INSTALLATION AND WIRING 17
2
2.5 Encoder cables dedicated to Mitsubishi motors
Use dedicated encoder cables to connect with Mitsubishi encoder-equipped motors.
 As the terminal block of the FR-A8AP is an insertion type, earth (ground) cables need to be modified. (Refer to page 15.)
FR-JCBL FR-V7CBL
For SF-JR/HR/JRCA/HRCA (with encoder) For SF-V5RU and SF-THY
Encoder
Positioning keyway
PZ2
PZ1
PB2
PB1
PA2
PA1
PG
SD
P
B
N
A
R
C
H
K
2mm2
ABCD
E
K
F
G
H
J
L
M
S
N
R
P
T
D/MS3106B20-29S
(As viewed from wiring side)
FR-A800
(FR-A8AP)
F-DPEVSB 12P 0.2mm2
Earth cable
Approx. 140 mm
60mm
L
D/MS3057-12A
D/MS3106B20-29S
11mm
Type Length
L (m)
FR-JCBL5 5
FR-JCBL15 15
FR-JCBL30 30

Encoder
Positioning keyway
PZ2
PZ1
PB2
PB1
PA2
PA1
SD
PG
G
F
D
C
B
A
R
S
2mm2
FR-A800
(FR-A8AP)
ABCD
E
K
F
G
H
J
L
M
S
N
R
P
T
D/MS3106B20-29S
(As viewed from wiring side)
Earth cable
F-DPEVSB 12P 0.2 mm
2
LD/MS3106B20-29S
D/MS3057-12A
11mm
60mm
Approx. 140 mm
Type Length
L (m)
FR-V7CBL5 5
FR-V7CBL15 15
FR-V7CBL30 30
• A P clip for earthing (grounding) a
shielded cable is provided.
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18 INSTALLATION AND WIRING
Connection terminal compatibility table
2.6 Terminals
Motor SF-JR/HR/JRCA/HRCA (with Encoder) SF-V5RU, SF-THY
Encoder cable FR-JCBL FR-V7CBL
FR-A8AP terminal
PA1 PA PA
PA2 PAR Keep this open.
PB1 PB PB
PB2 PBR Keep this open.
PZ1 PZ PZ
PZ2 PZR Keep this open.
PG 5E PG
SD AG2 SD
Terminal
Symbol Terminal Name Description
PA1 Encoder A-phase signal input terminal A-phase signal is input from the encoder.
For details of pulse signal,
refer to page 19.
PA2 Encoder A-phase inverse signal input terminal
PB1 Encoder B-phase signal input terminal B-phase signal is input from the encoder.
PB2 Encoder B-phase inverse signal input terminal
PZ1 Encoder Z-phase signal input terminal Z-phase signal is input from the encoder.
(Not used for the encoder feedback control.)
PZ2 Encoder Z-phase inverse signal input terminal
PG Encoder power supply (positive side) input
terminal
Input power for the encoder power supply.
Connect the external power supply (5 V, 12 V, 15 V, 24 V) and the encoder
power cable. When the encoder output is the differential line driver type, only 5
V can be input. Make sure the voltage of the external power supply the same
as the encoder output voltage. (Check the encoder specification.)
SD Encoder power supply ground terminal
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ENCODER SPECIFICATIONS AND PARAMETER SETTINGS 19
3
3ENCODER SPECIFICATIONS AND PARAMETER SETTINGS
3.1 Encoder
Position detection (pulse encoder)
NOTE
• 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 4096 ppr (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 1000 P/R to 4096 P/R
B/B signal 1000 P/R to 4096 P/R
Z/Z signal 1 P/R
A signal 1000 P/R to 4096 P/R
B signal 1000 P/R to 4096 P/R
Z signal 1 P/R
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
Differential line driver Complementary
Output pulse specifications
A
Position detector
Encoder
A
B
Z
abcd
P
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20 ENCODER SPECIFICATIONS AND PARAMETER SETTINGS
Power supply
Choose a power supply for encoder according to the encoder used (5 V/12 V/15 V/24 V). When the encoder output is the
differential line driver type, only 5 V can be input. Make sure the voltage of the external power supply the same as the encoder
output voltage. (Check the encoder specification.)
When an encoder is used under orientation control, encoder feedback control, and vector control, the power supply is shared
between the inverter and encoder.
• Specifications of the encoders equipped in the motors with encoders and the vector-control dedicated motors
NOTE
• When the input power supply voltage to the encoder and its output voltage differ, the protective function (E.ECT) may
be activated.
Item Encoder for SF-JR/HR/JRCA/HRCA Encoder for SF-V5RU, SF-THY
Resolution 1024 pulses/rev 2048 pulses/rev
Power supply voltage 5 VDC±10% 12 VDC±10%
Current consumption 150 mA
Output signal form A, B phases (90° phase shift)
Z phase: 1 pulse/rev
Output circuit Differential line driver 74LS113 equivalent Complementary
Output voltage H level: 2.4 V or more
L level: 0.5 V or less
H level: "Power supply for encoder-3 V" or more
L level: 3 V or less
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ENCODER SPECIFICATIONS AND PARAMETER SETTINGS 21
3
3.2 Parameter setting
3.2.1 Parameter for encoder
NOTE
• If operating at a frequency higher than 120 Hz with Pr.359 = "0 or 1", the motor rotation will be unstable.
Parameter
Number
Pr.
group Name Initial Value
Setting
Range Description
359 C141 Encoder rotation
direction 1
0
Set when using a motor for which
forward rotation is clockwise viewed
from the motor load shaft.
Set for the operation
at 120 Hz or less.
100
Set for the operation
at a frequency
higher than 120 Hz.
1
Set when using a motor for which
forward rotation is counterclockwise
viewed from the motor load shaft.
Set for the operation
at 120 Hz or less.
101
Set for the operation
at a frequency
higher than 120 Hz.
369 C140 Number of
encoder pulses 1024 0 to 4096 Set the number of encoder pulses output. Set the number of pulses before it is multiplied by 4.
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