1. Mitsubishi Electric Automation, Inc.
Presented to :
Product
Overview
FR- A800
VFD
Mitsubishi Electric Automation, Inc.
September 17, 2018

2. A800 Range Overview Horsepower (ND) (3rd Quarter 2014)
Here is a simple overview of the A800 range.
The main points :
The overall A800 range is the same as the A700 but there are some critical differences. All of these drives use the same “HD, ND, LD, SLD” rating system as A700.
First you can see that we have a new type of drive – the A which is a NEMA 12 stand alone drive. The A846 is a plenum-rated unit and has been tested and approved by UL, so it is actually a “UL12” device
Secondly, the standard drives up to 30HP are true plenum rated UL-1 drives. We never had that with the standard A700’s, only with the F700’s
The third point, above 400HP the A840’s are “sectional” types. This means that the drive rectifier and inverter stages are supplied separately. So this is a big change from how we did things with A700.
Horsepower (ND)
30 HP

3. Part Number Structure -06 : Conf. AND -N6 : UL-1 version
-60 : Conformal
Coating only
-06 : Conf. AND
busbar
coating
-U6 : Circuit for
3rd party
braking units
-1: FM analog output (pulse)
-2: CA analog output (4-20mA)
SLD Current Rating (16.7A)
2 : 230V Class
4 : 480V Class
6 : 600V Class
0 : Standard
2 : No converter (dc bus + inverter only)
6 : UL-12 version (IP55)

4. Summary of Old to New Comparisons …

5. Faster Response - Features
New High Speed Custom Processor
Response to signal :
5 to 20 ms → 2 to 3 ms*
Response to impact loads : 200 ms → 80 ms
*5 ms via network

6. Faster Response Times
Fast response to load and signal change is critical in
Wind / Unwind applications

7. Improved Speed Range
Maximum frequency now 590 Hz (35,000 rpm with 2 pole motor)
Speed Range for Vector Control modes extended

8. High Speed Operation
Smooth high speed operation ideal for precision machine tool applications

9. Improved Speed Range
200% torque at 0.3 Hz
200:1 speed range – open loop
Closed loop range of 1500 :1
Vector Control up to 400Hz

10. Advantages of Wide Speed Range
Better Control of High Inertia Loads
Faster acceleration and deceleration
Ideal for Hoisting
and
Crane Control

11. Control of IPM Motors - Recap
A800 can be used with conventional motors OR
The new generation of IPM motors
Tested with Marathon ‘SyMAX’
series
Moving Right Along, you will remember that we said that the A800 can now be used with IPM motors. IPM stands for ‘Internal Permanent Magnet’ motors and this design allows a much smaller and more efficient package to be used. In fact an IPM motor is a lot like a servo motor in many ways, and in principle it can also do simple positioning moves without the need for an encoder.

12. Advantages of IPM Motors
Smaller Frames
Reduced Energy Consumption
With an IPM motor, the motor rotor has permanent magnets embedded in it, which means that we do not need to waste energy energizing the rotor. Usually that electromagnetic field is induced in the rotor from the rotating magnetic field in the stator. So with a normal ‘Squirrel Cage’ induction motor, we have to constantly provide, and pay for, extra power to accomplish that.
Replacing that old squirrel cage rotor with permanent rare earth magnets also gives us a much more compact frame size, so IPM motors do not follow traditional NEMA frame size designs.
An IPM motor runs at the true ‘synchronous speed’ dictated by the output frequency so it allows better speed holding than a normal induction motor, which depends on having a certain amount of motor shaft ‘slip’ in order to be able to work.
So there are really 3 reasons that we might want to go with an IPM motor : a smaller frame size, reduced energy consumption, or, if we are controlling pumps and fans, increased energy savings, or to achieve simple positioning without a motor encoder. That would be especially useful in industries where a harsh environment means that an encoder will be vulnerable to damage. Of course, sometimes more than one of these advantages is of interest on the same job.
Ability to replace servo in some cases
Simple open loop positioning
No need for an encoder

13. Marathon ‘SyMAX’ FHP Series motors
Tested with
Auto-Tuning Feature
‘Zero Slip’ Speed Control (Open Loop)
The A800 drive is our first ‘general purpose’ drive that also has IPM capability. As designed, it can EITHER be used with our own range of IPM motors OR it has an auto-tuning feature that allows it to be used with the 3rd party IPM motors that are starting to appear on the market now. An advantage of being able to use Mitsubishi motors is that their data is already pre-programmed into the drives but currently these motors are not available outside of Japan – we’re working on that one.
So for the Americas we are basically in the same position that we are in with regular motors – i.e. we are working with 3rd party products and depending on auto-tuning to get it to work well.
We have tested the A800 with the Marathon ‘SyMAX’ FHP motors, so we are happy to recommend these, but we can also use the VFD with motors from other manufacturers.
The performance with 3rd party motors is not going to be as good as it is with Mitsubishi motors. In particular, starting torque will be lower ( somewhere in the 50% range) and the ability to do positioning will depend on extra engineering support – in other words some expert help will be needed to fine tune the settings for positioning, and that will need to be done on a ‘case by case’ basis.
So realistically we can use IPM motors for their compact size, their inherent energy-saving characteristics, and their excellent speed holding capabilities. If we need very high torque at low speed, and you will remember that A800 can potentially produce about 200% starting torque, then we are going to be able to do better with a normal induction motor. If we have large opportunities which will require IPM motors and positioning, that will be possible but we have to view that as a ‘project’

14. Pre-Selected Combinations
Frame sizes differ from
NEMA form factor
See Marathon Catalog
SB385 for more details
IPM motors are most commonly found for the smaller sizes, meaning up to about 30 HP. Very small ones can be either 230 or 460 V rated. In this chart, we have ‘matched’ up A800 with the most suitable IPM motor from Marathon’s ‘SyMAX’ range. If you are interested in learning more about The SyMAX motors, please refere to their catalog SB385, which can be downloaded from the Marathon web site.
* Based on ND

15. Safety Stop Functional Diagram - Standard
STO category stops
The next area that I want to look at is “Safety Stops” ; as we have introduced new drives, starting with the D700, we have been including a Safety drive capability and the A800 is no exception. Essentially a ‘redundant circuit’ is used so that the probability of dependably cutting off the power supply to the motor is now so high that extra hardware outside the drive is not necessary. When used with a safety relay or a safety PLC, this gives us the most common, and simplest category of safety stop, this is referred to as ‘STO’ , which stands for ‘Safe Torque Off’.
When not specifically required to be a safety drive, these terminals on the control terminal block are bridged with the white jumper wires you see here. Incidentally, the change from the conventional screw type terminal block to the ‘push in’ terminals is a requirement for safety drives, which is why this has changed from A700.

16. Safety Stop VFD – EN13849-1 (replaces EN954-1)
Risk table (PL)
Standard A800 is PLd
There are 2 standards which are referred to when specifying safety stops and since they are both ‘in common parlance’ lets take a look at them both. The first one is European standard EN , which replaces the old EN954-1, which still crops up from time to time in specifications. For anyone not familiar with how this all works, the customer makes an assessment of the severity of the mechanical hazard that the spinning motor might mean, how likely that is to ever happen and the ease of avoiding this. This all boils down to a PL or “Performance Level: grading from a to e, wehere ‘e’ would be the most severe case. As you can see, we are at point ‘d’ which is where most safety drives are.

17. Defines SIL (Safety Integrity) Levels 1 - 4 Standard A800 is SIL2
IEC 61508
Defines SIL (Safety Integrity) Levels 1 - 4
Standard A800 is SIL2
IEC61508 is a similar standard – this one is where the concept of the SIL or “Safety Integrity Level’ comes from. A similar decision-making tree is used, although the methodology is a little bit different. The standard A800 is capable of SIL level 2, where only SIL level 3 would be better.
It might seem as though there are a lot of ‘judgement calls’ for the customer to make here (such as how many deaths might be ‘catastrophic’ !) but actually there are ways that all this can be calculated mathematically. Customers may ask us for the reliability characteristics of the A800 as part of this process – if they do, the key information is in the Safety Stop Instruction manual which can be downloaded from the A800 launch section of the MEAU website.

18. Safety Function Categories (from IEC 61800-5-2)
STO Safe Torque Off
Cuts power to motor (coast)
SS1 Safe Stop 1
Partially controlled decel.
SS2 Safe Stop 2*
Controlled deceleration
Controlled stop position
SOS Safe Operating Stop*
Controlled deceleration
Controlled stop pos. (< 1 rev)
Lets take a look at the different Safety Function Categories: IEC61800 is a standard that comes up a lot because its different sections contain all kinds of requirements and rules for drive design. Section 5-2 gives us the definitions of the different categories of “Safety Stop” . It stands to reason that Safe Torque Off , which just cuts the motor power, might not be the safest thing that could happen. So there are other categories which envisage using the drive to ‘ramp down’ the motor before cutting the power. In the case of SS2 and SOS in this chart, there are extra requirements to actually stop the motor shaft in a specific position so for these and encoder is needed. This encoder itself also need to be a special type. SLS is a bit different because it relates to preventing over-speeding but again a special encoder is needed.
SLS Safely Limiting Speed *
Prevents motor over speed
* With safety encoder

19. Standard A800 is PLd and SIL2 (STO function)
Summary
Standard A800 is PLd and SIL2 (STO function)
So right now, A800 is Performance Level ‘d’ and SIL level 2, with the ‘STO’ function, which really amounts to a safe ‘coast to stop’. Already in development is a special option card which will extend this to Ple and SIL level 3 by allowing all of the other Safety Functions we looked at to be achieved. Also in the works are special communications options that will allow safe operation from PROFIsafe or the new Safety version of CC-Link IE.
When we have the new option card we will be able to perform all the other safety functions and the levels will be Ple and SIL level 3, which is ‘as good as it gets’ !
See Safety Stop Manual
(BCN-A A(E))
For more information

20. FR-Configurator 2 – New Features
Parameter Conversion Function
A700-A800
A500-A800 (planned)
With the arrival of A800, we have also released a new programming packaged called FR-Configurator 2 which has some interesting features which I want to take a look at.
The new software has a better ‘look’ and ‘feel’ than the previous package and, just my opinion, looks more professional than the old one which was unchanged for many years. We’ve tested it on all versions of Windows up to version 8 with good results.
The first new feature is the ability to convert A700 parameter sets into A800 parameter sets. In the near future, this will be extended so that an A A800 transition can also be made.

21. USB Stick Compatibility
Upload / Download
Parameter data to USB stick
Import ‘Trace Data’ via USB stick
One of the most important features of FR-Configurator 2 is a special tool that enable you to save parameter sets directly onto any normal USB stick and then use that to download the settings into any number of A800’s . That is a big improvement in flexibility - although previously we could store 3 parameter sets in the keypad, all those parameters first needed to be written to a drive and could then be copied into the keypad.
Additionally, “Trace Data” can be pulled out of the drive on a USB stick and that can be transferred into the software. Trace Data means key operating conditions prior to a drive error message, so it works a bit like a Black Box. You can see exactly what was going on in the time immediately before the drive tripped. To do this, the drive needs to remain powered up after the trip.
You can see from this slide that the A800 actually has 2 USB ports – a USB mini port which is the normal point of connection for the set up software and a conventional port which is for the USB stick.
As with previous versions of FR-Configurator with A700, you have the choice of communication with the drive via USB, via the PU port or via the RS 485 connection terminals, for example when it is necessary to communicate with multiple drives.

22. FR-Configurator 2 - Developer Function
Function Blocks also possible
FR-Configurator has an additional feature to allow programs to be written into the PLC of the drive. This gets away from the need to have a copy of the GX Developer software – FR-Configurator 2 can take care of all of that. Note that it will allow you to write using conventional ladder logic or to assign function blocks – your choice.

23. Improvements to Internal PLC (based on ‘L’ series)
Change parameters or setting frequency within program
Write function blocks
Edit within FR-Configurator 2
Use Time-Based operations in PLC mode (with LU08)
As I mentioned last time the A800 includes a greatly improved internal PLC which is closely based on the L series PLC. So this is a big step forward compared to A700
As I already mentioned, now you can create function blocks and change drive parameters or the speed output from directly within the program.

24. PLC Comparisons
Here is a comparison of the similarities and differences between the A800 internal PLC and the regular L series – as well as FX3S. You can see that the processing speed is appreciably slower. Since the drive only has the one processor, the response times of the drive itself can be affected by amount of data being processed. There is only room for 1 program but there are 90K bytes of memory capacity, the same as there is with L series. Also PLC programs cannot be changed while the drive is running. There are 128 I/O device points as opposed to 8192 in a full L series device but the amount of physical I/O is obviously limited by the number of terminals on the drive itself – so this can be increased by adding relay option cards like the FR-A8Ar, for example.

25. Braking and Regeneration
Brake chopper circuit included up to 75HP
New system to reduce regen. effect – Increased Magnetic Excitation Deceleration
Common dc bus allows regenerated energy to be shared out

26. Reduces the motors ability to act as a generator
Excitation Braking
New system to reduce regenerative effect
Heat energy is transferred to the motor and output current increases

27. Communications and Networking
RS485 (115.2 kbps) :
Mitsubishi protocol
Modbus RTU
EtherNET :
CCLink IE Field
EtherNET IP
ProfiNET
Ether CAT*
Modbus TCP*
Fieldbus:
CC-Link
SSCNet III/H
DeviceNET
Profibus (DVP0)
LONWORKS

28. Real Time Clock is now standard
Time Stamps error
messages
Optional LU08 keypad + battery maintains clock after power down
This slide is a copy from the first presentation but I included it again here to underline the difference between the standard DU08 (LED) keypad and the liquid crystal LU08.
The FR-LU08 has the same functionality as the PU07 and also contains a battery which will gives the A800 drive a true ‘real time clock’ , including the ability to do time stamping for error messages. The availability of a real time clock now means that the PLC program can also include time based activities, and of course it also means that we can have ‘time stamps’ for error messages – something we’ve wanted for a long time.
The A800 still has the time clock feature without the LU08 – but this means keeping power permanently applied to the drive – although this could just be the 24V dc supply that we looked at earlier.
It is still possible to use the PU07 keypad with the A800 (only via a connecting cable) but you are limited to the first 100 parameters. But even so it is probably a good choice if you need a panel mounted keypad for user operation and diagnostics.
Use Time-Based operations in PLC mode

29. Direct Connection of GOT2000
No Parameter changes required – enable ‘Automatic Connection’ feature in the GOT *
Connect via comms. terminals or PU port
Multiple VFD’s can be controlled from one GOT
Just think about connectivity, we looked last time at the different network options that are available but A800 can also be connected directly to an A800 without having to change any of the drive’s parameters for things like communications protocols. If you want to you can control a string of A800’s from a single GOT2000 , but in that case you would of course have to give each drive a different station number. This is possible using the ‘Automatic Connection’ feature in the GOT. Note that you can either connect the GOT to the drive’s RS 485 terminal block , or you could plug it directly into the drives PU port, which is an RJ45 connector.
* Set Station number with multiple drives

30. Advantages to Flexible Front End
Select smaller unit where the cont. current is higher
Run Multiple VFD’s from a single unit (shared bus)
Easy to implement 6, 12 or even 24 pulse inputs
We did touch on this ‘Flexible Front End’ feature last time but I want to take a closer look at the main points; just to recap, all A800 VFD’s bigger than 450HP at Normal Duty rating are supplied as the A842 type, which means that it is really just the dc bus and the ‘inverter’ stage of a drive. To compliment that, there is a new diode rectifier stage called FR-CC2 which can be connected to the A842 to feed it with the dc that it needs. Although this might seem complicated at first, this gives us many more options, such as making a drive system for 12 or even 24 pulse input or running multiple drives from a single big converter module. With A700, the diode stage was included but that meant it was sized for the ‘worst case’ condition of maximum output Amps – which would have been when the drive’s ‘SLD’ rating was selected. So actually it was far bigger than it needed to be in most cases.

31. Shared DC Bus (Separate Inverter Stages)
If you power multiple VFD’s from just one rectifier module, all the VFD’s are connected in parallel at the output of the CC2. What this means is that the dc bus voltage level is shared between however many drives are connected. With a lot of applications, where, say, 1 drive is driving and another one is over-hauling, the problems of regeneration can be avoided partially or entirely, because any rise caused by energy being regenerated by the overhauling motor is going to automatically get shared out evenly across the whole system.
In most cases, the combined system is also going to be much more compact and there will be more flexibility regarding how these components are laid out inside a panel.

32. 12, 18 or 24 Pulse Configuration
Multi-pulse configurations are a popular way of reducing the amount of current harmonic distortion produced by the drive. What happens is that a special transformer is used to supply different diode packs with 3 phase power with ‘offset’ phases; because of the difference in phasing, the harmonics produced in one section will cancel out some of the harmonics in the other section or sections. The CC2 rectifier stage actually has 12 diodes in it, not 6. Usually the diodes are paralleled together in pairs so they act like only 6. But if I want 12 pulse, I can remove the links between the 2 sets of diodes and now I can feed my 2 offset power supplies separately into each of the 2 sets of diodes.
If I want 18 pulse, I just use 3 small CC2 units and feed 3 phases into each one and then join the dc outputs in parallel
Obviously 24 pulse would be 2 CC2 units , with each pair of diodes split up.
A good 18 pulse solution will reduce the current harmonic distortion down from about 80 % to about 5% The bigger the drive gets, the more important it is to think about harmonic distortion.
Just ONE CC2 unit can be used for 12 pulse (contains 2 separate sets of 6 diodes)

33. FR-HC2 Active Bridge System
An Accessory for use with A700, F700 or A800
Eliminates Power Supply Distortion
While we are looking at the Flexible Front End, we should also consider this product - the FR-HC2 controller. As with the CC2, the job of the HC2 is to rectify ac into dc. So a power supply from it can be fed directly into the dc bus of an A842 in just the same way (in fact in could also be used with the smaller A840’s but we would be wasting the drive’s own diodes which would not be connected. But the HC2 is much smarter than the CC2; instead of using diodes for rectification, it uses power transistors which are synchronized with the mains incoming supply. This has the dual benefit of eliminating the harmonic distortion we otherwise have to clean up and also makes the system naturally regenerative, just like a 4 Quadrant dc drive is, or used to be back in the day !
HC2 actually comes as a kit of 4 parts so we should think of it as a system rather than 1 device
Makes the VFD
‘Naturally Regenerative’

34. provides the potential for true ‘4 Quadrant’ control of loads
2 Big Benefits….
Eliminating power distortion = IEEE519 compliance under virtually any circumstances
Natural Regeneration
provides the potential for true ‘4 Quadrant’ control of loads
So the HC2 gives us excellent power quality as well as total and indefinite control of the motor, either driving or overhauling. No energy is being wasted, as would be the case with using dynamic braking resistors, for example, because the regenerated energy is re-inverted into a sinewave which is synchronized with the incoming supply. So that energy can be used for something else.

35. 2. Natural Regeneration Coupled with the Flux
Vector capability of A700 and A800, true “4 quadrant control” is possible.
Combined with the excellent performance of the A800 when ‘driving’ a load, this gives you total control in all 4 quadrants : forwards / backwards, driving and overhauling and what happens when we are changing from one quadrant to another. So we ‘re really unleashing the full potential of the drive. It no longer matters how long we are regenerating for ; 100% regeneration 24 hours per day is absolutely no problem.

36. Available via the ‘downloads’ section of website :
Support Materials
Available via the ‘downloads’ section of website :
Product manuals – including option cards
Factory catalog
PLC programming manual
Safety Stop manual
Pocket Selection Guide
Product Images
Sales guidebook
Technology White Paper
Press Release
Launch Document + price list
Here’s a list of some of the support materials that we have prepared for the A800; just visit the A800 area of the meau website - here you can see the link. This is not an exhaustive list as we will be progressively adding new materials as the product roll-out moves forward. I strongly suggest that you avail yourself of a copy of the Pocket Selection Guide in electronic form.

37. Pocket Selection Guide
A700 Crossovers
230 and 480V Selection Guide
‘Sectional’ product information
Eventually this will be a 12 page printed ‘pocket guide’ like we use with the other drives but this has the A700 – A800 crossover information, the selection charts to help you choose the different components you need for any given HP rating or application
LVS Selection Chart

38. A700 VFD’s still available ‘to special order’ until further notice
Product Availability
FR-A820 All Sizes : April 2014
FR-A840 Up to 200HP : April 2014
FR-A HP : end / May 2014
FR-A842, FR-CC2 : 3rd Quarter 2014
FR-A860 : 3rd Quarter 2014
Just to finish up for today, here’s a summary of the planned launch schedule for A800; note that we will have everything in stock up to 250HP by the end of this month. The bigger, sectional units with the rectifier stages are planned to be available by the 3rd Quarter of this calendar year.
As and when the A800’s are available we will follow the usual practice of supplying the equivalent A700’s on a ‘special order basis’ so the lead times will be extended for these. But on this basis, A700 will still be available ‘for the foreseeable future’.
A700 VFD’s still available
‘to special order’ until further notice

39. Thank you for listening We appreciate your time
So that brings us to the end of this session - thanks very much for tuning in - I will do my best to answer any questions that you may have. If I can’t answer you right here and now I will investigate further and reply to you individually