CHAPTER 2

Design

2-1 Installation...............................................................................11
2-1-1 Dimensions.......................................................................................11
2-1-2 Installation Conditions......................................................................13
2-1-3 Removing and Mounting the Covers................................................14
2-2 Wiring ...................................................................................... 16
2-2-1 Terminal Block..................................................................................16
2-2-2 Standard Connections......................................................................22
2-2-3 Wiring around the Main Circuit.........................................................23
2-2-4 Wiring Control Circuit Terminals.......................................................35
2-2-5 Conforming to EC Directive..............................................................38

10
Design Chapter 2

2.1 Installation
2-1-1 Dimensions

3G3MV-A2001 to 3G3MV-A2007 (0.1 to 0.75 kW) 3-phase 200-VAC Input

3G3MV-AB001 to 3G3MV-AB004 (.01 to 0.4 kW) Single-phase 200-VAC
Input

Rated voltage Model Dimensions Weight

3G3MV- (mm) (kg)
D t
3-phase 200 VAC A2001 76 3 Approx. 0.6
A2002 76 3 Approx. 0.6
A2004 109 5 Approx. 0.9
A2007 128 5 Approx. 1.1
Single-phase 200- AB001 76 3 Approx. 0.6
VAC AB002 76 3 Approx. 0.7
AB004 131 5 Approx. 1.0

3G3MV-A2015 to 3G3MV-A2022 (1.5 to 2.2 kW) 3-phase 200-

VAC Input
3G3MV-AB007 to 3G3MV-AB015 (0.75 to 1.5 kW) Single-
phase 200-VAC Input
3G3MV-A4002 to 3G3MV-A4022 (0.2 to 2.2 kW) 3-phase 400-
VAC Input

Rated Model Dimensions Weight

voltage 3G3MV- (mm) (kg)
D
3-phase 200 A2015 131 Approx. 1.4
VAC A2022 140 Approx. 1.5
Single-phase AB007 140 Approx. 1.5
200 VAC AB015 156 Approx. 1.5
3-phase 400 A4002 92 Approx. 1.0
VAC A4004 110 Approx. 1.1

11
Design Chapter 2
A4007 140 Approx. 1.5
A4015 156 Approx. 1.5
A4022 156 Approx. 1.5

3G3MV-A2037 (3.7 kW) 3-phase 200-VAC Input

3G3MV-AB 022 (2.2 kW) Single-phase 200-VAC Input
3G3MV-A4037 (3.7 kW) 3-phase400-VAC Input

Rated voltage Model Dimensions Weight

3G3MV- (mm)
D
3-phase 200 VAC A2037 143 Approx. 2.1
Single-phase 200 AB002 163 Approx. 2.2
VAC
3-phase 400 VAC A4037 143 Approx. 2.1

3G3MV-AB037 (3.7 kW) Single-phase 200-VAC Input

Rated voltage Model Dimensions Weight

3G3MV- (mm) (kg)
D
Single-phase 200- AB037 Approx.

12
Design Chapter 2
VAC 2.9

2-1-2 Installation Conditions

Caution Be sure to install the product in the correct direction and provide
specified clearances between the Inverter and control panel or with
other devices. Not doing so may result in fire or malfunction.

Caution Do not allow foreign objects to enter inside the product. Doing may
result in fire or malfunction.

Caution Do not apply any strong impact. Doing may result in damage to the
product or malfunction

Caution Provide an appropriate stopping device on the machine side to

secure safety. (A holding brake is not a stopping device for securing
safety.) Not doing so may result in injury.

Caution Provide an external emergency stopping device that allows an

instantaneous stop of operation and power interruption. Not doing so
may result in injury.

Installation Direction and Dimensions

Installation the Inverter under the following conditions.
Ambient temperature for operation (panel-mounting): -10 to 50
Humidity: 90% or less (no condensation)
Install the Inverter in a clean location free from oil mist and dust. Alternatively,
install it in a totally enclosed panel that is completely protected by floating dust.
When installing or operating the Inverter, always take special care so that metal
powder, oil, water, or other foreign matter does not get into the Inverter.
Do not install the Inverter on inflammable material such as wood.

Direction

Install the Inverter on a vertical surface so that the characters on the nameplate
are oriented upward.

Dimensions
When installing the Inverter, always provide the following clearances to allow
normal heat dissipation from the Inverter.

W = 30 mm 100 mm Air
min. min.

Invert
Invert Invert Side
er
er er

W W W
100 mm Air
min.

13
Design Chapter 2

Ambient Temperature Control

To enhance operation reliability, the Inverter should be installed in an environment
free from extreme temperature changes.
If the Inverter is installed in an enclosed environment such as a box, use a cooling
fan or air Conditioner to maintain the internal air temperature below 50 .
The life of the built-in electrolytic capacitors of the Inverter is prolonged by
maintaining the internal air temperature as low as possible
The surface temperature of the Inverter may rise approximately 30 higher than
the ambient temperature. Be sure to keep away equipment and wires from the
Inverter as far as possible if the equipment and wires are easily influenced by
heat.

Protecting Inverter from Foreign Matter during Installation

Place a cover over the Inverter during installation to shield it from metal power
produced by drilling. Upon completion of installation, always remove the cover
from the Inverter. Otherwise, ventilation will be affected, causing the Inverter to
overheat.

2-1-3 Removing and Mounting the Covers

To mount the Inverter, it is necessary to remove the front cover, terminal
cover (unless the Inverter is a 200-V model), and the Digital Operator. To
wire the Inverter, it is necessary to remove the front cover, terminal cover
(unless the Inverter is a 200-Vmodel), and bottom cover from the Inverter.
Follow the instructions below to remove the covers from the Inverter. To
mount the covers, take the opposite steps.

Removing the Front Cover

Loosen the front cover mounting screws with a screwdriver.

Press the left and right sides of the front cover in the arrow 1 directions and lift the
bottom of the cover in the arrow 2 direction to remove the front cover as shown in
the following illustration.

14
Design Chapter 2

Removing the Terminal Cover

After the front cover is removed, press the left and right sides of the terminal
cover in the arrow 1 directions and lift the terminal cover in the arrow 2 direction
as shown in the following illustration.

Note None of the following 200-V models have a terminal cover. Instead, the front
cover is used as a terminal cover.3G3MV-A2001 (0.1 kW), 3G3MV-A2002 (0.2
kW), 3G3MV-2004 (0.4 kW), 3G3MV-A2007 (0.75kW), 3G3MV-AB001 (0.1 kW),
3G3MV-AB002 (0.2 kW), and 3G3MV-AB004 (0.4 kW)

Removing the Digital Operator

After removing the front cover, lift up the upper and lower right-hand sides
(positions A) of the Digital Operator in the arrow 1 direction as shown in the
following illustration.

Removing the Bottom Cover

After removing the front cover and terminal cover, press the bottom cover in the
arrow 1 direction based on position A as a fulcrum.

15
Design Chapter 2

2-2 Wiring
WARNING Wiring must be performed only after confirming that the power
supply has been turned OFF. Not doing so may result in electrical
shock.

WARNING Wiring must be performed by authorized personnel. Not doing so

may result in electrical shock.

WARNING Be sure to confirm operation only after wiring the emergency stop
circuit. Not doing so may result in injury.

WARNING Always connect the ground terminals to a ground of 100 or less

for the 200-VAC class, or 10 or less for the 400-VAC class. Not
connecting to a proper ground may result in electrical shock.

Caution Install external breakers and take other safety measures against
short-circuiting in external wiring. Not doing so may result in fire.

Caution Confirm that the rated input voltage of the Inverter is the same as
the AC power supply voltage. An incorrect power supply may result
in fire, injury, or malfunction.

Caution Connect the Braking Resistor and Braking Resistor Unit as specified
in the manual. Not doing so may result in fire.

Caution Be sure to write correctly and securely. Not doing so may result in
injury or damage to the product.

Caution Be sure to firmly tighten the screws on the terminal block. Not doing
so may result in fire, injury, or damage to the product.

Caution Do not connect an AC power to the U, V, or W output. Doing so may

result in damage to the product or malfunction.

2-2-1 Terminal Block

To wire the terminal block of the Inverter, remove the front cover, terminal
cover (unless the Inverter is a 200-V model), and bottom cover from the
Inverter. There is a label under the front cover indicating the arrangement
of main circuit terminals. Be sure to remove the label after wiring the
terminals. The output terminal of the motor has a label as well. Remove the
label before wiring the motor terminal.

Arrangement of Control Circuit Terminals

16
Design Chapter 2

Arrangement of Main Circuit Terminals

3G3MV-A2001 through 3G3MV-A2007 (0.1 through 0.75 kW):

3-phase 200-VAC Input
3G3MV-AB001 through 3G3MV-AB004 (0.1 through 0.4 kW):
Single-phase 200-VAC Input

Note For single-phase input, connect R/L1 and S/L2.

3G3MV-A2015 to 3G3MV-A2022 (1.5 to 2.2 kW): 3-phase 200-

VAC Input
3G3MV-AB007 to 3G3MV-AB015 (0.75 to 1.5 kW): Single-
phase
200-VAC Input
3G3MV-A4002 to 3G3MV-A4022 (0.2 to 2.2 kW): 3-phase 400-
VAC Input

Note For single-phase input, connect R/l1 and S/L2.

3G3MV-A2037 (3.7 kW): 3-phase 200-VAC Input

3G3MV-AB022 to 3G3MV-AB037 (2.2 to 3.7 kW): Single-phase
200-VAC Input
3G3MV-A4037 (3.7 kW): 3-phase 400-VAC Input

17
Design Chapter 2

Note For single-phase input, connect R/L1 and S/L2.

Main Circuit Terminals

Name Description
Symbo
l
R/L1 Power supply 3G3MV-A2 : 3-phase 200 to 230 VAC
S/L2 input terminals 3G3MV-AB : Single-phase 200 to 240 VAC (see
note 1)
T/L3 3G3MV-A4 : 3-phase 380 to 460 VAC
U/T1 Motor output 3-phase power supply output for driving motors.
terminals (see note 2)
V/T2 3G3MV-A2 and 3G3MV-AB : 3-phase 200 to
230 VAC
W/T3 3G3MV-A4 : 3-phase 380 to 460 VAC
B1 Braking Resistor Terminals for attaching an external Braking Resistor
connection or a Braking Resistor Unit. (Connect to detect
B2 terminals overvoltage during braking.)
+1 Connection Connect the DC reactor for suppressing harmonics
terminals+1 and to terminals+1 and +2.
+2 +2: When driving the Inverter with DC power, input
DC reactor the DC power to terminals +1 and -.
connection (Terminal +1 is a positive terminal.)
- terminals
+1 and -:
DC power supply
input terminals
Ground terminal Be sure to ground the terminal under the following
conditions.
3G3MV-A2 : Ground at a resistance of 100 or
less.
3G3MV-AB : Ground at a resistance of 100 or
less.
3G3MV-A4 : Ground at a resistance of 10 or
less.
To conform to EC Directives, connect to the neutral
point of the power supply.
Note Be sure to connect the ground terminal
directly to the
motor frame ground.

Note 1. Connect single-phase input to both the R/L1 terminal and the S/L2 terminal.

Note 2. The maximum voltage at the output sides corresponds to the power supply
voltage for Inverter input.

18
Design Chapter 2

Control Circuit Terminals

Symbol Name Specification

Input S1 Multi-function input 1 (Forward/Stop) Photocoupler
S2 Multi-function input 2 (Reverse/Stop) 8 mA at 24 VDC
S3 Multi-function input 3 (External fault:
Normally open)
S4 Multi-function input 4 (Fault reset)
S5 Multi-function input 5 (Multi-step speed
reference 1)
S6 Multi-function input 6 (Multi-step speed
reference 2)
S7 Multi-function input 7 (Inching frequency
command)
SC Sequence input common
FS Frequency reference power supply output 20 mA at 12 VDC
FR Frequency reference input 0 to 10 VDC (20
FC Frequency reference common k)
RP Pulse train input Response
frequency: 0 to
33 kHz (30% to
70%ED)
Output MA Multi-function contact output (Normally Relay output
open: During operation) 1 A max. at 30
MB Multi-function contact output (Normally VDC
closed: During operation) 1 A max. at 250
MC Multi-function contact output common VDC
P1 Multi-function photocoupler output 1 (Fault) 50-mA open
P2 Multi-function photocoupler output 2 (Fault) collector output
PC Multi-function photocoupler output common at 48 VDC max.
AM Multi-function analog output 2 mA max. at 0
AC Multi-function analog output common to 10 VDC
Communic R+ Receiver side Conforming to
a-tions R- RS-422/485
S+ Sender side
S-

Note Functions in parentheses are default settings.

19
Design Chapter 2

20
Design Section 2

Selecting Input Method

Switches SW1 and SW2, both of which are located above the control circuit
terminals, are used for input method selection. Remove the front cover and
optional cover to use these switches.

Selecting Sequence Input Method

By using SW7, NPN or PNP input can be selected as shown below.

21
Design Section 2
Selecting RS-422/485 Termination Resistance

Termination resistance can be selected by setting pin 1 of the SW2 to ON. The
default setting for the pin is OFF.

Selects RS-422/485 termination

OFF ON resistance

V I Selects frequency reference input

method

SW2

Communications Pin 1
method setting
RS-422 Set to ON
RS-485 Set to ON only if the Unit is the end
Slave

S+

S-

R+

R-

120 termination resistance (1/2

Pin 1 W)

Selecting Frequency Reference Input Method

By using pin 2 of SW2, voltage input or current input can be selected as the input
method for frequency reference. The default setting is for current input.
Parameter settings are required together with the selection of the frequency
reference input method.

Frequency reference input Pin 2 Frequency reference

method setting selection (parameter
n004)
Voltage input (default setting) V (OFF) Set value 2
Current input I (ON) Set value 3 or 4

Note Do not set pin 2 to ON for current input while voltage input is ON, otherwise the
resistor in their input circuit may burn out.

22
Design Section 2

2-2-2 Standard Connections

Note Connect single-phase 200VAC to terminals R/L1 and S/L2 of the 3G3MV-
AB .

Example of 3-wire Sequence Connection

RUN
Stop switc
switc h
h (ON)
(NC) S1 RUN input (Operates with the RUN
switch closed) switch closed)
S2 Stop input (Stops with the stop
switch opened)
Direction
switch
S3 Sequence input
common
SC Sequence input
common

Note Set parameter 052 to forward/reverse rotation command 0 for 3-wire sequence
input.

23
Design Section 2

2-2-3 Wiring around the Main Circuit

Wire Size, Terminal Screw, Screw Tightening Torque, and

Molded-case Circuit
Breaker Capacities

For the main circuit and ground, always use 600-V polyvinyl chloride (PVC) cables.
If any is long and may cause voltage drops, increase the wire size according to the
cable length.

3-phase 200-VAC Model

Model Terminal symbol Term Screw Wire Reco Molded

3G3MV- i-nal tighte size m- -case
scre n-ing (mm) mend circuit
w torque ed breake
(N.m) wire r
size capacit
(mm y (A)
)
A2001 R/L1, S/L2, T/L3, B1, B2, M3.5 0.8 0.75 to 2 5
-, +1, +2, U/T1, V/T2, 2
W/T3

A2002 R/L1, S/L2, T/L3, B1, B2, M3.5 0.8 0.75 to 2 5

-, +1, +2, U/T1, V/T2, 2
W/T3

A2004 R/L1, S/L2, T/L3, B1, B2, M3.5 0.8 0.75 to 2 5

-, +1, +2, U/T1, V/T2, 2
W/T3

A2007 R/L1, S/L2, T/L3, B1, B2, M3.5 0.8 0.75 to 2 10

-, +1, +2, U/T1 ,V/T2, 2
W/T3

A2015 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 2 20

-, +1, +2, U/T1 ,V/T2,
W/T3

A2022 R/L1, S/L2, T/L3, B1, B2, M4 1.2 3.5 to 3.5 20

-, +1, +2, U/T1, V/T2, 5.5
W/T3

A2037 R/L1, S/L2, T/L3, B1, B2, M4 1.2 5.5 5.5 30

-, +1, +2, U/T1, V/T2,
W/T3

24
Design Section 2

Single-phase 200-VAC Model

Model Terminal symbol Termi Term Wire Recom- Circuit

3G3M -nal i-nal size mende breaker
V- screw torq (mm) d wire capacity
ue size (A)
(N.m (mm)
)
AB001 R/L1, S/L2, T/L3, B1, B2, M3.5 0.8 0.75 to 2 5
-, +1, +2, U/T1, V/T2, 2
W/T3

AB002 R/L1, S/L2, T/L3, B1, B2, M3.5 0.8 0.75 to 2 5

-, +1, +2, U/T1, V/T2, 2
W/T3

AB004 R/L1, S/L2, T/L3, B1, B2, M3.5 0.8 0.75 to 2 10

-, +1, +2, U/T1, V/T2, 2
W/T3

AB007 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 3.5 20

-, +1, +2, U/T1, V/T2,
W/T3
2

AB015 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 5.5 20

-, +1, +2, U/T1, V/T2,
W/T3
2

AB022 R/L1, S/L2, T/L3, B1, B2, M4 1.2 8 to14 8 40

-, +1, +2, U/T1, V/T2,
W/T3

AB037 R/L1, S/L2, T/L3, B1, B2, M5 2.0 14 14 50

-, +1, +2, U/T1, V/T2,
W/T3
M4 1.2

3-phase 400-VAC Model

Model Terminal symbol Termi Screw Wire Recom- Molded-

3G3M -nal tighte size mende case
V- screw n-ing (mm) d wire circuit

25
Design Section 2
size breaker
(mm) capacito
r (A)
A4001 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 2 5
-, +1, +2, U/T1, V/T2,
W/T3

A4004 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 2 5

-, +1, +2, U/T1, V/T2,
W/T3

A4007 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 2 5

-, +1, +2, U/T1, V/T2,
W/T3

Model Terminal symbol Termi Screw Wire Recom Molded-

3G3M -nal tighte size - case
V- screw n-ing (mm) mende circuit
torqu d wire breaker
e size capacity
(N.m) (mm) (A)
A4015 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 2 10
-, +1, +2, U/T1, V/T2,
W/T3

A4022 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 2 10

-, +1, +2, U/T1, V/T2,
W/T3

A4037 R/L1, S/L2, T/L3, B1, B2, M4 1.2 2 to 5.5 3.5 20

-, +1, +2, U/T1, V/T2,
W/T3

Wiring on the Input Side of the Main Circuit

Installing a Molded-case Circuit Breaker

Always connect the power input terminals (R/L1, S/L2, and T/L3) and power
supply via a molded case circuit breaker (MCCB) suitable to the Inverter.

Choose an MCCB with a capacity of 1.5 to 2 times the Inverters rated current. For
the MCCBs time characteristics, be sure to consider Inverte the Inverters overload
Powe
protection (oneMCCB r
minute at 150% of the rated output current).
r
If the MCCB is to be used in common among multiple Inverters,
R/L1 or other devices,
set up asuppl
sequence such that the power supply will be turned OFF by a fault output,
3-phase/y in the following S/L
as shown diagram.
single- 2
T/L3
phase
200 VAC *
3-phase
400VAC MB
OFF ON Fault output
MC (NC)
26
Design Section 2

Note Use a 400/200 V transformer for a 400-V model.

Installing a Ground Fault Interrupter

Inverter outputs use high-speed switching, so high-frequency leakage

current is generated. In general, a leakage current of approximately 100
mA will occur for each Inverter (when the power cable is 1 m) and
approximately 5 mA for each additional meter of power cable. Therefore, at
the power supply input area, use a special-purpose breaker for Inverters,
which detect only the leakage current in the frequency range that is
hazardous to humans and excludes high-frequency leakage current.

For the special-purpose breaker for Inverter, choose a ground fault interrupter with
a sensitivity amperage of at least 10 mA per Inverter.
When using a general leakage breaker, choose a ground fault interrupter with a
sensitivity amperage of 200 mA or more per Inverter and with an operating
time of 0.1 s or more.

Installing a Magnetic Contactor

If the power supply of the main circuit is to be shut off because of the
sequence, a magnetic contactor can be used instead of a molded-case
circuit breaker.
When a magnetic contactor is installed on the primary side of the main
circuit to stop a load forcibly, however, the regenerative braking does not
work and the load coasts to a stop.

A load can be started and stopped by opening and closing the magnetic contactor
on the primary side. Frequently opening and closing the magnetic contactor,
however, may cause the Inverter to break down.
When the Inverter is operated with the Digital Operator, automatic operation
cannot be performed after recovery from a power interruption.
When using the Braking Resistor Unit, be sure to arrange a sequence in which the
thermal relay of the Unit turns the magnetic contactor OFF.

Connecting Input Power Supply to the Terminal Block

Input power supply can be connected to any terminal on the terminal block
because the phase sequence of input power supply is irrelevant to the
phase sequencce (R/L1, S/L2, and T/L3).

27
Design Section 2
Installing an AC Reactor

If the Inverter is connected to a large-capacity power transformer (660 kW

or more) or the phase advance capacitor is switched, an excessive peak
current may flow through the input power circuit, causing the converter
unit to break down.
To prevent this, install an optional AC reactor on the input side of the
Inverter.
This also improves the power factor on the power supply side.

Installing a Surge Absorber

Always use a surge absorber or diode for the inductive loads near the
Inverter, These inductive loads include magnetic contactors,
electromagnetic relays, solenoid valves, solenoid, and magnetic brakes.

Installing a Noise Filter on the Power Supply Side

Install a Noise Filter to eliminate noise transmitted between the power line
and the Inverter.

Wiring Example 1
Power supply MCCB 3G3IV-PHF 3G3MV

Noise SYSDRIVE M
Filter

MCCB
Programma
ble
Controller
Other controllers

Note Use a special-purpose Noise Filter for the SYSDRIVE 3G3MV.

Wiring Example 2

28
Design Section 2

Note Do not use any general-purpose noise filter. No general-purpose noise filter can
effectively suppress noise generated from the Inverter

Wiring on the output Side of the Main Circuit

Connecting the Terminal Block to the Load

Connect output terminal U/T1, V/T2, and W/T3 to motor lead wires U, V,
and W.
Check that the motor rotates forward command. Switch over any two of the
output terminals to each other and reconnect if the motor rotates in
reverse with the forward command.

Never Connect a Power Supply to Output Terminals

Never connect a power supply to output terminals U/T1, V/T2, and W/T3.
If voltage is applied to the output terminals, the internal circuit of the
Inverter will be damaged.

Never Short or Ground Output Terminals

If the output terminals are touched with bare hands or the output wires
come into contact with the Inverter casing, an electric shock or grounding
will occur. This is extremely hazardous.
Also, be careful not to shock the output wires.

Do not Use a Phase Advancing Capacitor or Noise Filter

Never connect a phase advance capacitor or LC/RC Noise Filter to the

output circuit.
Doing so will result in damage to the Inverter or cause other parts to burn.

Do not Use an Electromagnetic Switch of Magnetic Contactor

Do not connect an electromagnet switch of magnetic contactor to the

output circuit.
If a load is connected to the Inverter during running, an inrush current will
actuate the overcurrent protective circuit in the Inverter.

29
Design Section 2

Installing a Thermal Relay

The Inverter has an electronic thermal protection function to protect the

motor from overheating. If, however, more than one motor is operated with
one inverter or multi-polar motor is used, always install a thermal relay
(THR) between the Inverter and the motor and set n037 to 2 (no thermal
protection).
In this case, program the sequence so that the magnetic contactor on the
input side of the main circuit is turned OFF by the contact of the thermal
relay.

Installing a Noise Filter on the Output Side

Connect a Noise Filter to the output side of the Inverter to reduce radio
noise and induction noise.

Power MCCB 3G3MV 3G3IV-PHF

supply

SYSDRIVE Noise M
Filter

Induction noise Radio noise

Signal line
Controll AM
er radio

Induction Noise: Electromagnetic induction generates noise on the signal

line, causing the
controller to malfunction.

Radio Noise : Electromagnetic waves from the Inverter and cables cause
the broadcasting radio
receive to make noise.

Countermeasures against Induction Noise

As described previously, Noise Filter can be used to prevent induction noise
from being generated on the output side. Alternatively, cables can be
routed through a grounded metal pipe to prevent induction noise. Keeping
the metal pipe at least 30 cm away from the signal line considerably
reduces induction noise.

30
Design Section 2

Power MCCB 3G3MV Metal pipe

supply
SYSDRIVE M

30 cm min.

Signal line
Controll
er

Countermeasures against Radio Interference

Radio noise is generated from the Inverter as well as the input and output
lines. To reduce radio noise, install Noise Filter on both input and output
sides, and also install the Inverter in a totally enclosed steel box.
The cable between the Inverter and the motor should be as short as
possible.

Steel box

Power MCCB 3G3MV metal pipe

supply

Noise SYSDRIVE Noise M

Filter Filter

Cable Length between Inverter and Motor

If the cable between the Inverter and the motor is long, the high-frequency
leakage current will increase, causing the Inverter output current to
increase as well. This may affect peripheral devices.
To prevent this, adjust the carrier frequency (set in n080) as shown in the
table below.
For details, refer to the parameter settings.

Cable length 50 m max. 100 m max. More than 100

m

31
Design Section 2
Carrier 10 kHz max. 5 kHz max. 2.5 kHz max.
frequency

Ground Wiring

Always use the ground terminal of the 200-V Inverter with a ground resistance of
100 or less.
Similarly, always use the ground terminal of the 400-V Inverter with a ground
resistance of 10 or less.
Do not share the ground wire with other devices such as welding machines or
power tools.
Always use a ground wire that complies with technical standards on electrical
equipment and minimize the length of the ground wire.
Leakage current flows through the Inverter. Therefore, if the distance between the
ground electrode and the ground terminal is too long, the potential on the ground
terminal of the Inverter will become unstable.
When using more than one Inverter, be careful not to loop the ground wire.

Countermeasures against Harmonics

With the continuing development of electronics, the generation of
harmonics from industrial machines has been causing problems recently.

32
Design Section 2
The Ministry of International Trade and Industry provided some guidelines
in September 1994 for the suppression of harmonics from electrical
household appliances and electrical equipment in Japan. Since then, the
problem has been drawing considerable attention.
Refer to the following information for the definition of harmonics (i.e.,
harmonic currents with voltages) and countermeasures against the
generation of harmonics from the Inverter.

Harmonics

Definition
Harmonics consist of electric power produced from AC power and
alternating at frequencies that are integral multiples of the frequency of the AC
power.
The following frequencies are harmonics of a 60- or 50-Hz commercial
power supply.
Second harmonic: 120 (100) Hz
Third harmonic: 180 (150) Hz

Second harmonic (120 Hz)

Basic frequency (60)

Third harmonic (180 Hz)

Problems Caused by Harmonics Generation

The waveform of the commercial power supply will be distorted if the

commercial power supply contains excessive harmonics. Machines with
such a commercial power supply will malfunction or generate excessive
heat.

Basic frequency (60 Hz) Third harmonic (180 Hz)

Distorted current wave

form

Causes of Harmonics Generation

Usually, electric machines have built-in circuitry that converts commercial AC
power supply into DC
Power.
Such AC power, however, contains harmonics due to the difference in current flow
between DC and
AC.

Obtaining DC from AC Using Rectifiers and Capacitors

33
Design Section 2
DC voltage is obtained by converting AC voltage into a pulsating one-side
voltage with rectifiers and smoothing the pulsating one-side voltage with
capacitors. Such AC current, however, contains harmonics.

Inverter
The Inverter as well as normal electric machines has an input current
containing harmonics because the Inverter converts AC into DC. The output
current of the Inverter is comparatively high. Therefore, the ratio of
harmonics in the output current of the Inverter is higher than that of any
other electric machine.

Voltage

Time

Voltage Rectified

Time

Voltage Smoothed

Time
Current

A current flows into the

capacitors. The current Time
is different from the
voltage in waveform.

Countermeasures with Reactors against Harmonics

Generation

DC/AC Reactor
The DC reactor and the AC reactor suppress harmonics and currents that
change suddenly and greatly.
The DC reactor suppresses harmonics better than the AC reactor. The DC
reactor used with the AC reactor suppresses harmonics more effectively.
The input power factor of the Inverter is improved by suppressing the
harmonics of the input current of the Inverter

Connection
Connect the DC reactor to the internal DC power supply of the Inverter
after shutting OFF the power supply to the Inverter and making sure that
the change indicator of the Inverter turns OFF.
Do not touch the internal circuitry of the Inverter in operation, otherwise an
electric shock or burn injury may occur.

Wiring Method
[With DC Reactor]

34
Design Section 2

DC
reactor
(optional
Power MCCB )
suppl
R/L1 U/T1
y
S/L V/T2 M
2
3-phase 200 T/L3 W/T3
VAC,
SYSDRIVE
single-phase
3G3MV
200 VAC, or
3-phase 400
VAC

[With DC and AC Reactors]

DC
reactor
(optional
MCCB )
Power R/L1
supply U/T1
S/L V/T2 M
2
T/L3 W/T3
3-phase 200
VAC, SYSDRIVE
single-phase AC
3G3MV
200-VAC, or reactor
3-phase 400 (optional)
VAC

Reactor Effects
Harmonics are effectively suppressed when the DC reactor is used with the
AC reactor as shown in the following table.

Harmonic generation rate (%)

Harmonic 5th 7th 11th 13th 17th 19th 23rd 25th
s har- har- har- har- har- har- har- har-
suppressi moni moni moni moni moni moni moni moni
on c c c c c c c c
method

No reactor 65 41 8.5 7.7 4.3 3.1 2.6 1.8

AC reactor 38 41.5 7.4 3.4 3.2 1.9 1.7 1.3
DC reactor 30 13 8.4 5 4.7 3.2 3.0 2.2
DC and AC 28 9.1 7.2 4.1 3.2 2.4 1.6 1.4
reactors

Connecting the Braking Resistor and Braking Resistor Unit

When running a load with large inertia or a vertical axis, regeneration

energy will return to the Inverter. If OV (overvoltage) is generated during
deceleration, this indicates that the regeneration energy is exceeding the

35
Design Section 2
capacity of the Inverter. In this case, use a Braking Resistor or a Braking
Resistor Unit.

Connect the Braking Resistor as shown in the following diagram.

Note 1. When using a Braking Resistor, install a thermal relay to monitor the
temperature of the resistor.
Note 2. When using a Braking Resistor or a Braking Resistor Unit, be sure to include a
sequence whereby the power supply for the Inverter will be turned OFF in
the case of abnormal overheating. Not doing so may result in burning.

Braking Resistor: Use the output of the thermal relay used to monitor the
temperature of the
thermometer.
Braking Resistor Unit: Use the error contact output of the Braking Resistor Unit.

36
Design Section 2

37
Design Section 2

38
Design Section 2

39
Design Section 2

40
Design Section 2

41
Design Section 2
When using a Braking Resistor, be sure to set n902 (deceleration stall prevention
selection) to 1 (without deceleration stall prevent).

Invert
Powe MCCB XA er
r R/L1
suppl S/L2
y
T/L3
3-phase, 200 VAC (single- B1 B
phase) 2
Braking
200 VAC/3-phase 200 VAC)
(P (B) Resistor/Braki
XB OFF ON ) ng
XA (1 x (2 Resistor Unit
) )
SA

XB

SA

Contact points for thermal trip of

Braking
Resistor Unit or external thermal
relay

Braking Resistors and Braking Resistor Units for 200-V-class

Inverters

Inverter Braking Braking Resistor

3G3MV- Resistor Unit Minimum
(3% usage rate (10% usage rate Connecti
ED) ED) on
3G3IV- 3G3IV-
resistanc
e
A2001/AB0 PERF150WJ401 --- 300
01 (400)
A2002/AB0
02
A2004/AB0 PERF150WJ201 PLKEB20P7 (200, 70 200
04 (200) W)
A2007/AB0 120
07
A2015/AB0 PERF150WJ101 PLKEB21P5 (100, 260 60
15 (100) W)
A2022/AB2 PERF150WJ700 (70) PLKEB22P2 (70, 260
21 W)
A2037/AB0 PERF150WJ620 (62) PLKEB23P7 (40, 390 32
37 W)

Note Do not use resistance less than the minimum connection resistance value.
Doing so may damage the Inverter.

Braking Resistors and Braking Resistor Units for 400-V

class Inverters

42
Design Section 2
Inverter Braking Braking Resistor
3G3MV- Resistor Unit Minimum
(3% usage rate (10% usage rate Connecti
ED) ED) on
3G3IV- 3G3IV-
resistanc
e
A4002 PERF150WJ715 PLKEB40P7 (750, 70 750
A4004 (750) W)
A4007 510
A4015 PERF150WJ401 PLKEB41P5 (400, 260 240
(400) W)
A4022 PERF150WJ301 PLKEB42P2 (250, 260 200
(300) W)
A4037 PERF150WJ401 PLKEB43P7 (150, 390 100
(400) X 2 W)

Note Do not use resistances less than than the minimum connection resistance
value.
Doing so may damage the Inverter.

2.2.4 Wiring Control Circuit Terminals

A control signal line must be 50 m maximum and separated from power

lines.
The frequency reference must be input into the Inverter through shielded,
twisted-pair wires.

Wiring Control I/O Terminals

Wire the control input terminals (S1 to S7 and SC), the multi- function
contact output terminals (MA, MB, and MC) and the multi-function
photocoupler output terminals (P1, P2, PC) as described below.

Wire Used

Wire type Wire size Wire to be used

Single wire 0.5 to1.25 mm Polyethylene-shielded
Stranded wire 0.5 to 0.75 mm cable

Solderless Terminals for Control Circuit Terminals

The use of solderless terminals for the control circuit terminals is
recommended because solderless terminals are easy to connect securely.

Note When using the following solderless terminal, make sure that the wire size is
1.0
0.5 mm.
dia

Model: Phoenix Contacts A1 0.5-

8 8 WH
1
4

43
2.6 (Size:
Design Section 2

Wiring Method
1. Loosen the terminal screws with a thin-slotted screwdriver.

2. Insert the wires from underneath the terminal block.

3. Tighten the terminal screws firmly to a torque of 0.5 N.m.

Note 1. Always separate the control signal line from the main circuit cables and
other power cables.
Note 2. Do not solder the wires to the control circuit terminals. The wires may not
contact well with the
control circuit terminals if the wires are soldered.
Note 3. The end of each wire connected to the control circuit terminals must be
stripped for
approximately 5.5 mm.

Thin-slotted Control
screwdriver circuit
terminal
block

Strip the end for 5.5

mm Note Applying a torque of
if no solderless greater
terminal Wire than 0.5 N.m may
s Solderless
is used. damage the terminal
terminal or
block. If the tightening
wire
torque is insufficient,
without
however,
soldering
wires may be
disconnected.

Wiring Frequency Reference Input Terminals

Wire the frequency reference input terminals FR and FC as described below
for executing frequency references with the D/A Unit for digital-to-analog
data conversion or external power supply.

Wires Used

44
Design Section 2
Use shielded, twisted-pair wires for wiring in order to prevent the Inverter
from mal-functioning due to noise.

Wire type Wire size Wire to be used

Single wire 0.5 to1.25 mm Polyethylene-shielded
Stranded wire 0.5 to 0.75 mm cable for measurement
use

Solderless Terminals for Frequency Reference Input

Terminals
The use of solderless terminals for the frequency reference input terminals
is recommended because solderless terminals are easy to connect
securely.

Note Make sure that the wire size is 0.5 mm when using the following solderless
terminal.

1.0
dia

Model: Phoenix Contacts A1 0.5-8

8 WH
14

2.6 (Size:
dia mm)

Wiring Method

The wiring method for the frequency reference input terminals is the same as that
of the
control I/O terminals.
Always separate the control signal line from the main circuit cables and other
power cables.
Connect the shield to the ground terminal of the Inverter. Do not connect the
shield to the load.
Cover the shield with tape so that the shield will not come into contact with other
signal wires or
machines.

2-2-5 Conforming to EC Directive

45
Design Section 2
The following description provides the wiring method of the Inverter to
meet DC Directive requirements. If the following requirements are not
satisfied, the whole equipment incorporating the Inverter will need further
confirmation.

Standard Connection

Main Circuit Terminals

Control Circuit Terminals

Note I/O signals can be connected to a single shielded cable.

Conforming to EC Directives

Wiring the Power Supply

46
Design Section 2

Make sure that the Inverter and Noise Filter are grounded together.

Always connect the power input terminals (R/L1, S/l2, and T/L3) and power supply
via a dedicated
Noise Filter.
Reduce the length of the ground wire as much as possible.
Locate the Noise Filter as close as possible to the Inverter. Make sure that the
cable length between
the Noise Filter and the Inverter does not exceed 40 cm.
The following Noise Filter are available.

??? Please provide information on rasumi sei in the following three tables.

3-phase 200-VAC Noise Filter

Inverter 3-phase 200-VAC Noise Filter

(ntlp???)
Model 3G3MV- Model Rated current
3G3MV- (A)
A2001/A2002/A2004/A PRS2010V 10
2007
A2015/A2022 PRS2020V 20
A2037 PRS2030V 30

Single-phase 200-VAC Noise Filter

Inverter Single-phase 200-VAC Noise

Filter (ntlp???)
Model 3G3MV- Model Rated current
3G3MV- (A)
AB001/AB002/AB004 PRS1010V 10
AB007/AB015 PRS1020V 20
AB022 PRS1030V 30
AB037 PRS1050V 50

3-phase 400-VAC Noise Filter

Inverter 3-phase 400-VAC Noise Filter

(ntlp???)
Model 3G3MV- Model Rated current
3G3MV- (A)
A4002/A4004 PRS3005V 5
A4007/A4015/A4022 PRS3010V 10
A4037 PRS3015V 15

Connecting a Motor to the Inverter

When connecting a motor to the Inverter, be sure to use a cable with a braided
shield.
Reduce the length of the cable as short as possible and ground the shield on the
Inverter side as well as the motor side. Make sure that the cable length between
the Inverter and the motor does not exceed
20 cm. Furthermore, it is recommended that a clamp core (Clamp Filter) be
connected close to the output terminals of the Inverter.

Product Model
Manufacturer
Clamp Filter ZCAT3035-1330 TDK

47
Design Section 2

Wiring a Control Cable

Be sure to connect a cable with a braided shield to the control circuit terminals.
Ground the shield on the Inverter side only.

Grounding the Shield

In order to ground the shield securely, it is recommended that a cable
clamp be directly connected to the ground plate as shown
below.

Cable
Ground clamp
plate
Cabl
e

Shiel
d
Conforming to LVD
Always connect the Inverter and power supply via molded case circuit breaker
(MCCB) suitable to the Inverter for protecting the Inverter from damage that may
result from short-circuiting.
Use one MCCB per Inverter.
Select a suitable MCCB from the following table.

200-V Models

Inverter MCCB (Mitsubishi Electric)

Model Type Rated current
3G3MV- (A)
A2001 NF30 5
A2002 5
A2004 5
A2007 10
A2015 20
A2022 20
A2037 30
AB001 NF30 5
AB002 5
AB004 10
AB007 20
AB015 20
AB022 40
AB037 50

48
Design Section 2

400-V Models

Inverter MCCB (Mitsubishi Electric)

Model Type Rated current
3G3MV- (A)
A4002 NF30 5
A4004 5
A4007 5
A4015 10
A4022 10
A4037 20

Note To satisfy LVD requirements, the Inverter must be protected with a line breaker
in case a short- circuiting accident occurs. When using a single line breaker to be
shared with other Inverters or devices, make sure that the Inverters and devices
will be fully protected if there is a one-point short-circuit, otherwise the Inverters
and devices may be damaged.
The frequency reference power supply (FS) of the Inverter is of basic insulation
construction. When connecting the Inverter to peripheral devices, be sure to
increase the degree of insulation.

49