Danfoss VLT Active Front End AFE 302 Bedienungsanleitung

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT®Active Front End AFE 302

www.danfoss.com/drives

Contents

1 Introduction 4

1.1 Purpose of the Manual 4

1.2 Safety Symbols 4

1.3 Software Version 4

1.4 Approvals 4

1.5 Abbreviations 5

2 Safety Instructions and General Warning 6

2.1 Safety Regulations AFE 302 6

2.1.1 Disposal Instruction 6

2.1.2 High Voltage Warning 6

2.1.3 Safety Instructions 6

2.1.4 General Warnings 6

2.1.5 Before Commencing Repair Work 6

2.1.6 System Description 6

3 Crane System Design 8

3.1 Selection of Motor Voltage 8

3.1.1 Selection of AFE & LCL Filter 8

3.1.2 Selection of AFE for Different Applications 8

3.1.3 Selection of Output Filter (LC Filter) 8

3.1.4 Selection of Switching Frequency 8

3.1.5 Selection of LCL Filter 8

3.1.6 Crane Cable Concept 8

3.1.7 Grounding Concept 9

3.1.8 Cooling and Airflow 9

3.1.9 Selection of Transformer 10

3.2 Assembling the Frequency Converter System 11

3.2.1 Tools Required 11

3.2.2 General Tightening Torque Values 11

3.2.3 Exploded Views 11

3.2.4 MDCIC Connector Configuration 17

3.3 First Power Up/Commissioning Check List 17

3.4 E-House Design 18

3.4.1 Cables between AFE and LCL Filters 18

3.4.2 Cables to the Damping Resistors 18

3.5 Test with the Real System Transformer and Motors 18

3.5.1 Re-program the Frequency Converter Parameters 18

3.6 On-site Final Test 18

3.6.1 Change Parameters to Actual 18

Contents Operating Instructions

3.6.2 Run with Full Load 18

3.7 AFE Emergency and Restore Procedures 18

3.7.1 Emergency Run when One Slave Unit is Damaged 18

3.7.2 Restoration after Slave Unit is Repaired 19

3.7.3 Emergency Run when Master Unit is Damaged 19

3.7.4 Restoration after Master Unit is Repaired 20

3.7.5 Emergency Run When More Than One Unit is Damaged 20

3.8 Manual Shut Down Sequence 20

3.9 Start-up Sequence 21

3.10 Shut-down Sequence 22

4 How to Install 23

4.1 Overall Typical Frequency Converter Configuration 23

4.2 Pre-installation 24

4.2.1 Planning the Installation Site 24

4.2.2 Receiving the Frequency Converter 24

4.2.3 Transportation and Unpacking 24

4.2.4 Lifting 26

4.2.5 Mechanical Dimensions 27

4.2.6 Weight Information 31

4.3 Mechanical Installation 32

4.3.1 Tools Needed 32

4.3.2 General Considerations 32

4.3.3 Terminal Locations 32

4.3.4 Mains Torque 33

4.3.5 Mains Connection 33

4.3.6 Screened Cables 33

4.4 Electrical Installation 35

4.4.1 Control Wires 36

4.4.2 Power Connections 36

4.4.3 Grounding 36

4.4.4 Electrical Installation, Control Terminals 37

5 Specifications 38

5.1 General Specifications 38

5.2 Mains Supply 42

6 How to Programme 43

6.1 Parameter Selection 43

6.2 Parameters: 0-** Operation and Display 44

6.3 Parameters: 4-** Limits/Warnings 48

Contents Operating Instructions

6.4 Parameters: 5-** Digital In/Out 49

6.5 Parameters: 6-** Analog In/Out 52

6.6 Parameters: 7-** Controllers 53

6.7 Parameters: 8-** Communications and Options 54

6.8 Parameters: 14-** Special Functions 57

6.9 Parameters: 15-** AFE Information 59

6.10 Parameters: 16-** Data Read-outs 62

6.11 Parameters: 40-** Mains / Filter 64

6.12 Warnings/Alarm Messages 65

Index 71

Contents Operating Instructions

1 Introduction

1.1 Purpose of the Manual

1.1.1 How to Read these Operating

Instructions

Please read this manual carefully for proper use. Incorrect

handling of the frequency converter may cause improper

operation of the frequency converter or related equipment,

shorten lifetime or cause other troubles.

These Operating Instructions will help getting started,

installing, programming, and troubleshooting the AFE 302.

Chapter 1 Introduction, introduces the manual and informs

about the approvals, symbols, and abbreviations used in

this literature.

Chapter 2 Safety Instructions and General Warning, entails

instructions on how to handle the AFE 302 correctly.

Chapter 3 Crane System Design, describes the crane system

design associated with the frequency converters.

Chapter 4 How to Install, guides through the mechanical

and technical installation.

Chapter 6 How to Programme, describes how to operate

and programme the AFE 302 via the Local Control Panel

(LCP).

1.2 Safety Symbols

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation which could

result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which could

result in minor or moderate injury. It can also be used to

alert against unsafe practices.

NOTICE

Indicates important information, including situations that

can result in damage to equipment or property.

1.3 Software Version

VLT®Active Front End AFE 302

Operating Instructions

Software version: 1.15

1.4 Approvals

Table 1.1 Compliance Marks: CE and C-Tick

Introduction Operating Instructions

1.5 Abbreviations

AFE Active Front End

AC Alternating current

AWG American Wire Gage

A Ampere/AMP

AMA Automatic Motor Adaptation

ILIM Current limit

°CDegrees Celsius

DC Direct current

EMC Electro Magnetic Compatibility

ETR Electronic Thermal Relay

FC Frequency Converter

g Gram

Hz Hertz

HF High Frequency

ID Identification

IGBT Insulated Gate Biopolar Transistor

IP International Protection

IT Isolation Terra

kHz Kilohertz

kW Kilowatt

kWh Kilowatt-hour

LCP Local Control Panel

MW Megawatt

m Meter

uF Microfarad

mH Millihenry Inductance

mA Milliampere

MCM Thousand circular mils

ms Millisecond

min Minute

MCT Motion Control Tool

MDCIC Multi Drive Control Interface Card

NEMA National Electrical Manufacturers

Association

Nm Newton Meters

IM,N Nominal motor current

fM,N Nominal motor frequency

PM,N Nominal motor power

UM,N Nominal motor voltage

par. Parameter

PELV Protective Extra Low Voltage

PCB Printed Circuit Board

PLC Programmable Logic Controller

PN Part Number

IINV Rated Inverter Output Current

Regen Regenerative terminals

RCD Residual Current Device

RPM Revolutions Per Minute

RMS Root Mean Square

s Second

SW Software

SMPS Switching Mode Power Supply

nsSynchronous Motor Speed

IVLT,MAX The maximum output current

IVLT,N The rated output current supplied by the

frequency converter

TLIM Torque limit

THD Total Harmonic Distortion

THDi Total Harmonic Distortion in Current

THDu Total Harmonic Distortion in Voltage

V Volts

Introduction Operating Instructions

2 Safety Instructions and General Warning

2.1 Safety Regulations AFE 302

2.1.1 Disposal Instruction

Equipment containing electrical components

may not be disposed with domestic waste.

It must be separately collected with Electrical

and Electronic waste according to local and

currently valid legislation.

2.1.2 High Voltage Warning

WARNING

The voltage of the AFE 302 is dangerous whenever the

frequency converter is connected to mains. Incorrect

installation or operation of the frequency converter may

cause damage to the equipment, serious personal injury

or death. The instructions in this manual must

consequently be observed, as well as applicable local

and national rules and safety regulations.

WARNING

Installation in high altitudes

At altitudes above 2,000 m, contact Danfoss regarding

PELV.

2.1.3 Safety Instructions

•Make sure that the AFE 302 is properly connected

to earth.

•Protect users against supply voltage.

•Remember that the [Off] key on LCP is not a

safety switch. Pressing the [Off] key does not

disconnect the AFE 302 from the mains.

2.1.4 General Warnings

WARNING

Touching the electrical parts may be fatal even after the

equipment is disconnected from the mains.

Before carrying out the maintenance, the frequency

converter must be disconnected from the mains. It will

avoid the electrical shock hazard.

Check the discharge time on the nameplate for the exact

waiting period. Otherwise wait at least 40 min.

WARNING

When the AFE is on, the earth current from the AFE 302

frequency converter will exceed 3.5 mA. The earth cable

must have a good contact to the earth terminal 95. The

earth connection is done with the two separate cables.

The size of each cable needs to be a half of the mains

cable size in minimum.

2.1.5 Before Commencing Repair Work

1. Switch off the entire system.

2. Wait until the DC-link capacitor is discharged

fully. See period of time on the warning label.

3. Disconnect DC bus terminals 88 and 89.

4. Disconnect the soft charge supply connector from

the soft charge board.

CAUTION

The source of the MDCIC connector (MK105) is the AC

voltage from the front end of the LCL filter. Make sure to

switch off the mains switch.

CAUTION

The source of the fan voltage is from an external 400 V.

Make sure to switch off the external fan voltage source

switch.

2.1.6 System Description

NOTICE

The grounded Delta mains are not used.

An Active Front End (AFE) is sometimes called an active

rectifier, in comparison with a passive rectifier such as the

diode bridge. The AFE consists of LCL filter and the

inverter unit.

The AFE main features are as follows:

•sinusoidal input current and low harmonic

distortion in the mains

•unity power factor

•both rectifying and regenerating operation

•constant regulated DC voltage

Illustration 2.1 shows the AFE system example.

At start-up, the AFE must detect the mains frequency and

phase to synchronize the operation.

Safety Instructions and Gen... Operating Instructions

During the normal operation, the AFE DC-link voltage is

regulated to be constant. This means that the energy from

the decelerated motor is passed on to the mains as

regenerated electrical energy. A passive rectifier would

require a braking resistor to consume the surplus energy

as heat. The AFE is energy efficient for the application

where the motor deceleration is frequent. Also the brake

resistor space is saved.

The LCL filter allows the power flow. It also reduces the

ripple current of the fundamental frequency, switching

frequency, and their harmonics into the mains. A damping

resistor Rd is connected in series with the filter capacitor

Cf to stabilize the filter resonance.

The three inverter units are connected in parallel to

achieve the required power level. One AFE controller

regulates the three parallel-connected inverter units.

Transformer

AFE

Master Slave Slave

Control signals

130BA771.11

Illustration 2.1 Active Front End System Example

Safety Instructions and Gen... Operating Instructions

3 Crane System Design

3.1 Selection of Motor Voltage

The AFE system is designed to regulate a DC voltage of

630x1.08=680 V. 690 V motors are suitable for this system.

When the motors are used in the field weakening region

or with output filters, the motors with less than 650 V are

used.

3.1.1 Selection of AFE & LCL Filter

•AFE systems are built up based on standard 690

V hardware.

•Standard AFE hardware runs on 630 V mains

supply and DC-link voltage is 975 V.

3.1.2 Selection of AFE for Different

Applications

•The frequency converter power size in the flux

application must be one or two sizes higher than

the application needed. Also, the frequency

converter should not be higher than two to

maintain a good resolution on current sensors.

•The AFE electrical rating should be selected

based on the worst-case total power, including

the overload percentage, rather than a mere sum

of the motor power.

•Example:

Hoist motors 500 kW @ 650 V - Hoist

drives 800 kW

Travel motors 8x50 kW @ 650 V - Travel

drive 500 kW

Trolley motors 4x55 kW @ 650 V -

Trolley drive 400 kW

AFE/LCL – 1,2 MW continuous, with a

175% overload for a maximum 1 min.

3.1.3 Selection of Output Filter (LC Filter)

•The output filter is needed because of the long

motor cable configuration.

•Output filters should be sized based on the

frequency converter's maximum output current.

•The dU/dt filters can be used up to 100 m to

protect the motor. The sine-wave filters can be

used with any cable length (maximum of 1,000

m).

•Above 150 m cable length it is recommended to

use a sine-wave filter.

•The cable length is calculated as the sum of all

parallel cables.

•Filters must be designed to switching frequency

of the frequency converter. The resonance

frequency, f0, of the filter should be:

10×

fout

max

≤

0≤

fsw

•The resonant frequency must meet the following

equation, limited by the control frequency, fcon:

fcon

Switching frequency [kHz] Control frequency1) [kHz]

1.5 3

2 4

2.5 5

3 6

3.5 7

4 4

5 5

6 6

7 7

Table 3.1 Frequencies

1) The control frequency is an internal hardware frequency.

3.1.4 Selection of Switching Frequency

It is recommended that the switching frequency of AFE

and motor drives shall be equal or an integer multiple of

each other.

3.1.5 Selection of LCL Filter

The AFE system is designed in conjunction with the

recommended Danfoss LCL filters in which the physical

size, power rating and electrical parameters of the filters

are optimized.

If non-Danfoss filters are used, system performance and

stability may be degraded.

3.1.6 Crane Cable Concept

To reduce the high frequency noise on the mains line and

to meet the EMC emission limits, the electromagnetic

coupling should be avoided and the following rules have

to be applied:

Crane System Design Operating Instructions

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