Danfoss VLT Active Front End AFE 302 Manual de usuario

Operating Instructions MG33X202

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Active Front End AFE 302

www.danfoss.com/drives

*MG33X202*

130R0429 MG33X202 Rev. 2010-06-29

Contents

1 Introduction 4

1.1.1 How to Read these Operating Instructions 4

1.1.2 Symbols 4

1.1.3 Software Version 4

1.1.4 Approvals 4

1.1.5 Abbreviations 5

2 Safety Instructions and General Warning 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 Torque Tightening Values 11

3.2.3 Exploded Views 12

3.2.4 MDCIC Connector Configuration 15

3.3 First Power Up/Commissioning Check List 15

3.4 E-House Design 17

3.4.1 Cables between AFE and LCL Filters 17

3.4.2 Cables to the Damping Resistors 17

3.5 Test with the Real System Transformer and Motors 17

3.5.1 Re-program the Frequency Converter Parameters 17

3.6 On-site Final Test 17

3.6.1 Change Parameters to Actual 17

3.6.2 Run with Full Load 17

Contents VLT®Active Front End AFE 302 Operating Instructions Liebherr

MG.33.X2.02 - VLT®is a registered Danfoss trademark 1

3.7 AFE Emergency and Restore Procedures 17

3.7.1 Emergency Run with One Slave Unit Damaged 17

3.7.2 Restoration after Slave Unit Repaired 18

3.7.3 Emergency Run with Master Unit Damaged 18

3.7.4 Restoration after Master Unit Repaired 18

3.8 Manual Shut Down Sequence 19

3.9 Start-up Sequence 19

3.10 Shut-down Sequence 21

4 How to Install 22

4.1 Overall Frequency Converter Configuration 22

4.2 Pre-installation 23

4.2.1 Planning the Installation Site 23

4.2.2 Receiving the Frequency Converter 23

4.2.3 Transportation and Unpacking 23

4.2.4 Lifting 24

4.2.5 Mechanical Dimensions 26

4.2.6 Weight Information 28

4.3 Mechanical Installation 28

4.3.1 Tools Needed 28

4.3.2 General Considerations 28

4.3.3 Terminal Locations 29

4.3.4 Mains Torque 29

4.3.5 Mains Connection 29

4.3.6 Shielded Cables 30

4.3.7 Fuses 30

4.4 Electrical Installation 31

4.4.1 Control Wires 31

4.4.2 Power Connections 31

4.4.3 Earthing 31

4.4.4 Electrical Installation, Control Terminals 32

5 How to Programme 33

5.1 Parameter Selection 33

5.2 Parameters: 0-** Operation and Display 34

5.3 Parameters: 4-** Limits/Warnings 38

5.4 Parameters: 5-** Digital In/Out 39

5.5 Parameters: 7-** Controllers 41

5.6 Parameters: 8-** Communications and Options 42

5.7 Parameters: 14-** Special Functions 45

5.8 Parameters: 15-** AFE Information 47

Contents VLT®Active Front End AFE 302 Operating Instructions Liebherr

2 MG.33.X2.02 - VLT®is a registered Danfoss trademark

5.9 Parameters: 16-** Data Read-outs 50

5.10 Parameters: 40-** Mains / Filter 52

5.11 Warnings/Alarm Messages 53

Index 59

Contents VLT®Active Front End AFE 302 Operating Instructions Liebherr

MG.33.X2.02 - VLT®is a registered Danfoss trademark 3

1 Introduction

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

you about the approvals, symbols, and abbreviations used in

this literature.

Chapter 2, Safety Instructions and General Warnings, 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 you through the

mechanical and technical installation.

Chapter 5, How to Programme, shows you how to operate

and programme the AFE 302 via the Local Control Panel

(LCP).

1.1.2 Symbols

The following symbols are used in this manual:

WARNING

Indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not

avoided, may result in minor or moderate injury. It may also

be used to alert against unsafe practices.

CAUTION

Indicates a situation that may result in equipment or

property-damage-only accidents.

NOTE

Indicates highlighted information that should be regarded

with attention to avoid mistakes or operate equipment at

less than optimal performance.

✮Indicates default setting of parameter.

1.1.3 Software Version

VLT Active Front End AFE 302

Operating Instructions

Software version: 1.07

1.1.4 Approvals

Introduction VLT®Active Front End AFE 302 Operating Instructions Liebherr

4 MG.33.X2.02 - VLT®is a registered Danfoss trademark

1.1.5 Abbreviations

Active Front End AFE

Alternating current AC

American Wire Gage AWG

Ampere/AMP A

Automatic Motor Adaptation AMA

Current limit ILIM

Degrees Celsius °C

Direct current DC

Electro Magnetic Compatibility EMC

Electronic Thermal Relay ETR

Frequency Converter FC

Gram g

Hertz Hz

High Frequency HF

Identification ID

Insulated Gate Biopolar Transistor IGBT

International Protection IP

Isolation Terra IT

Kilohertz kHz

Kilowatt kW

Kilowatt-hour kWh

Local Control Panel LCP

Megawatt MW

Meter m

Microfarad uF

Millihenry Inductance mH

Milliampere mA

Million Cubic Meter MCM

Millisecond ms

Minute min

Motion Control Tool MCT

Multi Drive Control Interface Card MDCIC

National Electrical Manufacturers Association NEMA

Newton Meters Nm

Nominal motor current IM,N

Nominal motor frequency fM,N

Nominal motor power PM,N

Nominal motor voltage UM,N

Parameter par.

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Programmable Logic Controller PLC

Rated Inverter Output Current IINV

Regenerative terminals Regen

Residual Current Device RCD

Revolutions Per Minute RPM

Root Mean Square RMS

Second s

Software SW

Switching Mode Power Supply SMPS

Synchronous Motor Speed ns

The maximum output current IVLT,MAX

The rated output current supplied by the

frequency converter

IVLT,N

Torque limit TLIM

Total Harmonic Distortion THD

Volts V

Introduction VLT®Active Front End AFE 302 Operating Instructions Liebherr

MG.33.X2.02 - VLT®is a registered Danfoss trademark 5

2 Safety Instructions and General Warning

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 instal-

lation 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 2km, please contact Danfoss Drives

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 asafety

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.

Also make sure that the fan voltage supply is disconnected.

Check the discharge time on the nameplate for the exact

waiting period. Otherwise wait at least 40min.

NOTE

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

frequency converter will exceed 3.5mA. 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 the complete system off.

2. Wait for discharge of the DC-link. 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

MDCIC Mains Sync Connector (MK105) is supplying by

external 630V.

Switch off the main switch before you dismount the front

plate.

2.1.6 System Description

NOTE

The grounded Delta or IT mains will not be used.

In contrast to a passive diode rectifier front-end, an Active

Front End (AFE), sometimes called an Active Rectifier, is

designed with the IGBT-based inverrter. The topology of an

AFE is shown below. The AFE is comprised of the LCL filter

and the three-phase voltage source converter (IGBT with free

wheeling diodes).

The main purpose with the three-phase active rectifier is to

achieve:

•sinusoidal input current and low harmonic

distortion in the mains

•unity power factor

•both rectifying and regenerating operation

•constant regulated DC voltage

To operate properly, an AFE must continuously be

synchronized to the mains voltage and frequency. The

challenge is the start up sequence where the mains phase

must be sensed to achieve a smooth start of the AFE.

During normal operation, the DC-link voltage of the inverter

is regulated to a constant level independent of the power

Safety Instructions and Gen... VLT®Active Front End AFE 302 Operating Instructions Liebherr

6 MG.33.X2.02 - VLT®is a registered Danfoss trademark

flow direction. This means that the returned energy from the

motor and mechanical systems that are decelerated, is

passed on to the mains as regenerated electrical energy. A

passive diode rectifier front end would require a braking

resistor to consume the surplus energy as heat. In

applications with frequent decelerations an AFE is thus more

energy efficient. Also the practical aspects with removing the

heat from a braking resistor is eliminated.

The LCL filter reduces the ripple current of the switching

frequency and its harmonics into the mains. A damping

resistor Rd is connected in series with the filter capacitor Cf

to stabilize the filter resonance.

The three standard power units operate in parallel to achieve

the required power levels. The standard power units in the

AFE are identical to the power units in the frequency

converters. One AFE centralized controller regulates and

controls the three parallel power units.

Transformer

460 V

AFE

560 kW

Master

560 kW

Slave

560 kW

Slave

Control signals

130BA771.10

Illustration 2.1 Active Front End Topology

Safety Instructions and Gen... VLT®Active Front End AFE 302 Operating Instructions Liebherr

MG.33.X2.02 - VLT®is a registered Danfoss trademark 7

3 Crane System Design

3.1 Selection of Motor Voltage

The AFE system is designed to regulate a DC voltage of

630x1,08x1.41=690V. 690V motors are suitable for this

system.

Furthermore, whenever running the motors in the field

weakening region, or with output LC filters, it is necessary to

use the motors of less than 650V.

3.1.1 Selection of AFE & LCL Filter

•AFE systems are built up based on standard 690V

hardware.

•Standard AFE hardware runs on 630V mains supply

and DC-link voltage is 975V.

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 size should be selected based on asum of the

current rather than a sum of the power of the

connected motors.

•Example:

Hoist motors 500kW @650V -Hoist drives

800kW

Travel motors 8x50kW @ 650V - Travel

drive 500kW

Trolley motors 4x55kW @ 650V - Trolley

drive 400kW

AFE/LCL – 1,2MW continuous, with a

175% overload for a maximum 1min.

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 100m to protect

the motor. The sine-wave filters can be used with

any cable length (maximum of 1000m).

•Above 150m 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

1The control frequency is an internal hardware frequency.

3.1.4 Selection of Switching Frequency

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 VLT®Active Front End AFE 302 Operating Instructions Liebherr

8 MG.33.X2.02 - VLT®is a registered Danfoss trademark

1. Use the shielded cable between the sine-wave filter

and frequency converter.

2. Keep the unshielded cable away from the mains

cable. The two cables should not be run in parallel.

3. If the installation requires to route the motor cables

and mains cables in parallel, keep a distance of at

least 45cm between the two cables. Separate the

cables by placing them in different cable trays or in

different sections of a cable tray.

4. Use continuous cable trays and avoid “ladder-type”

cable trays.

5. Route the motor cable along the metallic grounded

conductors such as cable trays, rails from the

building structure, pipes, etc.

3.1.7 Grounding Concept

•Do the common grounding between AFE and

motor drives.

•The output filters and LCL should have low

impedance grounding to the AFE and motor

frequency drives.

•Ensure low impedance between entire crane

construction and the cabinets and the transformer.

•Use only one connection to the transformer.

3.1.8 Cooling and Airflow

Cooling

Cooling can be obtained, by using the cooling ducts in the

bottom and the top of the unit, by taking air in and out of

the back of the unit or by combining the cooling

possibilities.

Duct cooling

A dedicated option has been developed to optimize instal-

lation of IP00/chassis frequency converters in Rittal TS8

enclosures utilizing the fan of the frequency converter for

forced air cooling of the backchannel. The air out of the top

of the enclosure could but ducted outside a facility so the

heat losses from the backchannel are not dissipated within

the control room reducing air-conditioning requirements of

the facility.

Please see Installation of Duct Cooling Kit in Rittal enclosures,

for further information.

Back cooling

The backchannel air can also be ventilated in and out of the

back of a Rittal TS8 enclosure. This offers a solution where

the backchannel could take air from outside the facility and

return the heat losses outside the facility thus reducing air-

conditioning requirements.

NOTE

The ideal cooling air is dry and clean. When the air from

outside is used, filter mats and long air inlets could prevent

the dirty air problem. The condensation inside the frequency

converter, from the humid air, may require the drain outlet.

NOTE

Adoor/top fan(s) is required on the enclosure to remove the

heat losses not contained in the backchannel of the

frequency converter and any additional losses generated

from other components installed inside the enclosure. The

total required air flow must be calculated so that the

appropriate fans can be selected. Some enclosure manufac-

turers offer software for performing the calculations (i.e.

Rittal Therm software). If the VLT is the only heat generating

component in the enclosure, the minimum airflow required

at an ambient temperature of 45oCfor the D3 and D4 frame

sizes is 391m3/h (230cfm). The minimum airflow required at

an ambient temperature of 45oC for the E2 frame size is

782m3/h (460cfm).

Airflow

Table 3.1 shows the necessary airflow over the heat sink.

Enclosure

protection Frame size Door fan(s)/

Top fan airflow

Heatsink fan(s)

IP21 / NEMA 1

IP54 / NEMA 12

D1 and D2 170m3/h (100

cfm)

765m3/h (450

cfm)

E1 P250T5,

P355T7,

P400T7

340m3/h (200

cfm)

1105m3/h (650

cfm)

E1P315-

P400T5, P500-

P560T7

340m3/h (200

cfm)

1445m3/h (850

cfm)

IP21 / NEMA 1 F1, F2, F3 and

700m3/h (412

cfm)*

985m3/h (580

cfm)*

IP54 / NEMA 12 F1, F2, F3 and

525m3/h (309

cfm)*

985m3/h (580

cfm)*

IP00 / Chassis D3 and D4 255m3/h (150

cfm)

765m3/h (450

cfm)

E2 P250T5,

P355T7,

P400T7

255m3/h (150

cfm)

1105m3/h (650

cfm)

E2 P315-

P400T5, P500-

P560T7

255m3/h (150

cfm)

1445m3/h (850

cfm)

* Airflow per fan. Frame size F contain multiple fans.

Table 3.1 Heatsink Air Flow

Crane System Design VLT®Active Front End AFE 302 Operating Instructions Liebherr

MG.33.X2.02 - VLT®is a registered Danfoss trademark 9

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