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Danfoss VLT Active Front End AFE 302 Operating Instructions Manual

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MAKING MODERN LIVING POSSIBLE
Operating Instructions
®
VLT
Active Front End AFE 302
www.danfoss.com/drives

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Summary of Contents for Danfoss VLT Active Front End AFE 302

  • Page 1 MAKING MODERN LIVING POSSIBLE Operating Instructions ® Active Front End AFE 302 www.danfoss.com/drives...

  • Page 3: Table Of Contents

    3.4.1 Cables between AFE and LCL Filters 3.4.2 Cables to the Damping Resistors 3.5 Test with the Real System Transformer and Motors 3.5.1 Re-program the Frequency Converter Parameters 3.6 On-site Final Test 3.6.1 Change Parameters to Actual MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 4 4.4.3 Grounding 4.4.4 Electrical Installation, Control Terminals 5 Specifications 5.1 General Specifications 5.2 Mains Supply 6 How to Programme 6.1 Parameter Selection 6.2 Parameters: 0-** Operation and Display 6.3 Parameters: 4-** Limits/Warnings Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 5 6.7 Parameters: 8-** Communications and Options 6.8 Parameters: 14-** Special Functions 6.9 Parameters: 15-** AFE Information 6.10 Parameters: 16-** Data Read-outs 6.11 Parameters: 40-** Mains / Filter 6.12 Warnings/Alarm Messages Index MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 6: Introduction

    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. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 7: Abbreviations

    Printed Circuit Board Programmable Logic Controller Part Number Rated Inverter Output Current Regen Regenerative terminals Residual Current Device Revolutions Per Minute Root Mean Square Second Software SMPS Switching Mode Power Supply MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 8: Safety Instructions And General Warning

    WARNING CAUTION Installation in high altitudes At altitudes above 2,000 m, contact Danfoss regarding The source of the fan voltage is from an external 400 V. PELV. Make sure to switch off the external fan voltage source switch.
  • Page 9 The three inverter units are connected in parallel to achieve the required power level. One AFE controller regulates the three parallel-connected inverter units. Control signals Master Slave Slave Transformer Illustration 2.1 Active Front End System Example MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 10: Crane System Design

    500 kW The AFE system is designed in conjunction with the Trolley motors 4x55 kW @ 650 V - recommended Danfoss LCL filters in which the physical Trolley drive 400 kW size, power rating and electrical parameters of the filters AFE/LCL –...

  • Page 11: Grounding Concept

    When the application environment is humid, consider the condensation of the frequency converter which may require the drain outlet. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 12: Selection Of Transformer

    NOTICE Pressure Change (Pa) Illustration 3.2 E frame derating vs. pressure change (small Danfoss reviews/evaluates the LCL filter design for each fan), P355T7-P400T7 application especially when the new transformer is used. frequency converter air flow: 650 cfm (1105 m 11.4 18.1 30.8 69.5...

  • Page 13: Assembling The Frequency Converter System

    Shaft size Driver size Torque [in- Torque [Nm] Torx/hex lbs] T-20/7 mm T-25/8 mm T-30/10 mm T-40/13 mm T-50/17 mm 18 mm/19 mm Table 3.5 Torque Values MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 14 Illustration 3.7 Outside- and Inside View Illustration 3.5 Front Door View 9,10 Illustration 3.8 800 mm Cabinet Skeleton View Illustration 3.6 800 mm Cabinet Front Door and its Inside Views (One Drive Case) Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 15 Crane System Design Operating Instructions Illustration 3.9 800 mm Lower Front End View MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 16 Crane System Design Operating Instructions Illustration 3.10 1200 mm Cabinet Exploded View Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 17 Illustration 3.11 1600 mm Cabinet Exploded View Illustration 3.14 One-drive Configuration Control Panel View 9,10 5, 6, 7 Illustration 3.15 Two Independent Drive Configuration Control Panel View Illustration 3.12 1600 mm Cabinet Exploded View MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 18 Crane System Design Operating Instructions 6, 7 Illustration 3.16 600 mm Drive Cabinet Illustration 3.18 AFE E-frame Drive Open View Illustration 3.17 800 mm Drive Cabinet Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 19: Mdcic Connector Configuration

    • voltage between the phases L1/L2/L3 and earth Verify that system is not powered. should be 0 V. Please call Danfoss service if you • Verify the system is grounded to earth. can measure a voltage greater then 10 V here.

  • Page 20: E-House Design

    Check the DC-link voltage with a voltage meter at 3.4.2 Cables to the Damping Resistors the terminals before and after the DC fuses. The cables should be as short as possible. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 21: Restoration After Slave Unit Is Repaired

    Do not touch until the DC voltage is below 10 V. Bring back the ribbon cables on the MDCIC card in the original set-up (AFE Master to Inverter 1, AFE Slave left to Inverter 2, AFE Slave right to Inverter 3). MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 22: Restoration After Master Unit Is Repaired

    FK100 (Master) following FK101, FK102, and FK103. You do not skip the terminal sequence. You can go down to one unit. When one master unit is used, the part Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 23: Start-Up Sequence

    AFE: ACtive Front End End of Start-up CC: Control Card Sequence Protection Mode PC: Power Card due to the Start-up PLC: Programmable Logic Controller Failure SC: Soft Charge Illustration 3.19 Start-up Sequence Flow Chart MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 24: Shut-Down Sequence

    DC voltage level is End of Stop down to zero Sequence The DC capacitor can be discharged with the external resistor, which expedites the discharge process. Illustration 3.20 Shut-down Sequence Flow Cart Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 25: How To Install

    4 How to Install This chapter covers mechanical and electrical installations to and from power terminals and control card terminals. 4.1 Overall Typical Frequency Converter Configuration Illustration 4.1 Typical System Overview MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 26: Pre-Installation

    When the damage is noticed, please contact the shipping company immediately to claim the damage and let Danfoss know the situation to work for the corrective action. Illustration 4.2 Package Front View Danfoss A/S ©...
  • Page 27 How to Install Operating Instructions Illustration 4.3 Package Side View MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 28: Lifting

    NOTICE The lifting cable angle should be 60° or greater. The spreader bar is an acceptable way of lifting. A spreader bar is an acceptable way to lift the F Frame. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 29: Mechanical Dimensions

    BOTTOM VIEW BOTTOM VIEW BOTTOM VIEW Illustration 4.6 Dimensions 1597.0 4X 540.5 2X 493.5 2X 294.0 4X 219.4 4X 81.4 4X 65.6 CABINET BACK WALL Illustration 4.7 Dimensions 1600 mm Cabinet MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 30 OPENING OPENING 98.5 98.5 113.0 113.0 269.3 269.3 281.9 281.9 415.5 423.5 567.5 575.5 BLOCKED BLOCKED BLOCKED 600MM CABINET 800MM CABINET 1200MM CABINET Illustration 4.8 Door Swing View and Back View Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 31 How to Install Operating Instructions 2X 98.5 2X 113.0 2X 269.3 2X 281.9 BLOCKED BLOCKED Illustration 4.9 1600 mm Cabinet Door Swing View MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 32 (2.5) (19.5) (1.0) (4.7) (0.5) (8.9) 1043 (41.1) 1547 1502 1320 (60.9) (59.1) (52.0) (6.3) (10.6) (6.2) (8.9) (21.2) (23.0) (0.9) (1.0) (1.0) (1.0) (0.5) Illustration 4.10 Dimensions E-frame IP00 Drive Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 33: Weight Information

    1071 2361 1778 3875 1200 mm cabinet with inverter modules qty. 3, 2 x 800 mm cabinet with inverter modules qty. 2 Table 4.1 Weight Based on Shipping Package Crate Size MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 34: Mechanical Installation

    T/L3 93 EARTH GROUND BUS .0 [.00] .0 [.00] 600MM CABINET (AFE/HOIST 1&2) TROLLEY/ TRAVEL U,V,W 1200MM CABINET R,S,T 800MM CABINET HOIST 1&2 Illustration 4.11 Terminals for the Typical Crane System Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 35: Mains Torque

    Recommended fuses are of the type gG for small to immunity and low emissions. medium power sizes. For larger powers, aR fuses are recommended. Circuit breakers must be used, provided they meet the national/international regulations and they MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 36 4 A, 600 V 525-690 V P500-P1M6, KLK-15 15 A, 600 V 525-690 V Table 4.8 Fan Fuses Bussmann PN Rating FWC-20A-10F 20 A, 600 V Table 4.9 Fan Voltage/Softcharge Fuse Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 37: Electrical Installation

    A = analog, D = digital ® Terminal 37 is used for Safe Stop. For instructions on Safe Stop installation please refer to the VLT Frequency Converters - Safe Torque Off Operating Instructions. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 38: Control Wires

    For protection of the frequency converter the correctly rated fuses must be used or the unit must be with built-in fuses. The recommended fuses can be seen in the tables in Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 39: Electrical Installation, Control Terminals

    Pull out the cable. Max. 0.4 x 2.5 mm Wiring to Control Terminals 9 - 10 mm (0.37 in) Illustration 4.14 Strip Isolation Illustration 4.15 Insert Screwdriver and Cable Illustration 4.16 Control Cable Terminals MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 40: Specifications

    Voltage level, logic '1' NPN < 14 V DC Maximum voltage on input 28 V DC Pulse frequency range 0-110 kHz (Duty cycle) Minimum pulse width 4.5 ms Input resistance, R approx.4 kΩ Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 41 The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. PELV isolation +24 V Control Mains High voltage Functional isolation DC-Bus RS-485 Illustration 5.1 PELV Isolation of Analog Inputs MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 42 The USB connection is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals. The USB ground connection is not galvanically isolated from protection earth. Use only an isolated laptop as PC connection to the USB connector on the frequency converter. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 43 EN 61800-3, EN 61000-6-3/4, EN 55011 EN 61800-3, EN 61000-6-1/2, EMC standards, Immunity EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6 See section on special conditions in the Design Guide. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 44: Mains Supply

    1) The typical overload percentage is 150. The P1M2 to P1M6 overload percentage is 175. ± 15%. If the switching frequency is increased, the power 2) The efficiency is estimated at the nominal load condition. It is expected to be within loss rises. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 45: How To Programme

    4-** Limits Warnings 5-** Digital inputs and outputs includes relay controls 6-** Analog In/Out 7-** Controllers 8-** Communications and Options 14-** Special functions 15-** AFE information 16-** Data Read-Out 40-** Mains/Filter MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 46: Parameters: 0-** Operation And Display

    This parameter is and all others used the active set-up. unique for LCP and buses. Factory setup Set-up 1 Set-up 2 Set-up 3 Set-up 4 Active Set-up Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 47 Status word (STW) sent to the Bus Master. [1690] Alarm Word One or more alarms in a Hex code. [1691] Alarm Word 2 One or more alarms in a Hex code. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 48 A more complex password protection is available for OEMs upon request. Copy parameters from and to the LCP. Use these parameters for saving and copying set-ups from one frequency converter to another. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 49 LCP, Fieldbus or FC standard bus. 0-67 Bus Password Access Range: Function: [0 - 9999 ] Writing to this parameter enables users to unlock the frequency converter from bus/MCT 10 Set-up Software. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 50: Parameters: 4-** Limits/Warnings

    Warning Generate a warning when a fault condition is encountered. Disabled Take no action on fault condition. Select which reaction the AFE should take in case the frequency deviation set in parameter 4-91 Output Frequency Deviation Limit. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 51: Parameters: 5-** Digital In/Out

    Resets AFE after a TRIP/ALARM. Not all alarms can be reset. [8] Start (Default Digital input 18): Select start for a start/stop command. Logic ‘1’ = start, logic ‘0’ = stop. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 52 In this parameter, the function for the relay outputs is [255] DC-link on ref. AFE running and motor operation selected. The selection of each mechanical relay is realised allowed. in an array parameter. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 53 0.01 s [0.01 - This parameter makes it possible to delay 600.00 s] the cut-out time of the relays. The selection of each mechanical relay is realised in an array parameter. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 54: Parameters: 6-** Analog In/Out

    4 and 20 mA is desired at maximum output (100%), calculate the percentage value as follows: mA / desired maximum current × 100% i . e . 10 mA : × 100% = 200% Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 55: Parameters: 7-** Controllers

    Set the wanted proportional gain 1000.000 N/A] of the DC-link voltage controller. Too large value may lead to oscillations. Power size dependent. 7-63 DC-Link PI Integral Time Range: Function: 5.0 ms [1.0 - 1.000.0 ms] MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 56: Parameters: 8-** Communications And Options

    8-04 Control Word Timeout Function Option: Function: Stop Stop and trip 8-06 Reset Control Word Timeout Option: Function: Do not reset Do reset Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 57 [ 1 - 255 ] Enter the address for the FC (standard) [104] PPO 4 port. [105] PPO 5 Valid range: 1-126. [106] PPO 6 [107] PPO 7 [108] PPO 8 [200] Custom telegram 1 MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 58 (digital input) and/or via the bus. NOTICE This parameter is only active if 8-01 Control Site is set to [0] Digital and control word. Digital input Logic AND Logic OR Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 59: Parameters: 14-** Special Functions

    Automatic reset x 2 Select [0] Normal operation for normal Automatic reset x 3 operation of the frequency converter with the Automatic reset x 4 motor in the selected application. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 60 Range: Function: Size related [ 1 - 1 ] Set the actual number of power units. 12 13 FC 301 39 42 FC 301 & FC 302 Illustration 6.2 Test Plugs Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 61: Parameters: 15-** Afe Information

    View the value of the logged event. 2147483647 ] Interpret the event values according to this table: Digtal input Decimal value. See 16-60 Digital Input for description after converting to binary value. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 62 [-32767 - 32767 ] View an extra description of the error. [0 - 8 ] View the power card ordering number. This parameter is mostly used in combination with alarm 38 internal fault. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 63 0. Changes may not be visible until up to 30 s after implementation. 15-99 Parameter Metadata Array [30] Range: Function: [0 - 9999 ] This parameter contains data used by the MCT 10 Set-up Software. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 64: Parameters: 16-** Data Read-Outs

    [0.00 - 1856.00 A ] Returns the value of measured current as a mean value IRMS. 16-42 Voltage Illustration 6.3 Active Digital Inputs Range: Function: 0.0V [0.0 - 6000.0V] Shows the AFE output voltage when the AFE is running. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 65 Range: Function: code. [0 - 65535 ] View the extended fieldbus comm. option status word. For more information, refer to the relevant fieldbus manual. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 66: Parameters: 40-** Mains / Filter

    LCL filter. 40-14 Filter Capacity (Cf) Range: Function: 400 uF [0 - 65000 uF] Set the capacitance of the LCL filter. The value is for the delta configuration. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 67: Warnings/Alarm Messages

    Parameter 14-59 Actual Number of Inverter Units Illegal PS config AFEInitialized to Default Value New spare part 14-23 Typecode Setting New Type Code Table 6.6 Alarm/Warning Code List (X) Dependent on parameter MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 68 08000000 134217728 reserved Voltage Limit (W64) reserved 10000000 268435456 Option Change (A67) reserved reserved 20000000 536870912 AFE Initialized(A80) Feedback Fault Feedback Fault (W61, (A61, A90) W90) 40000000 1073741824 Safe Stop (A68) Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...
  • Page 69 Please check parameters associated with is exceeded. The warning will last approx. 8-12 s, then the the module and make sure module is properly inserted in AFE trips and issues an alarm. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 70: Phase Imbalance

    2324: Power card configuration is determined to the ALARM 38, Internal fault incorrect at power up. By this alarm it may be necessary to contact your Danfoss 2330: Power size information between the power cards supplier. Some possible alarm messages: does not match.

  • Page 71: 48 1.8 V Supply Low

    5 = rectifier module. WARNING 73, Safe stop auto restart Safe stopped. Note that with automatic restart enabled, the AFE may start when the fault is cleared. MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.

  • Page 72: New Spare Part

    EEPROM. Select the correct type code in 14-23 Typecode Setting according to the label on unit. Remember to select ‘Save to EEPROM’ to complete. ALARM 251, New Type Code The AFE has got a new type code. Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 73: Index

    Operating hours, 15-00..............59 Disposal instruction................6 Ordered Type Code String, 15-44........... 60 Drive Identification, 15-4*..............60 Output Frequency Deviation Function, 4-90......48 Drive Ordering Number, 15-46............60 Output Voltage Deviation Function, 4-93........48 MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 74 Running Hours, 15-01................. 59 Safety instruction..................6 Screened cable..................33 Serial communication................. 40 Start Select, 8-53................... 56 Surroundings..................41 Torque characteristics................. 38 Trip Reset, 14-2*..................57 Voltage level................... 38 Warnings....................65 Wire access....................32 Danfoss A/S © Rev. 05/2014 All rights reserved. MG33X402...

  • Page 75: Mg33X402 Danfoss A/S © Rev. 05/2014 All Rights Reserved

    Index Operating Instructions MG33X402 Danfoss A/S © Rev. 05/2014 All rights reserved.
  • Page 76 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies.

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