Danfoss VLT AFE 302 Operating Instructions Manual
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Danfoss VLT AFE 302 Operating Instructions Manual

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MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® Active Front End AFE 302

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Summary of Contents for Danfoss VLT AFE 302

  • Page 1 MAKING MODERN LIVING POSSIBLE Operating Instructions VLT® Active Front End AFE 302...

  • Page 2: Table Of Contents

    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 3.6.2 Run with Full Load ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 3 5.2 Parameters: 0-** Operation and Display 5.3 Parameters: 4-** Limits/Warnings 5.4 Parameters: 5-** Digital In/Out 5.5 Parameters: 7-** Controllers 5.6 Parameters: 8-** Communications and Options 5.7 Parameters: 14-** Special Functions 5.8 Parameters: 15-** AFE Information ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 4 ® Contents Active Front End AFE 302 Operating Instructions Liebherr 5.9 Parameters: 16-** Data Read-outs 5.10 Parameters: 40-** Mains / Filter 5.11 Warnings/Alarm Messages Index ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 5: Introduction

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

  • Page 6: Abbreviations

    Printed Circuit Board Programmable Logic Controller Rated Inverter Output Current Regenerative terminals Regen Residual Current Device Revolutions Per Minute Root Mean Square Second Software Switching Mode Power Supply SMPS Synchronous Motor Speed ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 7: Safety Instructions And General Warning

    WARNING external 630V. Switch off the main switch before you dismount the front Installation in high altitudes plate. At altitudes above 2km, please contact Danfoss Drives regarding PELV. 2.1.6 System Description 2.1.3 Safety Instructions NOTE The grounded Delta or IT mains will not be used.
  • Page 8 One AFE centralized controller regulates and controls the three parallel power units. Control signals 560 kW 560 kW 560 kW Master Slave Slave Transformer 460 V Illustration 2.1 Active Front End Topology ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 9: Crane System Design

    500kW The AFE system is designed in conjunction with the Trolley motors 4x55kW @ 650V - Trolley recommended Danfoss LCL filters in which the physical size, drive 400kW power rating and electrical parameters of the filters are AFE/LCL – 1,2MW continuous, with a optimized.

  • Page 10: Grounding Concept

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

  • Page 11: Selection Of Transformer

    630V and the 400V and these transformers should be physically separated. The 400V transformer must be close to or in the E-house to have a short ground cable. NOTE Danfoss will review/evaluate the LCL filter design for each 21.5 43.4 147.1 237.5 278.9 application, especially with a new transformer used.

  • Page 12: Assembling The Frequency Converter System

    IGBT fasteners. See the instructions included with those replacement parts for correct values. Shaft Size Driver Size Torx/ Torque (in- Torque (Nm) lbs) T-20/7mm T-25/8mm T-30/10mm T-40/13mm T-50/17mm 18mm/19mm Table 3.2 Torque Values Table ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 13: Exploded Views

    AUX Relay: 240V ac 2A VSYNC: 630V 1A NOTE The control circuit including the control card terminals are isolated galvanically from the power circuit by the reinforced isolation (PELV). Illustration 3.5 Outside View ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 14 ® Crane System Design Active Front End AFE 302 Operating Instructions Liebherr Illustration 3.6 Cabinet Skeleton, Inside View, and Connection View Inside the Lower Front Panel. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 15 Active Front End AFE 302 Operating Instructions Liebherr 9,10 Illustration 3.9 Cabinet Skeleton View Illustration 3.7 Outside- and Inside View Illustration 3.10 Connection View Inside the Lower Front Panel Illustration 3.8 Outside- and Inside View ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 16: Mdcic Connector Configuration

    Manually close input contactor (between AFE and LCL filter). Unplug the MK105 connector on the MDCIC. Measure MK105 of MDCIC harness to the input phases. Illustration 3.13 Outside View and Cabinet Skeleton ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 17 Start checking inverters and motors. between the phases L1/L2/L3 and earth should be • Save all parameter settings with . 0V. Please call Danfoss service if you can measure a • For the crane commissioning, measure THDu and voltage greater then 10V here.

  • Page 18: E-House Design

    Switch Crane off. Wait at least 20s. All LCPs must be completely off. Switch Crane on. The warning 78 will disappear. Now you can run the crane with only two AFE power units. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 19: Restoration After Slave Unit Repaired

    Switch Crane on. softcharge board of the damaged power unit. The AFE runs now with all 3 power units. Disconnect the ribbon cable from the Inverter 1 position at the MDCIC. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 20: Manual Shut Down Sequence

    AFE frequency converter is different from the one in the standard frequency converter. The “Ready” signal in the AFE frequency converter is on when the DC voltage is boosted to the level within the AFE regulation range. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 21 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 3.14 Start-up Sequence Flow Chart ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 22: 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 3.15 Shut-down Sequence Flow Cart ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 23: How To Install

    Active Front End AFE 302 Operating Instructions Liebherr 4 How to Install This chapter covers mechanical and electrical installations to and from power terminals and control card terminals. 4.1 Overall Frequency Converter Configuration Illustration 4.1 System Overview ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 24: 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. 4.2.3 Transportation and Unpacking The following illustrations show the front and side views of the frequency converter, shipping crate, respectively.

  • Page 25: Lifting

    The same principle is applied for the AFE cabinets. Illustration 4.4 1: Main Load Carrying Points 2: Main Load Carrying Points ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 26 The angle from the top of the frequency converter to the lifting cable should be 60° or greater. A spreader bar is an acceptable way to lift the F Frame. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 27: Mechanical Dimensions

    2X 81.4 73.0 3X 81.4 65.5 65.5 65.5 CABINET CABINET CABINET BACK BACK BACK WALL WALL WALL 600MM CABINET 800MM CABINET 1200MM CABINET BOTTOM VIEW BOTTOM VIEW BOTTOM VIEW Illustration 4.6 Dimensions ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 28 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 4.7 Door Swing View and Back View ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 29: Weight Information

    • Wrench with relevant metric sockets (7-17mm) of the enclosure where the frequency converter is mounted, • Extensions to wrench i.e. by using cable clamps. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 30: Terminal Locations

    Ensure that the fuses have the correct current and voltage rating. Terminal No. Function 91, 92, 93 Mains R/L1, S/L2, T/L3 Ground/Earth ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 31: Shielded Cables

    Short-circuit protection: use. The frequency converter must be protected against short- Supplementary fuses circuit to avoid electrical or fire hazard. Danfoss recommends using the fuses mentioned below to protect service Frame size Bussmann PN* Rating...

  • Page 32: Electrical Installation

    The radio interference will have been reduced. Use the fastening bolts of the devices as HF connection to the rear plate. It is necessary to remove insulating paint or similar from the fastening points. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 33: Electrical Installation, Control Terminals

    To remove the cable from the terminal: Insert a screw driver in the square hole. Pull out the cable. Max. 0.4 x 2.5mm 9 - 10 mm (0.37 in) ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 34: How To Programme

    4-** Limits Warnings 5-** Digital inputs and outputs includes relay controls 7-** Controllers 8-** Communications and Options 14-** Special functions 15-** AFE information 16-** Data Read-Out 40-** Mains/Filter ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 35: Parameters: 0-** Operation And Display

    Select the set-up to control the frequency converter functions. Index LCP value Factory Cannot be changed. It contains the Danfoss setup data set, and can be used as a data source {1,2} when returning the other set-ups to a known {1,2} state.
  • Page 36 One or more warnings in a Hex code. [1693] Warning Word 2 One or more warnings in a Hex code. [1694] Ext. Status Word One or more status conditions in a Hex code. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 37 Resets the AFE without setting it in Off 0-65 Personal Menu Password and 0-66 Access to Personal without OFF mode. A password is required when Menu w/o Password will be ignored. pressing [Reset] (see [2]). ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 38 [0] then this parameter will be ignored. 0-67 Bus Password Access Range: Function: [0 - 9999 ] Writing to this parameter enables users to unlock the frequency converter from bus/ MCT10. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 39: Parameters: 4-** Limits/Warnings

    40-00. 4-95 Output Voltage Deviation Timeout Range: Function: 0.001 s [0.000 - 60.000 s] Selects the max time where the voltage deviation set in par. 4-94 can be exceeded. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 40: Parameters: 5-** Digital In/Out

    Set-up select bit 1 (Default Digital input 32): Same as Set- can be reset. up select bit 0 [23]. [8] Start (Default Digital input 18): Select start for a start/ stop command. Logic ‘1’ = start, logic ‘0’ = stop. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 41 Function: 0.01 s [0.01 - 600.00 This parameter makes it possible to delay the cut-out time of the relays. The selection of each mechanical relay is realised in an array parameter. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 42: Parameters: 7-** Controllers

    Set the wanted proportional gain of 1000.000 N/A] 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] ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 43: 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 ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 44 Select the protocol for the FC (standard) port. Modbus RTU 8-31 Address Range: Function: Application [Application Enter the address for the FC dependent dependant] (standard) port. Valid range: 1 - 126. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 45 (digital input) and/or via the bus. NOTE This parameter is only active if par. 8-01 is set to [0] Digital and control word. Digital input Logic AND Logic OR ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 46: Parameters: 14-** Special Functions

    Automatic reset x 3 Select Control card test [1] to test the analog Automatic reset x 4 and digital inputs and outputs and the +10 V ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 47 Select Initialization [2] to reset all parameter values to default settings, except for 15-03 Power Up's, 15-04 Over Temp's, and 15-05 Over Volt's. The frequency converter will reset during the next power-up. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 48: Parameters: 15-** Afe Information

    Reset counter Select Reset [1] and press [OK] to reset the kWh counter to zero (see 15-02 kWh Counter). NOTE The reset is carried out by pressing [OK]. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 49 15-30 Fault Log: Error Code Array [10] Range: Function: [0 - 255 ] View the error code and look up its meaning in the Troubleshooting chapter of the FC 300 Design Guide. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 50 View the power card serial number. 5.8.5 15-9* Parameter Info 15-92 Defined Parameters Array [1000] [0 - 9999] View a list of all defined parameters in the AFE. The list ends with 0. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 51 [0.00 - 1856.00 A ] Returns the value of measured current as a mean value IRMS. 16-42 Voltage Range: Function: 0.0V [0.0 - 6000.0V] Shows the AFE output voltage when the AFE is running. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 52 View the two-byte Status word (STW) sent N/A] to the Bus-Master. Interpretation of the Status word depends on the fieldbus option installed and the Control word profile selected in 8-10 Control Profile. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 53 [0.00 - 650.00 Set the converter side mOhm] resistance of the LCL filter. 40-14 Filter Capacity Range: Function: 400 uF [0 - 65000 uF] Set the capacity of the LCL filter. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 54 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 5.3 Alarm/Warning Code List (X) Dependent on parameter ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 55 A trip lock is an action when an alarm occurs, which may cause damage to AFE or connected units. A Trip Lock situation can only be reset by a power cycling. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 56: Dc Link Voltage High

    The DC bus voltage is below the undervoltage limit of the below 10V. control system. The AFE is still active. Remove some of the load from terminal 50, as the 10V supply is overloaded. Max. 15 mA or minimum 590 Ω. ® MG.33.X2.02 - VLT is a registered Danfoss trademark...

  • Page 57: Phase Imbalance

    The fault is that the frequency converter is overloaded by ALARM 38, Internal fault: more than 100% for too long. By this alarm it may be necessary to contact your Danfoss WARNING/ALARM 13, Over Current: supplier. Some possible alarm messages: The peak current limit (approx.

  • Page 58: Heatsink Sensor

    Some possible The external 24 V DC backup power supply may be values and reasons are listed below. overloaded, otherwise Contact your Danfoss supplier. 2314: Could not read any data from the power card WARNING 48, 1.8V supply low: EEPROM.

  • Page 59: Power Unit Setup

    ALARM 247, Power card temperature This alarm is only for F Frame size units. It is equivalent to Alarm 69. The report value in the alarm log indicates which power module generated the alarm: ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 60 Control Word Timeout..............42 Fault Log: Time, 15-32................. 48 Mode, 14-20..................45 Fuses......................30 Running Hours, 15-01................. 47 Fusing....................... 31 Safety Instructions.................. 6 General Warnings................... 6 Shielded Cables..................30 Start Select, 8-53................... 44 ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 61 ® Index Active Front End AFE 302 Operating Instructions Liebherr Trip Reset....................45 Warnings....................53 Wire Access..................... 28 ® MG.33.X2.02 - VLT is a registered Danfoss trademark...
  • Page 62 130R0429 MG33X202 Rev. 2010-06-29 *MG33X202*...

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