Danfoss AFE 302 Operating guide

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Active Front End AFE 302

www.danfoss.com/drives

Contents Operating Instructions

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Safety Symbols

1.3 Software Version

1.4 Approvals

1.5 Abbreviations

2 Safety Instructions and General Warning

2.1 Safety Regulations AFE 302

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

3.1 Selection of Motor Voltage

4 4 4 4 4 5

6 6

8 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

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

3.4 E-House Design

3.4.1 Cables between AFE and LCL Filters 18

17 18

3.4.2 Cables to the Damping Resistors 18

3.5 Test with the Real System Transformer and Motors

3.5.1 Re-program the Frequency Converter Parameters 18

3.6 On-site Final Test

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

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

3.9 Start-up Sequence

3.10 Shut-down Sequence

4 How to Install

4.1 Overall Typical Frequency Converter Configuration

4.2 Pre-installation

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

20 21 22

23 23 24

4.2.6 Weight Information 31

4.3 Mechanical Installation

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

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

5.1 General Specifications

5.2 Mains Supply

38 38 42

6 How to Programme

6.1 Parameter Selection

6.2 Parameters: 0-** Operation and Display

6.3 Parameters: 4-** Limits/Warnings

43 43 44 48

Contents Operating Instructions

6.4 Parameters: 5-** Digital In/Out

6.5 Parameters: 6-** Analog In/Out

6.6 Parameters: 7-** Controllers

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

49 52 53 54 57 59 62 64 65

Introduction 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.

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

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.

Introduction Operating Instructions

1.5 Abbreviations

AFE Active Front End AC Alternating current AWG American Wire Gage A Ampere/AMP AMA Automatic Motor Adaptation I

LIM

°C 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

Nm Newton Meters I

M,N

par. Parameter PELV Protective Extra Low Voltage PCB Printed Circuit Board PLC Programmable Logic Controller PN Part Number I

INV

Regen Regenerative terminals RCD Residual Current Device RPM Revolutions Per Minute RMS Root Mean Square s Second SW Software SMPS Switching Mode Power Supply

Current limit Degrees Celsius

Association

Nominal motor current Nominal motor frequency Nominal motor power Nominal motor voltage

Rated Inverter Output Current

VLT,MAX

VLT,N

LIM

THD Total Harmonic Distortion THDi Total Harmonic Distortion in Current THDu Total Harmonic Distortion in Voltage V Volts

Synchronous Motor Speed The maximum output current The rated output current supplied by the frequency converter Torque limit

Safety Instructions and Gen...

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.

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

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.

General Warnings

2.1.4

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.

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.

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.

Transformer

AFE

Master Slave Slave

Control signals

130BA771.11

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.

2 2

Illustration 2.1 Active Front End System Example

Crane System Design

Operating Instructions

3 Crane System Design

The cable length is calculated as the sum of all

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.

Selection of AFE for Different

3.1.2 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.

Selection of Output Filter (LC Filter)

3.1.3

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.

•

parallel cables. Filters must be designed to switching frequency

•

of the frequency converter. The resonance frequency, f0, of the filter should be:

10×

out max

The resonant frequency must meet the following

•

equation, limited by the control frequency, f

con

Switching frequency [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.

Selection of Switching Frequency

3.1.4

It is recommended that the switching frequency of AFE and motor drives shall be equal or an integer multiple of each other.

Selection of LCL Filter

3.1.5

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.

Crane Cable Concept

3.1.6

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:

≤

con

Control frequency1) [kHz]

Crane System Design

Operating Instructions

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 45 cm 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 “laddertype” cable trays.

5. Route the motor cable along the metallic grounded conductors such as cable trays, rails from the building structure, pipes, etc.

Grounding Concept

3.1.7

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.

•

NOTICE

The door fan(s) is required on the Rittal cabinet to remove the heat losses from the frequency converter and other components inside the enclosure. The total air flow required must be calculated and the appropriate fan can be selected. Rittal Therm software can calculate the cooling air flow volume. If the frequency converter is the only heat generating source in the enclosure, the minimum airflow required at an ambient temperature of 45 °C for the D3 and D4 frame sizes is 391 m3/h (230 cfm). The minimum airflow required at an ambient temperature of 45 °C for the E2 frame size is 782 m3/h (460 cfm).

Airflow

Table 3.2 shows the necessary airflow over the heat sink.

Enclosure protection Frame size

IP54/NEMA 12 F1, F2, F3 and

IP00/Chassis D3 and D4

E2 P400T7

E2 P500P560T7

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

Table 3.2 Heatsink Air Flow

Door fan(s)/Top fan airflow

525 m3/h (309 cfm)*

255 m3/h (150 cfm)

Heatsink fan(s)

985 m3/h (580 cfm)*

765 m3/h (450 cfm)

1105 m3/h (650 cfm)

1445 m3/h (850 cfm)

3 3

Cooling and Airflow

3.1.8

Cooling

The cooling air can be channeled through the air ducts at the top and bottom of the unit, through the back of the unit, or through the combination of the both methods.

Duct cooling

The duct cooling kit is used to install IP00/chassis D and Eframe frequency converters in the Rittal TS8 enclosure. See Installation of Duct Cooling Kit in Rittal enclosures, for further information.

Back cooling

The D and E frame frequency converters can be mounted in the Rittal cabinet where the cabinet backplate has cutout, through which the back-channel cooling is available.

NOTICE

The ideal cooling air is clean and dry. When the cooling air is from outside, the filter mats and long air inlet may be considered to prevent the dirty air problem. When the application environment is humid, consider the condensation of the frequency converter which may require the drain outlet.

NOTICE

The fan runs for the following reasons:

1. AMA

2. DC Hold

3. Pre-Mag

4. The frequency converter current exceeds 60% of its nominal current rating.

5. The heat sink temperature exceeds its limit. The limit depends on the power size.

When the fan is activated, it will run for a minimum of 10 min.

External ducts

If additional duct work is added externally to the Rittal cabinet the pressure drop in the ducting must be calculated. Use the charts below to derate the frequency converter according to the pressure drop.

0 0.5 4.9 13 27.3 45.9 66 89.3 115.7 147

(%)

(Pa)

Pressure Increase

Drive Derating

130BB007.10

(%)

Drive Derating

0 0 0.1 3.6 9.8 21.5 43.4 76 237.5 278.9

(Pa)

Pressure Change

130BB010.10

147.1

(%)

Drive Derating

0 0.2 0.6 2.2 5.8 11.4 18.1 30.8 152.8 210.8

(Pa)

Pressure Change

130BB011.10

69.5

(%)

Drive Derating

0 25 50 75 100 125 150 175 225

130BB190.10

200

Pressure Change

Crane System Design Operating Instructions

Illustration 3.1 D frame derating vs. pressure change frequency converter air flow: 450 cfm (765 m3/h)

Illustration 3.2 E frame derating vs. pressure change (small fan), P355T7-P400T7 frequency converter air flow: 650 cfm (1105 m3/h)

Illustration 3.4 F1, F2, F3, F4 frame derating vs. pressure change frequency converter air flow: 580 cfm (985 m3/h)

Selection of Transformer

3.1.9

The output of the HT-transformer must be

•

specified for 630 V. It is recommended to use 2 separate transformers

•

for 630 V and the 400 V and these transformers should be physically separated. The 400 V transformer must be close to or in the E-house to have a short ground cable.

NOTICE

Danfoss reviews/evaluates the LCL filter design for each application especially when the new transformer is used.

Illustration 3.3 E frame derating vs. pressure change (large fan), P500T7-P560T7 frequency converter air flow: 850 cfm (1445m3/h)

Crane System Design Operating Instructions

3.2 Assembling the Frequency Converter System

3.2.1 Tools Required

Operating Instructions for the FC Series.

Metric socket set 7–19 mm Socket extensions 1/4" drive size, 4", 6" and 12" Torx driver set T8-T50 Torque wrench 0.675–19 Nm (6–168 in-lbs) Needle nose pliers Magnetic sockets Ratchet Hex wrench set Screwdrivers Standard and Phillips

Table 3.3 Tools Required

Additional Tools Recommended for Testing

Digital volt/ohmmeter (rated for 1200 V DC) Voltmeter Oscilloscope Clamp-on style ammeter Test cable PN 176F8766 Signal test board PN 176F8437 Power supply: 500-1000 V DC, 250 mA to supply external power to 4 power cards and the control card. Power supply : 24 V DC, 2 A for external 24 V power supply.

Table 3.4 Additional Tools

3.2.3

Exploded Views

Number Terminal and component description

1 Fan Voltage Supply (FVS) 2 Soft Charge Board (SC) 3 FVS Fuse (TB10) 4 SC Fuse (TB11) 5 Aux Fan Fuse 6 Fan Fuse 7 SMPS Fuse 8 Mains Terminals (R, S, T) 9 Aux Relay (TB12)

01 02 03 04 05 06

10 VSYNC (TB13) (Only for AFE Cabinet)

01-R, 02-S, 03-T 11 Control Card 12 MDCIC 13 Control Panel (Check the enlarged view) 14 DC Terminals (DC+ and DC-) 15 DC Bus Fuses

Table 3.6 Legend for Illustration 3.6 to Illustration 3.18

The rated voltage and maximum current magnitudes for the AUX relay and VSYNC terminals are as follows: AUX Relay: 240 V AC 2 A VSYNC: 630 V 1 A

NOTICE

The control circuit including the control card terminal is PELV isolated and it is also isolated from the power circuit galvanically.

3 3

General Tightening Torque Values

3.2.2

Table 3.5 tabulates the tightening torque values. The tightening toque values for the rectifier and IGBT modules are referred to in the instruction within the spare kits.

Shaft size Driver size

Torx/hex

M4 T-20/7 mm 10 1.0 M5 T-25/8 mm 20 2.3 M6 T-30/10 mm 35 4.0

M8 T-40/13 mm 85 10 M10 T-50/17 mm 170 19 M12 18 mm/19 mm 170 19

Table 3.5 Torque Values

Torque [in-

lbs]

Torque [Nm]

130BA667.10

130BA664.10

9,10

130BT258.10

9 9

130BA663.10

Crane System Design Operating Instructions

Illustration 3.7 Outside- and Inside View

Illustration 3.5 Front Door View

Illustration 3.8 800 mm Cabinet Skeleton View

Illustration 3.6 800 mm Cabinet Front Door and its Inside Views (One Drive Case)

130BA665.10

Crane System Design Operating Instructions

3 3

Illustration 3.9 800 mm Lower Front End View

5 6

130BA666.10

Crane System Design

Operating Instructions

Illustration 3.10 1200 mm Cabinet Exploded View

130BD818.10

9,10

5, 6, 7

130BD819.10

130BD820.10

130BT254.10

130BT255.10

Life Stop

Crane System Design Operating Instructions

3 3

Illustration 3.13 1600 mm Cabinet Exploded View

Illustration 3.11 1600 mm Cabinet Exploded View

Illustration 3.14 One-drive Configuration Control Panel View

Illustration 3.15 Two Independent Drive Configuration Control Panel View

Illustration 3.12 1600 mm Cabinet Exploded View

130BD836.10

130BD837.10

-C-

6, 7

130BD871.10

Crane System Design Operating Instructions

Illustration 3.16 600 mm Drive Cabinet

Illustration 3.18 AFE E-frame Drive Open View

Illustration 3.17 800 mm Drive Cabinet

Crane System Design

Operating Instructions

3.2.4 MDCIC Connector Configuration

The MDCIC board has the four connectors. The ribbon cables from the power units will be connected from FK100 to FK103.

For one power unit configuration, the part 176F9091 which consists of the DC/DC converter and the ribbon cable is connected to FK101. It generates an isolated 5 V from an internal 24 V for the RS-485 communication.

FK100 (Master) FK102 (Slave 2)

FK101 (Slave 1) FK103 (Slave 3)

Table 3.7 MDCIC Port Layout

3.3 First Power Up/Commissioning Check List

The following measurement equipment are recommended:

Voltage meter (1 kV AC/DC env. Cat III)

•

Current clamp min. 2 kA

•

Harmonic analyzer, only for commissioning

•

Check list

Check fan voltage supply (3x400 V).

•

Verify that system is not powered.

•

Verify the system is grounded to earth.

•

all AFEs and frequency converters

all motors

all filters

the whole crane construction

HT transformer

Check that there are no earth faults or short

•

circuits at the motor cables and motors. Check that the DC discharge resistor is connected

•

right and not shorted. Verify phase sequence and continuity for the

•

voltage sensing on the AFE as described below.

Make sure that power is not applied.

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.

Red wire of MK105 to phase R.

White wire of MK105 to phase

S. Black wire of MK105 to phase

All should be <0.2Ω.

Open the input contactor between AFE and LCL

•

filter. Verify that the mains voltage is 630 V RMS and

•

balanced. Apply power to the LCL filter and verify that the

•

rms current magnitude measured between the line and delta connection point is approximately same as the value using the following formula:

630×314 ×C×3

capacitance, delta value. Leave the AFE main contactors open and disallow

•

the AFE start signal in the PLC. Soft charge the system but do not enable the

•

main contactor. Let the softcharge circuit active for about 5min.

•

Check the voltage at the AFE Mains side when

•

the AFE is powered up by softcharge. The voltage between all phases should be 0 V. Also the voltage between the phases L1/L2/L3 and earth should be 0 V. Please call Danfoss service if you can measure a voltage greater then 10 V here. Do not switch on the mains contactors if you measure a voltage more than 10 V here.

Verify that the LCP readings for the DC-link

•

voltage from all the AFE and inverter drives are within ±2% of the value measured with the voltage meter. The estimated DC-link voltage value at 630 V mains voltage with no load is as follows:

890

+5 / − 10% =

= 630× 1,414+ 5 / −10%

Download all the AFE and frequency converter

•

settings with MCT 10 Set-up Software.

1. Capacitance value of the LC filter in the

2. Set the right LCL filter values in the AFE,

3. Set the right mains values in the AFE.

5. Total system capacitance par. 7-60 must

, where C is the LCL filter

mains_LL_RMS

inverter drive must be star equivalent.

the capacitance value of the LCL filter shall be entered as delta equivalent.

Parameter group 4-** Output Limits AFE – use factory settings.

be programmed with a sum of the DClink capacitance x 0,9.

× 2+5 / −10 %

3 3

Crane System Design

Use parameter group 7-** Controllers as follows:

Parameter 7-61 DC-Link

•

Reference is 975 V. Parameter 7-62 DC-Link PI

•

Switch Crane off.

•

Program the PLC to the normal start-up

•

sequence. Switch Crane on.

•

The AFE starts, but not any of the inverters, and

•

verify that the AFE and inverter LCP readings are 975 V DC and that they are within ±2% of a calibrated voltage meter.

Check if all fans are running after closing the

•

mains contactor. Start checking inverters and motors.

•

Save all parameter settings with MCT 10 Set-up

•

Software. For the crane commissioning, measure THDu and

•

THDi of the 630 V and 400 V terminals and document the results in the commissioning certificate.

Verify that the THD levels of the 400 V terminal

•

are complied to EN 61000-3 or other country specified harmonic requirements.

3.4

E-House Design

Proportional Gain (Kp) is calculated internally based on the power size and DC capacitance in parameter 7-60 DC-Link Total Capacity. Recommend to use the default value. The wrong setting could cause the unstable DC voltage regulation.

Parameter 7-63 DC-Link PI

•

Integral Time (Ti) is 5 ms in default.

3.4.1 Cables between AFE and LCL Filters

The cables should be as short as possible.

•

The connection must be made with shielded

•

cables.

The synchronization voltage cable which is connected to the AFE-MDCIC board MK105 must be separated from all power cables. The distance needs to be at least 50 cm from other power cables.

3.4.2

Cables to the Damping Resistors

Operating Instructions

3.5

Test with the Real System Transformer and Motors

3.5.1 Re-program the Frequency Converter Parameters

Set the mains voltage, mains frequency, the

•

transformer values, LCL filter values, and DC capacitance.

3.6 On-site Final Test

3.6.1 Change Parameters to Actual

Set actual cable length.

•

Check encoder wiring and encoder direction.

•

Optimize ramp time shapes.

•

Save parameter settings in the LCPs.

•

Run with Full Load

3.6.2

Check that AFE input voltage is stable. The

•

voltage waveform does not need to be sinusoidal.

Check that DC-link voltage is stable.

•

3.7

AFE Emergency and Restore Procedures

Chapter 3.7.1 Emergency Run when One Slave Unit is Damaged to chapter 3.7.4 Restoration after Master Unit is Repaired describe how to set up an emergency run and

how to restore the drive for the case where one of the three units are damaged. Chapter 3.7.5 Emergency Run When More Than One Unit is Damaged describes the case where the multiple units are damaged.

Emergency Run when One Slave Unit

3.7.1 is Damaged

NOTICE

The mains synchronization voltage is always connected to the MDCIC board. Make sure that the mains power switch is off before opening the frequency converter cabinet.

NOTICE

The power is reduced to two thirds of the original.

1. Switch Crane off.

2. Switch the circuit breaker in front of the damaged AFE power unit off.

3. Check the DC-link voltage with a voltage meter at the terminals before and after the DC fuses.

The cables should be as short as possible.

Crane System Design

Operating Instructions

NOTICE

Do not touch until the DC voltage is below 10 V.

4. Disconnect the DC-link fuses of the damaged power unit and AC connection.

5. Disconnect the softcharge connector on the softcharge board of the damaged power unit.

6. Disconnect the ribbon cable, from the damaged AFE power unit, on the MDCIC card.

7. If the removed connector is at Inverter 2 position, move the ribbon cable at Inverter 3 position to Inverter 2.

Turn the key switch to AFE emergency mode.

9. Switch Cane on.

10. Check on the AFE LCP if it is in set-up 2. The setup shift at the AFE is done with terminal 32 at AFE control card. Terminal 32 = 0 means set-up 1, Terminal 32 = 1 means set-up 2.

11. A warning 78 (power unit set-up) may come up at the AFE LCP.

12. Switch Crane off.

13. Wait at least 20 s. All LCPs must be completely off.

14. Switch Crane on.

15. The warning 78 disappears and the warning 77 (Reduced power mode) appears on LCP.

16. The AFE can run with two units with a reduced power.

Restoration after Slave Unit is

3.7.2 Repaired

1. Switch Crane on but do not run any frequency converter.

Turn the key switch to AFE normal mode.

3. A warning 78 appears on AFE LCP.

4. Check on the AFE LCP if it is in set-up 1. The setup shift at the AFE is done with terminal 32 at AFE control card. Terminal 32 = 0 means set-up 1, Terminal 32 = 1 means set-up 2.

5. Switch Crane off.

6. Check the DC-link voltage with a voltage meter at the terminals before and after the DC fuses.

NOTICE

Do not touch until the DC voltage is below 10 V.

7. 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).

8. Connect the softcharge connector on the softcharge board.

9. Connect the DC-link fuses and AC connection.

10. Switch on the circuit breaker in front of the AFE.

11. Switch Crane on.

12. The AFE runs now with all 3 power units.

3.7.3 Emergency Run when Master Unit is Damaged

NOTICE

The power is reduced to two thirds of the original.

1. Switch Crane off.

2. Switch the circuit breaker in front of the damaged AFE power unit off.

3. Check the DC-link voltage with a voltage meter at the terminals before and after the DC fuses.

NOTICE

Do not touch until the DC voltage is below 10 V.

4. Disconnect the DC-link fuses of the damaged power unit and AC connection.

5. Disconnect the softcharge connector on the softcharge board of the damaged power unit.

6. Disconnect the ribbon cable from the Inverter 1 position at the MDCIC.

7. Unplug the ribbon cable at Inverter 3 position on the MDCIC card and plug it at Inverter 1 position.

8. Plug this ribbon cable (what you plugged out from Inverter 3) on the connector Inverter 1. Now the right power unit will be the AFE Master.

Turn the key switch to AFE emergency mode.

10. Switch Crane on.

11. Check on the AFE LCP if it is in set-up 2.

12. A warning 78 may appear on AFE LCP.

13. Switch Crane off.

14. Wait at least 20 s. All LCPs must be completely off.

15. Switch Crane on.

16. The warning 78 disappears and the warning 77 appears on LCP.

17. The AFE can run with two units with a reduced power.

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Crane System Design Operating Instructions

3.7.4 Restoration after Master Unit is Repaired

1. Switch Crane on but do not run any frequency converter/motor.

Turn the key switch to AFE normal mode.

3. A warning 78 appears on AFE.

4. Check on the AFE LCP if it is in set-up 1 (see attached file LCP.pdf). The set-up shift at the AFE is done with terminal 32 at AFE control card. Terminal 32 = 0 means set-up 1, Terminal 32 = 1 means set-up 2.

5. Switch Crane off.

6. Check the DC-link voltage with a voltage meter at the terminals before and after the DC fuses.

3. Power up.

4. Power cycle.

NOTICE

Do not touch until the DC voltage is below 10 V.

7. 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).

8. Connect the softcharge connector on the softcharge board.

9. Connect the DC-link fuses an AC connection.

10. Switch on the circuit breaker in front of the AFE.

11. Switch Crane on.

12. The AFE runs now with all 3 power units.

Emergency Run When More Than

3.7.5 One Unit is Damaged

When multiple units are damaged, an emergency run with a minimum of one unit can be performed. The procedure of setting up the emergency run and restoring from the emergency run can be referred to in

chapter 3.7.1 Emergency Run when One Slave Unit is Damaged to chapter 3.7.4 Restoration after Master Unit is Repaired.

The following issues are considered:

1. In an emergency run, the door fan may not be in operation. It is recommended that the emergency configuration is only for a temporary usage.

2. An emergency run may cause the overcurrent alarm at start-up because the start-up current may be high for the number of units used. The switching frequency (parameter 14-01 Switching Frequency) may need to be increased from 1.5 kHz to 2 or 2.5 kHz.

3.8

Manual Shut Down Sequence

Stop all motor drives.

•

switch off the AFE start signal.

•

Open the mains contactor

•

Switch off the HT transformer if necessary

•

In emergency, command the AFE to stop and

•

open the AFE contactor, or pull the safe stop and open the AFE contactor.

(176F9091) needs to be connected at FK101 to have the RS-485 communication.

3a The warning message W78 (Power Unit

Setup) appears on LCP.

Change the number of the units in

parameter 14-59 Actual Number of Inverter Units.

4a The warning message W77 (Reduced

Power Mode) appears on LCP.

4b The power is reduced to the original

power multiplied by the number of active units over the original number of the units.

The key procedure of an emergency run is as follows:

1. Disconnect AC and DC sides of the damaged units.

2. Change the connector position at MDCIC.

2a The ribbon cables at the MDCIC are

connected from FK100 (Master) following FK101, FK102, and FK103. You do not skip the terminal sequence.

2b You can go down to one unit. When

one master unit is used, the part

Auxiliary Hardware Actions

AFE Drive Control PLC

: Assume that the AFE contactors and SC contactor are open prior to this start-up sequence.

Start-up Sequence

Crane ON

Contactor LCL cabs ON 2 sec Delay

Send close signal to the SC contactor.

Receive "Soft Charge Ready" signal within 20sec?

Protection Mode due to the Start-up Failure

Wait for 1 second to have the DC capacitors charged further.

Yes

Send the open signal to the SC contactor.

Wait for 1 second to make sure that the S/C contactor is open.

Send the close signal to the AFE contactors.

Wait for 0.5 second to have the DC capacitors charged fully.

Send the "Run" signal to the AFE drive.

Receive "DC-Link on Ref" signal from AFE within 5 sec?

End of Start-up Sequence

Yes

Protection Mode due to the Start-up Failure

3rd Try?

:The waiting period can be substituted by the contactor status signal.

: Assume that the AFE contactors are fully engaged within 2seconds.

:The waiting period can be substituted by the contactor status signal.

: Assume that the SC contactor is disengaged within 0.5sec. The DC capacitor discharge is negligble.

130BA783.12

Abbreviations: AFE: ACtive Front End CC: Control Card PC: Power Card PLC: Programmable Logic Controller SC: Soft Charge

When the DC voltage is within the target range, "DC-link on Ref" signal is on.

The AFE drive is active.

DC voltage is going up to the desired level.

The AFE contactors are closed.

The SC contactor is open.

Charge the DC bus through the SC circuit.

The SC contactor is closed.

When the PC becomes active, "Soft Charge Ready" signal is ON.

Crane System Design Operating Instructions

3.9 Start-up Sequence

Illustration 3.19 shows the typical AFE start-up sequence flow chart. The flow chart describes the interaction among Auxiliary Hardware, AFE Frequency Converters, and Liebherr Control PLC. The arrowed lines indicate the flow of the actions. The Liebherr PLC expects to receive the “Control Ready” and “Ready” signals from the AFE frequency converter and it will send “Run” signal to AFE frequency converter. The waiting periods and the number of tries are tentative. The “Control Ready” signal is on when the power in Control Card is on. The meaning of the "Ready" signal in the 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 where the AFE regulation is enabled.

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Illustration 3.19 Start-up Sequence Flow Chart

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