Danfoss AFE 302 Operating guide

Download

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.

3 3

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.

3 3

Illustration 3.19 Start-up Sequence Flow Chart

Send Open signals to the AFE and Mains contactors.

AFE/Inverter DrivesAuxiliary Hardware

Actions

Control PLC

130BA775.11

End of Stop Sequence

Stop Sequence

Wait for 1sec.

Send INV Stop signals to all the inverters

All the inverters control to reduce the speed to zero, if it is not zero.

Send AFE Stop signals to the AFE.

AFE is deactive.

DC voltage level is down to zero

DC voltage level is reduced.

Open the contactor.

The motor speed is reduced to zero.

"Running" signal is o when the speed is zero.

"Running" o?

Yes

Wait for 5min?

Protection Mode

Yes

The DC capacitor can be discharged with the external resistor, which expedites the discharge process.

: The wait period is tentative.

Crane System Design Operating Instructions

3.10 Shut-down Sequence

It is recommended to send a STOP signal to the AFE before shutting down the power.

Illustration 3.20 Shut-down Sequence Flow Cart

Fuse

Inv #1

Inv #2

Inv #3

Inv #4

RST

LCL Filter

Fuse

Disconnect

Main PC

Sub PC1

Sub PC2

gate signals

* Control gate signals

* Detect currents.

* Measure DC voltage.

* Control fans.

* Control gate signals

* Detect currents.

* Control fans.

* Control gate signals

* Detect currents.

* Control fans.

gate signals

444444

MDCIC

FC302

MDCIC Functions:

* Distribute the gate signals.

* Combine the current signals and

send it as a total rec current.

Detect the overcurrent (IMAX1)

per module per phase.

* Detect the main voltage phase to

synchronize AFE (Only for AFE)

Voltage

Detection

Fan

Volt

Soft

Charge

Soft

Charge

AFE #3

Contactor

Fuse:

AFE #2

Contactor

AFE #1

Contactor

Soft

Charge

Soft

Charge

Soft

Charge

Soft

Charge

SC Wire Fuse

Fuse:

Trolley

Travel

Fuse

Soft

Charge

Fan

Volt

Fan

Volt

Fan

Volt

Fan

Volt

Fan

Volt

Fan

Volt

Fan Volt Wire Fuse

SC Contactor

Hoist Master

Abbreviations:

AFE: Active Front End

CC: Control Card

MDCIC: Multi-Drive Control

Interface Card

PC: Power Card

Fan Volt Supply

400V Contactor

400V

630V

Boom

Switch

Hoist Master

130BA683.10

How to Install Operating Instructions

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

4 4

Illustration 4.1 Typical System Overview

130BB639.10

How to Install Operating Instructions

The typical 1.2 MW LCL filter components are described below:

1. Lc choke 100 uH

2. Lm choke 29 uH

3. Capacitor 10x 40 uF in delta, 30 pieces

Resistors 90 mΩ 4000 W, 3 pieces

Transportation and Unpacking

4.2.3

Illustration 4.2 and Illustration 4.3 show the front and side views of the frequency converter, shipping crate, respectively.

The unpacking procedure is as follows:

4.2 Pre-installation

4.2.1 Planning the Installation Site

Before performing the installation it is important to plan the installation of the frequency converter. Neglecting this may result in extra work during and after the installation. Select the best possible operation site by considering the followings:

Ambient operating temperature

•

Installation method

•

Cooling method

•

Position of the frequency converter

•

Cable routing

•

Power source supply configuration

•

Motor current rating with respect to the

•

frequency converter maximum current magnitude Fuse arrangement, either built-in fuses or the

•

properly rated external fusees

Receiving the Frequency Converter

4.2.2

1. Remove clips from one long side panel (A) and all around the top.

2. Remove the long side panel (A).

3. Remove the top panel (B).

4. Remove clips from one short side panel (C).

5. Remove the short side panel (C)

6. Remove the rest of the clips.

7. Remove the final two panels.

NOTICE

The package includes the plinth at the bottom of the frequency converter. The plinth allows proper cooling of the frequency converter during the shipment.

When receiving the frequency converters, please inspect the frequency converters for any damage which may occur during the transportation. 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

130BB640.10

How to Install Operating Instructions

4 4

Illustration 4.3 Package Side View

130BA658.10

130BA659.10

How to Install Operating Instructions

4.2.4 Lifting

Illustration 4.4 and Illustration 4.5 show the main load carrying points (1 and 2 in the illustrations) of the F-frame cabinets. Lift the cabinets with all the lifting eyes and/or use a bar to avoid bending the lifting holes of the frequency converters. The same principle is applied for the AFE cabinets.

Illustration 4.4 Main Load Carrying Points

Illustration 4.5 Main Load Carrying Points

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.

ADD 3MM BETWEEN TWO CABINET TO ACCOUNT FOR GASKET

1296.0 ALL CABINET

2003.4 ALL CABINET

597.0 797.0

65.5

0.0 CABINET BACK WALL

CABINET BACK WALL

73.0

338.4

540.5

61.1

CABINET FRAME 0.0

68.8

536.0

61.0

CABINET FRAME 0.0

65.5

0.0

140.8

392.7

426.7

678.7

736.0

102.0

695.0

2X 81.4

294.0

2X 219.4

493.5

540.5

CABLE

OPENING

CABLE

OPENING

CABLE

OPENING

AIR INLET

OPENING

AIR INLET

OPENING

AIR INLET

OPENING

AIR INLET

OPENING

AIR INLET

OPENING

AIR INLET

OPENING

2078.4 ALL CABINET WITH LIFT BRACKET

1197.0

605.6

635.2

65.5

0.0

61.0

CABINET FRAME 0.0

140.8

430.8

464.8

754.7

788.7

1078.7

89.7

1084.0

1136.0

3X 81.4

3X 222.8

294.0

493.5

540.5

BACK CHANNEL AIR IN

CABINET AIR OUT

CABINET AIR IN

600MM CABINET BOTTOM VIEW

800MM CABINET BOTTOM VIEW

1200MM CABINET BOTTOM VIEW

SEE VIEW A

VIEW A

BACK CHANNEL AIR OUT

130BA661.10

1597.0

2078.4

CABLE

OPENING

AIR INLET

OPENING

2X 61.0

2X 102.0

2X 695.0

2X 736.0

2X 678.7

2X 426.7

2X 392.7

2X 140.8

CABINET FRAME 0.0

0.0

CABINET

BACK WALL

4X 65.6

4X 81.4

4X 219.4

2X 294.0

2X 493.5

4X 540.5

AIR INLET

OPENING

AIR INLET

OPENING

AIR INLET

OPENING

CABLE

OPENING

130BD821.10

How to Install Operating Instructions

4.2.5 Mechanical Dimensions

4 4

Illustration 4.6 Dimensions

Illustration 4.7 Dimensions 1600 mm Cabinet

DOOR SWING

583.5591.5

783.5

583.5

AIR OUTLET OPENING

114.0

0.0

122.0

298.5

475.0

483.0

415.5

0.0

423.5

567.5

575.5

BLOCKED

600MM CABINET

98.5

0.0

113.0

269.3

281.9

800MM CABINET 1200MM CABINET

BLOCKED

96.7

0.0

91.0

366.4

422.4

681.9

706.0

AIR OUTLET

OPENING

98.5

0.0

113.0

269.3

281.9

101.1

0.0

99.7

395.1

462.7

759.2

826.8

1074.7

1093.7

130BA662.10

AIR OUTLET

OPENING

How to Install Operating Instructions

Illustration 4.8 Door Swing View and Back View

130BD822.10

0.0

2X 98.5 2X 113.0 2X 269.3 2X 281.9

0.0

2X 91.0

2X 96.7

2X 366.4

2X 422.4

2X 681.9

2X 706.0

2X 783.5

2X AIR OUTLET

OPENING

BLOCKED BLOCKED

How to Install Operating Instructions

4 4

Illustration 4.9 1600 mm Cabinet Door Swing View

130BA445.10

225

1320

585

269

156

498

539

1547

1502

160

1043

184

139

304

2X13

(2.5)

(23.0)

(52.0)

(6.2)

(19.5)

(10.6)

(21.2)

(60.9)

(5.5)

(12.0)

(7.3) (7.3)

(0.5)

(1.5)

120 (4.7)

(1.0)

(59.1)

(41.1)

(6.3)

(8.9)

225 (8.9)

(1.0)

(0.9)

(1.0)

(0.5)

IP00 / CHASSIS

How to Install Operating Instructions

Illustration 4.10 Dimensions E-frame IP00 Drive

How to Install Operating Instructions

4.2.6 Weight Information

Crate length

Table 4.1 Weight Based on Shipping Package Crate Size

Crate weight Cabinet weight Cabinet content

weight

[mm] [kg] [lbs] [kg] [lbs] [kg] [lbs] [kg] [lbs]

600 120 252 57 126 159 351 336 729 Cabinet and D frame frequency converter

800 130 273 76 168 306 675 512 1116 Inverter modules Qty. 2 1200 160 336 115 253 459 1012 734 1601 Inverter modules Qty. 3 1200 160 336 115 253 318 701 593 1290 600 mm cabinet qty. 2, D vrame

1600 260 546 153 337 612 1349 1025 2232 2 x 800 mm cabinet with inverter modules

2000 320 672 191 421 765 1687 1276 2780 1200 mm cabinet with inverter modules

2400 380 798 229 505 918 2024 1527 3327 2 x 1200 mm cabinet with inverter

2800 440 924 267 590 1071 2361 1778 3875 1200 mm cabinet with inverter modules

Total package weight

Package contents

frequency converters qty. 2

qty. 2, 1600 mm cabinet with inverter modules qty. 4

qty. 3, 800 mm cabinet with inverter modules qty. 2

modules qty. 3, 1600 mm cabinet with inverter modules qty. 4 800 mm cabinet with inverter modules qty. 2

qty. 3, 2 x 800 mm cabinet with inverter modules qty. 2

4 4

122.5 [4.82]

.0 [.00]

178.0 [7.01]

233.5 [9.19]

363.5 [14.31]

419.0 [16.50]

474.5 [18.68]

722.5 [28.44]

778.0 [30.63]

833.5 [32.82]

963.5

[37.93]

1019.0

[40.12]

1074.5

[42.30]

1382.0 [54.41]

1452.0 [57.17]

1522.0 [59.92]

1737.5 [68.41]

1807.5 [71.16]

1877.5 [73.92]

2093.0 [82.40]

2163.0 [85.16]

2233.0 [87.91]

2581.9 [101.65]

2641.9 [104.01]

2701.9 [106.37]

2906.9 [114.44]

2966.9 [116.81]

3026.9 [119.17]

297.5 [11.71]

[.00]

328.3

[12.93]

[.00]

380.3 [14.97]

252.1 [9.93]

.0 [.00]

127.5 [5.02]

265.6 [10.46]

300.1

[11.82]

349.1

[13.74]

383.6

[15.10]

432.6

[17.03]

467.1 [18.39]

865.6[34.08]

900.1

[35.44]

949.1

[37.37]

983.6

[38.72]

1032.6

[40.65]

1067.1[42.01]

1365.1 [53.75]

1480.1 [58.27]

1595.1 [62.80]

1729.8 [68.10]

1844.8 [72.63]

1959.8 [77.16]

2094.4 [82.46]

2209.4 [86.99]

2324.4 [91.51]

2553.3 [100.53]

2668.3 [105.05]

2783.3 [109.58]

2906.2 [114.42]

3021.2 [118.95]

3136.2 [123.47]

600MM CABINET

TROLLEY/

TRAVEL

U,V,W

1200MM CABINET

AFE

R,S,T

800MM CABINET

HOIST 1&2

UVW

224.8

[8.85]

[.00]

395.1 [15.56]

EARTH GROUND BUS

(AFE/HOIST 1&2)

FASTENER TORQUE: M10 19 NM (14 FT-LB)

+DC/118 -DC/117

CH22

FASTENER TORQUE: M10 19 NM (14 FT-LB)

+DC/118 -DC/117

FASTENER TORQUE: M10 19 NM (14 FT-LB)

U/T196 V/T2 97 W/T3 98

FASTENER TORQUE: M10 19 NM (14 FT-LB)

U/T196 V/T2 97 W/T3 98

FASTENER TORQUE: M10 19 Nm (14 FT-LB)

R/L1 91 S/L2 92 T/L3 93

FASTENER TORQUE: M10 19 Nm (14 FT-LB)

R/L1 91 S/L2 92 T/L3 93

FASTENER TORQUE: M10 19 Nm (14 FT-LB)

R/L1 91 S/L2 92 T/L3 93

130BA660.10

How to Install Operating Instructions

4.3 Mechanical Installation

The installation of the frequency converters must be prepared carefully. Review the mechanical drawings for the space requirement.

Crane or other lifting aid to place the frequency

•

converter in position

4.3.2 General Considerations

4.3.1 Tools Needed

Ensure the proper space at the top and bottom of the frequency converter, allowing enough air circulation and

Space

To perform the mechanical installation the following tools

are needed:

cable accessibility.

Wire access

Ensure that the proper cable access space is present.

Tape measure

•

Wrench with metric sockets (7-19 mm)

•

Extensions to wrench

•

Lifting bar to lift the unit (rod or tube Ø 20 mm)

•

When the IP00 D or E frame frequency converters are mounted on the Rittal cabinet, the cables to the frequency converter must be secured to the back panel of the cabinet. For example, the cable clamps can be used.

able to lift minimum 400 kg.

Terminal Locations

4.3.3

Illustration 4.11 Terminals for the Typical Crane System

How to Install

Operating Instructions

4.3.4 Mains Torque

Table 4.2 tabulates the tightening torque values for the mains and DC bus terminals.

Enclosure Terminal Torque Value Bolt size

E, F Mains,

DC bus

Table 4.2 Torque Values for Mains and DC Bus Terminals

19 Nm (168 inlbs)

M10

4.3.5 Mains Connection

The mains cables must be connected at the terminals 91, 92 and 93. The ground cable is connected at the terminal

94.

Terminal No. Function

91, 92, 93 94

Table 4.3 Mains Connection

Power (3x525-690 V AC)

P400-P560 4x240 (4x500 MCM) P630-P800 8x150 (8x300 MCM) P900-P1M2 12x150 (12x300 MCM) P1M4-P1M6 16x150 (16x300 MCM)

Table 4.4 Mains Cable Size

Mains R/L1, S/L2, T/L3 Ground

Max. Cable Size (mm2 (AWG))

NOTICE

Check the name plate to ensure that the mains voltage of the AFE matches the power supply of the crane.

Ensure that the power supply can supply the necessary current to the frequency converter.

Ensure that the fuses have the correct current and voltage rating.

Screened Cables

4.3.6

WARNING

Danfoss recommends using screened cables between the LCL filter and the frequency converter. Unshielded cables can be used between transformer and LCL filter input side.

It is important that screened and armoured cables are connected in a proper way to ensure the high EMC immunity and low emissions.

The connection can be made using either cable glands or clamps

EMC cable glands: Generally, available cable

•

glands can be used to ensure an optimum EMC connection.

EMC cable clamp: Clamps allowing easy

•

connection are supplied with the frequency converter.

4.3.7 Fuses

It is recommended to use fuses and/or circuit breakers on the supply side as protection in case of component breakdown inside the frequency converter (first fault).

NOTICE

This is mandatory to ensure compliance with IEC 60364 for CE or NEC 2009 for UL.

WARNING

Protect personnel and property against the consequence of component break-down internally in the frequency converter.

Branch circuit protection

To protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc., must be protected against short-circuit and overcurrent according to national/international regulations.

NOTICE

The recommendations do not cover branch circuit protection for UL.

Short-circuit protection

Danfoss recommends using the fuses/circuit breakers mentioned below to protect service personnel and property in case of component break-down in the frequency converter.

Overcurrent protection

The frequency converter provides overload protection to limit threats to human life, property damage and to avoid fire hazard due to overheating of the cables in the installation. The frequency converter is equipped with an internal overcurrent protection (parameter 4-18 Current Limit) that can be used for upstream overload protection (UL-applications excluded). Moreover, fuses or circuit breakers can be used to provide the overcurrent protection in the installation. Overcurrent protection must always be carried out according to national regulations.

The following tables list the recommended rated current. Recommended fuses are of the type gG for small to medium power sizes. For larger powers, aR fuses are recommended. Circuit breakers must be used, provided they meet the national/international regulations and they

4 4

How to Install

Operating Instructions

limit the energy into the frequency converter to an equal or lower level than the compliant circuit breakers. If fuses/circuit breakers according to recommendations are selected, possible damage on the frequency converter is mainly limited to damage inside the unit.

4.3.8 High Power Fuses

The fuses below are suitable for use on a circuit capable of delivering the Short Circuit Current Rating (SCCR) of 100,000 Amps (symmetrical).

525-690 V, frame sizes D, E and F

Size/Type

P630P900 P1M0 170M7082 2000 A, 700 V 20 695 32.2000 P1M2P1M4 P1M6 170M7084 3000 A,700 V

Table 4.5 Frame Size F, Line Fuses, 525-690 V

Size/Type

P630P1M6

Table 4.6 Frame Size F, Inverter Module DC Link Fuses, 525-690 V

*170M fuses from Bussmann use the -/80 visual indicator, -TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage may be substituted for the external use.

Bussmann

PN*

170M7081 1600 A, 700 V 20 695 32.1600

170M7083 2500 A, 700 V 20 695 32.2500

Bussmann

PN*

170M8611 1100 A,

Rating Siba

20 781 32. 1000

1000 V

Supplementary fuses

Frame size

D, E and F KTK-4 4 A, 600 V

Table 4.7 SMPS Fuse

Size/Type

P37K-P400, 525-690 V P500-P1M6, 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

Bussmann PN* Rating

Bussmann PN* LittelFuse Rating

KTK-4 4 A, 600 V

KLK-15 15 A, 600 V

Switch Mode Power Supply

Analog Output

Interface

relay1

* relay2

ON=Terminated OFF=Open

130BD835.10

50 (+10 V OUT)

53 (A IN)

54 (A IN)

55 (COM A IN)

0/4-20 mA

12 (+24V OUT)

13 (+24V OUT)

37 (D IN)

18 (D IN)

20 (COM D IN)

10Vdc 15mA 130/200mA

+ - + -

(COM A OUT) 39

(A OUT) 42

(P RS-485) 68

(N RS-485) 69

(COM RS-485) 61

S801

0/4-20 mA

RS-485

+10Vdc

0/-10Vdc -

+10Vdc

+10Vdc 0/4-20 mA

0/-10Vdc -

240Vac, 2A

24Vdc

240Vac, 2A

24V (NPN)

0V (PNP)

24V (NPN)

19 (D IN)

24V (NPN)

0V (PNP)

24V

(D IN/OUT)

0V (PNP)

24V (NPN)

(D IN/OUT)

24V

24V (NPN)

0V (PNP)

24V (NPN)

33 (D IN)

32 (D IN)

1 2

S201

S202

ON=0/4-20mA OFF=0/-10Vdc +10Vdc

400Vac, 2A

P 5-00

S801

3 Phase power

input

91 (L1) 92 (L2) 93 (L3)

DC+

DC-

How to Install Operating Instructions

4.4 Electrical Installation

4 4

Illustration 4.12 Diagram showing all electrical terminals without options. 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.

130BT340.10

How to Install Operating Instructions

4.4.1 Control Wires

Connect the shields to ground in a proper way to ensure optimum electrical immunity.

Connect the wires as described in the Operating Instructions for the frequency converter. Remember to connect the shields in a proper way to ensure optimum electrical immunity.

the fuses section. Always ensure that proper fusing is made according to the local regulation.

4.4.3 Grounding

The following basic issues need to be considered when installing a frequency converter to obtain electromagnetic compatibility (EMC):

Safety grounding: The frequency converter could

•

have a high leakage current. It must be grounded appropriately for safety reasons. Apply local safety regulations.

High-frequency grounding: Keep the ground wire

•

connections as short as possible.

Connect the frequency converters to the ground with the lowest possible conductor impedance. The lowest possible conductor impedance is obtained by keeping the conductor short and by using the large possible cross section conductors. The metal cabinets of the different devices are mounted on the cabinet rear plate using the lowest possible HF impedance. This avoids having different HF voltages for the individual devices and avoids the risk of radio interference currents running in connection cables that may be used between the devices. 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.

Illustration 4.13 Control Cable Installation

Power Connections

4.4.2

Cabling and fusing

NOTICE

Cables General All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (75°C) conductors are recommended.

The power cable connections are situated as shown below. The size of the cable cross section is determined according to the frequency converter's current rating and the local regulation requirement.

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

130BA150.10

9 - 10 mm

(0.37 in)

130BT312.10

130BT306.10

How to Install Operating Instructions

4.4.4 Electrical Installation, Control Terminals

To connect the cable to the terminal:

1. Strip insulation of 9-10 mm

Insert a screwdriver1) in the square hole.

3. Insert the cable in the adjacent circular hole.

4. Remove the screwdriver. The cable is now mounted to the terminal.

To remove the cable from the terminal:

Insert a screw driver1) in the square hole.

2. Pull out the cable.

Max. 0.4 x 2.5 mm

Wiring to Control Terminals

4 4

Illustration 4.14 Strip Isolation

Illustration 4.15 Insert Screwdriver and Cable

Illustration 4.16 Control Cable Terminals

Specifications Operating Instructions

5 Specifications

5.1 General Specifications

Mains supply (L1, L2, L3) Supply voltage 525-690 V -10/+5%

Mains voltage low/mains drop-out: During low mains voltage or a mains drop-out, the frequency converters continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the drive's lowest rated supply voltage. Power-up and full torque cannot be expected at mains voltage lower than 10% below the frequency converter’s lowest rated supply voltage.

Supply frequency 50/60 Hz ±5% Max. imbalance temporary between mains phases 3.0% of rated supply voltage True Power Factor (λ) ≥0.9 nominal at rated load Displacement Power Factor (cos ϕ) near unity (> 0.98) Switching on input supply L1, L2, L3 (power-ups) maximum 1 time/2 min. Environment according to EN60664-1 over-voltage category III/pollution degree 2

The unit is suitable for use on a circuit capable of delivering not more than 100.000 RMS symmetrical Amperes, 500/600/690 V maximum.

Torque characteristics Overload torque (constant torque) maximum 150% (typical)/175% (1.2 MW and above) for 60 s

1) Percentage relates to the nominal torque.

Digital inputs Programmable digital inputs 4 (6) Terminal number 18, 19, 271), 29, 32, 33, Logic PNP or NPN Voltage level 0-24 V DC Voltage level, logic'0' PNP < 5 V DC Voltage level, logic'1' PNP > 10 V DC Voltage level, logic '0' NPN Voltage level, logic '1' NPN Maximum voltage on input 28 V DC Pulse frequency range 0-110 kHz (Duty cycle) Minimum pulse width 4.5 ms Input resistance, R

> 19 V DC < 14 V DC

approx.4 kΩ

Mains

Functional isolation

PELV isolation

DC-Bus

High

voltage

Control

+24 V

RS-485

130BD834.10

Specifications Operating Instructions

Safe stop Terminal 373) (Terminal 37 is fixed PNP logic) Voltage level 0-24 V DC Voltage level, logic'0' PNP < 4 V DC Voltage level, logic'1' PNP >20 V DC Nominal input current at 24 V 50 mA rms Nominal input current at 20 V 60 mA rms Input capacitance 400 nF

All digital inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

1) Terminals 27 and 29 can also be programmed as output.

2) Except safe stop input Terminal 37.

3) See for further information about terminal 37 and Safe Stop.

Analog inputs Number of analog inputs 2 Terminal number 53, 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201/switch S202 = OFF (U) Voltage level -10 to +10 V (scaleable) Input resistance, R

approx. 10 kΩ Max. voltage ±20 V Current mode Switch S201/switch S202 = ON (I) Current level 0/4 to 20 mA (scaleable) Input resistance, R

approx. 200 Ω Max. current 30 mA Resolution for analog inputs 10 bit (+ sign) Accuracy of analog inputs Max. error 0.5% of full scale Bandwidth 100 Hz

The analog inputs are galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

5 5

Illustration 5.1 PELV Isolation of Analog Inputs

Specifications

Digital output Programmable digital/pulse outputs 2 Terminal number 27, 29 Voltage level at digital/frequency output 0-24 V Maximum output current (sink or source) 40 mA Maximum load at frequency output 1 kΩ Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output 32 kHz Accuracy of frequency output Maximum error: 0.1 % of full scale Resolution of frequency outputs 12 bit

1) Terminal 27 and 29 can also be programmed as input.

The digital output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Analog output Number of programmable analog outputs 1 Terminal number 42 Current range at analog output 0/4 to 20 mA Maximum load GND - analog output less than 500 Ω Accuracy on analog output Maximum error: 0.5% of full scale Resolution on analog output 12 bit

The analog output is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Operating Instructions

Control card, 24 V DC output Terminal number 12, 13 Output voltage 24 V +1, -3V Maximum load 200 mA

The 24 V DC supply is galvanically isolated from the supply voltage (PELV), but has the same potential as the analog and digital inputs and outputs.

Control card, 10 V DC output Terminal number ±50 Output voltage 10.5 V ±0.5 V Maximum load 15 mA

The 10 V DC supply is galvanically isolated from the supply voltage (PELV) and other high-voltage terminals.

Control card, RS-485 serial communication Terminal number 68 (P,TX+, RX+), 69 (N,TX-, RX-) Terminal number 61 Common for terminals 68 and 69

The RS-485 serial communication circuit is functionally separated from other central circuits and galvanically isolated from the supply voltage (PELV).

Control card, USB serial communication USB standard 1.1 (Full speed) USB plug USB type B plug

Connection to PC is carried out via a standard host/device USB cable. 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.

Specifications Operating Instructions

Relay outputs Programmable relay outputs 2 Relay 01 terminal number 1-3 (break), 1-2 (make) Maximum terminal load (AC-1)1) on 1-3 (NC), 1-2 (NO) (Resistive load) 240 V AC, 2 A Maximum terminal load (AC-15)1) (Inductive load @ cosφ0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 1-2 (NO), 1-3 (NC) (Resistive load) 60 V DC, 1 A Maximum terminal load (DC-13)1) (Inductive load) 24 V DC, 0.1 A Relay 02 (FC 302 only) terminal number 4-6 (break), 4-5 (make) Maximum terminal load (AC-1)1) on 4-5 (NO) (Resistive load) 400 V AC, 2 A Maximum terminal load (AC-15)1) on 4-5 (NO) (Inductive load @ cosφ0.4) 240 V AC, 0.2 A Maximum. terminal load (DC-1)1) on 4-5 (NO) (Resistive load) 80 V DC, 2 A Maximum terminal load (DC-13)1) on 4-5 (NO) (Inductive load) 24 V DC, 0.1 A Maximum terminal load (AC-1)1) on 4-6 (NC) (Resistive load) 240 V AC, 2 A Maximum terminal load (AC-15)1) on 4-6 (NC) (Inductive load @ cosφ0.4) 240 V AC, 0.2 A Maximum terminal load (DC-1)1) on 4-6 (NC) (Resistive load) 50 V DC, 2 A Maximum terminal load (DC-13)1) on 4-6 (NC) (Inductive load) 24 V DC, 0.1 A Minimum terminal load on 1-3 (NC), 1-2 (NO), 4-6 (NC), 4-5 (NO) 24 V DC 10 mA, 24 V AC 20 mA Environment according to EN 60664-1 overvoltage category III/pollution degree 2

1) IEC 60947 part 4 and 5 The relay contacts are galvanically isolated from the rest of the circuit by reinforced isolation (PELV).

5 5

Cable lengths and cross sections Maximum cross section to control terminals, flexible/ rigid wire without cable end sleeves 1.5 mm2/16 AWG Maximum cross section to control terminals, flexible wire with cable end sleeves 1 mm2/18 AWG Maximum cross section to control terminals, flexible wire with cable end sleeves with collar 0.5 mm2/20 AWG Minimum cross section to control terminals 0.25 mm2/24 AWG

Control card performance Scan interval 1 ms

Control characteristics Resolution of frequency ±0.003 Hz Repeat accuracy of precise start/stop (terminals 18, 19) ≤±0.1 ms System response time (terminals 18, 19, 27, 29, 32, 33) ≤ 2 ms

Surroundings Enclosure, frame size D and E IP 00/Chassis Enclosure, frame size F IP 54/Type 12 Vibration test 0.7 g Max. relative humidity 5% - 95%(IEC 721-3-3; Class 3K3 (non-condensing) during operation Aggressive environment (IEC 60068-2-43 Ambient temperature (with SFAVM switching mode)

- with derating Max. 55 °C

- at full continuous drive output current Max. 45 °C

1) For more information on derating, see special conditions in the Design Guide

Minimum ambient temperature during full-scale operation 0 °C Minimum ambient temperature at reduced performance -10 °C Temperature during storage/transport -25 to +65/70 °C Maximum altitude above sea level without derating 1,000 m

Derating for high altitude, see special conditions in the Design Guide

EMC standards, Emission EN 61800-3, EN 61000-6-3/4, EN 55011

EN 61800-3, EN 61000-6-1/2,

EMC standards, Immunity

See section on special conditions in the Design Guide.

EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5, EN 61000-4-6

class H25

Specifications Operating Instructions

Protection and Features

Temperature monitoring of the heatsink ensures that the frequency converter trips if the temperature reaches a

•

predefined level. An overload temperature cannot be reset until the temperature of the heatsink is below the values stated in the tables on the following pages (Guideline - these temperatures may vary for different power sizes, frame sizes, enclosure ratings etc.).

If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load).

•

Monitoring of the DC voltage ensures that the frequency converter trips if the DC circuit voltage is too low or too

•

high. The frequency converter constantly checks for critical levels of internal temperature, load current, and the DC

•

voltage. As a response to a critical level, the frequency converter can adjust the switching frequency and/ or change the switching pattern to ensure the performance of the frequency converter.

5.2 Mains Supply

5.2.1 Mains Supply 3x525-690 V AC

AFE 302 P400 P800 P1200 P1600

Typical Input at 550 V [kW] 315 710 1000 1400 Typical Input at 630 V [kW] 400 800 1200 1600 Enclosure IP00 E1 IP54 F1 IP54 F2 IP54 F1*2 Continuous input current at 550 V [A] 429 889 1317 1652

Intermittent input current (60 s overload) at 550 V [A] Typical DC voltage at 550 V [V] 850 850 850 850 Continuous output DC current at 550 V [A] 457 947 1403 1760 Continuous input current at 630 V [A] 410 850 1260 1580 Intermittent input current (60 s overload) at 630 V [A] Typical DC voltage at 630 V [V] 975 975 975 975 Continuous output DC current at 630 V [A] 425 882 1307 1639 Max. Cable size, mains [mm2 (AWG)]

Estimated power loss at 630 V [kW] 8 16 24 32 Weight IP00 for E and IP54 for F1 and F2 221 382 574 764 Weight Module [kg] NA 102 102 102 Effieciency Heatsink overtemp trip level [°C] Power card ambient trip [°C]

644 1334 2305 2891

615 1275 2205 2765

4x240 (4x500 mcm)

0.98 0.98 0.98 0.98 85 85 85 85 68 68 68 68

8x150 (8x300 mcm)

12x150 (12x300mcm)

16x150 (16x300mcm)

Table 5.1 Mains Supply 3x525-690 V AC

1) The typical overload percentage is 150. The P1M2 to P1M6 overload percentage is 175.

2) The efficiency is estimated at the nominal load condition. It is expected to be within ±15%. If the switching frequency is increased, the power loss rises.

How to Programme Operating Instructions

6 How to Programme

6.1 Parameter Selection

Parameters for AFE 302 are grouped into various parameter groups for easy selection of the correct parameters for optimized operation of the frequency converter.

0-** Operation and Display

Basic Settings, set-up handling

•

Display and Local Control Panel parameters for

•

choosing readouts, setting up selections and copying functions

4-** Limits Warnings

5-** Digital inputs and outputs includes relay controls

6 6

6-** Analog In/Out

7-** Controllers

8-** Communications and Options

14-** Special functions

15-** AFE information

16-** Data Read-Out

40-** Mains/Filter

How to Programme Operating Instructions

6.2 Parameters: 0-** Operation and Display

Parameters related to the basic functionality of the AFE. Parameters related to the function of the display and buttons.

6.2.1 0-0* Basic Settings

0-01 Language

Option: Function:

Defines the language to be used in the display.

[0] * English Part of Language packages 1 - 4

0-12 This Set-up Linked to

Option: Function:

This parameter sets the AFE to automatically synchronise the values of the 'not changeable during operation' parameters between this setup and the set-up selected in this parameter.

Note: The values in this setup are overwritten. [0] * Not linked [1] Set-up 1 [2] Set-up 2 [3] Set-up 3 [4] Set-up 4

0-13 Readout: Linked Set-ups

6.2.2 0-1* Set-up Operations

Define and control the individual parameter setups.

0-10 Active Set-up

Option: Function:

Select the set-up to control the frequency converter functions.

[0] Factory

setup

[1] * Set-up 1

[2] Set-up 2 [3] Set-up 3 [4] Set-up 4 [9] Multi Set-upRemote selection of set-ups using digital

Required to use emergency mode.

0-11 Edit Set-up

Option: Function:

[0] Factory setup [1] * Set-up 1 [2] Set-up 2 [3] Set-up 3 [4] Set-up 4 [9] Active Set-up

Cannot be changed. It contains the Danfoss data set, and can be used as a data source when returning the other set-ups to a known state.

Set-up 1 [1] to Set-up 4 [4] are the four separate parameter set-ups within which all parameters can be programmed.

inputs and the serial communication port. This set-up uses the settings from 0-12 This Set-up Linked to. Stop the frequency converter before making changes to open- and closed loop functions

Editing can either follow the active setup selection (parameter 0-10 Active Set-up), or be fixed at a setup number. This parameter is unique for LCP and buses.

Range: Function:

0* [0 -

255 ]

View a list of all the set-ups linked by means of 0-12 This Set-up Linked to. The parameter has one index for each parameter set-up. The parameter value displayed for each index represents which set-ups are linked to that parameter set-up.

Index LCP value

0 {0} 1 {1,2} 2 {1,2} 3 {3} 4 {4}

Table 6.2 Example: Set-up 1 and Set-up 2 are linked

0-14 Readout: Edit Set-ups / Channel

Range: Function:

0* [-2147483648 -

2147483647 ]

View the setting of 0-11 Edit Set-up for each of the 4 different communication channels. When the number is displayed as a hex number, as it is in the LCP, each number represents one channel. Numbers 1-4 represent a set-up number; ‘F’ means factory setting; and ‘A’ means active set-up. The channels are, from right to left: LCP, FC-bus, USB, HPFB1-5. Example: The number AAAAAA21h means that the FC bus selected Set-up 2 in 0-11 Edit Set-up, the LCP selected Set-up 1 and all others used the active set-up.

How to Programme Operating Instructions

6.2.3 0-2* LCP Display

Parameters used to select what kind of information (e.g. power, current, frequency) should be displayed in the STATUS window.

0-20 Display Line 1.1 Small

Option: Function:

Select a variable for display in line 1,

left position. [0] None No display value selected. [1501] Running Hours [1502] kWh Counter [1600] Control Word Present control word [1603] Status Word Present status word. [1630] DC Link Voltage Intermediate circuit voltage in the AFE. [1634] Heatsink Temp. Present heat sink temperature of the

AFE. The cut-out limit is 95 ±5°C;

cutting back in occurs at 70 ±5°C. [1635] Inverter Thermal Percentage load of the inverters. [1636] Inv. Nom.

Current [1637] Inv. Max. Current Maximum current of the AFE. [1639] Control Card

Temp. [1641] Current Value of measured current [1642] Voltage Shows the actual mains voltage, when

[1643] Frequency Returns the actual mains frequency,

[1644] Power [kW] Returns the calculated mains power in

[1645] Power [hp] Returns the calculated mains power in

[1660] Digital Input Signal states form the 6 digital

[1665] Analog Output

42 [mA] [1666] Digital Output

[bin] [1671] Relay Output [bin Shows all the relay settings. [1680] Fieldbus CTW 1 Control word (CTW) received from the

[1682] Fieldbus REF 1 Main reference value sent with control

[1684] Comm. Option

STW [1685] FC Port CTW 1 Control word (CTW) received from the

[1686] FC Port REF 1 Status word (STW) sent to the Bus

[1690] Alarm Word One or more alarms in a Hex code. [1691] Alarm Word 2 One or more alarms in a Hex code.

Nominal current of the AFE.

Temperature of the control card.

the AFE is running.

when the AFE is running.

HP.

terminals (18, 19, 27, 29, 32 and 33). Input 18 corresponds to the bit at the far left. Signal low = 0; Signal high =

1. Shows the value at output 42 in mA.

Binary value of all digital outputs.

Bus Master.

word from the Bus Master. Extended fieldbus communication option status word.

Bus Master.

Master.

0-20 Display Line 1.1 Small

Option: Function:

[1692] Warning Word 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.

0-21 Display Line 1.2 Small

Option: Function:

[1641] * Mains Current

[A]

Select a variable for display in line 1, middle position. The options are the same as listed for parameter group 0-2* LCP Display.

0-22 Display Line 1.3 Small

Option: Function:

[1644] * Power [kW] Select a variable for display in line 1, right

position. The options are the same as listed for parameter group 0-2* LCP Display.

0-23 Display Line 2 Large

Option: Function:

[1643] * Frequency [Hz] Select a variable for display in line 2.

The options are the same as those listed for parameter group 0-2* LCP Display.

0-24 Display Line 3 Large

Option: Function:

Select a variable for display in line 2.

[1630] * Counter [kWh]

The options are the same as those listed for 0-20 Display Line 1.1 Small.

0-25 My Personal Menu

Range: Function:

Size related*

[0 9999]

Define up to 50 parameters to appear in the Q1 Personal Menu, accessible via the [Quick Menu] key on the LCP. The parameters are displayed in the Q1 Personal Menu in the order they are programmed into this array parameter. Delete parameters by setting the value to ‘0000’. For example, this can be used to provide quick, simple access to just one or up to 50 parameters which require changing on a regular basis (e.g. for plant maintenance reasons) or by an OEM to enable simple commissioning of their equipment.

6 6

How to Programme Operating Instructions

6.2.4 0-4* LCP Keypad

0-50 LCP Copy

Option: Function:

Enable, disable and password protect individual keys on the LCP.

0-40 [Hand on] Key on LCP

Option: Function:

[0] Disabled Key disabled avoids accidental usage of the key.

[1] * Enabled [Hand On] key enabled

[2] Password

Avoid unauthorised start in Hand mode. If parameter 0-40 [Hand on] Key on LCP is included in My Personal Menu, define the password in 0-65 Personal Menu Password. Otherwise, define the password in parameter 0-60 Main Menu Password.

0-41 [Off] Key on LCP

[0] * No copy [1] All to LCP [2] All from LCP [3] Size indep. from LCP

0-51 Set-up Copy

Option: Function:

[0] * No copy No function [1] Copy to set-up 1 [2] Copy to set-up 2 [3] Copy to set-up 3 [4] Copy to set-up 4 [9] Copy to all

6.2.6 0-6* Password

Option: Function:

[0] Disabled Avoids accidental stop of the AFE. [1] * Enabled [2] Password

Avoids unauthorised stop. If 0-41 [Off] Key on LCP is included in the Quick Menu, then define the password in parameter 0-65 Quick Menu Password.

0-42 [Auto on] Key on LCP

0-60 Main Menu Password

Range: Function:

100* [-9999 -

9999 ]

Define the password for access to the Main Menu via the [Main Menu] key. If 0-61 Access to Main Menu w/o Password is set to [0] Full access, this parameter is ignored.

Option: Function:

[0] Disabled avoid accidental start of the AFE in Auto mode. [1] * Enabled [2] Password Avoids unauthorised start in Auto mode. If

0-42 [Auto on] Key on LCP is included in the Quick Menu, then define the password in parameter 0-65 Quick Menu Password.

0-43 [Reset] Key on LCP

Option: Function:

[0] Disabled No effect when [Reset] is pressed. Avoids

accidental alarm reset.

[1] Enabled [2] Password

[7] Enabled

without OFF

[8] Password

without OFF

Avoids unauthorised resetting. If parameter 0-43 [Reset] Key on LCP is included in the Quick Menu, then define the password in parameter 0-65 Quick Menu Password.

Resets the AFE without setting it in Off mode.

Resets the AFE without setting it in Off mode. A password is required when pressing [Reset] (see [2]).

0-61 Access to Main Menu w/o Password

Option: Function:

[0] * Full access

[1] LCP: Read

only

[2] LCP: No

access

[3] Bus: Read

only

[4] Bus: No

access

[5] All: Read only Read-only function for parameters on LCP,

[6] All: No access No access from LCP, Fieldbus or FC standard

Disables password defined in parameter 0-60 Main Menu Password.

Prevent unauthorised editing of Main Menu parameters.

Prevent unauthorised viewing and editing of Main Menu parameters.

Read-only functions for parameters on Fieldbus and/or FC standard bus.

No access to parameters is allowed via Fieldbus and/or FC standard bus.

Fieldbus or FC standard bus.

bus is allowed.

If [0] Full access is selected, parameter 0-60 Main Menu

Password, 0-65 Personal Menu Password and 0-66 Access to Personal Menu w/o Password are ignored.

NOTICE

6.2.5 0-5* Copy/Save

Copy parameters from and to the LCP. Use these parameters for saving and copying set-ups from one frequency converter to another.

A more complex password protection is available for OEMs upon request.

How to Programme Operating Instructions

0-65 Quick Menu Password

Range: Function:

200* [-9999 -

9999 ]

Define the password for access to the Quick Menu via the [Quick Menu] key. If

parameter 0-66 Access to Quick Menu w/o Password is set to [0] Full access, this

parameter is ignored.

0-66 Access to Quick Menu w/o Password

If 0-61 Access to Main Menu w/o Password is set to [0] Full access then this parameter is ignored.

Option: Function:

[0] * Full access

[1] LCP: Read only Prevents unauthorised editing of Quick

[3] Bus: Read only Read only functions for Quick Menu

[5] All: Read only Read only function for Quick Menu

Disables the password defined in parameter 0-65 Quick Menu Password.

Menu parameters.

parameters on Fieldbus and/or FC standard bus.

parameters on LCP, Fieldbus or FC standard bus.

6 6

0-67 Bus Password Access

Range: Function:

0* [0 - 9999 ] Writing to this parameter enables users to

unlock the frequency converter from bus/MCT 10 Set-up Software.

How to Programme Operating Instructions

6.3 Parameters: 4-** Limits/Warnings

6.3.1 4-1* Limits

Use these parameters to adjust warning limits for power. Warnings are shown on the LCP, can be programmed as outputs, and can be read out via the serial bus in the Extended Status Word.

4-18 Current Limit

Range: Function:

Size related* [ 1.0 - 1000.0 %] This is a true current limit

function.

4-91 Output Frequency Deviation Limit

Range: Function:

20%* [1 - 50%] Selects the max deviation in procentage from

the nominiel mains frequency set in parameter

40-01 Mains Frequency

4-92 Output Frequency Deviation Timeout

Range: Function:

0.001 s* [0.000 - 60.000s]Selects the max time where the frequency deviation set in parameter

4-91 Output Frequency Deviation Limit

can be exceeded.

4-93 Output Voltage Deviation Function

6.3.2 4-5* Adjustable Warnings

4-52 Warning Regen Limit

Range: Function:

Size related*

4-53 Warning Power Limit

Range: Function:

Size related*

[0-2*Nominal NO Power kW]

Enter the regen power limit. When the regenerative power exceeds this limit the display reads Regen Limit. The signal outputs can be programmed to produce a status signal on terminals 27 or 29 and on relay outputs 01 or 02.

Enter the active power limit. When the active power exceeds this limit the display reads Power Limit. The signal outputs can be programmed to produce a status signal on terminals 27 or 29 and on relay outputs 01 or 02.

Option: Function:

Select the time-out function. The time-out function activates when the output vontage exceeds the deviation limit set in parameter 4-91 Output Frequency Deviation Limit for the time set in parameter 4-92 Output Frequency Deviation Timeout.

[0] * Trip Generate an alarm trip when a fault condition is

encountered.

[1] Warning Generate a warning when a fault condition is

encountered.

[2] Disabled Take no action on fault condition.

Select which reaction the AFE should take in case the voltage deviation set in parameter 4-94 Output Voltage Deviation Limit is exeeded.

4-94 Output Voltage Deviation Limit

Range: Function:

20%* [1 - 50%] Selects the max deviation in procentage from

the nominiel mains voltage set in parameter 40-00 Mains Voltage.

6.3.3 4-9* Output Limits

4-90 Output Frequency Deviation Function

Option: Function:

Select the time-out function. The time-out function activates when the output frequency exceeds the deviation limit set in parameter 4-91 Output Frequency Deviation Limit for the time set in parameter 4-92 Output Frequency Deviation

Timeout

[0] * Trip Generate an alarm trip when a fault condition is

encountered.

[1] Warning Generate a warning when a fault condition is

encountered.

[2] Disabled Take no action on fault condition.

Range: Function:

0.001 s* [0.000 - 60.000s]Selects the max time where the voltage deviation set in parameter

4-94 Output Voltage Deviation Limit

can be exceeded.

Select which reaction the AFE should take in case the frequency deviation set in parameter 4-91 Output Frequency Deviation Limit.

4-95 Output Voltage Deviation Timeout

How to Programme Operating Instructions

6.4 Parameters: 5-** Digital In/Out

Parameters for configuring the I/O mode. NPN/PNP and setting up I/O to Input or Output.

5-00 Digital I/O Mode

Option: Function:

Digital inputs and programmed digital outputs are pre-programmable for operation either in PNP or NPN

systems. [0] * PNP No reaction to signals transmitted to the terminal. [1] NPN Resets the frequency converter after a TRIP/ALARM.

Not all alarms can be reset.

NOTICE

When changing this parameter, a power cycle must be carried out before the parameter change is active.

This parameter cannot be adjusted while the AFE is running.

5-01 Terminal 27 Mode

Option: Function:

[0] Input Defines terminal 27 as a digital input. [1] * Output Defines terminal 27 as a digital output.

This parameter cannot be adjusted while the AFE is running.

5-02 Terminal 29 Mode

Option: Function:

[0] Input Defines terminal 29 as a digital input. [1] * Output Defines terminal 29 as a digital output.

This parameter cannot be adjusted while the AFE is running.

5-1* Digital Inputs

6.4.1

Parameters for configuring the input functions for the input terminals.

NOTICE

For the parameters in group 5-1* Digital Inputs it is possible to choose between the different possible functions related to the input on this terminal.

[0] No

operation

[1] Reset Resets AFE after a TRIP/ALARM. Not all alarms

[8] Start (Default Digital input 18): Select start for a

No reaction to signals transmitted to the terminal.

can be reset.

start/stop command. Logic ‘1’ = start, logic ‘0’ = stop.

5-10 Terminal 18 Digital Input

Option: Function:

[0] No operation [1] Reset [8] * Start [23] * Set-up select bit0Select Set-up select bit 0 or Select Set-

up select bit 1 to select one of the four set-ups. Setparameter 0-10 Active Set-up to Multi Set-up.

[24] * Set-up select bit1(Default Digital input 32): Same as Set-

up select bit 0 [23].

5-11 Terminal 19 Digital Input

Option: Function:

[0] No operation [1] * Reset [8] Start [23] * Set-up select bit0Select Set-up select bit 0 or Select Set-

up select bit 1 to select one of the four set-ups. Setparameter 0-10 Active Set-up to Multi Set-up.

[24] * Set-up select bit1(Default Digital input 32): Same as Set-

up select bit 0 [23].

5-12 Terminal 27 Digital Input

Option: Function:

[0] * No operation [1] Reset [8] Start [23] * Set-up select bit0Select Set-up select bit 0 or Select Set-

up select bit 1 to select one of the four set-ups. Setparameter 0-10 Active Set-up to Multi Set-up.

[24] * Set-up select bit1(Default Digital input 32): Same as Set-

up select bit 0 [23].

5-13 Terminal 29 Digital Input

Option: Function:

[0] * No operation [1] Reset [8] Start [23] * Set-up select bit0Select Set-up select bit 0 or Select Set-

up select bit 1 to select one of the four set-ups. Setparameter 0-10 Active Set-up to Multi Set-up.

[24] * Set-up select bit1(Default Digital input 32): Same as Set-

up select bit 0 [23].

6 6

How to Programme

Operating Instructions

5-14 Terminal 32 Digital Input

Option: Function:

[0] * No operation [1] Reset [8] Start [23] * Set-up select bit0Select Set-up select bit 0 or Select Set-

up select bit 1 to select one of the four set-ups. Setparameter 0-10 Active Set-up to Multi Set-up.

[24] * Set-up select bit1(Default Digital input 32): Same as Set-

up select bit 0 [23].

5-15 Terminal 33 Digital Input

Option: Function:

[0] * No operation [1] Reset [8] Start [23] * Set-up select bit0Select Set-up select bit 0 or Select Set-

up select bit 1 to select one of the four set-ups. Setparameter 0-10 Active Set-up to Multi Set-up.

[24] * Set-up select bit1(Default Digital input 32): Same as Set-

up select bit 0 [23].

5-31 Terminal 29 Digital Output

Option: Function:

[0] * No operation

[1] Control ready The control board receives supply

[2] Drive ready The frequency converter is ready for

[9] Alarm An alarm activates the output. There are

[252] Regen limit Active when actual regenerative power is

[253] Power limit Active when actual active power is above

[254] Soft charge

ready

[255] DC-link on ref. AFE running and motor operation

Default for all digital outputs and relay outputs

voltage.

operation and applies a supply signal on the control board.

no warnings.

above the value set in parameter 4-52

Warning Regen Limit

the value set in parameter 4-53 Warning Power Limit.

DC bus charged

allowed.

In this parameter, the function for the terminal 29 digital output is selected.

6.4.2 5-3* Digital Outputs

Parameters for configuring the output functions for the output terminals. The 2 solid-state digital outputs are common for terminals 27 and 29. Set the I/O function for terminal 27 in parameter 5-01 Terminal 27 Mode, and set the I/O function for terminal 29 in 5-02 Terminal 29 Mode. These parameters cannot be adjusted while the AFE is running.

5-30 Terminal 27 Digital Output

Option: Function:

[0] No operation

[1] Control ready The control board receives supply

[2] Drive ready The frequency converter is ready for

[9] Alarm An alarm activates the output. There are

[252] Regen limit Active when actual regenerative power

[253] Power limit Active when actual active power is

[254] Soft charge

ready

[255] * DC-link on ref. AFE running and motor operation

Default for all digital outputs and relay outputs

voltage.

operation and applies a supply signal on the control board.

no warnings.

is above the value set in parameter 4-52

Warning Regen Limit

above the value set in parameter 4-53 Warning Power Limit.

DC bus charged

allowed.

5-4* Relays

6.4.3

Parameters for configuring the timing and the output functions for the relays

(Relay 1 [0], Relay 2 [1])

5-40 Function Relay

Option: Function:

[0] No operation

[1] Control ready The control board receives supply

[2] Drive ready The frequency converter is ready for

[9] Alarm An alarm activates the output. There are

[252] Regen limit Active when actual regenerative power

[253] Power limit Active when actual active power is

[254] * Soft charge

ready

[255] DC-link on ref. AFE running and motor operation

Default for all digital outputs and relay outputs

voltage.

operation and applies a supply signal on the control board.

no warnings.

is above the value set in parameter 4-52

Warning Regen Limit

above the value set in parameter 4-53 Warning Power Limit.

DC bus charged

allowed.

In this parameter, the function for the relay outputs is selected. The selection of each mechanical relay is realised in an array parameter.

How to Programme Operating Instructions

5-41 On Delay, Relay

Range: Function:

0.01 s* [0.01 -

600.00 s]

This parameter makes it possible to delay the cut-in time of the relays. The selection of each mechanical relay is realised in an array parameter.

5-42 Off Delay, Relay

Range: Function:

0.01 s* [0.01 -

600.00 s]

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.

6 6

130BD869.10

(mA)

0/4

100%

Current

Analogue output Min Scale par. 6-51

Variable for output

Analogue Output Max Scale par. 6-52

How to Programme Operating Instructions

6.5 Parameters: 6-** Analog In/Out

6.5.1 6-5* Analog Output 1

6-52 Terminal 42 Output Max Scale

Range: Function:

Parameters for configuring analog output 1, i.e. Terminal

42. Analog outputs are current outputs: 0/4 to 20 mA. Common terminal (terminal 39) is the same terminal and has the same electrical potential for analog common and digital common connection. Resolution on the analog output is 12 bit.

6-50 Terminal 42 Output

Option: Function:

[0] * No

operation

[103] Current Signal represents the unit current. The

[106] Power Signal represents the unit power. The unit

[133] Current

4-20mA

[136] Power

4-20mA

No signal is provided on the analog output.

inverter max. current (taken from parameter 16-37 Inv. Max. Current) is equal to 20 mA.

nominal power (taken from parameter 15-41 Power Section) is equal to 20 mA. Signal represents the unit current with 0 equal to 4 mA. The inverter max. current (taken from parameter 16-37 Inv. Max. Current) is equal to 20 mA. Signal represents the unit power with 0 equal to 4 mA. The unit nominal power (taken from parameter 15-41 Power Section) is equal to 20 mA.

Illustration 6.1 Scale Output

6-51 Terminal 42 Output Min Scale

Range: Function:

0 %* [0 - 200%]Scale for the minimum output (0 or 4 mA) of

the analogue signal at terminal 42. Set the value to be the percentage of the full range of the variable selected in 6-50 Terminal 42 Output.

6-52 Terminal 42 Output Max Scale

Range: Function:

100%* [0.00 –

200%]

Scale the maximum output of the selected analog signal at terminal 42. Set the value to the maximum value of the current signal output. Scale the output to give a current lower than 20 mA at full scale; or 20 mA at an output below 100% of the maximum signal value. If 20 mA is the desired output current at a value between 0-100% of the full-scale output, programme the percentage value in the parameter, i.e. 50% = 20 mA. If a current between 4 and 20 mA is desired at maximum output (100%), calculate the percentage value as follows:

20 mA/

i.e

. 10mA:

desired maximum current

×100 % =200 %

×100 %

How to Programme Operating Instructions

6.6 Parameters: 7-** Controllers

6.6.1 7-6* DC-Link PI Ctrl.

7-60 DC-Link Total Capacity

Range: Function:

70560.0 u(=) F*

[0.0 -

1000000.0 uF]

Set the capacitance equal to 90% of the capacitance of all the AFE and inverter drives connected in the common DC bus.

Power size dependent.

FC 302T7Nameplate

DC capacitance (mF)

P400P560 P630P800 P900P1M0 P1M4P1M6

Table 6.3 Capacitance

11.20 10.08

22.40 20.16

33.60 30.24

44.80 40.32

7-61 DC-Link Reference

Range: Function:

980 V* [1.414*Nominal

Voltage-1125 V]

Set the voltage reference for the DC-Link voltage controller. Line voltage dependent.

7-62 DC-Link PI Proportional Gain

Range: Function:

67.214* [0.000 = Off -

1000.000 N/A]

Set the wanted proportional gain of the DC-link voltage controller. Too large value may lead to oscillations. Power size dependent.

90% DC capacitance (mF)

6 6

7-63 DC-Link PI Integral Time

Range: Function:

5.0 ms* [1.0 - 1.000.0 ms]

How to Programme Operating Instructions

6.7 Parameters: 8-** Communications and

6.7.2 8-1* Control Word Settings

Options

Parameters for configuring the option control word profile.

6.7.1 8-0* General Settings

8-01 Control Site

Option: Function:

[0] * Digital and ctrl.

word [1] Digital only Control by using digital inputs only. [2] Control word only Control by using control word only.

The setting in this parameter overrides the settings in 8-50 Coasting Select to 8-56 Preset Reference Select.

8-02 Control Word Source

Option: Function:

[0] None [1] * FC RS485 [2] FC USB

8-03 Control Word Timeout Time

Range: Function:

1 s* [ 0.1 -

18000 s]

This parameter specifies which action should be performed, if a timeout of the control word occurs.

Control by using both digital input and control word.

Enter the maximum time expected to pass between the reception of two consecutive telegrams. If this time is exceeded, it indicates that the telegram communication has stopped. The function selected in 8-04 Control Word Timeout Functionis then carried out. A valid control word triggers the time-out counter.

This parameter selects the interpretation of the control word and status word. Valid selections are determined by installed option.

8-10 Control Word Settings

Option: Function:

[0] * FC AFE profile

Bit AFE Profile

Bit = 0 Bit = 1

0 - 1 - 2 - 3 - 4 - 5 - 6 Stop Start 7 No Function Reset 8 - 9 - 10 Data not valid Data valid 11 - 12 - 13 - 14 - 15 - -

Table 6.4 Bus Control Word

8-04 Control Word Timeout Function

Option: Function:

[0] * Off [2] Stop [5] Stop and trip

8-06 Reset Control Word Timeout

Option: Function:

[0] * Do not reset [1] Do reset

How to Programme Operating Instructions

Bit AFE Profile

Bit = 0 Bit = 1

0 Control not ready Control ready 1 Unit not ready Unit ready 2 Soft charge not

ready 3 No trip Trip 4 - 5 - 6 No TripLock TripLock 7 No warning Warning 8 DC-link not on

reference 9 Local control Remote control 10 Not ramping Ramping 11 Not running Running 12 - 13 No DC voltage

warning 14 No current limit Current limit 15 No Thermal

warning

Table 6.5 Bus Status Word

Soft charge ready

DC-link on reference

DC voltage warning

Thermal warning

8-13 Configurable Status Word STW

Option: Function:

Bit 12 to 15 of the STW is config-

urable for various status signals. [0] No function [1] * Profile default [2] Alarm 68 only [3] Trip except Alarm 68 [16] T37 DI status

6.7.3 8-3* FC Port Settings

8-32 FC Port Baud Rate

Option: Function:

[0] 2400 Baud Baud rate selection for the FC (standard) port.

[1] 4800 Baud [2] 9600 Baud [3] 19200 Baud [4] 38400 Baud [5] 57600 Baud [6] 76800 Baud [7] 115200 Baud

8-35 Minimum Response Delay

Range: Function:

10 ms* [ 1 - 10000

ms]

Specify the minimum delay time between receiving a request and transmitting a response. This is used for overcoming modem turnaround delays.

8-36 Max Response Delay

Range: Function:

Size related*

[ 11 10001 ms]

Specify the maximum permissible delay time between transmitting a request and receiving a response. If a response from the frequency converter is exceeding the time setting, then it is discarded.

8-37 Max Inter-Char Delay

Range: Function:

Size related*

[ 0.00 -

35.00 ms]

Specify the maximum permissible time interval between receipt of 2 bytes. This parameter activates time-out if transmission is interrupted. This parameter is active only when 8-30 Protocol is set to [1] FC MC protocol.

6 6

8-30 Protocol

Option: Function:

[0] * FC Communication according to the FC Protocol as

described in the VLT AutomationDrive Design Guide, RS-485 Installation and Set-up.

[1] FC MC Select the protocol for the FC (standard) port.

8-31 Address

Range: Function:

Size related* [ 1 - 255 ] Enter the address for the FC (standard)

port. Valid range: 1-126.

Enables use of freely configurable telegrams or standard telegrams for the FC port.

8-40 Telegram Selection

Option: Function:

[1] * Standard Telegram 1 [101] PPO 1 [102] PPO 2 [103] PPO 3 [104] PPO 4 [105] PPO 5 [106] PPO 6 [107] PPO 7 [108] PPO 8 [200] Custom telegram 1

How to Programme Operating Instructions

6.7.4 8-5* Digital/Bus

Parameters for configuring the control word digital/bus merging.

NOTICE

These parameters are active only when 8-01 Control Site is set to [0] Digital and control word.

8-53 Start Select

Option: Function:

Allows a choice between controlling the Start function via the terminals (digital input)

[0] Digital input [1] Bus [2] Logic AND [3] * Logic OR

and/or via the bus.

NOTICE

This parameter is only active if

8-01 Control Site is set to [0] Digital and control word.

How to Programme Operating Instructions

6.8 Parameters: 14-** Special Functions

6.8.1 14-0* AFE Switching

14-01 Switching Frequency

Select the AFE switching frequency. Changing the switching frequency can help to reduce acoustic noise from the AFE. Default depend on power size.

Option: Function:

[0] 1.0 kHz [1] 1.5 kHz Default switching frequency

for 355-1200 kW, 690V

[2] 2.0 kHz Default switching frequency

for 250-800 kW, 400V and 37-315 kW, 690V

[3] 2.5 kHz [4] 3.0 kHz Default switching frequency

for 18.5-37 kW, 200V and 37-200 kW, 400V

[5] 3.5 kHz [6] 4.0 kHz Default switching frequency

for 5.5 – 15 kW, 200V and 11-30 kW, 400V

[7] 5.0 kHz Default switching frequency

for 0.25 – 3,7 k W, 200V and

0.37-7.5 kW, 400V

[8] 6.0 kHz [9] 7.0 kHz [10] 8.0 kHz [11] 10.0 kHz [12] 12.0kHz [13] 14.0 kHz [14] 16.0kHz

6.8.2 14-2* Trip Reset

14-20 Reset Mode

Select the reset function after tripping. Once reset, the frequency converter can be restarted.

Option: Function:

[5] Automatic reset x 5 [6] Automatic reset x 6 [7] Automatic reset x 7 [8] Automatic reset x 8 [9] Automatic reset x 9 [10] Automatic reset x 10 [11] Automatic reset x 15 [12] Automatic reset x 20 [13] Infinite Automatic Reset

Select Infinite Automatic Reset [13] for continuous resetting after tripping.

NOTICE

The AFE may start without warning. If the specified number of AUTOMATIC RESETs is reached within 10min, the frequency converter enters Manual reset [0] mode. After the Manual reset is performed, the setting of 14-20 Reset Mode reverts to the original selection. If the number of automatic resets is not reached within 10min, or when a Manual reset is performed, the internal AUTOMATIC RESET counter returns to zero.

NOTICE

Automatic reset will also be active for resetting safe stop function.

14-21 Automatic Restart Time

Range: Function:

10s* [0 - 600 s] Enter the time interval from trip to start of the

automatic reset function. This parameter is active when 14-20 Reset Mode is set to Automatic reset [1] - [13].

6 6

Parameters for configuring auto reset handling, special trip handling and control card self test or initialisation.

NOTICE

Remember to set switches S201 (A53) and S202 (A54) as specified below when performing a control card test in

14-20 Reset Mode

Select the reset function after tripping. Once reset, the frequency converter can be restarted.

Option: Function:

[0] * Manual reset

[1] Automatic reset x 1

[2] Automatic reset x 2 [3] Automatic reset x 3 [4] Automatic reset x 4

Select Manual reset [0], to perform a reset via [RESET] or via the digital inputs. Select Automatic reset x 1…x20 [1]-[12] to perform between one and twenty automatic resets after tripping.

parameter 14-22 Operation Mode [1]. Otherwise, the test fails.

14-22 Operation Mode

Option: Function:

Use this ameter to specify normal operation; to perform tests; or to initialise all parameters except 15-03 Power Up's, 15-04 Over Temp's and 15-05 Over Volt's. This function is active only when the power is cycled to the frequency converter. Select [0] Normal operation for normal operation of the frequency converter with the motor in the selected application.

130BA097.12

FC 302

FC 301

FC 301 & FC 302

1312 18 37322719 29 33 20

5039 42 5453 55

191812 13 203327 32

How to Programme Operating Instructions

14-22 Operation Mode

Option: Function:

Select [1] Control card test to test the analog and digital inputs and outputs and the +10 V control voltage. The test requires a test connector with internal connections. Use the following procedure for the control card test:

Select [1] Control card test.

2. Disconnect the mains supply and wait for the light in the display to go out.

3. Set switches S201 (A53) and S202 (A54) = ‘ON’/I.

4. Insert the test plug (see Illustration 6.2).

5. Connect to mains supply.

6. Carry out various tests.

7. The results are displayed on the LCP and the frequency converter moves into an infinite loop.

Parameter 14-22 Operation Mode is automatically set to Normal operation. Carry out a power cycle to start up in Normal operation after a control card test.

If the test is OK

LCP read-out: Control Card OK. Disconnect the mains supply and remove the test plug. The green LED on the Control Card lights up.

If the test fails

LCP read-out: Control Card I/O failure. Replace the frequency converter or Control card. The red LED on the Control Card is turned on. Test plugs (connect the following terminals to each other): 18 - 27 - 32; 19 - 29

- 33; 42 - 53 - 54

14-22 Operation Mode

Option: Function:

Select [2] Initialisation 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

resets during the next power-up. Parameter 14-22 Operation Mode also reverts to the default setting [0] Normal operation.

[0] * Normal

operation

[1] Control card

test [2] Initialisation [3] Boot mode

14-29 Service Code

Range: Function:

[000000] 000000 Hex - FFFFF For internal service

only.

0 N/A* [-2147483647 - 2147483647

N/A]

Service use only

6.8.3 14-5* Environment

These parameters help the frequency converter to operate under special environmental conditions.

14-52 Fan Control

Option: Function:

[0] * Auto [1] [2] [3] On 100%

14-53 Fan Monitor

Option: Function:

[0] Disabled [1] * Warning [2] Trip Select which reaction the frequency converter

On 50% On 75%

should take in case a fan fault is detected.

14-59 Actual Number of Inverter Units

Range: Function:

Size related* [ 1 - 1 ] Set the actual number of power units.

Illustration 6.2 Test Plugs

How to Programme Operating Instructions

6.9 Parameters: 15-** AFE Information

6.9.1 15-0* Operating Data

15-00 Operating Hours

Range: Function:

0h* [0 - 2147483647 h] View how many hours the AFE has

run. The value is saved when the AFE is turned off.

15-01 Running Hours

Range: Function:

0h* [0 -

2147483647 h]

View how many hours the AFE has run. Reset the counter in parameter 15-07 Reset Running Hours Counter. The value is saved when the AFE is turned off.

15-02 kWh Counter

Range: Function:

0kWh* [0 - 2147483647

kWh]

Registering the power consumption of the system as a mean value over one hour. Reset the counter in 15-06 Reset kWh Counter.

15-03 Power Up's

Range: Function:

0* [0 - 2147483647] View the number of times the AFE has

been powered up.

15-04 Over Temp's

Range: Function:

0* [0 - 65535] View the number of frequency converter

temperature faults which have occurred.

15-05 Over Volt's

Range: Function:

0* [0 - 65535] View the number of AFE overvoltages which

have occurred.

15-06 Reset kWh Counter

Option: Function:

[0] * Do not reset No reset of the kWh counter is desired.

[1] Reset counter Press [OK] to reset the kWh counter to zero

(see 15-02 kWh Counter).

NOTICE

The reset is carried out by pressing [OK].

15-07 Reset Running Hours Counter

Option: Function:

[0] * Do not reset [1] Reset

counter

Select [1] Reset and press [OK] to reset the Running Hours counter to zero (see 15-01 Running Hours). This parameter cannot be selected via the serial port, RS-485. Select [0] Do not reset if no reset of the Running Hours counter is desired.

6.9.2 15-2* Historic Log

View up to 50 logged data items via the array parameters in this parameter group. For all parameters in the group, [0] is the most recent data and [49] the oldest data. Data is logged every time an event occurs. Events in this context are defined as a change in one of the following areas:

1. Digital input

2. Digital outputs (not monitored in this SW release)

3. Warning word

4. Alarm word

5. Status word

6. Control word

7. Extended status word

Events are logged with value, and time stamp in msec. The time interval between two events depends on how often events occur (maximum once every scan time). Data logging is continuous but if an alarm occurs, the log is saved and the values can be viewed on the display. This feature is useful, for example when carrying out service following a trip. View the historic log contained in this parameter via the serial communication port or via the display.

15-20 Historic Log: Event

Array [50]

Range: Function:

0* [0 - 255 ] View the event type of the logged events.

15-21 Historic Log: Value

Array [50]

Range: Function:

0* [0 -

2147483647 ]

View the value of the logged event. Interpret the event values according to this table:

6 6

Digtal input Decimal value. See

16-60 Digital Input for description after converting to binary value.

How to Programme Operating Instructions

15-21 Historic Log: Value

Array [50]

Range: Function:

Digital output (not monitored in this SW release)

Warning word Decimal value. See

Alarm word Decimal value. See

Status word Decimal value. See

Control word Decimal value. See

Extended status word

Decimal value. See

parameter 16-66 Digital Output [bin] for

description after converting to binary value.

16-92 Warning Word for description.

16-90 Alarm Word for description.

16-03 Status Word for description after converting to binary value.

16-00 Control Word for description. Decimal value. See

parameter 16-94 Ext. Status Word for description.

15-22 Historic Log: Time

Array [50]

0* [0 - 2147483647s]View the time at which the logged

event occurred. Time is measured in ms since frequency converter start.

15-32 Fault Log: Time

Array [10]

0* [0 - 2147483647 s] View the time when the logged event

occurred. Time is measured in seconds from frequency converter start-up.

6.9.4 15-4* Drive Identification

Parameters containing read only information about the hardware and software configuration of the AFE.

15-40 AFE Type

Option: Function:

View the AFEtype. The read-out is identical to the FC 300 Series power field of the type code definition, characters 1-6.

15-41 Power Section

Option: Function:

View the AFE type. The read-out is identical to the FC 300 Series power field of the type code definition, characters 7-10.

15-42 Voltage

Option: Function:

View the AFE type. The read-out is identical to the FC 300 Series power field of the type code definition, characters 11-12.

15-43 Software Version

Range: Function:

0* [0 - 5 ] View the combined SW version (or ‘package

version’) consisting of power SW and control SW.

6.9.3 15-3* Alarm Log

Parameters in this group are array parameters, where up to 10 fault logs can be viewed. [0] is the most recent logged data, and [9] the oldest. Error codes, values, and time stamp can be viewed for all logged data.

15-30 Fault Log: Error Code

Array [10]

Range: Function:

0* [0 - 255 ]

15-31 Alarm Log: Value

Array [10]

Range: Function:

0* [-32767 - 32767 ] View an extra description of the error.

View the error code and look up its meaning in .

This parameter is mostly used in combination with alarm 38 internal fault.

Option: Function:

View the type code string used for re-ordering the AFE in its original configuration.

15-45 Actual Typecode String

Range: Function:

0* [0 - 40 ] View the actual type code string.

15-46 AFE Ordering No

Option: Function:

View the 8-digit ordering number used for re-ordering the AFE in its original configuration.

15-47 Power Card Ordering No

Range: Function:

0* [0 - 8 ] View the power card ordering number.

15-44 Ordered Typecode String

How to Programme Operating Instructions

15-48 LCP Id No

Range: Function:

0* [0 - 20 ] View the LCP ID number.

15-49 SW ID Control Card

Range: Function:

0* [0 - 20 ] View the control card software version number.

15-50 SW ID Power Card

Range: Function:

0* [0 - 20 ] View the power card software version number.

15-51 AFE Serial Number

Option: Function:

View the AFE serial number.

15-53 Power Card Serial Number

Range: Function:

0* [0 - 19 ] View the power card serial number.

6 6

6.9.5 15-9* Parameter Info

15-92 Defined Parameters

Array [1000]

0* [0 - 9999] View a list of all defined parameters in the AFE.

The list ends with 0.

15-93 Modified Parameters

Array [1000]

Range: Function:

0* [0 - 9999 ] View a list of the parameters that have been

changed from their default setting. The list ends with 0. Changes may not be visible until up to 30 s after implementation.

15-99 Parameter Metadata

Array [30]

Range: Function:

0* [0 - 9999 ] This parameter contains data used by the MCT

10 Set-up Software.

How to Programme Operating Instructions

6.10 Parameters: 16-** Data Read-outs

6.10.1 16-0* General Status

16-43 Frequency

Range: Function:

0.0 Hz* [0.0 - 6500.0 Hz] Returns the actual AFE frequency,

when the AFE is running.

16-00 Control Word

Range: Function:

0* [0 - FFFF] View the Control word sent from the AFE via the

serial communication port in hex code.

16-03 Status Word

16-44 Power [kW]

Range: Function:

0.00 kW * [0.00 - 1000.00

kW]

Returns the calculated AFE power on basis of the actual voltage and current.

Range: Function:

0* [0 - FFFF] View the Status word sent from the AFE via the

serial communication port in hex code.

6.10.2 16-3* AFE Status

16-30 DC Link Voltage

Range: Function:

0 V* [0 - 10000 V] View a measured value. The value is filtered

with a 30 ms time constant.

16-34 Heatsink Temp.

Range: Function:

0°C*

[0 - 255 °C]

View the AFE heatsink temperature. The cutout limit is 90 ± 5°C, and the motor cuts back in at 60 ± 5°C.

16-45 Power [hp]

Range: Function:

0.00 hp * [0.00 - 1000.00

hp]

Returns the calculated AFE power on basis of the actual mains voltage and mains current.

16-49 Current Fault Source

Range: Function:

0* [0 - 8 ] Value indicates source of current faults including

short circuit, over current, and phase imbalance (from left): 1-4 Inverter 5-8 Rectifier 0 No fault recorded

6.10.3 16-6* Inputs and Outputs

16-35 Inverter Thermal

Range: Function:

0 %* [0 - 100 %] View the percentage load.

16-36 Inv. Nom. Current

Range: Function:

A* [0.01 - 10000.00 A] View the inverter nominal current.

16-60 Digital Input

Range: Function:

0* [0 -

1023 ]

View the signal states from the active digital inputs. Example: Input 18 corresponds to bit no. 5, ‘0’ = no signal, ‘1’ = connected signal. Bit 6 works in the opposite way, on = '0', off = '1' (safe stop input).

16-37 Inv. Max. Current

Range: Function:

A* [0.01 - 10000.00 A] View the inverter maximum current.

16-39 Control Card Temp.

Range: Function:

0 °C* [0 - 100 °C] View the temperature on the control card,

stated in °C

Bit 0 Digital input term. 33 Bit 1 Digital input term. 32 Bit 2 Digital input term. 29 Bit 3 Digital input term. 27 Bit 4 Digital input term. 19 Bit 5 Digital input term. 18 Bit 6 Digital input term. 37 Bit 10-63 Reserved for future terminals

16-41 Current

Range: Function:

0.00 A * [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.

Readout choice (Par. 16-71): Relay output (bin):

Power card relay 02 Power card relay 01

130BD870.10

0 0 bin

How to Programme Operating Instructions

16-65 Analog Output 42 [mA]

Range: Function:

0* [0 - 30 ] View the actual value at output 42 in mA. The

value shown reflects the selection in 6-50 Terminal 42 Output.

16-66 Digital Output [bin]

Range: Function:

0* [0 - 15 ] View the binary value of all digital outputs.

16-71 Relay Output [bin]

Range: Function:

0* [0 - 511 ] View the settings of all relays.

Illustration 6.5 Relay Settings

16-85 FC Port CTW 1

Range: Function:

0* [0 - 65535 ] View the 2-byte control word (CTW) received

from the bus master. Interpretation of the control word depends on the fieldbus option installed and the control word profile selected in 8-10 Control Profile.

16-86 FC Port REF 1

Range: Function:

0* [-200 -

200 ]

View the 2-byte status word (STW) sent 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.

6.10.5 16-9* Diagnosis Read-Outs

NOTICE

When using MCT 10 Set-up Software, the readout parameters can only be read online, i.e. as the actual status. This means that the status is not stored in the MCT 10 Set-up Software file.

6 6

6.10.4 16-8* Fieldbus & FC Port

Parameters for reporting the BUS references and control words.

16-80 Fieldbus CTW 1

Range: Function:

0* [0 -

16-82 Fieldbus REF 1

Range: Function:

0* [-200 - 200 ] View the 2-byte word sent with the control

16-84 Comm. Option STW

Range: Function:

0* [0 - 65535 ] View the extended fieldbus comm. option

65535 ]

View the 2-byte control word (CTW) received from the bus master. Interpretation of the control word depends on the fieldbus option installed and the control word profile selected in 8-10 Control Profile. For more information, refer to the relevant fieldbus manual.

word from the bus master to set the reference value. For more information, refer to the relevant fieldbus manual.

status word. For more information, refer to the relevant fieldbus manual.

16-90 Alarm Word

Range: Function:

0* [0 - 4294967295 ] View the alarm word sent via the serial

communication port in hex code.

16-91 Alarm Word 2

Range: Function:

0* [0 - 4294967295 ] View the alarm word sent via the serial

communication port in hex code.

16-92 Warning Word

Range: Function:

0* [0 - 4294967295 ] View the warning word sent via the serial

communication port in hex code.

16-93 Warning Word 2

Range: Function:

0* [0 - 4294967295 ] View the warning word sent via the serial

communication port in hex code.

16-94 Ext. Status Word

Range: Function:

0* [0 - 4294967295 ] Returns the extended warning word sent

via the serial communication port in hex code.

How to Programme Operating Instructions

6.11 Parameters: 40-** Mains / Filter

6.11.1 40-0* Mains Data

40-00 Mains Voltage

Range: Function:

630 V* [[525-690 V]] Set the mains voltage line to line.

40-01 Mains Frequency

Option: Function:

[0] * 50 Hz Set the mains nominal frequency. [1] 60 Hz

40-02 Mains Inductance

Range: Function:

0.039 mH* [0.000 - 65.000

mH]

Set the Inductance of the mains. This could be the transformer.

40-03 Mains Resistance

Range: Function:

0.50 mOhm* [0.00 - 650.00

mOhm]

Set the value of the mains resistance. This could be the transformer.

6.11.2 40-1* LCL Filter

40-10 Mains Side Inductance (Lm)

Range: Function:

0.029 mH* [0.000 - 65.000

mH]

40-11 Mains Side Resistance (Rm)

Range: Function:

0.19 mOhm* [0.00 - 650.00

mOhm]

40-12 Converter Side Inductance (Lc)

Range: Function:

0.100 mH* [0.000 - 65.000

mH]

40-13 Converter Side Resistance (Rc)

Range: Function:

0.48 mOhm* [0.00 - 650.00

mOhm]

40-14 Filter Capacity (Cf)

Range: Function:

400 uF* [0 - 65000 uF] Set the capacitance of the LCL filter.

Set the main side inductance of the LCL filter.

Set the main side resistance of the LCL filter.

Set the converter side inductance of the LCL filter.

Set the converter side resistance of the LCL filter.

The value is for the delta configuration.

How to Programme

Operating Instructions

6.12 Warnings/Alarm Messages

No. Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference

1 10 Volts low X 5 DC link voltage high X 6 DC link voltage low X 7 DC over-voltage X X 8 DC under voltage X X 9 Inverter overloaded X X 13 Over Current X X X 14 Earth Fault X X X 15 Hardware mismatch X X 16 Short Circuit X X 17 Control word time-out (X) (X) 23 Internal Fan Fault X 24 External Fan Fault X 29 Heatsink temp X X X 33 Inrush Fault X X 34 Fieldbus communication fault X X 36 Mains failure X X 37 Phase imbalance X 38 Internal Fault X X 39 Heatsink sensor X X 40 Overload of Digital Output Terminal

41 Overload of Digital Output Terminal

29 46 Pwr. card supply X X 47 24 V supply low X X X 48 1.8 V supply low X X 59 Current limit X 62 Output Frequency Limit X 64 Voltage Limit X X 65 Control Board Over-temperature (X) (X) X 66 Heat sink Temperature Low X 67 Option Configuration has Changed X 68 Safe Stop Alarm/trip only 69 Pwr. Card Temp X X 70 Illegal FC configuration X 71 Output voltage limit X 77 Reduced power mode X

78 Power Unit Setup X

79 Illegal PS config X X 80 AFEInitialized to Default Value X 250 New spare part X 251 New Type Code X X

(X)

8-04 Control Word Timeout Function

14-53 Fan Monitor 14-53 Fan Monitor

5-00 Digital I/O Mode, 5-01 Terminal

27 Mode

5-00 Digital I/O Mode, 5-02 Terminal

29 Mode

Parameter 14-59 Actual Number of

Inverter Units

Parameter 14-59 Actual Number of

Inverter Units

14-23 Typecode Setting

6 6

Table 6.6 Alarm/Warning Code List

(X) Dependent on parameter

How to Programme Operating Instructions

A trip is the action when an alarm has appeared. The trip will stop the AFE operation and change the digital output at terminal 27 to Low, which will result in coasting the motor. It can be reset by pressing the reset button or make a reset by a digital input (parameter group 5-1* Digital Inputs [1]). The origin event that caused an alarm cannot damage the AFE or cause dangerous conditions. 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.

Warning yellow

Alarm flashing red

Trip locked yellow and red

Table 6.7 LED indication

Alarm Word Extended Status Word Bit Hex Dec Alarm Word Alarm Word 2 Warning Word Warning

Word 2

0 00000001 1 ServiceTrip, Read/

Write

1 00000002 2 Heatsink temp. (A29) ServiceTrip,

(reserved)

2 00000004 4 Earth Fault (A14) ServiceTrip,

Typecode/ Sparepart

3 00000008 8 Ctrl.Card Temp (A65) ServiceTrip,

(reserved)

4 00000010 16 Ctrl. Word TO (A17) ServiceTrip,

(reserved) 5 00000020 32 Over Current (A13) reserved Over Current (W13) reserved 6 00000040 64 reserved reserved 7 00000080 128 reserved reserved 8 00000100 256 reserved reserved 9 00000200 512 Inverter Overld. (A9) reserved Inverter Overld (W9) reserved Power limit (W253) 10 00000400 1024 DC under Volt (A8) reserved DC under Volt (W8) Regen limit (W252) 11 00000800 2048 DC over Volt (A7) reserved DC over Volt (W7) 12 00001000 4096 Short Circuit (A16) reserved DC Voltage Low (W6) reserved 13 00002000 8192 Inrush Fault (A33) reserved DC Voltage High (W5) 14 00004000 16384 Mains ph. Loss (A4) reserved 15 00008000 32768 reserved 16 00010000 65536 reserved 17 00020000 131072 Internal Fault (A38) 10V Low (W1) Password Timelock 18 00040000 262144 Fans error Fans Warn Password Protection 19 00080000 524288 20 00100000 1048576 reserved reserved 21 00200000 2097152 reserved reserved 22 00400000 4194304 Fieldbus Fault (A34) reserved Fieldbus Fault (W34) reserved 23 00800000 8388608 24 V Supply Low

(A47) 24 01000000 16777216 Mains Failure (A36) reserved Mains Failure (W36) reserved 25 02000000 33554432 1.8V Supply Low

(A48) 26 04000000 67108864 reserved Low Temp (W66) reserved 27 08000000 134217728 reserved Voltage Limit (W64) reserved 28 10000000 268435456 Option Change (A67) reserved reserved 29 20000000 536870912 AFE Initialized(A80) Feedback Fault

30 40000000 1073741824 Safe Stop (A68)

reserved 24V Supply Low (W47) reserved

reserved Current Limit (W59) reserved

(A61, A90)

Heatsink temp. (W29) reserved

Earth Fault (W14) reserved

Ctrl.Card Temp (W65) reserved

Ctrl. Word TO (W17)

Feedback Fault (W61, W90)

reserved Ramping

Extended Status Word

How to Programme

Alarm Word Extended Status Word Bit Hex Dec Alarm Word Alarm Word 2 Warning Word Warning

31 80000000 2147483648 Extended Status Word

Table 6.8 Description of Alarm Word, Warning Word and Extended Status Word

Operating Instructions

Word 2

Extended Status Word

The alarm words, warning words and extended status words can be read out via serial bus or optional fieldbus for diagnose. See also parameter 16-94 Ext. Status Word.

WARNING 1, 10 Volts low

The 10 V voltage from terminal 50 on the control card is below 10 V. Remove some of the load from terminal 50, as the 10V supply is overloaded. Max. 15 mA or minimum 590 Ω.

WARNING 5, DC-link voltage high

The DC bus voltage is higher than the overvoltage limit of the control system. The AFE is still active.

WARNING 6, DC link voltage low

The DC bus voltage is below the undervoltage limit of the control system. The AFE is still active.

WARNING/ALARM 7, DC over voltage

If the DC bus voltage exceeds the limit, the AFE trips after a time.

ALARM 14, Earth fault

There is a discharge from the output phases to earth. Turn off the AFE and remove the earth fault.

ALARM 15, Incomplete hardware

A fitted option is not handled by the present control board (hardware or software).

ALARM 16, Short-circuit

There is short-circuiting in the outout phases. Turn off the AFE and remove the short-circuit.

WARNING/ALARM 17, Control word timeout

There is no communication to the AFE. The warning will only be active when 8-04 Control Word

Timeout Function is NOT set to OFF. Parameter 8-03 Control Word Timeout Time could possibly

be increased.

3 x 525-690 V

[V DC] Undervoltage 553 Voltage warning low 585 Voltage warning high 1084 Overvoltage 1130 The voltages stated are the DC bus voltage of the AFE with a tolerance of ± 5%.

Table 6.9 Alarm/Warning Limits

WARNING/ALARM 21, Parameter error

The parameter is out of range. The parameter number is reported in LCP. The affected parameter must be set to a valid value.

WARNING 23, Internal fan fault

The fan warning function is an extra protection function that checks if the fan is running/mounted. The fan warning can be disabled in 14-53 Fan Monitor (set to [0] Disabled).

WARNING 24, External fan fault

The fan warning function is an extra protection function

WARNING/ALARM 8, DC under voltage

If the DC bus voltage drops below the “voltage warning low” limit (see Table 6.9), the frequency converter checks if 24 V backup supply is connected. If no 24 V backup supply is connected, the frequency converter trips after a given time (depending on the unit). To check whether the supply voltage matches the AFE, see chapter 5.1 General Specifications.

WARNING/ALARM 9, Inverter overloaded

The AFE is about to cut out because of an overload (too high current for too long). The counter for electronic, thermal protection gives a warning at 98% and trips at 100%, while giving an alarm. The AFE cannot be until the counter is below 90%. The fault is that the frequency converter is overloaded by more than 100% for too long.

WARNING/ALARM 13, Over Current

The peak current limit (approx. 200% of the rated current) is exceeded. The warning will last approx. 8-12 s, then the AFE trips and issues an alarm.

that checks if the fan is running/mounted. The fan warning can be disabled in 14-53 Fan Monitor (set to [0] Disabled).

ALARM 29, Heat sink temperature

The temperature of the AFE heat sink has exeeded the limit. P400; 110 °C P800/PIM2: 95 °C The temperature fault is cannot be reset untill the temperature of the heat sink has dropped th a safe level. P400: 95 °C P800/PIM2: 80 °C

ALARM 33, Inrush fault

Too many power ups have occured within a short time period. See the chapter General Specifications for the allowed number of power ups within one minute.

WARNING/ALARM 34, Fieldbus communication fault

The fieldbus on the communication option card is not working correctly. Please check parameters associated with the module and make sure module is properly inserted in

6 6

How to Programme

Slot A of the frequency converter. Check the wiring for fieldbus.

ALARM 36, Mains failure

The mains failure alarm is generated at the start of DC bus regulation if the AFE cannot detect a valid mains frequency.

ALARM 37, Phase imbalance

There is a current imbalance between the power units

ALARM 38, Internal fault

By this alarm it may be necessary to contact your Danfoss supplier. Some possible alarm messages:

256-511A defect has been detected with the power EEPROM

data. This could indicate that an incorrect spare part was

used or that the power EEPROM was updated with incorrect data.

512-767A defect has been detected with the control card

EEPROM data.

768-1

A problem has occurred while attempting to initialize or

023

restore parameter information.

1024-

A problem has been encountered while attempting to

1276

send internal communication between options or the power card. A report value of 1027 may indicate a hardware failure.

1080-

A software version error has been detected.

1295

1296-

An option with old software has been installed.

1311

1312-

An unsupported option has been installed.

1327

1360-

There is a version mismatch between the installed

1375

options and components.

1376-

An installed option did not properly initialize.

1391

1536-

An exception in the control card has been registered.

1791

Extra information is written to the LCP.

1792-

The DSP has reported a communication fault.

2047

2064-

An installed option has illegally restarted.

2079

2080-

An installed option did not initialize within the allowed

2127

time period.

Operating Instructions

2304-

The is a communication problem with the power card or

2559

the power card configuration is invalid. Some possible values and reasons are listed below. 2314: Could not read any data from the power card EEPROM. 2315: Could not read software version from the power card. 2316: Did not receive initial communication from the power card. 2324: Power card configuration is determined to the incorrect at power up. 2330: Power size information between the power cards does not match. 2333: Unsupported power card installed. 2335: Unsupported power size. 2336: The power card has stopped communicating.

2560-

A communication problem has been encountered with

2815

the DSP.

2816-

An internal system error has occured.

3071

3072-

Parameter value outside its limits. Perform an initiali-

5119

zation. Subtract 3072 from the report value to obtain the parameter number causing the alarm. For example: Error code 3238: 3238-3072=166 is outside the limit.

NOTICE

ALARM 21 replaces this report value range.

5120-

An installed option is not compatible with the control

5375

card.

5376-

The control card has a encountered an internal memory

5631

error.

5632+The control card has encountered an internal error.

Table 6.10 Internal Fault Codes

ALARM 39, Heatsink sensor

No feedback from the heatsink temperature sensor. The signal from the IGBT thermal sensor is not available on

the power card. The problem could be on the power card, on the gate drive card, or the ribbon cable between the power card and gate drive card.

WARNING 40, Overload of Digital Output Terminal 27

Check the load connected to terminal 27 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and 5-01 Terminal 27 Mode.

WARNING 41, Overload of Digital Output Terminal 29

Check the load connected to terminal 29 or remove shortcircuit connection. Check 5-00 Digital I/O Mode and 5-02 Terminal 29 Mode.

ALARM 46, Power card supply

The supply on the power card is out of range. There are three power supplies generated by the switch

mode power supply (SMPS) on the power card: 24 V, 5 V, ±18 V. When powered with 24 V DC with the MCB 107

How to Programme

Operating Instructions

option, only the 24 V and 5 V supplies are monitored. When powered with three phase mains voltage, all three supplied are monitored.

WARNING 47, 24 V supply low

The external 24 V DC backup power supply may be overloaded, otherwise Contact your Danfoss supplier.

WARNING 48, 1.8 V supply low

Contact your Danfoss supplier.

WARNING 59, Current limit

The required current for regulating the DC bus has exceeded the maximum rating of the AFE. The maximum rating is given in 16-37 Inv. Max. Current

WARNING 62, Output Frequency at Maximum Limit

The output frequency exceeds the deviation limit specified in 4-91 Output Frequency Deviation Limit and 4-92 Output Frequency Deviation Timeout. ALARM/WARNING is generated after exceeding the timeout period.

WARNING 64, Voltage Limit

A warning is generated, when the AFE controller saturates. This indicated that the AFE no longer has enough voltage overhead for the real and reactive current control. An alarm is generated , when the PWM controller has exceeded 98% duty cycle.

WARNING/ALARM/TRIP 65, Control Card Over Temperature

Control card over temperature: The cut-out temperature of the control card is 80 °C.

WARNING 66, Heatsink Temperature Low

The heat sink temperature is measured as 0 °C. This could indicate that the temperature sensor is defect and thus the fan speed is increased to the maximum in case the power unit or control card is very hot.

ALARM 67, Option Configuration has Changed

One or more options has either been added or removed since the last power down.

ALARM 68, Safe Stop

Safe Stop has been activated. To resume normal operation, apply 24 V DC to T-37. Press [Reset] key on LCP.

ALARM 70, Illegal FC Configuration

Actual combination of control board and power board is illegal.

ALARM 71, Output voltage limit

The output voltage exceeds the deviation limit specified in

4-94 Output Voltage Deviation Limit and 4-95 Output Voltage Deviation Timeout. ALARM/WARNING is generated after

exceeding the timeout period.

WARNING 73, Safe stop auto restart

Safe stopped. Note that with automatic restart enabled, the AFE may start when the fault is cleared.

WARNING 77, Reduced power mode

This warning indicates that the AFE is operating in reduced power number of power units (Emergency Mode). All functionality is active, but reduced current limits are imposed.

WARNING 78, Power unit setup

The power unit setup warning indicates that the AFE detects a different number of power units than what it is configured for (parameter 14-59 Actual Number of Inverter Units) The AFE is not allowed to run in this mode.

Troubleshooting

When replacing an F-frame module, this will occur if the power specific data in the module power card does not match the rest of the frequency converter. Please confirm the spare part and its power card are the correct part number.

ALARM 79, Illegal power section configuration

The scaling card is the incorrect part number or not installed. Also MK102 connector on the power card could not be installed.

ALARM 80, Drive Initialised to Default Value

Parameter settings are initialised to default setting after a manual (three-finger) reset. Or a programmed reset(parameter 14-22 Operation Mode).

ALARM 244, Heatsink temperature

This alarm is only for F Frame size units. It is equivalent to Alarm 29. The report value in the alarm log indicates which power module generated the alarm:

1 = left most inverter module. 2 = middle inverter module in frame size F2 or

F4. 2 = right inverter module in frame size F1 or F3. 3 = right inverter module in frame size F2 or F4. 5 = rectifier module.

ALARM 245, Heatsink sensor

This alarm is only for F Frame size units. It is equivalent to Alarm 39. The report value in the alarm log indicates which power module generated the alarm:

1 = left most inverter module. 2 = middle inverter module in frame size F2 or

F4. 2 = right inverter module in frame size F1 or F3. 3 = right inverter module in frame size F2 or F4. 5 = rectifier module.

6 6

How to Programme

ALARM 246, Power card supply

This alarm is only for F Frame size units. It is equivalent to Alarm 46. The report value in the alarm log indicates which power module generated the alarm:

1 = left most inverter module. 2 = middle inverter module in frame size F2 or

F4. 2 = right inverter module in frame size F1 or F3. 3 = right inverter module in frame size F2 or F4. 5 = rectifier module.

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:

1 = left most inverter module. 2 = middle inverter module in frame size F2 or

F4. 2 = right inverter module in frame size F1 or F3. 3 = right inverter module in frame size F2 or F4. 5 = rectifier module.

ALARM 248, Illegal power section configuration

This alarm is only for F Frame unit size. It is equivalent to Alarm 79. The report value in the alarm log indicates which power module generated the alarm:

1 = left most inverter module. 2 = middle inverter module in frame size F2 or

F4. 2 = right inverter module in frame size F1 or F3. 3 = right inverter module in frame size F2 or F4. 5 = rectifier module.

ALARM 250, New Spare Part

The power or Switch Mode Power Supply has been exchanged. The AFE type code must be restored in the 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.

Operating Instructions

Index Operating Instructions

Index

AFE Serial No, 15-51............................................................................. 61

Airflow......................................................................................................... 9

Alarm log, 15-3*.................................................................................... 60

Alarm messages.................................................................................... 65

Analog inputs......................................................................................... 39

Analog output....................................................................................... 40

Approval..................................................................................................... 4

Automatic Restart Time, 14-21........................................................ 57

Back cooling.............................................................................................. 9

Branch circuit protection................................................................... 33

Cable lengths and cross sections.................................................... 41

Cabling..................................................................................................... 36

CE compliance mark.............................................................................. 4

Communication option...................................................................... 68

Configurable Status Word STW, 8-13............................................ 55

Control cable.......................................................................................... 35

Control card............................................................................................ 40

Control card performance................................................................. 41

Control card, 24 V DC output........................................................... 40

Control card, USB serial communication..................................... 40

Control characteristics........................................................................ 41

Control Site, 8-01.................................................................................. 54

Control terminals.................................................................................. 37

Control Word Timeout Function, 8-04.......................................... 54

Cooling....................................................................................................... 9

Copy/save, 0-5*..................................................................................... 46

Duct cooling............................................................................................. 9

Electrical installation.................................................................... 35, 37

Environment, 14-5*.............................................................................. 58

Fan Monitor, 14-53............................................................................... 58

Fault Log: Time, 15-32......................................................................... 60

FC port setting, 8-3*............................................................................ 55

Fuse........................................................................................................... 33

Fusing....................................................................................................... 36

General setting, 8-0*............................................................................ 54

General status, 16-0*........................................................................... 62

General warning...................................................................................... 6

Grounding............................................................................................... 36

Heatsink Temp., 16-34........................................................................ 62

High power fuses.................................................................................. 34

Hist. Log: Time, 15-22.......................................................................... 60

Historic Log, 15-2*................................................................................ 59

KWh Counter, 15-02............................................................................. 59

Language................................................................................................. 44

LCP Copy, 0-50....................................................................................... 46

LCP keypad, 0-4*................................................................................... 46

Lifting........................................................................................................ 26

DC bus...................................................................................................... 67

DC-link...................................................................................................... 67

Defined Parameters, 15-92................................................................ 61

Diagnosis Read-Outs, 16-9*.............................................................. 63

Digital input............................................................................................ 38

Digital output......................................................................................... 40

Display line 2 large............................................................................... 45

Display Line 3 Large, 0-24.................................................................. 45

Disposal instruction............................................................................... 6

Drive Identification, 15-4*................................................................. 60

Drive Ordering Number, 15-46........................................................ 60

Mains connection................................................................................. 33

Mains Frequency, 40-01..................................................................... 64

Mains supply (L1, L2, L3).................................................................... 38

Mains torque.......................................................................................... 33

Mechanical installation...................................................................... 32

Operating Data, 15-0*......................................................................... 59

Operating hours, 15-00...................................................................... 59

Ordered Type Code String, 15-44................................................... 60

Output Frequency Deviation Function, 4-90............................. 48

Output Voltage Deviation Function, 4-93................................... 48

Index Operating Instructions

Over Temps, 15-04............................................................................... 59

Over Volts, 15-05................................................................................... 59

Parameter Info, 15-9*.......................................................................... 61

Password, 0-6*....................................................................................... 46

Power Ups, 15-03.................................................................................. 59

Protection and features...................................................................... 42

Relay output.................................................................................... 41, 50

Relay outputs......................................................................................... 50

Repair work............................................................................................... 6

Reset Control Word Timeout, 8-06................................................. 54

Reset mode, 14-20................................................................................ 57

RS-485 serial communication.......................................................... 40

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

Index Operating Instructions

www.danfoss.com/drives

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. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

Danfoss A/S Ulsnaes 1 DK-6300 Graasten www.danfoss.com/drives

130R0429 MG33X402 Rev. 05/2014

*MG33X402*

Danfoss AFE 302 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual