Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
Introductionvacon • 3
11280.emf
1.INTRODUCTION
The AFE unit is a regenerative power converter for the front-end of a common DC bus product line.
The AFE unit is used with inverter hardware and special software. An external L(CL)-filter and
charging circuit is needed. This unit is selected when low harmonics are required. The connection
of AFE drive has been described in Figure .
The Regenerative Application is easy and flexible to use due to its versatile fieldbus features. The
parameters of the Regenerative Application are explained in Chapter 8.
The basic I/O-configuration of the AFE drive consists of OPT-A1 and OPT-A2 option cards. The basic
I/O configuration has been described in Table 5. An option card OPT-B5 can be used if additional
digital outputs are needed. Configuration has been described in Table 6.
By default the control place (P3.1) of the AFE drive is keypad.
This application requires NXP control board 661 or 761.
Figure 1. AFE connection
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
2
vacon • 8Operation
3.OPERATION
3.1Main contactor control
The AFE application controls the main contactor of the system with Relay Output RO2. When charging of the DC bus is ready, the main contactor will be closed. The status of the main contactor is
monitored via digital input (Default is DIN4). The digital input used for monitoring is chosen with parameter P2.3.1.4.
NOTE! Main Contactor feedback is required for correct AFE functionality.
Faults can be set to open the main contactor by selecting the response "3=Fault, DC OFF". When a
fault occurs, the drive will open Relay Output RO2 that controls the main contactor after one second
(See wiring details from VACON
ulating before an open command is given. If the DC is still high enough when a fault reset is given,
the drive will close the Relay Output R02.
An external charging circuit is needed to charge the DC bus.
The AFE start up sequence has been illustrated in Figure and fault handling in Figure .
®
NX Active Front End User Manual). Thus the drive will stop mod-
3
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
Operationvacon • 9
Time* 500 ms
Stop
AFE 1
Run
Stop
AFE 2
Run
Stop
AFE 3
Run
Stop
AFE 4
Run
11281.emf
3.2Quick Start instructions
NOTE! Before taking any commissioning actions, read carefully the safety instructions in VACON®
NXS/P User Manual.
1. Connect the unit according to Figure .
2. Power up the control unit
3. Set Basic parameters G2.1(see Table 21).
4. Check that the digital input parameters (P2.3.1.1 - P2.3.1.10) have been set according to connections. All the unused input signals must be set to "0 = Not used" state, except for the main
contactor feedback which must be used.
5. Change the control place to I/O (P3.1).
6. Precharge the unit.
In case of parallel AFE:
1. Set the Parallel AFE parameter (P2.1.4) = YES (in every AFE). (This will set also DC Drooping to
4.00%)
2. Set the Start Up Delay in AFE units so that starting is in sequence with e.g. 500 ms intervals.
Figure 2.
Figure 3.Setting the Start Up Delay in AFE units
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
3
vacon • 10Operation
Init
SoftwareInit
complete
11282.emf
Ready to
switch on
Charging the DC link
with external charging circuit
DC link voltage
> 0.8*DC nominal?
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Main Conctactor
Close throughRO2
RunEnable (P2. 3.1.1)
And
Main contactor Ack (P2.3.1.4)?
(programmable)
Ready to Run
(Ready led is on)
Run command from I/O,
Keypad or Fieldbus. Depends
on the se lected contro l place (P3.1)
Startup delay
(P2.6.3) elapsed?
Synchronise
with mains
Synchnronizing
OK?
Synchnronizing
tries > 5
AFE Running
(Ready led is on)
Fault F10:
LineSyncFail
Figure 4. AFE start sequence
3
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
Operationvacon • 11
11284.emf
AFE Running
Fault active
Stop the AFE
Is response
Main contactor
open?
Yes
No
Faul t ack nowle dge
Main contactor
open
Main contactor
close
Fault
acknowledge
Figure 5.Fault handling in AFE application
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
3
vacon • 12CONTROL IO
K1
NXOPTA1
NXOPTA2
Termi nalSig nalDescription
1
+10 VrefReference voltege output
2
AI1+
Analogue input 1.•
Range 0-10V, Ri= 200
Ω
Range 0-20 nA, Ri= 250
Ω
Analogue input 2.•
Range 0-10V, Ri= 200Ω•
Range 0-20 nA, Ri= 250Ω
3
AI1-
I/O ground
4
AI2+
5
AI2-
6
+24V
7
GNDI/O ground
8
DIN1
Contact closed = Start Request
9
DIN2
10
DIN3
11
CMA
Common for DIN 1—DIN 3
12
+24V
13
GNDI/O ground
14
DIN4
Contact closed = MCC Closed
15
DIN5
16
DIN6
Rising edge will reset•
active faults.
17
CMB
18
AOA1+
Output range selected by jumpers.
Range 0—20 mA. R
L
, max. 500Ω
Range 0—10 V. R
L
> 1kΩ
19
AOA1-
20
21
22
23
DOA1
Digital output
Ready / Warning (Blinking)
mA
9429_uk
Voltege for•
potentiometer, etc.
Analogue input 1Input range
selected by jumpers.
Default range: Voltage 0–10 V
Ground for reference
and controls
Ground for reference
and controls
Analogue input 2
Input range selected by
jumpers.
Default range:•
Current 0 – 20 mA
Voltage for switches, etc.
max 0.1 A
Start Request
Programmable G2.3.1
Programmable G2.3.1
Programmable P2.3.1
No function defined at default
No function defined at default
No function defined at default
Connect to GND or +24V
Voltage for switches (see #6)
Ground for reference and
controls
Main Contactor Acknowledge
Programmable G2.2.1
Fault Reset
Programmable G2.3.1
Connect to GND or +24V
Analogue output 1
Programmable G2.3.1
Programmable
Open collector, I≤50mA,
U≤48 VDC
RO 1
RO 1
RO 1
24
25
26
RO 2
RO 2
RO 2
Relay output 1
Run State
Programmable G2.4.2
Relay output 2
Main Contactor Control
Cannot be reprogrammed
G2.4.1
Switchin capacity
24 VCD / 8 A
250 VAC / 8 A
125 VDC / 0.4 A
Fixed to main contactor
control.
Closes when DC at 80 % of
nominal DC.
Opens when DC below 75 %•
of nominal DC
220
VAC
K1
Control voltage output
Programmable G2.3.1
Common for DIN4—DIN6
4.CONTROL IO
Table 5. Default I/O configuration
4
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
The default I/O configuration if the option card PT-B5 is used:
Table 6. Default I/O configuration
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
4
vacon • 14AFE Application - Monitoring values
5.AFE APPLICATION - MONITORINGVALUES
This chapter presents the lists of parameters within the respective parameter groups.
Column explanations
Code
Parameter= Name of the parameter
Min= Minimum value of the parameter
Max= Maximum value of the parameter
Unit= Unit of the parameter value; given if available
Default= Value preset by factory
Cust= Customer's own setting
ID= ID number of the parameter
The manual presents the signals that are not normally visible for monitoring. These are not parameters or standard monitoring signals. These signals are presented with [Letter], e.g. [FW]MotorRegulatorStatus.
[V]Normal monitoring signal
[P]Normal parameter in application.
[FW]
[A]
Firmware signal, can be monitored with NCDrive when signal type Firmware is
selected
Application signal, can be monitored with NCDrive when signal type Application is
selected
= Location indication on the keypad; shows the operator the present parameter
number
[R]Reference type parameter on keypad.
[F]Function. Signal is received as an output of function.
[DI]Digital input signal.
5
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
AFE Application - Monitoring valuesvacon • 15
5.1Monitoring values
The monitoring values are actual values of parameters and signals as well as statuses and measurements. Monitoring values cannot be edited.
5.1.1Monitoring 1
Table 7. Monitoring 1
CodeSignalUnitIDDescription
V1.1.1DC VoltageV1108Measured DC Link voltage in Volts
Used DC voltage reference by the
regenerative unit in percentage of
Nominal DC Voltage.
Nominal DC voltage = 1.35 * Supply
voltage
V1.1.2
Used DC Voltage
Reference
%1200
V1.1.3Total CurrentA1104
V1.1.4Active Current%1125
V1.1.5Reactive Current%1157
V1.1.6Active PowerkW1511
V1.1.7Power %%5
V1.1.8Status Word43
V1.1.9Supply FrequencyHz1101
V1.1.10Supply VoltageV1107
Total current of the regenerative unit
in Amperes.
Reactive current of the regenerative
drive in percentage of Rated Line
Current.
> 0 power from AC side to DC side
< 0 power from DC side to AC side
Reactive current of the regenerative
drive in percentage of Rated Line
Current.
> 0 Inductive current
< 0 Capacitive current
> 0 power from AC side to DC side
< 0 power from DC side to AC side
> 0 power from AC side to DC side
< 0 power from DC side to AC side
Supply frequency in ##.## Hz. The
sign indicates the phase order.
Input AC voltage, RMS line to line
Volts.
V1.1.11Line Frequency D7Hz1654Measured line frequency by OPT-D7
V1.1.12Line Voltage D7V1650Measured line voltage by OPT-D7
Signed phase difference compared
V1.1.13D7 Synch.Error1659
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
to measurement with optD7 card (-
3072...3071) = -180...180deg
5
vacon • 16AFE Application - Monitoring values
5.1.2Monitoring values 2
Table 8. Monitoring values 2
CodeSignalUnitIDDescription
V1.2.1Unit Temperature°C1109Heat sink temperature
V1.2.2CurrentA1113Unfiltered current
V1.2.3DC VoltageV44Unfiltered DC Voltge
V1.2.4Operation Hoursh1856Operation hours in format of #,##
V1.2.5
V1.2.6Line Votlage THD%1670
Reactive Current
Reference
%1389
Used reactive current reference
100.0 = Rated Line Current
Total harmonic distortion of the
line voltage
5.1.3FieldBus Monitoring values
Table 9. FieldBus Monitoring values
CodeSignalUnitIDDescription
V1.3.1Main Control Word1160Control word from fieldbus
V1.3.2Main Status Word1162Status word to fieldbus
V1.3.3Fault Word 11172
V1.3.4Fault Word 21173
V1.3.5Warning Word 11174Alarm Word 1
V1.3.6Warning74Last active warning code
V1.3.7Fault History37Last active fault
V1.3.8Aux Control Word 11161
V1.3.9Aux Status Word1163
5.1.4IO Monitoring values
Table 10. IO Monitoring values
CodeSignalUnitIDDescription
V1.4.1DIN1, DIN2, DIN315
V1.4.2DIN4, DIN5, DIN616
V1.4.3DIN Status 156
V1.4.4DIN Status 257
V1.4.5Analogue Input 1%13
V1.4.6Analogue Input 2%14
V1.4.7Analogue Out 1%26
V1.4.8PT100 Temp. 1°C50
V1.4.9PT100 Temp. 2°C51
V1.4.10PT100 Temp. 3°C52
Digital Inputs A1, A2 and A3
Status (sum)
Digital Inputs B4, B5 and B6
Status (sum)
5
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AFE Application - Monitoring valuesvacon • 17
Table 10. IO Monitoring values
CodeSignalUnitIDDescription
V1.4.11DO1, RO1, RO217
Digital Output and Relay 1&2
Status (sum)
5.1.5Unit Monitoring Values
Table 11. Unit Monitoring Values
CodeSignalUnitIDDescription
V1.5.1Unit Nominal VoltageV1117Unit rated AC Voltage
V1.5.2Unit Nominal CurrentA1118
V1.5.3U Phase CurrentA1149U Phase RMS current
V1.5.4V Phase CurrentA1150V Phase RMS current
V1.5.5W Phase CurrentA1151W Phase RMS current
5.1.6Monitoring 1 values
V1.1.1DC-
LINK VOLTAGE [# V] ID 1108
Measured DC voltage, filtered.
V1.1.2U
SED DC VOLTAGE REFERENCE [#,## %] ID 1200
Used DC voltage reference by the regenerative unit in percentage of Nominal DC Voltage.
Nominal DC Voltage = Supply Voltage * 1.35
DC Voltge = Supply Voltage * 1.35 * Boost
e.g.
621 Vdc = 400 Vac * 1.35 * 1.15
V1.1.3T
OTAL CURRENT [A] ID 1104
Total current of the regenerative unit in Amperes, filtered.
V1.1.4A
CTIVE CURRENT [#,# %] ID 1125
Active current in percentage of System Rated Current. A negative value means that the current is
flowing to AC side from DC side i.e. regenerating.
V1.1.5R
EACTIVE CURRENT [#,# %] ID 1157
Reactive current of the regenerative drive in percentage of System Rated Current.
Positive value means Inductive current.
Negative value means capacitive current.
V1.1.6P
OWERKW [KW] ID 1511
Drive output power in kW.
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
5
vacon • 18AFE Application - Monitoring values
A negative value means that current is flowing to AC side from DC side i.e. regenerating.
V1.1.7P
OWER % [#,# %] ID 5
Drive output power in percentage.
A negative value means that current is flowing to AC side from DC side i.e. regenerating.
V1.1.8S
TATUS WORD (APPLICATION) ID 43
Application Status Word combines different drive statuses to one data word.
Table 12. Application Status Word
FALSETRUE
b0
b1Not in Ready stateReady
b2Not RunningRunning
b3No FaultFault
b4Positive frequencyNegative frequency
b5No fault or AutoResetFaultFault or Auto Reset Fault
b6Run DisabledRun Enable
b7No WarningWarning
b8Charging Switch closed (internal)
b9Main Contactor Control (DO Final)
b10Main Contactor Feedback
b11
b12No Run RequestRun Request
b13Motoring SideGenerator Side
b14F1, F31 or F41 active
b15
V1.1.9S
UPPLY FREQUENCY [#,## HZ] ID 1101
Supply frequency in ##.## Hz .The sign indicates the phase order. Updated when the drive is in run
state. Updated also in stop state when OPT-D7 is used or Regen Options B9 is activated.
V1.1.10S
UPPLY VOLTAGE [#,# V] ID 1107
Input AC voltage, RMS line to line Volts. Updated when the drive is in run state.
Updated also when OPT-D7 is used.
V1.1.11L
INE FREQUENCY [#,## HZ] ID 1654
Measured Line Voltage Frequency when using OPT-D7 option board in slot C.
5
V1.1.12L
INE VOLTAGE [# V] ID 1650
Measured line voltage rms value when using OPT-D7 option board in slot C.
V1.1.13D7 S
YNCH ERROR [# V] ID 1659
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
AFE Application - Monitoring valuesvacon • 19
Voltage angle error between OPT-D7 line voltage and AFE unit voltage. If error is not close to zero
when in run state phase order of OPT-D7 may be wrong.
5.1.7Monitoring 2 values
V1.2.1U
NIT TEMPERATURE [# °C] ID 1109
Temperature of the unit in degrees Celsius.
V1.2.2C
URRENT [A] ID 1113
Unfiltered current of the drive.
V1.2.3DC V
OLTAGE [# V] ID 44
Unfiltered DC Voltage.
V1.2.4O
PERATION HOURS [#,## H] ID1856
This shows operation hours of the drive. P2.6.7 is used to enter the old value if software is updated.
V1.2.5R
EACTIVE CURRENT REFERENCE [#,# %] ID1389
Used reactive current reference 100.0 = Rated Line Current.
Positive value means Inductive current.
Negative value means capacitive current.
V1.2.6L
INE VOLTAGE THD ID1670
OPT-D7 measured line voltage THD.
5.1.8Fieldbus monitoring values
V1.3.1M
AIN CONTROL WORD ID 1160
Control word from fieldbus. The table below is for the bypass operation for such fieldbus board that
natively supports this or can be parameterized to bypass mode.
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
5
vacon • 20AFE Application - Monitoring values
Table 13. Main Control Word
FALSETRUE
b0DC charge Contactor close
b1OFF2 =Stop
b2Reserved for future use.
b3Run
b4Reserved for future use.
b5Reserved for future use.
b6Reserved for future use.
b7Reset0>1 Reset fault.
b8Set DC Voltage Ref 1
b9Set DC Voltage Ref 2
b10Fieldbus Control
b11Watchdog
0= No Action
1= Close DC charge contactor
0=stop Active. Regenerative control is
stopped.
1=stop not active
0= Drive stop command
1= Drive start command
DC Voltage Reference 1, see details in
Chapter 8.4 "FB Reference Control".
DC Voltage Reference 2, see details in
Chapter 8.4 "FB Reference Control".
0= No control from fieldbus
1=Control from fieldbus
0>1>0>1…1 sec square wave clock.
This is used to check the data communication between fieldbus master
and the drive. Used to generate FB
Comm. Fault. This monitoring can be
switched off by setting P2.8.4.2 FB
Watchdog Delay=0. The drive’s internal communication monitoring is still
active at this time.
5
b12Reserved for future use.
b13Reserved for future use.
b14Reserved for future use.
b15Reserved for future use.
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
AFE Application - Monitoring valuesvacon • 21
V1.3.1MAIN CONTROL WORD (IN DEVICENET) ID 1160
Table 14. Main Control Word (in DeviceNet)
FALSETRUE
b0Run
b1
b2Reset0>1 Reset fault.
b3
b4
b5Fieldbus Control
b6
b7
b8
b9
b10
b11
b12
b13
b14
b15
0= Drive stop command
1= Drive start command
0= No control from fieldbus
1=Control from fieldbus
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
5
vacon • 22AFE Application - Monitoring values
V1.3.2 MAIN STATUS WORD ID 1162
Status word to fieldbus. The table below gives details for the bypass operation of such fieldbus
boards that natively support this or can be parameterized to bypass mode.
Table 15. Main Status Word
FALSETRUE
0=Drive not ready to switch on
b0Ready On
b1Ready Run
b2Running
b3Fault
b4Off2 Status
b5Reserved for future use.
b6Reserved for future use.
1=Drive ready to switch Main Contactor ON
0=Drive not ready to run
1=Drive ready and Main Contactor is
ON
0=Drive not running
1=Drive in Run state (Modulating)
0=No active fault
1=Fault is active
0= Run Disabled. Drive in stop state
1= Run Enabled. Drive can be started.
b7Warning
b8At Reference
b9Fieldbus Control Active
b10Above Limit
b11Reserved for future use.
b12Reserved for future use.
b13Reserved for future use.
b14Reserved for future use.
b15Watchdog
0= No active warnings
1= Warning active
0= DC Voltage Ref and Act DC Voltage
are not same.
0=Fieldbus control not active
1=Fieldbus control active
0= DC Voltage is below the level specified by P2.5.6.1
1=The DC Voltage is above the specified level by P2.5.6.1
Same as received on bit 11 of the
main control word.
5
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AFE Application - Monitoring valuesvacon • 23
V1.3.3FAULT WORD 1 ID 1172
Table 16. Fault Word 1
FALSETRUE
b0Over CurrentF1
b1OvervoltageF2
b2Under voltageF9
b3Not used
b4Earth FaultF3
b5Not used
b6Unit Over TemperatureF14
b7Over TemperatureF59, F56, F71
b8Input Phase lossF11
b9Not used
b10Device FaultF37, F38, F39, F40, F44, F45
b11Not used
b12Not used
b13Not used
b14Not used
b15Not used
V1.3.4F
b0Not used
b1Charging Switch FaultF5
b2Not used
b3Drive Hardware faultF4, F7
b4Under TemperatureF13
b5EPROM or Checksum faultF22
b6External faultF51
b7Not used
b8Internal CommunicationF25
b9IGBT TemperatureF31, F41
AULT WORD 2 ID 1173
Table 17. Fault Word 2
FALSETRUE
b10Not used
b11Cooling fanF32, F70
b12Application faultF35
b13Drive Internal faultF33, F36, F8, F26
b14Main Switch openF64
b15Not used
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
5
vacon • 24AFE Application - Monitoring values
V1.3.5WARNING WORD 1 ID 1174
Table 18. Warning Word 1
FALSETRUE
b0Not used
W29: Thermistor warning,
b1Temperature protection
b2
b3Supply Phase WarningW11
b4Not used
b5Not used
b6Not used
b7Drive over temperatureW14
b8Not used
b9Not used
b10Fan Warning
b11Not used
b12Not used
W56: FPT100 warning or
W71: LCL over temperature warning
W32: Fan Cooling
W70: LCL Fan monitor warning
b13Not used
b14Not used
b15Not used
V1.3.6W
Last active warning number.
V1.3.7L
Last active fault number.
ARNING ID74
AST ACTIVE FAULT ID37
5
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
AFE Application - Monitoring valuesvacon • 25
V1.3.8AUX CONTROL WORD ID 1161
Table 19. Aux Control Word
FALSETRUE
b0Reserved for future use.
b1Reserved for future use.
b2Reserved for future use.
b3Reserved for future use.
b4Reserved for future use.
b5Reserved for future use.
b6Reserved for future use.
b7Reserved for future use.
b8Reserved for future use.
b9Reserved for future use.
b10Reserved for future use.
b11Reserved for future use.
0= DC Voltage Level control from
Main Control Word (MCW) is not
b12
b13DO control
b14Reserved for future use.
b15Reserved for future use.
Enable DC Level control from
MCW
active and DC Voltage reference is
from fieldbus data (reference value).
1= DC Voltage Level control from
MCW is enabled
This signal can be connected to digital output with parameters in G2.4.1
Local contacts: http://drives.danfoss.com/danfoss-drives/local-contacts/
5
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