Danfoss VACON NXP GRID CONVERTER Application guide

VACON® NXP

AC DRIVES

GRID CONVERTER APPLICATION MANUAL

ARFIFF03

arfiff03 Grid Converter	VACON® · 3

				Table of contents
				Document: DPD01599C
				Software code: ARFIFF03V164
				Version release date: 31.5.2021
1.	General ....................................................................................................................................			8
	1.1	AFE Control...............................................................................................................................		8
	1.2	Island (Static Power Supply)....................................................................................................		8
	1.3	Micro Grid..................................................................................................................................		9
	1.4	Shaft Generator ......................................................................................................................		10
	1.5	Acronyms ................................................................................................................................		11
	1.6	Compatibility issues in parameters between versions........................................................		12
2.	Quick start and operation principles .....................................................................................			13
	2.1	Quick start instructions..........................................................................................................		13
	2.2	In case of parallel AFE: ..........................................................................................................		13
	2.3	Pre-Charging of DC ................................................................................................................		15
	2.4	Main circuit breaker control (MCB).......................................................................................		16
	2.5	Start Sequence .......................................................................................................................		17
	2.6	Stop sequence ........................................................................................................................		18
	2.7	afe mode; Start Stop timing diagram....................................................................................		19
	2.8	Operation principle: Droop Speed Control Mode .................................................................		20
	2.9	Operation principle: Isochronous Speed Control Mode.......................................................		20
	2.10	Voltage compensation............................................................................................................		21
	2.11	OPT-D7....................................................................................................................................		22
	2.12	Master Follower .....................................................................................................................		23
		2.12.1	General .......................................................................................................................	23
		2.12.2 Grid Converter Standard master follower................................................................		23
		2.12.3	Grid Converter DriveSynch........................................................................................	23
		2.12.4	Grid Converter D2-Synch...........................................................................................	23
3.	Control I/O .............................................................................................................................			25
	3.1	Slot A and Slot B terminals....................................................................................................		25
	3.2	Terminal To Function (TTF) ...................................................................................................		25
	3.3	Defining inputs and outputs...................................................................................................		26
	3.4	Defining a terminal in NCDrive..............................................................................................		27
4.	Monitoring signals .................................................................................................................			28
	4.1	Monitoring value tables..........................................................................................................		28
		4.1.1	Monitoring values 1....................................................................................................	28
		4.1.2	Monitoring values 2....................................................................................................	29
		4.1.3	Fieldbus monitoring values.......................................................................................	29
		4.1.4	I/O monitoring values.................................................................................................	30
		4.1.5	Master/Follower.........................................................................................................	30
		4.1.6	Licence key activation................................................................................................	30
		4.1.7	Line Monitoring ..........................................................................................................	30
		4.1.8	Active Limits ...............................................................................................................	31
		4.1.9	PI Power Controller ...................................................................................................	31

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	4.2 Description of monitoring values ..........................................................................................				32
		4.2.1	Monitoring 1 values....................................................................................................		32
		4.2.2	Monitoring 2 values....................................................................................................		35
		4.2.3	Fieldbus monitoring values.......................................................................................		37
		4.2.4	I/O monitoring values.................................................................................................		43
		4.2.5	Master Follower .........................................................................................................		44
		4.2.5.1		Currents ...................................................................................................................	45
		4.2.5.2		Statuses ....................................................................................................................	46
		4.2.6	Activation status.........................................................................................................		47
		4.2.7	Line Monitoring ..........................................................................................................		48
		4.2.8	Active Limits ...............................................................................................................		48
		4.2.9	PI Power Controller ...................................................................................................		48
5.	Parameter list			........................................................................................................................	49
	5.1	Basic parameters ...................................................................................................................			49
	5.2	Reference ................................................................................................................handling			49
		5.2.1	DC .................................................................................................Reference Tuning		50
		5.2.2 Power .................................................................................../ Frequency reference			50
		5.2.3 PID ...................................................................................Power Controller for AFE			50
		5.2.4	Reactive ....................................................................................................Reference		51
		5.2.5	AC .................................................................................................voltage reference		52
	5.3	Ramp control ..........................................................................................................................			52
	5.4	Input signals ...........................................................................................................................			52
		5.4.1	Basic .............................................................................................................settings		52
		5.4.2	Digital ..............................................................................................................inputs		53
		5.4.3	Analogue ........................................................................................................input 1		54
		5.4.4	Analogue ........................................................................................................input 2		54
		5.4.5	Analogue ........................................................................................................input 3		54
		5.4.6	Analogue ........................................................................................................input 4		55
	5.5	Output signals.........................................................................................................................			55
		5.5.1	Digital .................................................................................................output signals		55
		5.5.2	Delayed ..............................................................................................................DO 1		56
		5.5.3	Delayed ..............................................................................................................DO 2		56
		5.5.4	Analogue ......................................................................................................output 1		57
		5.5.5	Analogue ......................................................................................................output 2		58
		5.5.6	Analogue ......................................................................................................output 3		59
		5.5.7	Options........................................................................................................................		59
	5.6	Limit settings..........................................................................................................................			60
		5.6.1	Current ...............................................................................................................limit		60
		5.6.2	Power .................................................................................................................limit		60
		5.6.3	Frequency ..........................................................................................................limit		60
		5.6.4	Micro ...................................................................................................................Grid		60
		5.6.5	DC ...................................................................................................................voltage		61
	5.7	Drive control ...........................................................................................................................			61
		5.7.1	AFE .................................................................................................................control		61
		5.7.2	Identification...............................................................................................................		62
		5.7.3	Active .................................................................................................Compensation		62

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arfiff03 Grid Converter				VACON® · 5
	5.8	Master/Follower .....................................................................................................................		62
	5.9	Protections..............................................................................................................................		63
		5.9.1	General .......................................................................................................................	63
		5.9.2	Temperature Sensor Protections .............................................................................	64
		5.9.3	Earth fault...................................................................................................................	64
		5.9.4	Fieldbus fault..............................................................................................................	64
		5.9.5	External fault..............................................................................................................	65
		5.9.6	Grid voltage D7 ...........................................................................................................	65
		5.9.7	Grid frequency ............................................................................................................	65
		5.9.8	Voltage ........................................................................................................................	65
		5.9.9	Over Load....................................................................................................................	66
		5.9.10	D7 Protections............................................................................................................	66
		5.9.11	Cooling protection......................................................................................................	66
		5.9.12	Extra............................................................................................................................	66
	5.10	Fieldbus...................................................................................................................................		67
	5.11	Micro Grid................................................................................................................................		69
		5.11.1	Free Select .................................................................................................................	69
	5.12	Synchronisation to external grid ...........................................................................................		70
	5.13	Reserved .................................................................................................................................		70
	5.14	ID control functions................................................................................................................		71
		5.14.1	Value control ..............................................................................................................	71
		5.14.2	DIN ID control 1..........................................................................................................	71
		5.14.3	DIN ID control 2..........................................................................................................	71
		5.14.4	DIN ID control 3..........................................................................................................	72
		5.14.5	DIN ID control 4..........................................................................................................	72
		5.14.6	Signal Fault function..................................................................................................	72
		5.14.7	ID Controlled Digital Output 1 ...................................................................................	72
		5.14.8	ID Controlled Digital Output 1 ...................................................................................	72
	5.15	Auto reset................................................................................................................................		73
	5.16	Grid voltage PI ........................................................................................................................		73
	5.17	Keypad control (M3) ...............................................................................................................		73
	5.18	System menu (M6)..................................................................................................................		73
	5.19	Expander boards (M7) ............................................................................................................		73
6.	Description of parameters.....................................................................................................			74
	6.1	Basic parameters ...................................................................................................................		74
		6.1.1	Transformer parameters ..........................................................................................	76
	6.2	Reference handling ................................................................................................................		77
		6.2.1	DC Reference Tuning .................................................................................................	78
		6.2.2	Power / Frequency reference ...................................................................................	79
		6.2.3	PID Power Controller.................................................................................................	82
		6.2.4	Reactive Current Reference......................................................................................	83
		6.2.5	AC Voltage Reference ................................................................................................	84
	6.3	Ramp control ..........................................................................................................................		86
	6.4	Input signals ...........................................................................................................................		88
		6.4.1	Basic settings .............................................................................................................	88
		6.4.2	Digital input signals ...................................................................................................	89

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	6.4.2.1 Synchronization to external grid ...............................................................................			91
	6.4.2.2		Forced control place .................................................................................................	93
	6.4.3	Analogue inputs 1-4...................................................................................................		95
	6.4.3.1 Analogue input to any parameter .............................................................................			97
6.5	Output signals.........................................................................................................................			98
	6.5.1	Digital output signals.................................................................................................		98
	6.5.1.1 Fieldbus digital inputs connection.............................................................................			99
	6.5.2	Delayed digital output 1 & 2 ....................................................................................		100
	6.5.3	Analogue output 1 & 2 & 3.......................................................................................		102
	6.5.4	Options......................................................................................................................		105
6.6	Limit settings........................................................................................................................			107
	6.6.1	Current limits ...........................................................................................................		107
	6.6.2	Power limits..............................................................................................................		111
	6.6.3	Frequency limits.......................................................................................................		112
	6.6.4	Micro Grid limits.......................................................................................................		113
	6.6.5	DC voltage regulators ..............................................................................................		114
6.7	Drive control .........................................................................................................................			116
	6.7.1	AFE Control ..............................................................................................................		121
	6.7.2	Identification.............................................................................................................		122
	6.7.3	Active Compensation ...............................................................................................		122
6.8	Master Follower ...................................................................................................................			123
6.9	Protections............................................................................................................................			125
	6.9.1	General settings .......................................................................................................		125
	6.9.2	Temperature Sensor Protections ...........................................................................		129
	6.9.2.1		Individual channel monitoring ................................................................................	131
	6.9.3	Earth fault.................................................................................................................		132
	6.9.4	Fieldbus ....................................................................................................................		133
	6.9.5	External fault............................................................................................................		133
	6.9.6	Grid voltage D7 .........................................................................................................		133
	6.9.7	Grid frequency ..........................................................................................................		135
	6.9.8	Supply voltage ..........................................................................................................		136
	6.9.9	Over Load Protection ...............................................................................................		138
	6.9.10	D7 protections ..........................................................................................................		139
	6.9.11	Cooling protection....................................................................................................		140
	6.9.12	Extra..........................................................................................................................		141
6.10	Fieldbus.................................................................................................................................			142
6.11	Micro Grid (uGrid).................................................................................................................			145
	6.11.1.1		Generator Simulation ...........................................................................................	147
	6.11.1.2 AFE operation mode selection..............................................................................			148
6.12	Synch to external grid ..........................................................................................................			149
6.13	Reserved		...............................................................................................................................	150
6.14	ID functions...........................................................................................................................			151
	6.14.1	Value control ............................................................................................................		151
	6.14.2	DIN ID control...........................................................................................................		153
	6.14.3	Signal Fault Function...............................................................................................		154
	6.14.4	ID Controlled Digital Output ....................................................................................		155
6.15	Auto Reset.............................................................................................................................			156
6.16	Grid voltage PI controller.....................................................................................................			157

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arfiff03 Grid Converter				VACON® · 7
		6.16.1	Grid voltage PI OPT-D7 limits .................................................................................	157
7.	Keypad control parameters .................................................................................................			158
8.	FB Status and control in detail ............................................................................................			159
	8.1	FB DC Reference ..................................................................................................................		159
	8.2	State machine: Basic............................................................................................................		160
		8.2.1	FB Control Word Basic ............................................................................................	160
	8.3	State Machine: Standard......................................................................................................		161
		8.3.1	Control Word: Standard...........................................................................................	161
	8.4	State machine: Vacon AFE 1 ................................................................................................		162
		8.4.1	Control Word: Vacon AFE 1 .....................................................................................	162
	8.5	State machine: Vacon AFE 2 ................................................................................................		163
		8.5.1	Control Word: Vacon AFE 2 Profile (3)....................................................................	163
	8.6	FB Status Word.....................................................................................................................		165
	8.7	FB Micro Grid Control Word 1 ID1700.................................................................................		167
9.	Problem solving ...................................................................................................................			168
10.	Commissioning ....................................................................................................................			169
	10.1	Open loop voltage compensation ........................................................................................		169
		10.1.1	Parameters affect ....................................................................................................	169
		10.1.2	No load tuning ..........................................................................................................	169
		10.1.3	Tuning on the fly.......................................................................................................	169
		10.1.4	Tuning with load bank..............................................................................................	170
		10.1.5	Tuning against strong grid ......................................................................................	170
		10.1.6	Closed Loop Voltage Control ...................................................................................	170
11.	Fault codes		..........................................................................................................................	171

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8 · VACON®	arfiff03 Grid Converter

1. General

This application is not kept backwards compatible. See chapter Compatibility issues before you update the application. The Grid Converter application is used to make AC grids with a possibility to operate in parallel with other power sources. The Grid Converter application has 3 different operation modes:

-Standard AFE mode.

-Island mode.

-Micro Grid mode.

1.1AFE Control

AFE function keeps constant DC voltage. AFE mode transfers power between DC and AC. AFE cannot create grid by itself, it needs to be connected to existing grid.

	MCB Control
	Q2
G1	Filter	U2
	U1

UDC

~

=

Figure 1.

1.2Island (Static Power Supply)

Island mode generates constant voltage and frequency. In island mode DC Voltage is not controlled.

Island mode cannot operate in parallel with other power sources in AC side, because the drive will not balance reactive or active power with other power sources.

DC voltage level needs to be considered to have correct voltage on AC side in different load situations, considering voltage losses in LCL filter and in transformer.

D7

=

~

T1

MCB Control

U3 Filter U4 D Y U5

Q1

T2

U4 = Transf. GC Side

U5 = Transf. Grid Side

Figure 2.

S1

<![if ! IE]>

<![endif]>Grid

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arfiff03 Grid Converter	VACON® · 9

1.3Micro Grid

Micro Grid mode controls the grid voltage and frequency. It functions like an ordinary generator. Micro Grid mode does not control DC Voltage.

With the help of voltage droop and frequency droop, more than one Micro Grid and/or Generators can work together.

D7

=

~

D7

=

~

		T1
MCB Control
U3		U4		U5
	Filter		D	Y
					S1
				Q1
				T2
		U4 = Transf. GC Side
		U5 = Transf. Grid Side
					Q2
				G1

	T1
MCB Control
U3	U4		U5
Filter	D	Y	Q1	S1
		T2
	U4 = Transf. GC Side
	U5 = Transf. Grid Side

Figure 3.

<![if ! IE]>

<![endif]>Ship Grid

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10 · VACON®	arfiff03 Grid Converter

1.4Shaft Generator

The shaft generator is a system where the generator is connected to the main engine shaft that also runs the main propulsion. The disadvantage is that the main engine must run at nominal speed even if full power to the propeller is not necessary.

With the shaft generator system power goes through the drives. One converts power from the generator to DC link, and the other makes a ship grid with constant 50 Hz or 60 Hz, thus there is no direct connection to the generator. The main engine can run at a more efficient speed without changing grid frequency.

One drive operates as an AFE on the generator side and the other operates on Island mode or Micro Grid mode on the grid side.

-The start command to generator side drive.

-Both drives can make DC charging if powered by +24 Vdc.

-When DC is at an 80% of nominal, the generator side and the grid side breakers close.

-The generator side AFE is started to boost DC first.

-The grid side Grid Converter is started and will synchronise to grid.

-The drives take power from the bypass, and the PMS opens the SG contactor.

-You can decrease the speed of the main diesel engine to be more economical.

NOTE! If it is necessary to have these systems in parallel, the system bus communication is reserved for parallel Micro Grid units on the grid side. The control must be arranged separately for each drive.

SG

		Q4
MCB Control		UDC
	U2 ~
Q2
Filter

U5

=

D7

=

~

G1

					G2			T3
							<![if ! IE]> <![endif]>Grid	Auxilliary loads
								including single
MCB Control		T1					<![if ! IE]> <![endif]>Ship	phase loads
U3					Q1	Q3
	Filter		D	Y
				T2

ST

BT

Figure 4.

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arfiff03 Grid Converter	VACON® · 11

1.5Acronyms

AC	=	Alternating Current
AI	=	Analogue Input
AIO	=	All-In-One Applications
AM	=	Asynchronous Motor
ASIC	=	Application Specific Integrated Circuit
CL	=	Closed Loop
DC	=	Direct Current
DI	=	Digital Input
DO	=	Digital Output
DS	=	DriveSynch
FB	=	Field Bus
FFT	=	Function To Terminal
FW	=	Firmware
FWP	=	Field Weakening Point
FWPV	=	Field Weakening Point Voltage
GE	=	Greater or Equal
HW	=	Hardware
I/f	=	Current / Frequency
Id	=	Magnetization Current
IGBT	=	Insulated Gate Bipolar Transistor
INV	=	Inversion
Iq	=	Torque Producing Current
LT	=	Less Than
MF	=	Master-Follower
OL	=	Open Loop
PID	=	Proportional Integral Derivative
PM	=	Permanent Magnet
PMSM	=	Permanent Magnet Synchronous Motor
PU	=	Per Unit
RO	=	Relay Output
RS	=	Reset Set
SB	=	System Bus
Sep.Ex SM	=	Separately Excitated Synchronous Motor
SM	=	Synchronous Machine
SPC	=	Speed Control
SQS	=	Sfe Quick Stop
SR	=	Set Reset
SRM	=	Synchronous Reluctance Motor
SS1	=	Safe Stop 1
STO	=	Safe Torque Off
SW	=	Software
TC	=	Torque Control
TC	=	Time Constant
TTF	=	Terminal To Function
U/f	=	Voltage / Frequency
UV	=	Under Voltage

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1.6Compatibility issues in parameters between versions

Update Note 1: This application parameters are not kept backwards compatible if new features or improvements would be difficult to implement by doing so. Read this change note and chapter “Compatibility issues in parameters between versions” from manual before updating the application.

Update Note 2: It’s recommended to use compare function for parameter changes when updating application, especially in cases when version number change is considerably high.

Application is constantly developed; this includes changing parameter default values, and if parameters are directly downloaded to drive improved default values may be lost.

Update Note 3: If OPT-D7 PI voltage control is needed in uGrid mode, do not use versions V082 or V083.

V092

•Major Compatibility Issue: P2.1.7 System Nom. DC is initialized to unit nominal DC value.

▪500 Vac unit: 675 Vdc

▪690 Vac unit: 931 Vdc

o When the transformer ratio was other than 1:1: MCB closing limit and DC-Link Voltage reference values were based on grid voltage after transformer. This was causing reference handling problems when given AC values were in range of different voltage class unit.

o DC Voltage Reference in AFE mode is based always to System Nom DC parameter.

V089

oCompatibility Issue: Voltage MotPot is adjusting now field weakening point voltage. Units have been changed from [V] to [%]. This enables more accurate adjustment and adjustment rate.

V087

oMinor Compatibility Issue: FB Actual Speed signal changed to use Filtered DC-Link Voltage signal (ID1108) instead of unfiltered DC Voltage signal.

V081

o Compatibility Issue: Parameters “PID Activation” and “FreqScaleMinAO” had same ID1807. “FreqScaleMinAO” DI changed to ID1809.

o Major Compatibility Issue: Fieldbus State Machine o See full details from latest manual.

o Not Used -> Basic, As in Fieldbus manual

oStandard –> NEW Standard, Application level state machine, this was Basic in earlier versions than V081 i.e. as in Fieldbus manual.

oFB Status and FB Control word modified to be more suitable for AFE use, following idea of ProfiDrive standard.

V080

oMinor compatibility issue: Monitoring and parameter values unified with other premium drive applications.

V128

oMinor compatibility issue: P2.7.8 Control Options2 B1 is no longer available, this has been replaced with P2.9.1.15 FaultWarnIndicat parameter.

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arfiff03 Grid Converter	VACON® · 13

2. Quick start and operation principles

NOTE! Before you start the commissioning, read the safety instructions in the user manual of your product.

To use the Island, Micro Grid, or Shaft generator operation, you need a licence key. The AFE mode is available without a licence.

This application requires an NXP3 control board VB761 or newer.

The control place (P3.1) of the Micro Grid drive is Keypad as a default.

The basic I/O configuration of the Grid Converter drive consists of OPT-A1, OPT-A2, and OPT-D7 option boards. The basic I/O configuration is described in Table 1.

OPT-D7 is required when the Grid Converter unit is needed to start with zero power to the grid. If grid frequency is not monitored with OPT-D7, the unit may go generator side or directly to full power because different reference frequency and grid frequency.

The Grid Converter is utilised by using AFE hardware with special software. An external LC(L)-filter and charging circuit is needed. This unit is selected when low harmonics are required. The principle connection of AFE drive has been described in Figure 5.

The external 24 Vdc is recommended for control board(s). It enables the setting of parameters even when the power unit itself is not powered. This is important also when software updates are made. Some default I/O configuration of the application can cause unexpected DO operation. When the control board is powered, the drive can give information from the status of the system if, for example, the drive I/O is used for an overall system monitoring.

The external 24 Vdc is required for the drives in cases where the start command starts the control board-controlled precharging operation.

2.1Quick start instructions

1.Connect the unit according to the Figure 5.

2.Power up the control unit with 24 Vdc.

3.Set the basic parameters (G2.1)

4.Check that the digital input parameters (G2.4.2) have been set according to the connections.

5.Change the control place according to the system requirements.

6.Charge the unit.

2.2In case of parallel AFE:

1.Set P2.1.5 Parallel AFE to Yes. This will also set DC Drooping to 3.00% (Default).

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Figure 5. Connection

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2.3Pre-Charging of DC

This AFE application has its own charging control, P2.5.1.13 DC Charge (24 Vdc required for control board) and charging protection in case the external charging cannot get DC voltage to required level within set time P2.9.1.6 Charge Max Time (provided that the DC Voltage reaches the under voltage fault level).

The charging function is activated when P2.5.1.13 DC Charge is A.1 or higher. When the control place is IO, Keypad or NCDrive, charging is started from the start command.

Charging is not started if:

-Drive is in fault state.

-P2.4.2.26 Enable CB Close is FALSE

-P2.4.2.8 Run Enable is FALSE

-P2.4.2.19 Quick Stop is FALSE

Charging is also stopped if above conditions occur during charging or if the start command is removed.

For fieldbus control, charging is started with B0 of FB Control Word on the supporting FB profiles. Charging is also stopped if B0 goes low. Also MCB is opened if already closed.

DC Charge (F80) is given if 85 % of DC Nominal is not reached within P2.9.1.6 Charge Max Time and charging is stopped.

DC Charging is stopped when the drive receives feedback from P2.4.2.4 MCB Feedback.

NOTE! Use suitably sized DC Charging resistor. To select the correct size, check Pulse loadability for time duration set in for Max Charge Time parameter.

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2.4Main circuit breaker control (MCB)

The Grid Converter application controls the circuit breaker of the system with the relay output RO2. When the DC bus is charged, the MCB will be closed. The status of the MCB is monitored via a digital input. The digital input used for monitoring is selected with parameter P2.3.1.3. Faults can be set to open the MCB by selecting a response to a fault to be 3=Fault, DC OFF.

An external charging circuit is necessary to charge the DC bus but drive can control this circuit if 24 Vdc is provided for the control board.

Closing limit is 85% of the nominal DC Voltage.

Opening limit is 75% of the nominal DC Voltage.

Nominal DC Voltage = Grid Nom Voltage (P2.1.1) * 1.35.

Over Current (F1), Hardware IGBT (F31) and Software IGBT (F41) faults will open MCB immediately to protect the drive.

NOTE! The MCB feedback is necessary for the correct operation of the Grid Converter application.

NOTE! Only the drive controls its own MCB. If additional interlocks or opening commands are needed, these commands must go through the drive.

NOTE! UPS may be needed during short circuit situation to keep MCB closed if control voltage is taken from the grid where the short circuit occurs.

NOTE! Missing feedback signal prevent drive going to ready state. MCB Feedback can be monitored from Status Word B10.

NOTE! If feedback is not used there will be three second forced delay on internally generated MCB feedback signal. MCB Feedback can be monitored from Status Word B10.

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arfiff03 Grid Converter	VACON® · 17

2.5Start Sequence

	Start
	Ready to switch
	on
	Charge	Fault
		Reset
	DC-Link
NO	DC-Link
	> 85 %

YES

Close Main

Contactor

Main Contactor	NO		MCC Fault
Closed

Run Enable

NO

YES

Ready To Run

Start Signal

NO

YES

Synchronize with mains

	NO		Line Synch Fault
Synch OK
			F10

YES

Running

Figure 6. AFE start sequence

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18 · VACON®	arfiff03 Grid Converter

2.6Stop sequence

Modulating

No

MCB Closed

F64 A4

Yes

No

F64 A2

Stop Request

MCB Closed

(If DC > 85 %)

(Delayed)

Yes

Open MCB

No

Yes

Stop Modulation

(If Run State)

Open MCB

Yes

MCB Closed F64 A3

(Delayed)

No

End

Figure 7. Stop sequence

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arfiff03 Grid Converter	VACON® · 19

2.7afe mode; Start Stop timing diagram

<![if ! IE]>

<![endif]>P. Start Delay

Stable DC

MCB Close level

DC Voltage

FB CW.B00

Control in

FB Control

FB CW.B03

IO Start

Contro in

IO Control

IO MCB Open

Command

Charge Control

MCB Close Control

MCB Feedback

Ready

Run

Above example when “Standard” state machine is used. With “Basic” state machine operation is like in IO Control.

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20 · VACON®	arfiff03 Grid Converter

2.8Operation principle: Droop Speed Control Mode

When the power demand increases, all generators on the grid allow frequency to droop. This will balance the load between all the generators on the grid. Then the power management system gives all generators a command to increase frequency so that the grid frequency is maintained at its nominal value.

When the load is reducing on the grid, the frequency of the generators will increase, and the power management system gives a command to decrease frequency.

Freq.	Change
52,0 Hz	+4%
51,5 Hz	+3%
				D
				r
51,0 Hz	+2%			oopi
		<![if ! IE]> <![endif]>Loading		ng
50,5 Hz	+1%		<![if ! IE]> <![endif]>-loading
						Related
			<![if ! IE]> <![endif]>Un			Load
50,0 Hz
			25%	50%	75%	100%
49,5 Hz	-1%
49,0 Hz	-2%
48,5 Hz	-3%
48,0 Hz	-4%

Figure 8.

2.9Operation principle: Isochronous Speed Control Mode

In the isochronous speed control mode, the Micro Grid frequency reference is kept the same as the grid frequency with help of OPT-D7. This will keep power at zero regardless of grid frequency. While drive operates in drooping mode, the actual power is controlled by base current reference. This reference needs to be controller by power management system (PMS) that will handle power sharing between different machines on the grid.

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arfiff03 Grid Converter	VACON® · 21

2.10Voltage compensation

Grid Converter system will have voltage losses. Depending on the system, the losses may be more than 50 Vac when operating close to Grid Converter nominal currents with low power factor between points U3 and U5. This voltage loss needs to be compensated so that the grid voltage stays at nominal. This also sets requirements for the needed DC link voltage.

50 Hz

	Q2		~
SG	Filter	U2		UDC
	U1		=

Figure 9.

D7		T1		60 Hz
		MCB Control
=	U3	U4	U5
		Filter	Q1	S1
~
			T2
		U4 = Transf. GC Side
		U5 = Transf. Grid Side

Voltage compensation

<![if ! IE]>

<![endif]>Utility Grid

The normal operation voltage range in a land-based grid is usually between 80% and 115% of the grid nominal voltage.

The voltage losses compensation is handled separately for Active power (kW) and Reactive power (kVar), the latter being more significant. The Active power voltage losses are compensated with Inductor Losses parameter (P2.2.6.6) and Reactive power voltage losses are compensated with Inductor Size parameter (P2.2.6.5).

Uncompensated system may result in unnecessary reactive power circulation in a grid between the different power sources and wrong grid voltage.

OPT-D7 can be used to compensate the voltage losses (closed loop voltage compensation) but it is recommended to do an open loop voltage compensation tuning in case of OPT-D7 failure. When the OPT-D7 measurements exceed the set limit values, the voltage compensation falls back to open loop control.

Inductor Size and Losses affect

Grid Nom. Voltage: 400 Vac, Reactive Current: 30%, Active Current 50%, Inductor Size: 15%, Inductor Losses: 15%, Voltage Correction: 0 Vac.

Reactive Increase:	400	Vac×30%×15%=18 Vac
Active Increase:	400	VacIncrease: or Losses: 15% 400 Vac×50%×15%×15%=4.5 Vac
Total increase:	18 Vac+4.5 Vac =22.5 Vac

See also document: Voltage Compensation Vxxx.pdf.

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22 · VACON®	arfiff03 Grid Converter

2.11OPT-D7

OPTD7 is an AC sinusoidal voltage measurement board. Using this board, the drive measures the line voltage, the frequency and the voltage angle information.

The drive can compare this information with its output voltage angle when it runs. This feature can be used to make synchronisations to a grid that is measured. For example, for line synchronisation purposes you can use APFIFF44 LineSynch II Application. That will work as a smooth starter.

In Grid Converter application this can be used:

-To synchronise to existing external grid while the drive is running to enable bumpless transfer from a generator operation to a shore powered operation in a ship.

-To control the grid voltage (Voltage losses compensation).

-To enable a zero power connection to an existing grid.

-To help in the commissioning of drive active power and reactive power voltage losses compensation when the actual grid voltage is visible in NCDrive.

The OPT-D7 board is delivered with the transformer which is suitable for a voltage range up to 690 Vac. The transformer cannot be used with a pulse width modulated (PWM) voltage input.

It is possible to use a customised transformer when the input voltage to be measured is not within the OPT-D7 transformer voltage range. The transformation ratio parameter can be adjusted according to the transformer primary to secondary ratio. See details in the OPT-D7 user manual.

Synchronisation to the grid can be made without the OPT-D7 when the drive operates in the AFE or the Micro Grid mode. This requires that the output terminals of the drive are connected to the existing grid when the drive is in the STOP state. When a start command has been given in AFE or Micro Grid mode, the drive will make standard AFE synchronisation. Depending on the operation mode, the drive will start to keep constant DC voltage (AFE) or start to share power based on grid frequency (Micro Grid). Using OPT-D7 for synchronisation will make the start of the drive smoother.

If the drive does not detect an existing line voltage or frequency in Micro Grid mode, the output voltage is raised defined time (VoltageRiseTime). In the Island mode, the detection of the grid is not made and the voltage is raised from zero in the set time (VoltageRiseTime).

NOTE: The OPT-D7 board (in slot C) is mandatory for the Grid Converter unit.

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arfiff03 Grid Converter	VACON® · 23

2.12Master Follower

2.12.1General

In master follower modes master is sending control word and DC Voltage reference to follower drives. Follower drives send a status word to master including some command see details from monitoring values description.

Start command is synchronized

Master sends run request to followers when all drives indicates that MCB is closed.

o Status is monitored even if follower do not have own MCB or status from the MCB. If any of the drive goes state where MCB is needed to open all drives will open the MCB. Control signals to follower drives

oDC voltage reference, can be selected in follower drive if used master or own reference.

2.12.2Grid Converter Standard master follower

In standard master follower mode modulation is not synchronized in any way through system bus communication. This mode can be used when all the units can work independently but e.g. start and DC-Link voltage reference is only wanted to give master drive and only four units are needed for parallel operation.

3-LCL-filters are needed to use Up to 4 parallel units.

2.12.3Grid Converter DriveSynch

In DriveSynch master follower modulation is synchronized between the drives, basically all follower will do exactly what master will do.

3-pole LC-filters or standard sine-filters can be used instead of LCL-filters when common point is connected to transformer.

Up to 4 parallel units.

2.12.4Grid Converter D2-Synch

In D2-Synch each unit operate independently only modulation switching is synchronised to eliminate rotating currents.

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24 · VACON®					arfiff03 Grid Converter
	Applicable if MV
	400-690 / MV

OPT-D7

Transformer

<![if ! IE]>

<![endif]>for <1m length cable-11V Limit performance EMC better

MCB						See note 1.
Control
	MCB
	Feedback

<![if ! IE]>

<![endif]>Optional

<![if ! IE]>

<![endif]>Optional

OPT-A1	N	<![if ! IE]> <![endif]>Optional
OPT-A2

	OPT-D7	X
	OPT-D2	P
	OPT-??
		Master

Optical

Fibre

See note 2.

OPT-A1	N	OPT-A1	N
OPT-A2		OPT-A2
OPT-D7	X		X
OPT-D2	P	OPT-D2	P
OPT-??		OPT-??
	Follower		Follower
	Backup Master
			DC-Link Fuses
			According to
			Discrimination Study
	One option is to have many
	parallel fuses (not drawn
	here). Each fuse protects
	one battery string and
	cable.

Optional

Drive

Supply

Cable

L

R

See note 4.

See note 3.

NOTE:

1.Breaker to be equipped with optional precharging of Sine-Filter capacitors

(Can be parallel smaller breaker with resistors for example). Precharge will precharge DC-link capacitors as well.

2.High Frequency (HF) capacitors to be installed to limit Common Mode Voltage (CMV) for the batteries.

3.Breaker to be equipped with precharging of DC-Link capacitors

(Can be parallel smaller breaker with resistors for example) 4. Verify that the battery side fuse selection is according to discrimination.

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arfiff03 Grid Converter	VACON® · 25

3. Control I/O

3.1Slot A and Slot B terminals

Table 1. Minimum recommended I/O configuration.

OPT-A1

Terminal

Signal

Description

1

+10Vref

Reference voltage output

Voltage for potentiometer, etc.

2

AI1+

Analogue input 1.

Input range selected by jumpers.

Range 0-10V, Ri = 200

Default range: Voltage 0 – 10 V

Range 0-20 mA Ri = 250

3

AI1-

I/O Ground

Ground for reference and controls

4

AI2+

Analogue input 2.

Input range selected by jumpers.

5

AI2-

Range 0-10V, Ri = 200

Default range: Current 0 – 20 mA

Range 0-20 mA Ri = 250

6

+24V

Control voltage output

Voltage for switches, etc. max 0.1 A

7

GND

I/O ground

Ground for reference and controls

8

DIN1

Programmable G2.2.1

9

DIN2

Programmable G2.2.1

10

DIN3

Programmable G2.2.1

11

CMA

Common for DIN 1– DIN 3

Connect to GND or +24V

12

+24V

Control voltage output

Voltage for switches (see #6)

13

GND

I/O ground

Ground for reference and controls

14

DIN4

MCB Feedback

0 = MCB open

Programmable G2.2.1

1 = MCB closed

15

DIN5

Quick Stop

0 = Quick Stop Active

Programmable G2.2.1

1 = No Quick Stop

16

DIN6

Programmable G2.2.1

17

CMB

Common for DIN4– DIN6

Connect to GND or +24V

18

AO1+

Analogue output 1

Programmable

19

AO1-

Range 0– 20 mA/RL, max. 500

20

DO1

Digital output

Programmable P2.3.1.1

READY

Open collector, I 50mA, U 48 VDC

OPT-A2

21

RO1

Relay output 1

Switching capacity

22

RO1

Programmable P2.3.1.2

24 VDC / 8 A

23

RO1

250 VAC / 8A

125 VDC / 0.4 A

24

RO2

Relay output 2

This RO is not programmable.

25

RO2

MCB control

Fixed for MCB Control (Close)

26

RO2

3.2Terminal To Function (TTF)

The programming principle of the input and output signals in the Grid Converter Application is different compared to the conventional method used in other VACON® NX applications.

In the conventional programming method, Function to Terminal Programming Method (FTT), you have a fixed input or output that you define a certain function for. The applications mentioned above, however, use the Terminal to Function Programming method (TTF) in which the programming pro¬cess is carried out the other way round: Functions appear as parameters which the operator defines a certain input/output for.

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26 · VACON®	arfiff03 Grid Converter

3.3Defining inputs and outputs

Connecting a certain input or output with a certain function (parameter) is done by giving the parameter an appropriate value. The value is formed of the Board slot on the VACON® NX control board (see VACON® NX User Manual) and the respective signal number, see below.

READY

I/Oterm

Function name AI Ref Faul/Warn

DigOUT:B.1

Slot	Terminal number
Terminal type

Example: You want to connect the digital output function Reference fault/warning (parameter 2.3.3.7) to the digital output DO1 on the basic board NXOPTA1 (see VACON® NX User Manual).

First find the parameter 2.3.3.7 on the keypad. Press the Menu button right once to enter the edit mode. On the value line, you will see the terminal type on the left (DigIN, DigOUT, An.IN, An.OUT) and on the right, the present input/output the function is connected to (B.3, A.2 etc.), or if not connected, a value (0.#).

When the value is blinking, hold down the Browser button up or down to find the desired board slot and signal number. The program will scroll the board slots starting from 0 and proceeding from A to E and the I/O selection from 1 to 10.

Once you have set the desired value, press the Enter button once to confirm the change.

READY	READY	READY
I/Oterm	I/Oterm	I/Oterm

AI Ref Faul/Warn	AI Ref Faul/Warn				AI Ref Faul/Warn				enter
DigOUT:0.0	DigOUT:0.0				DigOUT:B.1

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arfiff03 Grid Converter	VACON® · 27

3.4Defining a terminal in NCDrive

If you use the VACON® NCDrive Programming Tool for parametrizing you will have to establish the connec¬tion between the function and input/output in the same way as with the control panel. Just pick the address code from the drop-down menu in the Value column (see the Figure below).

Figure 3 1. Screenshot of NCDrive programming tool; Entering the address code

				Be ABSOLUTELY sure not to connect two functions to one and
				same output in order to avoid function overruns and to ensure
				flawless operation.
	WARNING

Note: The inputs, unlike the outputs, cannot be changed in RUN state.

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28 · VACON®	arfiff03 Grid Converter

4. Monitoring signals

The menu M1 (Monitoring) has all the monitoring values. Values are only for monitoring and cannot be altered on the control panel.

4.1Monitoring value tables

4.1.1Monitoring values 1

Code

Parameter

Unit

Form.

ID

Description

V1.1.1

DC-Link Voltage

V

#

1108

Measured DC Link voltage in volts,

filtered.

Used DC voltage reference by the

regenerative unit in % of Nominal DC

V1.1.2

DC Voltage Ref.

%

#,##

1200

voltage.

Nominal DC voltage = 1.35 * supply

voltage

V1.1.3

DC Voltage Act.

%

#,##

7

Same scaling as DC Voltage Ref.

V1.1.4

Total Current

A

Varies

1104

Filtered current

V1.1.5

Active Current

%

#,#

1125

> 0 power from AC side to DC side

< 0 power from DC side to AC side

V1.1.6

Reactive Current

%

#,#

1157

V1.1.7

Power kW

kW

Varies

1508

> 0 power from AC side to DC side

< 0 power from DC side to AC side

V1.1.8

Power %

%

#,#

5

> 0 power from AC side to DC side

< 0 power from DC side to AC side

V1.1.9

Status Word

#

43

V1.1.10

Supply Frequency

Hz

#,##

1

Drive output frequency

V1.1.11

Supply Voltage

V

#,#

1107

Drive output voltage

V1.1.12

Line Frequency D7

Hz

#,##

1654

Measured line frequency

V1.1.13

Line Voltage D7

V

#

1650

Measured line voltage

V1.1.14

AC Voltage Reference

V

#

1556

Used AC Voltage Reference

V1.1.15

DC Ref Max Lim

%

#,##

1606

Internal limit for DC Voltage Ref.

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arfiff03 Grid Converter	VACON® · 29

4.1.2Monitoring values 2

Code

Parameter

Unit

Form.

ID

Description

V1.2.1

DC Voltage

V

#

44

Measured DC Link voltage in

volts, unfiltered.

0 = AFE

V1.2.2

Operation Mode

#

1615

1 = Island

2 = Micro Grid

Used current reference is

V1.2.3

Used Current Ref

%

#,#

1704

negated to parameter value.

Made to compare values in

NCDrive easier to Active current

V1.2.4

D7 Synch. Error

#

1659

Synchronisation error to external

grid

V1.2.5

Cos Phi Actual

#,###

1706

V1.2.6

Unit Temperature

°C

#

1109

V1.2.7

Freq. Reference

Hz

#,#

1752

Used line frequency reference

V1.2.8

Current

A

Varies

1113

Unfiltered current

V1.2.9

Operation Hours

h

#,##

1856

V1.2.10

Reactive Current

%

#,#

1389

Reference

V1.2.11

Grid State

#

1882

V1.2.12

Mindex

%

#,#

1858

Modulation Index

V1.2.13

Phase U Current

A

Varies

39

rms, 1 second linear filtering

V1.2.14

Phase V Current

A

Varies

40

rms, 1 second linear filtering

V1.2.15

Phase W Current

A

Varies

41

rms, 1 second linear filtering

V1.2.16

DC-Link Current

A

Varies

72

V1.2.17

DC-Link ActCurr

%

#,#

1158

V1.2.18

Crest Factor

#,###

1101

4.1.3Fieldbus monitoring values

Code	Parameter	Unit	Form.	ID	Description
V1.3.1	FB Control Word		#	1160	Control word from fieldbus
V1.3.2	FB Status Word		#	68	Status word to fieldbus
V1.3.3	Fault Word 1		#	1172
V1.3.4	Fault Word 2		#	1173
V1.3.5	Warning Word 1		#	1174
V1.3.6	FB Micro Grid CW1		#	1700	Control for Micro Grid operations
V1.3.7	FB Micro Grid SW1		#	1701	Status of Micro Grid operations
V1.3.8	Last Active Warning		#	74
V1.3.9	Last Active Fault		#	37
V1.3.10	MC Status		#	64
V1.3.11	FB Analogue Out		#,##	48

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30 · VACON®	arfiff03 Grid Converter

4.1.4I/O monitoring values

Code	Parameter	Unit	Form.	ID	Description
V1.4.1	DIN1, DIN2, DIN3		#	15
V1.4.2	DIN4, DIN5, DIN6		#	16
V1.4.3	DIN Status 1		#	56
V1.4.4	DIN Status 2		#	57
V1.4.5	Analogue Input 1	%	#,##	13
V1.4.6	Analogue Input 2	%	#,##	14
V1.4.7	Analogue input 3	%	#,##	27	AI3, unfiltered.
V1.4.8	Analogue input 4	%	#,##	28	AI4, unfiltered.
V1.4.9	Analogue Out 1	%	#,##	26
V1.4.10	Analogue Out 2	%	#,##	50	AO2
V1.4.11	Analogue Out 3	%	#,##	51	AO3
V1.4.12	PT100 Temp. 1	°C	#,#	50
V1.4.13	PT100 Temp. 2	°C	#,#	51
V1.4.14	PT100 Temp. 3	°C	#,#	52
V1.4.15	PT100 Temp. 4	°C	#,#	69
V1.4.16	PT100 Temp. 5	°C	#,#	70
V1.4.17	PT100 Temp. 6	°C	#,#	71

4.1.5Master/Follower

Code

Parameter

Unit

Form.

ID

Description

V1.5.1

SB SystemStatus

#

1819

V1.5.2

Master CW

#

93

Code

Parameter

Unit

ID

Description

V1.5.3.1

Current D1

A

Varies

1820

V1.5.3.2

Current D2

A

Varies

1821

V1.5.3.3

Current D3

A

Varies

1822

V1.5.3.4

Current D4

A

Varies

1823

Code

Parameter

Unit

ID

Description

V1.5.4.1

Status Word D1

#

1828

V1.5.4.2

Status Word D2

#

1829

V1.5.4.3

Status Word D3

#

1830

V1.5.4.4

Status Word D4

#

1831

4.1.6

Licence key activation

Code

Parameter

Unit

Form.

ID

Description

Give this number to the

V1.6.1

Serial Number Key

#

1997

technical support of the

manufacturer in case of licence

key problems.

V1.6.2

Licence Status

#

1996

4.1.7

Line Monitoring

Code

Parameter

Unit

Form.

ID

Description

V1.7.1

Line Voltage D7

Hz

#,##

1654

Measured line voltage

V1.7.2

Line Frequency D7

V

#

1650

Measured line frequency

V1.7.3

Line Voltage THD

%

#,##

1670

Line voltage total harmonic

distortio

V1.7.4

Line Voltage HF RMS

V

#,#

1671

RMS of high frequency

components

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