Danfoss VLT AAF006 Operating Instructions Manual

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MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Active Filter AAF006

www.danfoss.com/drives

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Product Overview

1.3.1 Working Principle 4

1.3.2 IEEE519 Compliance 5

1.4 Ordering Information

1.4.1 Filter Configurator 6

1.4.2 Ordering Form Type Code 6

2 Safety

2.1 Safety Symbols

2.2 Qualified Personnel

2.3 Safety Precautions

3 Mechanical Installation

3.1 Pre-installation

3.1.1 Planning the Installation Site 8

3.1.2 Receiving the Active Filter 8

3.1.3 Transportation and Unpacking 8

3.1.4 Lifting 8

3.1.5 Mechanical Dimensions 9

3.2 Mechanical Installation

3.2.1 Tools Needed 11

3.2.2 Clearance Requirements 11

3.2.3 Power Terminal Locations 12

3.2.4 Cooling and Airflow 13

3.2.5 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) 14

4 Electrical Installation

4.1 Safety Instructions

4.2 Electrical Installation

4.2.1 Power Connections 15

4.2.2 Grounding 16

4.2.3 EMC Interference 17

4.2.4 Extra Protection (RCD) 18

4.2.5 RFI Switch 18

4.2.6 Torque 18

4.2.7 Current Transformer (CT) 18

4.2.8 Auto CT Detection 22

Contents Operating Instructions

4.2.9 Summation Transformers 23

4.2.10 Operating with Capacitor Banks 24

4.2.11 Fuses 26

4.2.12 Mains Disconnectors 26

4.2.13 Control and CT Cable Routing 26

4.2.14 Control Wire Installation 26

4.2.15 Unscreened Control Wires 27

4.2.16 Electrical Installation, Control Cables 28

4.3 Installation Checklist

5 User Interface

5.1 Local Control Panel Operation

5.1.1 Modes of Operation 30

5.1.2 How to Operate Graphical LCP (GLCP) 30

5.1.3 Changing Data 33

5.1.4 Changing a Text Value 33

5.1.5 Changing a Group of Numeric Data Values 33

5.1.6 Changing of Data Value, Step-by-Step 33

5.1.7 Readout and Programming of Indexed Parameters 33

5.1.8 Quick Transfer of Parameter Settings with the LCP 34

5.1.9 Initialisation to Default Settings 34

5.1.10 RS485 Bus Connection 35

5.1.11 Connection to a PC 35

6 Applications and Basic Programming

6.1 Paralleling of Active Filters

6.2 Programming

6.3 Description of Parameters

6.4 0-** Operation/Display

6.5 5-** Digital I/O Mode

6.6 8-** General Settings

6.7 14-2* Trip Reset

6.8 15-** Drive Information

6.9 16-** Data Readouts

6.10 300-** AF Settings

6.11 301-** AF Readouts

6.12 Parameter Lists

6.12.1 Default Settings 62

6.12.2 0-** Operation/Display 63

6.12.3 5-** Digital In/Out 64

6.12.4 8-** Comm. and Options 64

Contents Operating Instructions

6.12.5 14-** Special Functions 65

6.12.6 15-** FC Information 65

6.12.7 16-** Data Readouts 67

6.12.8 300-** AF Settings 68

6.12.9 301-** AF Readouts 68

7 RS485 Installation and Set-up

7.1 Installation and Set-up

7.2 Network Configuration

7.3 FC Protocol Message Framing Structure

7.3.12 Conversion 73

7.4 How to Access Parameters in Modbus RTU

8 Maintenance, Diagnostics and Troubleshooting

8.1 Maintenance and Service

8.2 Warning and Alarm Types

8.3 Active Filter Warning and Alarm Definitions

9 Specifications

9.1 Power Rating

9.2 Derating for Altitude and Ambient Temperature

9.3 Acoustic Noise

10 Appendix

10.1 Abbreviations and Conventions

Index

Contents Operating Instructions

1 Introduction

1.1 Purpose of the Manual

These operating instructions provide information for safe installation and commissioning of the filter.

The operating instructions are intended for use by qualified personnel. Read and follow the operating instructions to use the filter properly, and pay particular attention to the safety instructions and general warnings. Keep these operating instructions available with the filter at all times.

VLT® is a registered trademark.

1.2 Additional Resources

Resources available to understand advanced active filter functions and programming:

•

The VLT® Advanced Active Filter Service Manual provides information on troubleshooting and testing for field service technicians, as well as disassembly and assembly instructions.

1.3

Product Overview

1.3.1 Working Principle

The VLT® Advanced Active Filter is used for harmonic current mitigation and reactive current compensation. The unit can integrate with various systems and applications as a centrally installed filter or be combined with a VLT

frequency converter as a packaged low harmonic drive solution.

M M

130BB717.10

Illustration 1.1 Multiple Working Environments

The active shunt filter monitors all 3-phase line currents and processes the measured current signal via a digital signal processor system. The filter then compensates by actively imposing signals in counter phase to the unwanted elements of the current (harmonic distortion).

130BB718.10

Illustration 1.2 Active Filter Principles

The filter sets different IGBT switches in real time feeding a DC voltage into the grid, which creates counter phase signals. A built-in LCL filter smooths the compensated current waveform, ensuring that the IGBT switching frequency and DC component is not imposed to the grid. The filter operates on generator or transformer supply and can reduce individual motor loads, non-linear loads, or

Introduction

Operating Instructions

mixed loads. Non-linear loads (diode feed loads) must hold AC coils to protect against overcurrent of the input diodes.

Control

Manual

Disconnect

Fuse

Option

Soft charge

circuit

130BB719.10

Illustration 1.3 Block Diagram

The filter allows either overall or selective harmonic compensation modes. In overall compensation mode, all harmonics are reduced. In this mode, the filter balances the load to reduce uneven load distribution among the 3 phases. The steady state performance allows compensation of harmonics to the 40th order, but the ultra-quick current injection allows the filter to compensate flicker and other quick and short-term phenomena. In selective mode, the user can program acceptable individual harmonic levels between 5th and 25th order. In selective mode, the filter does not reduce harmonics in twos and threes, and does not support phase load balancing and flicker reduction. See parameter 300-00 Harmonic Cancellation Mode.

Program the filter priority as either reactive current or harmonic compensation. If harmonic compensation is first priority, the filter uses the current needed for harmonic reduction and uses energy for reactive current correction only if there is excess. The filter automatically and continuously assigns energy between first and second priority to provide the highest possible mitigation of both reactive and harmonic compensation. The power factor is optimised continuously and the supply transformer is used to its maximum capacity. See parameter 300-01 Compen- sation Priority.

The active filter has an optional RFI filter for Class A1 equal to category C2.

1.3.2

IEEE519 Compliance

The active filter is designed to meet IEEE519 recommendation for Isc/Il >20 for even individual harmonic levels. The filter has a progressive switching frequency that creates a wide frequency spread, giving lower individual harmonic levels above the 50th harmonic level.

Introduction

Operating Instructions

1.4 Ordering Information

1.4.1 Filter Configurator

Use the ordering number system to design an active filter according to the application requirements. For the VLT® Active Filter AAF 006 Series, it is possible to order standard filters and filters with integral options by sending a type code string describing the product to the local Danfoss sales office. For example: AAF006A190T4E21HXXGCXXXSXXXXAXBXCFXXXDX

This section describes each character in the type code. In the example, a standard 190 A active filter in an enclosure with IP21 protection rating is selected for a 380–480 V net. The internet-based configurator configures the right filter for the right application and generates a type code string. The configurator automatically generates an 8-digit sales number to be delivered to the local sales office. It is also possible to establish a project list with several products and send it to a Danfoss sales representative. The configurator can be found at www.danfoss.com/BusinessAreas/DrivesSolutions/.

1.4.2 Ordering Form Type Code

130BB504.10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

A FA x0 0 A T 4 E H x G C x x x x x x x B x C x x x x xDAS

Illustration 1.4 Type Code Example

Possible choice

Product groups 1-3 AAF Series 4-6 006 Current rating 7-10 A190: 190 A

A250: 250 A A310: 310 A

A400: 400 A Phases 11 T: 3 Phases Mains Voltage 12 4: 380–480 V AC Enclosure 13-15 E21: IP21/Nema Type1

E54: IP54/Nema Type 12

E2M: IP21/Nema Type 1 with

mains shield

E5M: IP54/Nema Type 12 with

mains shield RFI filter 16-17 HX: No RFI filter

H4: RFI filter, Class A1 (optional) Display (LCP) 19 G: Graphical Local Control Panel

(LCP) Coating PCB 20 C: Coated PCB Mains option 21 X: No mains option

3: Mains disconnect and fuse

7: Fuse Adaptation A 22 Reserved Adaptation B 23 Reserved Software release 24-27 Reserved Software language

28 Reserved

A options 29-30 AX: No A option B options 31-32 BX: No B option C-option configuration

33-37 CFxxx: CO-option occupied with

active filter control card

D options 38-39 DO: 24 V back-up

DX: No options

Table 1.1 Type Code Definitions

176F3535 Backwall cooling kit for D14 (IP54) 176F3537 Backwall cooling kit for E1 (IP54)

Table 1.2 Optional Kits

Introduction

Operating Instructions

2 Safety

2.1 Safety Symbols

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation that could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that 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.

2.2 Qualified Personnel

Correct and reliable transport, storage, installation, operation and maintenance are required for the troublefree and safe operation of the active filter. Only qualified personnel are allowed to install or operate this equipment.

Qualified personnel is defined as trained staff, who are authorised to install, commission, and maintain equipment, systems and circuits in accordance with pertinent laws and regulations. Additionally, the personnel must be familiar with the instructions and safety measures described in this document.

2.3

Safety Precautions

WARNING

HIGH VOLTAGE

Active filters contain high voltage when connected to AC mains input. Failure to perform installation, start-up, and maintenance by qualified personnel can result in death or serious injury.

WARNING

DISCHARGE TIME

The active filter contains DC-link capacitors, which can remain charged even when the filter is not powered. Failure to wait the specified time after power has been removed before performing service or repair work can result in death or serious injury.

Voltage

[V]

Output Current

[A]

Minimum waiting

time

(minutes)

380–480 190–400 20

High voltage can be present even when the warning indicator

lights are off.

Table 2.1 Discharge Time

WARNING

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the filter properly can result in death or serious injury.

•

Ensure correct grounding of the equipment by a certified electrical installer.

WARNING

EQUIPMENT HAZARD

Contact with rotating shafts and electrical equipment can result in death or serious injury.

•

Ensure that only trained and qualified personnel perform installation, start up, and maintenance.

•

Ensure that electrical work conforms to national and local electrical codes.

•

Follow the procedures in this document.

CAUTION

INTERNAL FAILURE HAZARD

An internal failure in the filter can result in serious injury when the filter is not properly closed.

•

Before applying power, ensure all safety covers are in place and securely fastened.

Safety Operating Instructions

2 2

3 Mechanical Installation

3.1 Pre-installation

3.1.1 Planning the Installation Site

NOTICE

Due to the size and clearance requirements of the active filter, it is important to pre-plan installation. Failure to do so may result in additional work during and after installation.

Select the best possible operation site by considering the following:

•

Ambient temperature conditions.

•

Altitude at installation point.

•

Installation and compensation method.

•

Cooling.

•

Position of the active filter.

•

CT installation point and possibility to reuse existing CTs.

•

Cable routing and EMI conditions.

•

Ensure the power source supplies the correct voltage and frequency.

•

If the unit is without built-in fuses, ensure that the external fuses are rated correctly.

3.1.2

Receiving the Active Filter

When receiving the unit, ensure that the packaging is intact, and note any damage that may have occurred during transport. In case of damage, immediately contact the shipping company to claim the damage.

NOTICE

Damaged packaging can indicate rough transportation which may have caused interior failures in the unit. Claim damages even if the exterior of the unit seems intact.

3.1.3 Transportation and Unpacking

Place the active filter as close as possible to its final installation site before unpacking it. Keep the filter on the pallet and boxed as long as possible to avoid damage.

3.1.4

Lifting

Always lift the unit in the dedicated lifting eyes. Use a bar to avoid bending the lifting holes.

130BB642.10

Illustration 3.1 Recommended Lifting Method for AAF 006, Enclosure Sizes D14 and E1

NOTICE

The lifting bar must be able to handle the weight of the unit. See chapter 3.1.5 Mechanical Dimensions for weights. Maximum diameter for the bar is 25 mm (1 inch). The angle from the top of the unit to the lifting cable should be > 60°.

NOTICE

The plinth is required to allow airflow to the unit to provide proper cooling.

Mechanical Installation Operating Instructions

3.1.5 Mechanical Dimensions

1020.1 [40.2]

199.5 [7.9]

1394.0 [54.9]

1552.8 [61.1]

603.8 [23.8]

555.9 [21.9]

377.8 [14.9]

27.0 [1.1]

414.1 [16.3]

74.1 [2.9]

[8.9]

1780.5 [70.1]

221.6 [8.7]

273.2 [10.8]

130BC632.10

117.4 [4.6]

184.5 [7.3]

369.0 [14.5]

148.0 [5.8]

304.0 [12.0]

1755.5 [69.1]

251.0 [9.9]

160.0 [6.3]

13.0 [.5]

221.0 [8.7]

[225.0]

Illustration 3.2 AAF006 190 A, Enclosure Size D13

1 Minimum clearance from the ceiling 2 Backwall cooling option

Table 3.1 Legend to Illustration 3.2 and Illustration 3.3

Mechanical Installation Operating Instructions

3 3

600.0 [23.6]

493.5 [19.4]

1230.0 [48.4]

27.0 [1.1]

72.2 [2.8]

389.0 [15.3]

[8.9]

283.3 [11.2]

270.9 [11]

198.2 [7.8]

730.7 [28.8]

1394.1 [54.9]

1544.5 [60.8]

2001.0 [78.8]

184.5 [7.3]

369.0 [14.5]

553.5 [21.8]

23.3 [.9]

249.1 [9.8]

160.0 [6.3]

130BC633.10

225.0

Illustration 3.3 AAF006 250-400 A, Enclosure Size E1

Enclosure D14 E1

Enclosure protection

IP 21/54 21/54 NEMA Type 1/12 Type 1/12

Nominal current rate

190 A 250 A, 310 A, 400 A

Shipping dimensions Height

(mm/in.)

750/29.5 864/34

Width (mm/in.)

737/29 737/29

Depth (mm/in.)

1943/76.5 2203/86.7

Weight (kg/ lbs.)

283/623.9 500/1102.3

Unit dimensions Height

(mm/in.)

1780/70 2000/78.7

Width (mm/in.)

600/23.6 600/23.6

Depth (mm/in.)

380/14.9 494/19.4

MaximumWeight (kg/ lbs.)

238/524.7 453/998.7

Table 3.2 Mechanical Dimensions

Mechanical Installation

Operating Instructions

3.2 Mechanical Installation

Before installing the active filter, examine the mechanical drawings in chapter 3.1.5 Mechanical Dimensions to become familiar with the space demands.

3.2.1 Tools Needed

To perform the mechanical installation, the following tools are needed:

•

Drill with a 10 or 12 mm drill bit.

•

Tape measure.

•

Screw driver.

•

Wrench with 7–17 mm metric sockets.

•

Wrench extensions.

•

Sheet metal punch for conduits or cable glands.

•

Lifting bar to lift the unit (rod or tube maximum Ø 25 mm/0.9 in., able to lift minimum 1000 kg/ 2205 lbs.).

•

Crane or other lifting aid to place the unit in position.

•

Torx T50 tool.

3.2.2

Clearance Requirements

Space

Ensure proper space above and below the unit to allow airflow and cable access. In addition, ensure adequate space in front of the unit for the door to open (Illustration 3.4, Illustration 3.5).

67.3 [2.7]

575.9 [22.7]

574.2 [22.6]

130BC634.10

Illustration 3.4 Door Clearance IP21/IP54 Enclosure Type, Size D14

105.7 [4.2]

577.4 [22.7]

576.7 [22.7]

130BC635.10

Illustration 3.5 Door Clearance, IP21/IP54 Enclosure Type, Size E1

Wire access

Ensure that proper cable access including the necessary bending allowance.

NOTICE

Power cables are heavy and difficult to bend. To make installation easier, consider the optimum position of the unit before delivery.

NOTICE

All cable lugs/shoes must mount within the width of the terminal bus bar.

Mechanical Installation Operating Instructions

3 3

3.2.3 Power Terminal Locations

Consider the position of the terminals when designing for cable access. See Illustration 3.6, Illustration 3.7, Illustration 3.8, and Illustration 3.9

88.0 [3.5]

204.0 [8.0]

289.7 [11.4]

29.0 [1.1]

266.2 [10.5]

476.0 [18.7]

259.7 [10.2]

130BC636.10

Illustration 3.6 Terminal Location of D14 with Disconnect

284.1 [11.2]

83.7 [3.3]

167.2 [6.6]

241.9 [9.5]

271.9 [10.7]

505.0 [19.9]

486.0 [19.1]

130BC637.10

Illustration 3.7 Terminal Location of D14 without Disconnect

65.0 [2.6]

130.0 [5.1]

343.0 [13.5]

19.6 [.8]

628.7 [24.8]

194.0 [7.6]

75.0 [3.0]

719.1 [28.3]

389.0 [15.3]

730.7 [28.8]

130BC638.10

Illustration 3.8 Terminal Location of E1 with Disconnect

719.1 [28.3]

609.1 [24.0]

75.0 [3.0]

188.0 [7.4]

112.0 [4.4]

224.0 [8.8]

537.0 [21.1]

605.6 [23.8]

130BC639.10

Illustration 3.9 Terminal Location of E1 without Disconnect

NOTICE

Each terminal allows up to 4 cables with cable lugs or use of a standard box lug. Ground is connected to the relevant termination point in the unit.

Mechanical Installation Operating Instructions

3.2.4 Cooling and Airflow

There are different ways to cool the active filter:

•

Use the cooling ducts in the top and bottom of the unit

•

Take air into the back of the unit

•

Combine top, bottom, and back airflow

Back cooling

The active filter has a back channel cooling system where 85% of all heat is ducted via an IP54 segregated back channel. This reduces the needed airflow inside the enclosure and ensures less moisture and dust across vital components.

The back channel air is normally ventilated via the plinth inlet and ducted out the top of the enclosure. The design of the back channel can also take air from the control room and duct it back out again. This is supported to ease stress on the control room air conditioner and conserve energy. To support a backwall inlet, the unit air inlet has to be blocked via an optional cover and the air outlet ducted via an optional top duct.

NOTICE

The active filter fan runs for the following reasons:

•

Active filter running.

•

Specific heat sink temperature exceeded (power size dependent).

•

Specific power card ambient temperature exceeded (power size dependent).

•

Specific control card ambient temperature exceeded.

Once the fan is started, it runs for a minimum of 10 minutes.

External ducts

If additional duct work is added externally to the enclosure, the pressure drop in the ducting must be calculated. Use Illustration 3.10 and Illustration 3.11 to derate the unit according to the pressure drop.

0 0.5 4.9 13 27.3 45.9 66 89.3 115.7 147

(%)

(Pa)

Pressure Increase

Filter Derating

130BB932.10

Illustration 3.10 Enclosure Size D, Derating vs. Pressure Change Air Flow: 450 cfm (765 m3/h)

(%)

Filter Derating

0 0 0.1 3.6 9.8 21.5 43.4 76 237.5 278.9

(Pa)

Pressure Change

130BB933.10

147.1

Illustration 3.11 Enclosure Size E, Derating vs. Pressure Change Air Flow: 725 cfm (1230 m3/h)

Mechanical Installation Operating Instructions

3 3

3.2.5 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12)

Cables are connected through the gland plate from the bottom. Remove the plate and plan where to place the entry for the glands or conduits. Illustration 3.12 and Illustration 3.13 show the gland plate openings in bottom views.

NOTICE

The gland plate ensures the specified protection degree, and enables proper cooling of the unit. If the gland plate is not mounted, the unit may trip on Alarm 69, Pwr. Card

Temp.

55.9 [2.2]

257.0 [10.1]

21.9 [.9]

560.0 [22.0]

110.6 [4.4]

182.8 [7.2]

181.9 [7.2]

350.0 [13.8]

130BC640.10

Illustration 3.12 Enclosure Size D14, Bottom View

361.7 [14.2]

20.0 [.8]

560.0 [22.0]

154.8 [6.1]

257.6 [10.1]

40.0 [1.6]

520.0 [20.5]

48.9 [2]

Illustration 3.13 Enclosure Size E1, Bottom View

130BB736.11

Illustration 3.14 Mounting of Base Plate, E1

The base plate of the enclosure size E can be mounted from either inside or outside of the enclosure, allowing flexibility in the installation process. If mounted from the bottom, the glands and cables can be mounted before the unit is placed on the pedestal.

Mechanical Installation Operating Instructions

4 Electrical Installation

4.1 Safety Instructions

See chapter 2 Safety for general safety instructions.

CAUTION

SHOCK HAZARD

The active filter can cause a DC current in the PE conductor.

•

When a residual current-operated protective device (RCD) is used for protection against electrical shock, only an RCD of Type B is permitted on the supply side.

Failure to follow the recommendation means the RCD may not provide the intended protection.

4.2 Electrical Installation

4.2.1 Power Connections

Cabling and fusing

NOTICE

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. UL applications require 75 °C copper conductors. 75° and 90 °C copper conductors are thermally acceptable for use in non-UL applications.

The power cable connections are situated as shown in Illustration 4.1. The mains connection is fitted to the mains switch if this is included. Dimension the cable cross-section in accordance with the filter current rating, including skin and proximity effects, derating, and local legislation.

Connect mains to terminals 91, 92 and 93. Connect ground to the terminal on the immediate right of terminal 93.

Terminal number Function

91, 92, 93 94

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

Table 4.1 Mains and Ground Connections

The conductor predominantly carries currents of high frequencies so the distribution of current is not evenly dispersed throughout the cross-section of the conductor. This is due to 2 independent effects known as skin effect and proximity effect. Both require derating and, consequently, the mains cable of the active filter is rated at a higher current than the filter rating itself.

3 Phase

power

input

130BA026.10

91 (L1)

92 (L2)

93 (L3)

95 PE

Illustration 4.1 Mains Connection Diagram

NOTICE

It is insufficient to rate the power cable for the filter current rating alone due to skin and proximity effects.

The required derating is calculated as 2 separate factors:

•

The skin factor depends on frequency of current, cable material, and cable dimensions.

•

The proximity factor depends on the number of conductors, diameters and distance between the individual cables.

The proximity effect is depending on the number of conductors, diameters and distance between the individual cables.

The optimised mains cable is:

•

Copper wires.

•

Single conductors.

•

Bus bars.

Electrical Installation Operating Instructions

4 4

Copper affects skin less than aluminum, and bus bars have a larger surface area than cables, reducing the skin effect factor. Proximity effects of single conductors are negligible. The cable specifications in Table 4.2 take both skin and proximity effects into account:

Filter Minimum CU wire

mm2 (AWG)

Equivalent RMS

cable for CU

Minimum ALU wire

mm2 (AWG)

Equivalent RMS current for ALU

Maximum wire

mm2 (AWG)

190 A

70 mm2 (2/0)

225 A

95 mm2 (3/0)

240 A

2*150 mm2 (2*300 MCM)

250 A

120 mm2 (4/0)

295 A

150 mm2 (300 MCM)

315 A

4x240 mm2 (4x500 MCM)

310 A

240 mm2 (500 MCM)

365 A

2*95 mm2 (2*3/0)

390 A

4x240 mm2 (4x500 MCM)

400 A

2*95 mm2 (2*3/0)

470 A

2*150 mm2 (2*300 MCM)

500 A

4x240 mm2 (8x900 MCM)

Table 4.2 Allowed Active Filter Mains Cable with Typical Cable Manufacturer Data

Due to the built-in LCL filter, the unit does not feed the main wire with high dU/dt signals. Doing so reduces the radiated emission through the mains cable. Cable screen/shielding can thus be omitted allowing the mains cables to be connected without considering EMC requirements. The active filter can run at long cable runs. Cable length is limited by the voltage drop. It is advised to keep the cable lengths to less then 200 m.

Active filters have either built-in or customer-supplied fuses. See chapter 4.2.11 Fuses for fuse recommendations. Always ensure proper fusing according to local regulation.

4.2.2

Grounding

Consider the following basic issues when installing an active filter, to obtain electromagnetic compatibility (EMC):

•

Safety grounding: The active filter has leakage current and must be grounded appropriately for safety reasons. Apply local safety regulations.

•

High-frequency grounding: Keep the ground wire connections as short as possible.

•

Use high-strand wire to reduce electrical interference.

•

Do not use pigtails.

Connect the different ground systems at the lowest possible conductor impedance. Obtain the lowest possible conductor impedance by keeping the conductor as short as possible and using the greatest possible surface area. The metal cabinets of the different devices are mounted on the enclosure back plate using the lowest possible high frequency impedance. This avoids having different high frequency 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 is reduced. To obtain a low HF impedance, use the fastening bolts of the devices as a high-frequency connection to the back plate. Remove any insulating paint or similar substances from the fastening points.

130BB739.11

Ground terminals

Illustration 4.2

Electrical Installation Operating Instructions

4.2.3 EMC Interference

130BC643.10

1 Advanced active filter (AAF) 6

Potential equalisation wire [minimum 16 mm2/AWG 6] 2 Customer control termination points for options A and B 7 Clearance, minimum 200 mm (7.9 in) 3 Cable clamp 8 Mains, 3-phase and reinforced PE 4 Screened control wiring 9 Cable gland 5 Customer control input 10 External current transformer connections

Illustration 4.3 EMC-correct Installation

NOTICE

EMC INTERFERENCE

Use screened cables for control wiring. Separate AAF mains input cable from other cables and control wiring. Minimum 200 mm (7.9 in) clearance between mains and control cables is required. Maximise this clearance to minimise EMC emissions. Doing so reduces the risk of interference between the AAF and other electronic devices.

Electrical Installation Operating Instructions

4 4

4.2.4 Extra Protection (RCD)

ELCB, RCD, GFCI relays or multiple protective groundings are often used as extra protection, or needed to provide compliance with local safety regulations. In case of a ground fault, a DC component may develop in the fault current. Observe local regulations when using ELCB relays. To reassure effective protection and unintended tripping of protective relays, all relays must be suitable for protection of 3-phase equipment with active current infeed and for a brief discharge during power-up. Use a relay type with adjustable trip amplitude and time characteristics. Select a current sensor with sensitivity of more then 200 mA and not less than 0.1 s operation time.

4.2.5

RFI Switch

Mains supply isolated from ground (IT mains)

If the active filter is supplied from an isolated mains source (IT mains, floating delta and grounded delta) or TT/TN-S mains with grounded leg, the RFI switch is recommended to be turned off (OFF) 1) via 14-50 RFI Filter on the unit. For further reference, see IEC 364-3. In OFF mode, the internal RFI capacities between the chassis and the intermediate circuit are cut off to avoid damage to the intermediate circuit. Refer to the application note VLT® on IT mains. It is important to use isolation monitors that are capable for use together with power electronics (IEC 61557-8).

NOTICE

Marine grids are typically IT type grids.

4.2.6 Torque

Correct torque is imperative for all electrical connections. Incorrect torque results in a bad electrical connection. Torque values are provided in Table 4.3.

Enclosure size Torque Bolt size

D 19 Nm (168 in.-lbs.) M10 E 19 Nm (168 in.-lbs.) M10

Table 4.3 Correct Torque Values

Use a torque wrench to ensure correct torque.

176FA247.12

Nm/in-lbs

-DC 88

+DC 89

R/L1 91

S/L2 92

T/L3 93

U/T1 96

V/T2 97

W/T3

Illustration 4.4 Use a Torque Wrench to Tighten the Bolts

4.2.7

Current Transformer (CT)

The filter operates in close loop operation by receiving current signals for external current transformers. The received signal is processed and the filter reacts according to programmed actions.

CAUTION

Incorrect current transformer connection, installation or configuration leads to unintended and uncontrollable behaviour of the filter.

NOTICE

The current transformers are not part of the filter package and must be purchased separately.

CT specification

The active filter supports most CTs. The CTs must have the following specifications:

Technical specification of active filter, passive CT

RMS Maximum measured RMS current Accuracy 0.5% or better (Class 0.5) Secondary rated current

1A or 5A (5A is recommended)

Set-up via hardware Rated frequency 50/60 Hz Rated power/burden

See Table 4.5 (AAF burden equals 2 mΩ)

Table 4.4 CT Specifications

Electrical Installation

Operating Instructions

Rated power/ burden [VA]

5 7.5 10 15 30

Impedance of current CT [Ω]

≤ 0.15 ≤ 0.25 ≤ 0.35 ≤ 0.55 ≤ 1.15

Table 4.5 Rated Power/Burden

NOTICE

All other technical data such as dynamic rated current, maximal permitted operating voltage, thermal dimensioning of continuous current, thermal dimensioning of short-time current, overcurrent limit, isolation class, working temperature range etc. are specific values of the system and have to be defined during the project planning phase of the equipment.

RMS specification

The minimum RMS is determined by the total current that passes through the current transformer. It is important that the current sensor is not too small, leading to saturation of the sensor. Add 10% margin and pick the next following bigger standard RMS rate. Use current transformers that have an RMS rating close to the maximum current flowing through it to allow the highest possible accuracy of the measurement and so an ideal compensation.

CT burden

To ensure that the current transformer performs according to specifications, the rated burden should not be above the true current requirement of the active filter. The burden of the CT depends on the wire type and the cable length between the CT and the filter CT connection terminal. The filter itself contributes with 2 mΩ.

NOTICE

The accuracy of the CT is depending on wire type and length of the cable between filter and current transformer.

Calculate the required (minimum) CT burden as: [VA]=25*[Ω/M] *[M]+1.25 [Ω/M] being the cable resistance in Ω/meter, [M] being the cable length in meters.

Table 4.6 shows the minimum CT burden for different wire gauge at wire length of 50 m and standard wire resistance value:

Wire Gauge [mm2/AWG]

Resistance

[Ω/km]

Wire length

[meters/feet]

Minimum CT

burden [VA]

1.5/#16 13.3 50/164 >16.6

2.5/#14 8.2 50/164 >10.2 4/#12 5.1 50/164 > 6.3 6/#10 3.4 50/164 > 4.2 10/#8 2 50/164 > 2.5

Table 4.6 Minimum CT Burden

For a fixed CT burden, calculate the maximum allowed wire length as: [M]=([VA]-1.25)/(25*[Ω/M])

Below the maximum wire length of CT with 2.5 mm2 wires and resistor value equal 8.2 Ω/km:

Wire Gauge

[mm2/ AWG]

Resistance

[Ω/km]

Minimum CT

burden [VA]

Wire length [meter/feet]

2.5/#14 8.2 5 <18/60

2.5/#14 8.2 7.5 <30/100

2.5/#14 8.2 10 <42/140

2.5/#14 8.2 15 <67/220

2.5/#14 8.2 30 <140/460

Table 4.7 Maximum CT Wire Length

Example

Calculation example for correct current transformer for an application with: RMS=653 A, Distance between filter and CTs of 30 m. RMS=653*1.1=719 A, CT RMS=750 A. Burden: 30 m@2.5 mm2 wire =>25*0.0082*30+1.25=7.4=>7.5 [VA].

Current transformer installation

The unit only supports 3 CT installations. Install external CTs on all 3 phases to detect the harmonic content of the grid. The flow direction of the sensor is indicated by an arrow in most cases. The arrow points in the direction of the current flow and so towards the load. If the flow direction is programmed incorrectly, the polarity can be changed via active filter parameter 300-25 CT Polarity, which can program the polarity of the CTs in each of the 3 phases individually.

L1 L2

K L

91 92 93 L1 L2 L3

130BB510.12

Illustration 4.5 CT Connections

Electrical Installation Operating Instructions

4 4

1 or 5 A CT set-up

To allow for possible reuse of already present CT transformers, the active filter allows use of either 1 A or 5 A CTs. The filter is as standard set-up for 5 A CT feedback. If the CTs are 1 A, redirect the CT terminal plug from slot MK101, position 1, to MK108, position 2, on the AFC card. See Illustration 4.6.

130BB950.10

Illustration 4.6 AFC Card

Individual or group compensation

The compensation of the filter depends on the signal that is returned from the current transformers. The point of installation for these sensors is to determine the loads that are corrected.

Illustration 4.7 shows current transformers installed in front of the entire installation with the filter compensating all loads on the transformer. Illustration 4.8 shows current transformers installed in front of distribution bus 2 and 1 frequency converter, so the filter only compensates for those.

M M

PCC1

PCC2

130BB511.11

AAF

Illustration 4.7 CT on PCC Side

PCC1

PCC2

130BB512.10

AAF

Illustration 4.8 CT on Load Side

If the CTs are installed on the secondary side of the transformer and so in front of the entire load, the filter compensates all loads simultaneously. See Illustration 4.7.

Electrical Installation

Operating Instructions

If, as in Illustration 4.8, the CTs are installed in front of only some of the loads, the filter does not compensate unwanted current deformation of the frequency converter and motor on the right hand side. If CTs are installed in front of a single load, the filter only compensates the 1 load and so form individual load compensation.

CTs can be installed on the source side (PCC–point of common coupling), or on the load side via

parameter 300-26 CT Placement

NOTICE

The default setting is PCC side installation

PCC1

AAF

130BB513.11

Illustration 4.9 Current Transformers Installed on Source (PCC) Side for Group Compensation

PCC1

AAF

M M

130BB514.11

Illustration 4.10 Current Transformers Installed on Load Side for Group Compensation

If the current transformers are installed on the source (PCC) side, the filter expects a sinusoidal (corrected) signal feedback from the 3 sensors. If the sensors are installed on the load side, the received signal is subtracted from the ideal sine wave to calculate the necessary corrected current.

NOTICE

Erratic filter operation can be a result of incorrect current transformers connection point programming parameter 300-26 CT Placement.

Electrical Installation Operating Instructions

4 4

4.2.8 Auto CT Detection

The active filter performs an auto detection of the installed CT. The CT auto detection can be conducted both while the system is running and when there is no load. The filter injects a prefixed current of known amplitude and phase angle and measures the returned CT input. The performance is conducted on each phase individually for several frequencies to check that phase sequence and RMS are set correctly.

The Auto CT detection is pending on the following conditions:

•

Active filter bigger than 10% of CT RMS rate.

•

CTs installed on source (PCC) side (auto CT not possible for load side CT installation).

•

Only one CT per phase (not possible for summation CTs).

•

CTs are part of below standard range:

600 750

1000 1250 1500 2000 2500 3000 3500 4000

Table 4.8 Primary Rating [A]

Most restrictions on the CTs come from the installation, such as required cable length, temperature conditions, square section of conductors, standard or split core layout, etc. A broad range of different current transformers can be used independently of brand and type. For specific CT requirements contact the local supplier or go to www.deif.com/

Secondary Primary Accuracy Burden Type Description

5 or 1A 30–7500A 0.2–0.5-1 1.0–45 V A ASR

ASK EASR EASK

Measuring current transformer for cables and bus bars

5 or 1A 100–5000A 0.5–1 1.25–30 V A KBU Split core current transformer 5 or 1A 5 or 1A 0.5–1 15–30 V A KSU/SUSK Summation current transformer

Table 4.9 Standard CT Range from Deif: Fits Most Applications

Electrical Installation Operating Instructions

4.2.9 Summation Transformers

Multiple current sources

Summation CTs are needed when the filter is to compensate current from several sources. This is often the case if a filter is installed in systems with generator backup or where the filter is only to compensate a limited number of loads, for example, marine installations.

M M

PCC1

130BB515.11

AAF

Illustration 4.11 Summation CTs on Generator Back-up Applications (PCC-side)

AAF

PCC1

130BB516.11

Illustration 4.12 Summation CTs Example for Individual Harmonic Compensation (Load Side)

Summation current transformers are available with multiple (2–5) inputs and a common output. For applications where summations CTs are used to add current from several sources, make sure that all CTs connected to the summation are from the same manufacturer and that the following aspects are the same:

•

Polarity.

•

Primary rating.

•

RMS value.

•

Accuracy (class 0.5).

•

Location (PCC or load-side).

•

Phase sequence.

NOTICE

Use summation CTs with great caution and always ensure correct phase sequence, current direction, primary and secondary rating. Incorrect installation causes problems with filter operation.

The current transformers burden calculation includes all wires in the installation and must be conducted for the longest total wire string when using summation CTs.

Electrical Installation

Operating Instructions

4 4

Total current [A] Maximum individual harmonic compensation

I5 I7 I11 I13 I17 I19 I23 I25

190 133 95 61 53 38 34 30 27 250 175 125 80 70 50 45 40 35 310 217 155 99 87 62 56 50 43 400 280 200 128 112 80 72 64 56

Table 4.10 Maximum Individual Harmonic Compensation

4.2.10 Operating with Capacitor Banks

The active filter is able to run with capacitor banks as long as the resonance frequency of the capacitor bank is not in the operation range of the active filter.

NOTICE

Always use de-tuned capacitor banks in installations with frequency converters and active filters to avoid resonance phenomena, unintended tripping or component breakdown.

For de-tuned capacitors, the resonance frequency capacitors should be tuned for an inter-harmonic number lower than the 3rd harmonic.

NOTICE

If installed with capacitor banks of any kind, the active filter must operate in selective compensation mode.

The capacitor bank should be installed upstream of the filter toward the transformer. If this is not possible, install the current transformers such that they do not measure both needed current compensation and the capacitor corrected current.

PCC1

AAF

130BB517.11

Illustration 4.13 Capacitor bank mounted upstream. CTs do not measure capacitor current.

Illustration 4.13 shows recommended installation of the active filter and CT placement in installations containing capacitor banks.

PCC1

130BB518.11

AAF

Illustration 4.14 Incorrect Installation

Electrical Installation Operating Instructions

PCC1

130BB519.11

AAF

Illustration 4.15 CTs Do Not Measure Capacitor Current

For installations where the CT connection point can be moved, the configuration shown in Illustration 4.15 is also possible. In some retrofit applications, summation CTs are needed to ensure that the capacitor current is not measured.

Summation CTs can also be used to subtract 2 signals from each other and so subtract the capacitor bank corrected current from the total current.

NOTICE

Use summation CTs with an accuracy of 0.5% of better.

PCC1

130BB520.11

AAF

Illustration 4.16 Capacitor Bank Mounted on PCC with CTs Ensuring that Capacitor Corrected Current is not Measured.

Electrical Installation Operating Instructions

4 4

4.2.11 Fuses

Branch circuit protection

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

Short circuit protection

Protect the active filter against short circuit to avoid electrical or fire hazard. Danfoss recommends using the fuses in Table 4.11 and Table 4.12 to protect service personnel and equipment in case of an internal failure in the device.

Overcurrent protection

The active filter is equipped with an internal overcurrent protection that avoids overload in normal running conditions. Overload protection is needed in case of internal failures to avoid fire hazard due to overheating of the cables in the installation. Use fuses or circuit breakers for overcurrent protection and comply with local and national regulations.

Mains fuses

Active Filter Bussmann Rating

AAF006, 190 A 170M3018 350 A, 700 V AAF006, 250 A 170M4017 700 A, 700 V AAF006, 310 A 170M4017 700 A, 700 V AAF006, 400 A 170M6013 900 A, 700 V

Table 4.11 Recommended Mains Fuses

Supplemental fuses

Active Filter Protection Fuse Rating

AAF006, 190– 400A SMPS

Bussmann

KTK-4 4 A, 600 V AAF006, 190– 400A Fan

Littelfuse

KTK-15

15 A, 600

V AAF006, 190– 400A

Soft-charge resistor

Bussmann FNQ-

R 1 A, 600 V AAF006, 190– 400A CT

Bussmann FNQ-

R 3 A, 600 V

Table 4.12 Recommended Supplemental Fuses

4.2.12

Mains Disconnectors

Enclosure

size Power & voltage Type

D A190 380–480 V ABB OETL-NF200A

E A250 380–480 V ABB OETL-NF400A E A310 380–480 V ABB OETL-NF400A E A400 380–480 V ABB OETL-NF800A

Table 4.13 Mains Disconnect Part Numbers

4.2.13

Control and CT Cable Routing

Tie down all control wires to the designated control cable routing. Connect the shields properly to ensure optimum electrical immunity.

CT connection

Make connections on the terminal block below the active filter card. Place the cable in the path inside the filter and secure it with other control wires.

4.2.14 Control Wire Installation

All terminals to the control cables are located on the control or AFC board.

To connect the cable to the terminal:

1. Strip insulation 9–10 mm (0.4 in.)

130BA150.10

9 - 10 mm

(0.37 in)

Illustration 4.17 Stripped Insulation

2. Insert a screwdriver (maximum 0.4x2.5 mm) in the square hole.

130BT312.10

Illustration 4.18 Inserting the Cable

3. Insert the cable in the adjacent circular hole.

130BT311.10

Illustration 4.19 Removing the Screwdriver

Electrical Installation Operating Instructions

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Danfoss VLT AAF006 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual