MAKING MODERN LIVING POSSIBLE
VLT® Active Filter AAF00x
Instruction Manual
Contents VLT Active Filter AAF 00x
Contents
1 How to Read the Instruction Manual
1.1.1 Copyright, Limitation of Liability and Revision Rights 1-1
2 Safety
2.1.2 General Warning 2-1
2.1.3 Before Commencing Repair Work 2-1
2.1.4 Special Conditions 2-2
2.1.5 Avoid Unintended Start 2-2
2.1.6 IT Line Power 2-2
3 Introduction to VLT Active Filter AAF00x
3.1.1 Working Principle 3-1
3.1.2 Filter Configurator 3-2
3.1.3 Ordering Form type code 3-3
4 How to Install
4.1 How to Get Started
4.2 Pre-installation
1-1
2-1
3-1
4-1
4-1
4-1
4.2.1 Planning the Installation Site 4-1
4.2.2 Receiving the Active Filter 4-2
4.2.3 Transportation and Unpacking 4-2
4.2.4 Lifting 4-3
4.2.5 Mechanical Dimensions 4-4
4.3 Mechanical Installation
4.3.3 Terminal Locations - Frame size D 4-10
4.3.4 Terminal Locations - Frame size E 4-11
4.3.5 Cooling and Airflow 4-11
4.4 Field Installation of Options
4.4.1 Installation of Input Plate Options 4-14
4.5 Electrical Installation
4.5.1 Power Connections 4-15
4.5.7 Current Transformer (CT) 4-22
4.5.8 Auto CT Detection 4-25
4.5.9 Summation Transformers 4-26
4.5.10 Active Filter Operating with Capacitor Banks 4-27
4-9
4-14
4-15
4.5.11 Fuses 4-28
4.5.13 Control and CT Cable Routing 4-29
4.5.15 Unshielded Control Wires 4-30
MG.90.V2.22 - VLT® is a registered Danfoss trademark
Contents VLT Active Filter AAF 00x
4.6.1 Electrical Installation, Control Cables 4-32
4.7 Paralleling of Active Filter Units
4.8 Final Set-Up and Test
5 How to Operate the Active Filter
5.1.1 How to Operate Graphical LCP (GLCP) 5-1
5.1.6 Tips and Tricks 5-4
6 How to Program
6.2.1 Main Menu 6-4
6.3 0-** Operation/Display
6.4 5-** Digital I/O Mode
6.5 8-** General Settings
6.6 14-2* Trip Reset
6.7 15-0* Operating Data
6.8 16-0* General Status
6.9 300-**
6.10 301-**
6.11 Parameter Lists
4-34
4-36
5-1
6-1
6-4
6-11
6-14
6-17
6-19
6-23
6-25
6-27
6-28
6.11.1 Default settings 6-28
6.11.2 Operation/Display 0-** 6-29
6.11.3 Digital In/Out 5-** 6-30
6.11.4 Comm. and Options 8-** 6-30
6.11.5 Special Functions 14-** 6-31
6.11.6 Adj. Freq. Drive Information 15-** 6-32
6.11.7 Data Readouts 16-** 6-33
6.11.8 AF Settings 300-** 6-34
6.11.9 AF Readouts 301-** 6-35
7 RS-485 Installation and set-up
7.2 Network Configuration
7.3 FC Protocol Message Framing Structure
7.3.1 Content of a Character (byte) 7-2
7.3.3 Message Length (LGE) 7-3
7.3.5 Data Control Byte (BCC) 7-3
7.3.6 The Data Field 7-3
7.3.8 Parameter Number (PNU) 7-5
7-1
7-2
7-2
7.3.9 Index (IND) 7-5
7.3.10 Parameter Value (PWE) 7-5
MG.90.V2.22 - VLT® is a registered Danfoss trademark
Contents VLT Active Filter AAF 00x
7.3.11 Data Types Supported by VLT AutomationDrive 7-5
7.3.12 Conversion 7-6
7.3.13 Process Words (PCD) 7-7
7.4 How to Access Parameters
7.4.1 Parameter Handling 7-7
7.4.3 IND 7-7
7.4.4 Text Blocks 7-7
7.4.5 Conversion Factor 7-7
7.4.6 Parameter Values 7-7
8 General Specifications
8.1 Electrical Data
8.1.1 Power Rating 8-1
9 Troubleshooting
7-7
8-1
8-1
9-1
MG.90.V2.22 - VLT® is a registered Danfoss trademark
Contents VLT Active Filter AAF 00x
MG.90.V2.22 - VLT® is a registered Danfoss trademark
How to Read the Instruction... VLT Active Filter AAF 00x
1 How to Read the Instruction Manual
1 1
1.1.1 Copyright, Limitation of Liability and
Revision Rights
This publication contains information proprietary to
Danfoss. By accepting and using this manual, the user
agrees that the information contained herein will be used
solely for operating equipment from Danfoss or equipment
from other vendors provided that such equipment is
intended for communication with Danfoss equipment over
a serial communication link. This publication is protected
under the copyright laws of Denmark and most other
countries.
Danfoss does not warrant that a software program
produced according to the guidelines provided in this
manual will function properly in every physical, hardware
or software environment.
Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or
representation, either expressed or implied, with respect to
this documentation, including its quality, performance or
fitness for a particular purpose.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or
property damage-only accidents.
NOTE!
Indicates highlighted information that should be observed
in order to avoid mistakes or operate equipment at less
than optimal performance.
Approvals
In no event shall Danfoss be liable for direct, indirect,
special, incidental or consequential damages arising from
the use, or the inability to use information contained in
this manual, even if advised of the possibility of such
damages. In particular, Danfoss is not responsible for any
costs, including but not limited to those incurred as a
result of lost profits or revenue, loss or damage of
equipment, loss of computer programs, loss of data, the
costs to substitute these, or any claims by third parties.
Danfoss reserves the right to revise this publication at any
time and to make changes to its contents without prior
notice or any obligation to notify former or present users
of such revisions or changes.
Symbols
The following symbols are used in this manual.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
MG.90.V2.22 - VLT® is a registered Danfoss trademark 1-1
How to Read the Instruction... VLT Active Filter AAF 00x
11
1-2 MG.90.V2.22 - VLT® is a registered Danfoss trademark
Safety VLT Active Filter AAF 00x
2 Safety
2.1.1 Safety Note
WARNING
The voltage of the active filter is dangerous whenever
connected to line power. Incorrect installation of the filter
or options may cause damage to the equipment, serious
personal injury or death. Consequently, the instructions in
this manual, as well as national and local rules and safety
regulations, must be complied with.
Safety regulations
1. The filter must be disconnected from line power
if repair work is to be carried out. Check that the
line power supply has been disconnected and
that the necessary time has passed before
removing line power plugs.
2. The [OFF] key on the control panel does not
disconnect the equipment from line power and is
thus not to be used as a safety switch.
3. Correct protective grounding of the equipment
must be established and the user must be
protected against supply voltage in accordance
with applicable national and local regulations.
4. The ground leakage currents are higher than
3.5mA.
5. Do not remove the plugs for the line power while
the filter is connected to line power supply.
Check that the line power supply has been
disconnected and that the necessary time has
passed before removing line power plugs.
6. Please note that the filter has voltage inputs
other than L1, L2 and L3, when external 24V DC
have been installed. Make sure that all voltage
inputs have been disconnected and that the
necessary time has passed before commencing
repair work.
Installation at high altitudes
NOTE!
At altitudes above 9843 ft [3 km], please contact Danfoss
Drives regarding PELV.
2.1.2 General Warning
WARNING
Touching the electrical parts may be fatal - even after the
equipment has been disconnected from line power.
Before touching any potentially live parts of the unit, wait
at least as follows:
380–480 V, 190–400A, wait at least 20 minutes.
Shorter time is allowed only if indicated on the nameplate
for the specific unit. Be aware that there may be high
voltage on the DC links even when the control card LEDs
are turned off. A red LED is mounted on a circuit board
inside the active filter to indicate the DC bus voltages. The
red LED will stay lit until the DC link is 50V DC or lower.
CAUTION
Leakage current
The ground leakage current from the filter exceeds 3.5mA.
According to IEC 61800-5-1 a reinforced protective ground
connection must be ensured by means of an PE wire with the same cable cross-section as the line power wiring
- must be terminated separately.
Residual Current Device
This product can cause DC current in the protective
conductor. Where a residual current device (RCD) is used
for extra protection, only an RCD of Type B (time delayed)
shall be used on the supply side of this product. Protective
grounding of the filter and the use of RCDs must always
follow national and local regulations.
Before Commencing Repair Work
2.1.3
WARNING
Hazardous Voltage!
1. Disconnect the filter from line power
2. Wait at least the amount of time indicated in
section General Warning above
Failure to follow recommendations could result in death or
serious injury.
2 2
MG.90.V2.22 - VLT® is a registered Danfoss trademark 2-1
Safety VLT Active Filter AAF 00x
2.1.4 Special Conditions
2.1.6 IT Line Power
22
Electrical ratings:
The rating indicated on the nameplate of the active filter is
based on a typical 3-phase line power supply, within the
specified voltage, current and temperature range, which is
expected to be used in most applications.
The unit also supports other special applications, which
affect the electrical ratings of the filter. Special conditions
that affect the electrical ratings might be:
High temperature applications which require
•
derating of the electrical ratings
High altitude installation which require derating
•
of the electrical ratings
Marine applications with more severe environ-
•
mental conditions
Consult the relevant clauses in these instructions for
information about the electrical ratings.
Installation requirements:
The overall electrical safety of the active filter requires
special installation considerations regarding:
Fuses and circuit breakers for overcurrent and
•
short-circuit protection
Selection of power cables (line power and relays)
•
Grid configuration (IT,TN, grounded leg, etc.)
•
Safety of low-voltage terminals (PELV conditions)
•
Consult the relevant clauses in these instructions for
information about the installation requirements.
NOTE!
IT line power
Do not connect the unit with RFI filters to line power
supplies with a voltage between phase and ground of
more than 440V for 400V.
For 400V IT line power and delta ground (grounded leg),
AC line voltage may exceed 440V between phase and
ground.
14-50 RFI Filter can be used to disconnect the internal RFI
capacitors from the RFI filter to ground.
Disposal Instructions
2.1.7
Equipment containing electrical components
may not be disposed of together with domestic
waste.
It must be separately collected with electrical
and electronic waste according to local and
currently valid legislation.
Avoid Unintended Start
2.1.5
NOTE!
While the active filter is connected to line power, the
device can be started/stopped using digital commands,
bus commands, references or via the Local Control Panel.
Disconnect the unit from line power whenever
•
personal safety considerations make it necessary
to avoid unintended start.
To avoid unintended start, always activate the
•
[OFF] key before changing parameters.
2-2 MG.90.V2.22 - VLT® is a registered Danfoss trademark
M
M M
130BB717.10
130BB718.10
Control
Manual
Disconnect
Fuse
Option
Soft charge
circuit
130BB719.10
Introduction to VLT Active ... VLT Active Filter AAF 00x
3 Introduction to VLT Active Filter AAF00x
3.1.1 Working Principle
VLT® Active Filter AAF00x is a device for harmonic current
mitigation and reactive current compensation. The unit is
designed for installation in various systems and
applications as centrally installed filter(s) or combined with
a VLT Adjustable frequency drive as a packaged low
harmonic drive solution.
The active shunt filter monitors all three 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.
The counter phase signals are generated by setting
different IGBT switches in real time feeding a DC voltage
into the grid. The compensated current waveform is
smoothened via a built-in LCL filter making sure that the
IGBT switching frequency and DC component is not
imposed to the grid. The filter is able to operate on
generator or transformer supply and is able to reduce
individual motor, non-linear loads or mixed loads. All
nonlinear-loads (diode feed loads) must hold AC coils to
protect these units against overcurrent of the input diodes.
The factory settings allow for fast start-up, though
dedicated programming is possible through the local user
control panel LCP allowing adaptation to more demanding
applications.
The filter allows either overall or selective harmonic
compensation modes. In overall compensation mode all
harmonics will be reduced towards zero. In this operation
mode the filter will also balance out the load to reduce
uneven load distribution between the three phases. The
steady state performance will allow the compensation of
harmonics until the 40th order, though the ultra-quick
current injection allows the filter to also compensate flicker
and other quick and short-term phenomenon. In selective
mode, the filter allows the user to program acceptable
individual harmonic levels between the 5th and 25th
orders. In selective mode the filter will not reduce even
harmonic orders or triplings, nor will it support phase load
balancing and flicker reduction.
3
3
MG.90.V2.22 - VLT® is a registered Danfoss trademark 3-1
In addition to the harmonic compensation mode the filter
also allows the user to program the filter priority from
either reactive current or harmonic compensation. If
harmonic compensation is chosen as the first priority, the
filter will use the necessary current for harmonic reduction
and energy for reactive current correction, though only if
Introduction to VLT Active ... VLT Active Filter AAF 00x
3
excess energy is at hand. The filter will automatically and
continuously assign energy between first and second
priorities to provide the highest possible mitigation of
both reactive and harmonic compensation. This ensures
that the true power factor is continuously optimized and
that the highest possible utilization of the supply
transformer current is secured. Filter LCP provides a userfriendly programming structure and allows multiple
readouts on the LCP. Some readouts are calculated and
approximated values and, consequently, they cannot be
compared with readouts of a power quality analyzer due
to different sample rates and harmonic order content.
It is not possible to overload the active filter due to the
self protection circuitry that automatically reduces the
compensated current to a level where the filter is at a
stable temperature condition. If the mitigation demand is
higher than the filter rating, the filter will compensate to
the best of its ability and leave remaining harmonics or
reactive currents unaffected.
The active filter is standard equipped with an RFI filter
fulfilling the EMC industrial (second) environment standard
IEC55011 Class A2 equal category C3 of IEC61800-3.
English, German, French, Danish, Dutch, Spanish, Swedish,
Italian and Finnish.
Language package 2
English, German, Chinese, Korean, Japanese, Thai,
Traditional Chinese and Bahasa Indonesian.
Language package 3
English, German, Slovenian, Bulgarian, Serbian, Romanian,
Hungarian, Czech and Russian.
Language package 4
English, German, Spanish, English US, Greek, Brazilian
Portuguese, Turkish and Polish.
To order filters with a different language package, please
contact your local sales office.
Filter Configurator
3.1.2
It is possible to design an active filter according to the
application requirements by using the ordering number
system. For the VLT Active Filter AAF 00x Series, you can
order standard filters and filters with integral options by
sending a type code string describing the product to the
local Danfoss sales office, i.e.:
AAF 00XA190T4E21H2xGCXXXSXXXXAxBXCFXXXDx
The meaning of the characters in the string can be located
in the following pages containing the ordering numbers
and option settings. In the example above a standard 190A
Active Filter is chosen in an IP21 enclosure for a 380–480V
net. From the Internet based configurator, you can
configure the right filter for the right application and
generate the type code string. The configurator will
automatically generate an 8-digit sales number to be
delivered to your local sales office. Furthermore, you can
establish a project list with several products and send it to
a Danfoss sales representative. The configurator can be
found on the global Internet site: www.danfoss.com/drives.
Filters will automatically be delivered with a language
package relevant to the region from which it is ordered.
Four regional language packages cover the following
languages:
Language package 1
3-2 MG.90.V2.22 - VLT® is a registered Danfoss trademark
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
Introduction to VLT Active ... VLT Active Filter AAF 00x
3.1.3 Ordering Form type code
3
3
Possible choice
Product groups 1-3 AAF
Series 4-6 005
Current rating 7-10 A190: 190Amp
A250: 250Amp
Phases 11 T: Three Phases
AC Line Voltage 12 4: 380–480V AC
enclosure 13-15 E21: IP21/Nema Type1
ESH: IP54 hybrid
RFI filter 16-17 H2: RFI filter, Class A2
(standard)
H4: RFI filter, Class A1 (optional)
Display (LCP) 19 G: Graphical Local Control
Panel (LCP)
Coating PCB 20 C: Coated PCB
Line power option 21 X: No AC line option
3: Line power 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
D options 38-39 DX: No Options
33-37 CFxxx: CO option occupied
with active filter control card
Possible choice
Product groups 1-3 AAF
Series 4-6 006
Current rating 7-10 A190: 190Amp
A250: 250Amp
A310: 310Amp
A400: 400 Amp
Phases 11 T: Three Phases
AC Line Voltage 12 4: 380–480V AC
enclosure 13-15 E21: IP21/Nema Type1
E54: IP54/Nema Type 12
E2M: IP21/Nema Type 1 with line
power shield
E5M: IP54/Nema Type 12 with
line power shield
RFI filter 16-17 H2: RFI filter, Class A2 (standard)
H4: RFI filter, Class A1 (optional)
Display (LCP) 19 G: Graphical Local Control Panel
(LCP)
Coating PCB 20 C: Coated PCB
Line power option 21 X: No AC line option
3: Line power 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 AQ: MCA-122 Modbus TCP
AX: No A option
B options 31-32 BX: No B option
C option configuration
D options 38-39 DO: 24V backup
33-37 CFxxx: CO option occupied with
active filter control card
DX: No Options
MG.90.V2.22 - VLT® is a registered Danfoss trademark 3-3
3
Introduction to VLT Active ... VLT Active Filter AAF 00x
3-4 MG.90.V2.22 - VLT® is a registered Danfoss trademark
K L
K L
K L
L1
L2
L3
92
L2
91
L1
93
L3
95
6
5
4
3
2
1
CTs
130BB720.11
How to Install VLT Active Filter AAF 00x
4 How to Install
4.1 How to Get Started
This chapter covers mechanical and electrical installations
to and from power terminals and control card terminals.
4.1.1 How to Get Started
The active filter is designed to achieve a quick and EMCcorrect installation by following the steps described below.
WARNING
Read the safety instructions before installing the unit.
Failure to follow recommendations could result in death or
serious injury.
Mechanical Installation
Mechanical mounting
•
Electrical Installation
Connection to Line and Protecting Ground
•
CT connection and cables
•
Fuses and circuit breakers
•
Control terminals - cables
•
Quick set-up
Local Control Panel of filter
•
Programming
•
4 4
Figure 4.1 Diagram showing basic installation, including line
power and CTs.
4.2 Pre-installation
4.2.1 Planning the Installation Site
NOTE!
Before performing the installation, it is important to plan
the installation of the filter. Neglecting this may result in
extra work during and after installation.
Select the best possible operation site by considering the
following (see details on the following pages):
Ambient temperature conditions
•
Altitude at installation point
•
Installation and compensation method
•
How to cool the unit
•
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-1
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.
How to Install VLT Active Filter AAF 00x
4.2.2 Receiving the Active Filter
When receiving the unit, please make sure that the
packaging is intact, and be aware of any damage that
might have occurred to the unit during transport. If
damage has occurred, immediately contact the shipping
company to make a damage claim.
44
NOTE!
Damaged packaging can indicate inappropriate transport
which might have resulted in internal unit damage. Even
though the unit seems to be intact externally, make sure
to survey the damage.
4.2.3 Transportation and Unpacking
Before unpacking the active filter it is recommended that it
is located as close as possible to the final installation site.
Keep the filter on the pallet and boxed, as long as possible
to avoid scratches and dents.
4-2 MG.90.V2.22 - VLT® is a registered Danfoss trademark
130BB494.10
130BB642.10
How to Install VLT Active Filter AAF 00x
4.2.4 Lifting
Always lift the unit in the dedicated lifting eyes. Use a bar
to avoid bending the lifting holes.
4 4
Figure 4.3 Recommended Lifting Method for AAF 006, Frame
Sizes D13 and E9.
Figure 4.2 Recommended Lifting Method for AAF 005, Frame
Sizes D9 and E7.
NOTE!
The lifting bar must be able to handle the weight of the unit. See Mechanical Dimensions for the weight of the different
frame sizes. Maximum diameter for bar is 1 in [25mm]. The angle from the top of the unit to the lifting cable should be 60°
or greater.
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-3
1733,6
[68]
1553,4
[61]
1853,6
[73]
200.0
[8]
377,8
[15]
130BB495.10
840
How to Install VLT Active Filter AAF 00x
NOTE!
Note the plinth is provided in the same packaging as the filter, but is not always attached to frame during shipment. The
plinth is required to allow airflow to the unit to provide proper cooling. The plinth of the D and E-frames filters should be
mounted before the unit is lifted to its final position.
4.2.5 Mechanical Dimensions
44
Figure 4.4 Frame size D9, AAF05
4-4 MG.90.V2.22 - VLT® is a registered Danfoss trademark
1732
[68.2]
1553
[61.1]
200
[7.9]
602
[23.7]
1781
[70.1]
378
[14.9]
130BB961.10
1549,9
[61]
2119,8
[83]
159,2
[8]
493,5
[19]
2000,1
[79]
130BB496.10
840
How to Install VLT Active Filter AAF 00x
4 4
Figure 4.5 Frame size D13, AAF06
Figure 4.6 Frame size E7, AAF05
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-5
2004.50 mm
1491.35 mm
493.23 mm
2000
[78,78]
195
[7,68]
491,19
[19,43]
130BB644.10
1498
[59,06]
600
How to Install VLT Active Filter AAF 00x
44
Figure 4.7 Frame size E9, AAF06
4-6 MG.90.V2.22 - VLT® is a registered Danfoss trademark
How to Install VLT Active Filter AAF 00x
Mechanical dimensions and rated power
Frame size D9 E7
4 4
Version AAF05 AAF05
enclosure protection
Nominal current rate 190A 250A
Shipping Dimensions Height (in
Filter Dimensions Height (in
IP 21/54 hybrid 21/54 hybrid
NEMA Type 1 Type 1
[mm])
Width (in
[mm])
Depth (in
[mm])
Weight (lbs
[kg]):
[mm])
Width (in
[mm])
Depth (in
[mm])
Max weight
(lbs [kg])
72.9 [1852] 83.1 [2111]
44 [1118] 44 [1118]
37.3 [947] 37.3 [947]
15.8 [400] 17.7 [450]
68.2 [1732] 78.7 [2000]
33 [840] 33 [840]
15 [380] 19.4 [494]
646 [293] 776 [352]
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-7
130BB646.10
130BB645.10
How to Install VLT Active Filter AAF 00x
Mechanical dimensions and rated power
Frame size D13 E9
44
Version AAF06 AAF06
enclosure protection
Nominal current rate 190A 250, 310, 400A
Shipping Dimensions Height (in
Filter Dimensions Height (in
IP 21/54 21/54
NEMA Type 1/12 Type 1/12
[mm])
Width (in
[mm])
Depth (in
[mm])
Weight (lbs
[kg]):
[mm])
Width (in
[mm])
Depth (in
[mm])
Max weight
(lbs [kg])
29.5 [750] 34 [864]
29 [737] 29 [737]
76.5 [1943] 86.7 [2203]
13.4 [340] 19.7 [500]
68.5 [1740] 78.7 [2000]
23.6 [600] 23.6 [600]
15 [380] 19.4 [494]
646 [293] 1010 [458]
4-8 MG.90.V2.22 - VLT® is a registered Danfoss trademark
849.1
[33.4]
3x771.0
[30.4]
130BB497.10
599.60 mm
600
[23]
380
[15]
130BB721.11
600
[23]
How to Install VLT Active Filter AAF 00x
4.3 Mechanical Installation
Preparation of the mechanical installation of the filter must
be done carefully to ensure a proper result and to avoid
additional work during installation. Start taking a close
look at the mechanical drawings in 4.2.5 Mechanical
Dimensions to become familiar with the space demands.
4.3.1 Tools Needed
To perform the mechanical installation, the following tools
are needed:
Drill with 0.39 or 0.47 in [10 or 12 mm] drill bit.
•
Tape measure
•
Screw driver
•
Wrench with relevant metric sockets (7–17mm)
•
Wrench extensions
•
Sheet metal punch for conduits or cable
•
connectors
Lifting bar to lift the unit (rod or tube max. Ø 1 in
•
[25mm], able to lift minimum 2204 lbs [1000 kg]).
Crane or other lifting aid to place the unit in
•
position
Torx T50 tool
•
General Considerations
4.3.2
Space
Ensure proper space above and below the unit to allow
airflow and cable access. In addition, space in front of the
unit must be considered to allow the panel door to be
opened.
4 4
Figure 4.8 Space in front of IP21/IP54 enclosure type, frame size
D9.
Figure 4.9 Space in front of IP21/IP54 enclosure type, frame size
D13.
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-9
849,0
[33]
889,1
[35]
130BB498.10
597.00 mm
1068.91 mm
1069
[42,08]
597
[23,50]
130BB722.10
How to Install VLT Active Filter AAF 00x
44
Figure 4.10 Space in front of IP21/IP54 enclosure type, frame
size E7.
Figure 4.11 Space in front of IP21/IP54 enclosure type, frame
size E9.
Wire access
Ensure that proper cable access is present including the
necessary bending allowance.
NOTE!
All cable lugs/shoes must mount within the width of the
terminal bus bar.
4.3.3 Terminal Locations - Frame size D
Consider the following position of the terminals when
designing for cables access.
4-10 MG.90.V2.22 - VLT® is a registered Danfoss trademark
130BB425.10
0
[.0]
0
[.0]
0
[.0]
3x277,1
[10.9]
239,6
147,7
[10.6]
[5.8]
263,6
[10.4]
35,6
[13.8]
R/L1 91 T/L3 93S/L
3X 276,87
[10.9]
0
[.0]
267,4
[10.5]
0
[.0]
120,8
[4.8]
236,8
[9.3]
0
[.0]
324,8
[12.8]
130BB723.10
130BB431.10
332.5
[13.1]
.0
[.0]
.0
[.0]
.0
[.0]
407.5
[16.0]
332.0
[13.1]
88.0
[3.5]
168.0
[6.6]
323,9
[12,8]
0
[0]
0
[0]
0
[0]
380,7
[15]
169,7
[6,6]
258,7
[10,2]
348,7
[13,7]
130BB724.10
How to Install VLT Active Filter AAF 00x
Figure 4.12 Terminal Location of Frame D9
4 4
Figure 4.14 Terminal Location of Frame E7
Figure 4.13 Terminal Location of Frame D13
Be aware that the power cables are heavy and hard to
bend. Consider the optimum position of the unit for
ensuring easy installation of the cables.
Terminal Locations - Frame size E
4.3.4
Give thought to the following terminal positions when
designing the cable access.
Figure 4.15 Terminal Location of Frame E9
NOTE!
Note that the power cables are heavy and difficult to
bend. Consider the optimum position of the unit for
ensuring easy installation of the cables.
Each terminal allows for the use of up to 4 cables with
cable lugs or the use of standard box lug. Ground is
connected to relevant termination point in the unit.
4.3.5 Cooling and Airflow
Cooling
Cooling can be obtained in different ways, by using the
cooling ducts in the bottom and the top of the unit, by
taking air in the back of the unit or by combining the
cooling possibilities.
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-11
90
80
70
60
50
40
30
20
10
0
0 0.5 4.9 13 27.3 45.9 66 89.3 115.7 147
(%)
(Pa)
Pressure Increase
Filter Derating
130BB932.10
90
80
70
60
50
40
30
20
10
0
(%)
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
How to Install VLT Active Filter AAF 00x
Back cooling
The design of the active filter is built on 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 moist and dust
External ducts
If additional duct work is added externally to the Rittal
cabinet, the pressure drop in the ducting must be
calculated. Use the charts below to derate the unit
according to the pressure drop.
ventilation across vital components.
The back channel air is normally ventilated via the plinth
44
inlet and ducted out the top of the enclosure. The design
of the back channel does, however, also allow air to be
taken from outside the control room and dusted back out
again. This is supported to ease stress on the control room
air conditioner and so conserve energy. To support back
wall inlet, the unit air inlet has to be blocked via an
optional cover and the air outlet ducted via an optional
top duct.
NOTE!
A door fan is required on the enclosure to remove the
heat losses not contained in the back channel of the unit
and any additional losses generated from other
components installed inside the enclosure. The total
required air flow must be calculated so that the
appropriate fans can be selected. Some enclosure
manufacturers offer software for performing the
calculations (e.g., Rittal Therm software).
Figure 4.16 D frame Derating vs. Pressure Change
Air flow: 450 cfm (765 m3/h)
Airflow
The necessary airflow over the heatsink must be ensured.
The flow rate is shown below.
Enclosure
Frame size D13/D9 E9, E7
Door fan
Heatsink
Table 4.1 Heatsink Air Flow
IP21 / IP54 IP21/54
340m3/h (200 cfm) 340m3/h (200 cfm)
765m3/h (450 cfm) 1230m3/h (725 cfm)
NOTE!
For the active filter, the fan runs for the following reasons:
1. Active filter running
2. Specific heatsink temperature exceeded (power
size dependent)
3. Specific Power Card ambient temperature
exceeded (power size-dependent)
4. Specific Control Card ambient temperature
exceeded
Once the fan is started, it will run for a minimum of 10
minutes.
4-12 MG.90.V2.22 - VLT® is a registered Danfoss trademark
Figure 4.17 E frame Derating vs. Pressure Change
Air flow: 725 cfm (1230m3/h)
Connector/Conduit Entry - IP21
4.3.6
(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 connectors or conduits. Prepare holes in the
marked area on the drawing.
246,0
[10]
20,0
[1]
380,0
[15]
419,7
[17]
55,9
[2]
2X
130BB499.10
560
[22.0]
350
[13.8]
20
[.8]
2X370
[14.6]
2X200
[7.9]
60
[2.4]
69,5
[2.74]
70,4
[2.77]
203
[8.0]
246
[9.7]
2X113
[4.4]
60
[2.3]
115
[4.5]
2X223
[8.8]
70
[2.8]
130BB963.10
130BB500.10
800,0
[32]
361,7
[14]
55,9
[2]
380,0
[15]
20,0
[1]
2X 370
[15]
60
[2.5]
2X 200
[8]
2X 112.75
[4.5]
2X 222.75
[9]
74.6
[3]
350
[14]
70
[3]
202.75
[8]
84.6
[3.5]
560
[22]
361.7
[14.5]
70.4
[3]
20
[1]
130BB734.10
5.10
[.2]
How to Install VLT Active Filter AAF 00x
NOTE!
The connector plate must be fitted to the active filter to
ensure the specified protection degree, as well as ensuring
proper cooling of the unit. If the connector plate is not
mounted, the unit may trip on Alarm 69, Pwr. Card Temp
Cable entries viewed from the bottom of the filter
4 4
Figure 4.20 Frame Size E7
Figure 4.18 Frame Size D9
Figure 4.19 Frame Size D13
Figure 4.21 Frame Size E9
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-13
130BB736.10
How to Install VLT Active Filter AAF 00x
44
Figure 4.22 Mounting of bottom plate, E
The bottom plate of the E frame can be mounted from either inside or outside of the enclosure, allowing flexibility in the
installation process, i.e., if mounted from the bottom the connectors and cables can be mounted before the unit is placed
on the pedestal.
4.4
Field Installation of Options
4.4.1 Installation of Input Plate Options
This section is for the field installation of input option kits available for active filters.
Do not attempt to remove RFI filters from input plates. Damage may occur to RFI filters if they are removed from the input
plate.
D9 177G2348 177G2344 177G2346 177G2347 177G2343 177G2345
E7 176F0253 176F0255 176F0257 176F0258 176F0260
D13 177G2348 177G2344 177G2346 177G2347 177G2343 177G2345
E9 176F0253 176F0255 176F0257 176F0258 176F0260
Fuses Disconnect and
Fuse
RFI Fuses & RFI Fuses, RFI &
Disconnect
None
4-14 MG.90.V2.22 - VLT® is a registered Danfoss trademark
How to Install VLT Active Filter AAF 00x
consequently, the line power wire of the active filters must
4.5 Electrical Installation
be rated at a higher current than the filter rating itself.
4.5.1 Power Connections
Cabling and fusing
NOTE!
Cables General
All cabling must comply with national and local
regulations on cable cross-sections and ambient
temperature. UL applications require 167°F [75°C] copper
conductors. 7167°F [75°C] and 194°F [90° and 90 °C]
copper conductors are thermally acceptable for use in nonUL applications.
NOTE!
It is insufficient to rate the power cable for the filter
current rating alone due to skin and proximity effects.
4 4
The power cable connections are situated as shown below.
The AC line input connections are fitted to the line power
switch if this is included. Dimensioning of the cable crosssection must be done in accordance with the filter current
rating including skin and proximity effects, derating and
local legislation.
The line power supply must be connected to terminals 91,
92 and 93. Ground is connected to the terminal to the
right of terminal 93.
Terminal No.
91, 92, 93
94
The conductor predominantly carries currents of high
frequencies so the current distribution is not evenly
dispersed throughout the conductor cross-section. This is
due to two independent effects known as skin effect and
proximity effect. Both effects make derating necessary and,
Filter
190A
250A
310A
400A
Function
Line power R/L1, S/L2, T/L3
Ground
Min CU wire Min ALU wire Max wire
70mm2 (2/0) 95mm2 (3/0) 2*150mm2 (2*300MCM)
120mm2 (4/0) 150mm2 (300MCM) 4x240mm2 (4x500MCM)
240 mm2 (500MCM) 2*95mm2 (2*3/0) 4x240mm2 (4x500MCM)
2*95mm2 (2*3/0) 2*150mm2 (2*300MCM) 4x240mm2 (8x900MCM)
The required derating is calculated as two separate factors:
one for the skin effect and one for the proximity effect.
The skin factor depends on the conduction frequency,
cable material and cable dimensions. The proximity effect
depends on the number of conducts, diameters and the
distance between the individual cables.
The optimized line power wire is:
Copper wires
•
Single conducts
•
Bus bars
•
The reason for this is that copper has a lower skin effect
factor than aluminum. Bus bars have a greater surface area
compared to cables, which also reduces the skin effect
factor. The proximity effects of single conductions are
negligible.
The following cables specifications take both skin and
proximity effects into account:
Table 4.2 Allowed Active Filter Line Cable with Typical Cable Manufacturer Data
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-15
130BB501.10
8
7
6
5
4
3
1
9
2
How to Install VLT Active Filter AAF 00x
Due to the built-in LCL filter, the unit will not feed the main wire with high dU/dt signals. That reduces the radiated
emission through the power cable. Cable screen can thus be omitted, allowing the line cables to be connected without
considering EMC requirements.
The active filter will be able to operate on long cable runs. Cable length is limited by the voltage drop. It is advised to keep
the cable lengths below 656 ft [200 m].
To protect the active filter, the recommended fuses must be used or the unit must have built-in fuses. Recommended fuses
44
can be seen in the tables of the fuse section. Always ensure that proper fusing is done according to local regulations.
Figure 4.23 Frame size D9
RFI 5) LCL line reactor
1)
2) Line power wire connection 6) LCL capacitors
R S T 7) LCL filter reactor
L1 L2 L3 8) CT wire connection point
3) Input plate 9) Fan/SMPS fuse
4) Back channel fan
4-16 MG.90.V2.22 - VLT® is a registered Danfoss trademark
130BB738.11
7
3
2
1
6
8
4
5
10
9
How to Install VLT Active Filter AAF 00x
4 4
Figure 4.24 Frame size D13
MG.90.V2.22 - VLT® is a registered Danfoss trademark 4-17
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