Danfoss VLT Active Front End AFE 302 User manual

Operating Instructions MG33X202
MAKING MODERN LIVING POSSIBLE
Operating Instructions
VLT® Active Front End AFE 302
www.danfoss.com/drives
*MG33X202*
130R0429 MG33X202 Rev. 2010-06-29

Contents
1 Introduction 4
1.1.1 How to Read these Operating Instructions 4
1.1.2 Symbols 4
1.1.3 Software Version 4
1.1.4 Approvals 4
1.1.5 Abbreviations 5
2 Safety Instructions and General Warning 6
2.1.1 Disposal Instruction 6
2.1.2 High Voltage Warning 6
2.1.3 Safety Instructions 6
2.1.4 General Warnings 6
2.1.5 Before Commencing Repair Work 6
2.1.6 System Description 6
3 Crane System Design 8
3.1 Selection of Motor Voltage 8
3.1.1 Selection of AFE & LCL Filter 8
3.1.2 Selection of AFE for Different Applications 8
3.1.3 Selection of Output Filter (LC Filter) 8
3.1.4 Selection of Switching Frequency 8
3.1.5 Selection of LCL Filter 8
3.1.6 Crane Cable Concept 8
3.1.7 Grounding Concept 9
3.1.8 Cooling and Airflow 9
3.1.9 Selection of Transformer 10
3.2 Assembling the Frequency Converter System 11
3.2.1 Tools Required 11
3.2.2 General Torque Tightening Values 11
3.2.3 Exploded Views 12
3.2.4 MDCIC Connector Configuration 15
3.3 First Power Up/Commissioning Check List 15
3.4 E-House Design 17
3.4.1 Cables between AFE and LCL Filters 17
3.4.2 Cables to the Damping Resistors 17
3.5 Test with the Real System Transformer and Motors 17
3.5.1 Re-program the Frequency Converter Parameters 17
3.6 On-site Final Test 17
3.6.1 Change Parameters to Actual 17
3.6.2 Run with Full Load 17
Contents VLT®Active Front End AFE 302 Operating Instructions Liebherr
MG.33.X2.02 - VLT®is a registered Danfoss trademark 1

3.7 AFE Emergency and Restore Procedures 17
3.7.1 Emergency Run with One Slave Unit Damaged 17
3.7.2 Restoration after Slave Unit Repaired 18
3.7.3 Emergency Run with Master Unit Damaged 18
3.7.4 Restoration after Master Unit Repaired 18
3.8 Manual Shut Down Sequence 19
3.9 Start-up Sequence 19
3.10 Shut-down Sequence 21
4 How to Install 22
4.1 Overall Frequency Converter Configuration 22
4.2 Pre-installation 23
4.2.1 Planning the Installation Site 23
4.2.2 Receiving the Frequency Converter 23
4.2.3 Transportation and Unpacking 23
4.2.4 Lifting 24
4.2.5 Mechanical Dimensions 26
4.2.6 Weight Information 28
4.3 Mechanical Installation 28
4.3.1 Tools Needed 28
4.3.2 General Considerations 28
4.3.3 Terminal Locations 29
4.3.4 Mains Torque 29
4.3.5 Mains Connection 29
4.3.6 Shielded Cables 30
4.3.7 Fuses 30
4.4 Electrical Installation 31
4.4.1 Control Wires 31
4.4.2 Power Connections 31
4.4.3 Earthing 31
4.4.4 Electrical Installation, Control Terminals 32
5 How to Programme 33
5.1 Parameter Selection 33
5.2 Parameters: 0-** Operation and Display 34
5.3 Parameters: 4-** Limits/Warnings 38
5.4 Parameters: 5-** Digital In/Out 39
5.5 Parameters: 7-** Controllers 41
5.6 Parameters: 8-** Communications and Options 42
5.7 Parameters: 14-** Special Functions 45
5.8 Parameters: 15-** AFE Information 47
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5.9 Parameters: 16-** Data Read-outs 50
5.10 Parameters: 40-** Mains / Filter 52
5.11 Warnings/Alarm Messages 53
Index 59
Contents VLT®Active Front End AFE 302 Operating Instructions Liebherr
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1 Introduction
1.1.1 How to Read these Operating
Instructions
Please read this manual carefully for proper use. Incorrect
handling of the frequency converter may cause improper
operation of the frequency converter or related equipment,
shorten lifetime or cause other troubles.
These Operating Instructions will help getting started,
installing, programming, and troubleshooting the AFE 302.
Chapter 1, Introduction, introduces the manual and informs
you about the approvals, symbols, and abbreviations used in
this literature.
Chapter 2, Safety Instructions and General Warnings, entails
instructions on how to handle the AFE 302 correctly.
Chapter 3, Crane System Design,describes the crane system
design associated with the frequency converters.
Chapter 4, How to Install, guides you through the
mechanical and technical installation.
Chapter 5, How to Programme, shows you how to operate
and programme the AFE 302 via the Local Control Panel
(LCP).
1.1.2 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.
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 regarded
with attention to avoid mistakes or operate equipment at
less than optimal performance.
✮Indicates default setting of parameter.
1.1.3 Software Version
VLT Active Front End AFE 302
Operating Instructions
Software version: 1.07
1.1.4 Approvals
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1.1.5 Abbreviations
Active Front End AFE
Alternating current AC
American Wire Gage AWG
Ampere/AMP A
Automatic Motor Adaptation AMA
Current limit ILIM
Degrees Celsius °C
Direct current DC
Electro Magnetic Compatibility EMC
Electronic Thermal Relay ETR
Frequency Converter FC
Gram g
Hertz Hz
High Frequency HF
Identification ID
Insulated Gate Biopolar Transistor IGBT
International Protection IP
Isolation Terra IT
Kilohertz kHz
Kilowatt kW
Kilowatt-hour kWh
Local Control Panel LCP
Megawatt MW
Meter m
Microfarad uF
Millihenry Inductance mH
Milliampere mA
Million Cubic Meter MCM
Millisecond ms
Minute min
Motion Control Tool MCT
Multi Drive Control Interface Card MDCIC
National Electrical Manufacturers Association NEMA
Newton Meters Nm
Nominal motor current IM,N
Nominal motor frequency fM,N
Nominal motor power PM,N
Nominal motor voltage UM,N
Parameter par.
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Programmable Logic Controller PLC
Rated Inverter Output Current IINV
Regenerative terminals Regen
Residual Current Device RCD
Revolutions Per Minute RPM
Root Mean Square RMS
Second s
Software SW
Switching Mode Power Supply SMPS
Synchronous Motor Speed ns
The maximum output current IVLT,MAX
The rated output current supplied by the
frequency converter
IVLT,N
Torque limit TLIM
Total Harmonic Distortion THD
Volts V
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2 Safety Instructions and General Warning
2.1.1 Disposal Instruction
Equipment containing electrical components
may not be disposed with domestic waste.
It must be separately collected with Electrical
and Electronic waste according to local and
currently valid legislation.
2.1.2 High Voltage Warning
WARNING
The voltage of the AFE 302 is dangerous whenever the
frequency converter is connected to mains. Incorrect instal-
lation or operation of the frequency converter may cause
damage to the equipment, serious personal injury or death.
The instructions in this manual must consequently be
observed, as well as applicable local and national rules and
safety regulations.
WARNING
Installation in high altitudes
At altitudes above 2km, please contact Danfoss Drives
regarding PELV.
2.1.3 Safety Instructions
•Make sure that the AFE 302 is properly connected
to earth.
•Protect users against supply voltage.
•Remember that the [OFF] key on LCP is not asafety
switch. Pressing the [OFF] key does not disconnect
the AFE 302 from the mains.
2.1.4 General Warnings
WARNING
Touching the electrical parts may be fatal even after the
equipment is disconnected from the mains.
Also make sure that the fan voltage supply is disconnected.
Check the discharge time on the nameplate for the exact
waiting period. Otherwise wait at least 40min.
NOTE
When the AFE is on, the earth current from the AFE 302
frequency converter will exceed 3.5mA. The earth cable must
have a good contact to the earth terminal 95. The earth
connection is done with the two separate cables. The size of
each cable needs to be a half of the mains cable size in
minimum.
2.1.5 Before Commencing Repair Work
1. Switch the complete system off.
2. Wait for discharge of the DC-link. See period of
time on the warning label.
3. Disconnect DC bus terminals 88 and 89.
4. Disconnect the soft charge supply connector from
the soft charge board.
CAUTION
MDCIC Mains Sync Connector (MK105) is supplying by
external 630V.
Switch off the main switch before you dismount the front
plate.
2.1.6 System Description
NOTE
The grounded Delta or IT mains will not be used.
In contrast to a passive diode rectifier front-end, an Active
Front End (AFE), sometimes called an Active Rectifier, is
designed with the IGBT-based inverrter. The topology of an
AFE is shown below. The AFE is comprised of the LCL filter
and the three-phase voltage source converter (IGBT with free
wheeling diodes).
The main purpose with the three-phase active rectifier is to
achieve:
•sinusoidal input current and low harmonic
distortion in the mains
•unity power factor
•both rectifying and regenerating operation
•constant regulated DC voltage
To operate properly, an AFE must continuously be
synchronized to the mains voltage and frequency. The
challenge is the start up sequence where the mains phase
must be sensed to achieve a smooth start of the AFE.
During normal operation, the DC-link voltage of the inverter
is regulated to a constant level independent of the power
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flow direction. This means that the returned energy from the
motor and mechanical systems that are decelerated, is
passed on to the mains as regenerated electrical energy. A
passive diode rectifier front end would require a braking
resistor to consume the surplus energy as heat. In
applications with frequent decelerations an AFE is thus more
energy efficient. Also the practical aspects with removing the
heat from a braking resistor is eliminated.
The LCL filter reduces the ripple current of the switching
frequency and its harmonics into the mains. A damping
resistor Rd is connected in series with the filter capacitor Cf
to stabilize the filter resonance.
The three standard power units operate in parallel to achieve
the required power levels. The standard power units in the
AFE are identical to the power units in the frequency
converters. One AFE centralized controller regulates and
controls the three parallel power units.
Transformer
460 V
AFE
560 kW
Master
560 kW
Slave
560 kW
Slave
Control signals
130BA771.10
Lm
Lt
Cf
LC
Rd
Illustration 2.1 Active Front End Topology
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3 Crane System Design
3.1 Selection of Motor Voltage
The AFE system is designed to regulate a DC voltage of
630x1,08x1.41=690V. 690V motors are suitable for this
system.
Furthermore, whenever running the motors in the field
weakening region, or with output LC filters, it is necessary to
use the motors of less than 650V.
3.1.1 Selection of AFE & LCL Filter
•AFE systems are built up based on standard 690V
hardware.
•Standard AFE hardware runs on 630V mains supply
and DC-link voltage is 975V.
3.1.2 Selection of AFE for Different
Applications
•The frequency converter power size in the flux
application must be one or two sizes higher than
the application needed. Also, the frequency
converter should not be higher than two to
maintain a good resolution on current sensors.
•The size should be selected based on asum of the
current rather than a sum of the power of the
connected motors.
•Example:
Hoist motors 500kW @650V -Hoist drives
800kW
Travel motors 8x50kW @ 650V - Travel
drive 500kW
Trolley motors 4x55kW @ 650V - Trolley
drive 400kW
AFE/LCL – 1,2MW continuous, with a
175% overload for a maximum 1min.
3.1.3 Selection of Output Filter (LC Filter)
•The output filter is needed because of the long
motor cable configuration.
•Output filters should be sized based on the
frequency converter's maximum output current.
•The dU/dt filters can be used up to 100m to protect
the motor. The sine-wave filters can be used with
any cable length (maximum of 1000m).
•Above 150m cable length it is recommended to
use a sine-wave filter.
•The cable length is calculated as the sum of all
parallel cables.
•Filters must be designed to switching frequency of
the frequency converter. The resonance frequency,
f0, of the filter should be:
10 × fout
max
≤ f
0≤
fsw
3
•The resonant frequency must meet the following
equation, limited by the control frequency, fcon:
f
0<
fcon
6
Switching frequency [kHz] Control frequency1[kHz]
1.5 3
2 4
2.5 5
3 6
3.5 7
4 4
5 5
6 6
7 7
1The control frequency is an internal hardware frequency.
3.1.4 Selection of Switching Frequency
The switching frequency of AFE and motor drives shall be
equal or an integer multiple of each other.
3.1.5 Selection of LCL Filter
The AFE system is designed in conjunction with the
recommended Danfoss LCL filters in which the physical size,
power rating and electrical parameters of the filters are
optimized.
If non-Danfoss filters are used, system performance and
stability may be degraded.
3.1.6 Crane Cable Concept
To reduce the high frequency noise on the mains line and to
meet the EMC emission limits, the electromagnetic coupling
should be avoided and the following rules have to be
applied:
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1. Use the shielded cable between the sine-wave filter
and frequency converter.
2. Keep the unshielded cable away from the mains
cable. The two cables should not be run in parallel.
3. If the installation requires to route the motor cables
and mains cables in parallel, keep a distance of at
least 45cm between the two cables. Separate the
cables by placing them in different cable trays or in
different sections of a cable tray.
4. Use continuous cable trays and avoid “ladder-type”
cable trays.
5. Route the motor cable along the metallic grounded
conductors such as cable trays, rails from the
building structure, pipes, etc.
3.1.7 Grounding Concept
•Do the common grounding between AFE and
motor drives.
•The output filters and LCL should have low
impedance grounding to the AFE and motor
frequency drives.
•Ensure low impedance between entire crane
construction and the cabinets and the transformer.
•Use only one connection to the transformer.
3.1.8 Cooling and Airflow
Cooling
Cooling can be obtained, by using the cooling ducts in the
bottom and the top of the unit, by taking air in and out of
the back of the unit or by combining the cooling
possibilities.
Duct cooling
A dedicated option has been developed to optimize instal-
lation of IP00/chassis frequency converters in Rittal TS8
enclosures utilizing the fan of the frequency converter for
forced air cooling of the backchannel. The air out of the top
of the enclosure could but ducted outside a facility so the
heat losses from the backchannel are not dissipated within
the control room reducing air-conditioning requirements of
the facility.
Please see Installation of Duct Cooling Kit in Rittal enclosures,
for further information.
Back cooling
The backchannel air can also be ventilated in and out of the
back of a Rittal TS8 enclosure. This offers a solution where
the backchannel could take air from outside the facility and
return the heat losses outside the facility thus reducing air-
conditioning requirements.
NOTE
The ideal cooling air is dry and clean. When the air from
outside is used, filter mats and long air inlets could prevent
the dirty air problem. The condensation inside the frequency
converter, from the humid air, may require the drain outlet.
NOTE
Adoor/top fan(s) is required on the enclosure to remove the
heat losses not contained in the backchannel of the
frequency converter 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 manufac-
turers offer software for performing the calculations (i.e.
Rittal Therm software). If the VLT is the only heat generating
component in the enclosure, the minimum airflow required
at an ambient temperature of 45oCfor the D3 and D4 frame
sizes is 391m3/h (230cfm). The minimum airflow required at
an ambient temperature of 45oC for the E2 frame size is
782m3/h (460cfm).
Airflow
Table 3.1 shows the necessary airflow over the heat sink.
Enclosure
protection Frame size Door fan(s)/ Top fan airflow
Heatsink fan(s)
IP21 / NEMA 1
IP54 / NEMA 12
D1 and D2 170m3/h (100
cfm)
765m3/h (450
cfm)
E1 P250T5,
P355T7,
P400T7
340m3/h (200
cfm)
1105m3/h (650
cfm)
E1P315-
P400T5, P500-
P560T7
340m3/h (200
cfm)
1445m3/h (850
cfm)
IP21 / NEMA 1 F1, F2, F3 and
F4
700m3/h (412
cfm)*
985m3/h (580
cfm)*
IP54 / NEMA 12 F1, F2, F3 and
F4
525m3/h (309
cfm)*
985m3/h (580
cfm)*
IP00 / Chassis D3 and D4 255m3/h (150
cfm)
765m3/h (450
cfm)
E2 P250T5,
P355T7,
P400T7
255m3/h (150
cfm)
1105m3/h (650
cfm)
E2 P315-
P400T5, P500-
P560T7
255m3/h (150
cfm)
1445m3/h (850
cfm)
* Airflow per fan. Frame size F contain multiple fans.
Table 3.1 Heatsink Air Flow
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NOTE
The fan runs for the following reasons:
1. AMA
2. DC Hold
3. Pre-Mag
4. The frequency converter current exceeds 60% of
the its nominal current rating.
5. The heat sink temperature exceeds its limit. The
limit depends on the power size.
Once the fan is started it will run for minimum 10min.
External ducts
If additional duct work is added externally to the Rittal
cabinet the pressure drop in the ducting must be calculated.
Use the charts below to derate the frequency converter
according to the pressure drop.
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
Drive Derating
130BB007.10
Illustration 3.1 D frame derating vs. pressure change
frequency converter air flow: 450cfm (765m3/h)
90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 0 0.1 3.6 9.8 21.5 43.4 76 237.5 278.9
(Pa)
Pressure Change
130BB010.10
147.1
Illustration 3.2 E frame derating vs. pressure change (small fan),
P250T5 and P355T7-P400T7
frequency converter air flow: 650cfm (1105m3/h)
90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 0.2 0.6 2.2 5.8 11.4 18.1 30.8 152.8 210.8
(Pa)
Pressure Change
130BB011.10
69.5
Illustration 3.3 E frame derating vs. pressure change (large fan),
P315T5-P400T5 and P500T7-P560T7
frequency converter air flow: 850cfm (1445m3/h)
90
80
70
60
50
40
30
20
10
0
(%)
Drive Derating
0 25 50 75 100 125 150 175 225
130BB190.10
200
Pressure Change
Illustration 3.4 F1, F2, F3, F4 frame derating vs. pressure change
frequency converter air flow: 580cfm (985m3/h)
3.1.9 Selection of Transformer
•The output of the HT-transformer must be
specified for 630V.
•It is recommended to use 2 separate transformers
for 630V and the 400V and these transformers
should be physically separated. The 400V
transformer must be close to or in the E-house to
have a short ground cable.
NOTE
Danfoss will review/evaluate the LCL filter design for each
application, especially with a new transformer used.
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3.2 Assembling the Frequency Converter
System
3.2.1 Tools Required
Operating Instructions for the FC Series.
Metric socket set 7–19mm
Socket extensions 100–150mm (4in and 6in)
Torx driver set T10 - T50
Torque wrench 0.675–19Nm (6–170in-lbs)
Needle nose pliers
Magnetic sockets
Ratchet
Hex wrench set
Screwdrivers Standard and Philips
Additional Tools Recommended for Testing
Digital volt/ohmmeter (must be rated for 1200 VDC for 690 Vunits)
Voltmeter
Oscilloscope
Clamp-on style ammeter
Test cable p/n 176F8766
Signal test board p/n 176F8437
Power supply: 610 -800 VDC, 250 mA to supply external power to
4 power cards and the control card.
Power supply : 24VDC, 2 A for external 24V power supply.
3.2.2 General Torque Tightening Values
For fastening hardware described in this manual, the torque
values in the table below are used. These values are not
intended for diode or IGBT fasteners. See the instructions
included with those replacement parts for correct values.
Shaft Size Driver Size Torx/
Hex
Torque (in-
lbs)
Torque (Nm)
M4 T-20/7mm 10 1.0
M5 T-25/8mm 20 2.3
M6 T-30/10mm 35 4.0
M8 T-40/13mm 85 10
M10 T-50/17mm 170 19
M12 18mm/19mm 170 19
Table 3.2 Torque Values Table
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3.2.3 Exploded Views
Number Terminal and component description
1 Fan Voltage Supply (FVS)
2 Soft Charge Board (SC)
3 FVS Fuse (TB10)
4 SC Fuse (TB11)
5 Aux Fan Fuse
6 Fan Fuse
7 SMPS Fuse
8 Mains Terminals (R, S, T)
9 Aux Relay (TB12)
01 02 03 04 05 06
10 VSYNC (TB13) (Only for AFE Cabinet)
01-R, 02-S, 03-T
11 Control Card
12 MDCIC
13 Control Panel (Check the enlarged view)
The rated voltage and maximum current magnitudes for the
AUX relay and VSYNC terminals are as follows:
AUX Relay: 240V ac 2A
VSYNC: 630V 1A
NOTE
The control circuit including the control card terminals are
isolated galvanically from the power circuit by the reinforced
isolation (PELV).
130BA667.10
Illustration 3.5 Outside View
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1
3
3
8
4
2
5
6
7
4
13
130BA666.10
Illustration 3.6 Cabinet Skeleton, Inside View, and Connection View Inside the Lower Front Panel.
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130BA664.10
9,10
11 12
Illustration 3.7 Outside- and Inside View
130BT258.10
9 9
11 11
Illustration 3.8 Outside- and Inside View
130BA663.10
1
2
8
2
4
13
Illustration 3.9 Cabinet Skeleton View
130BA665.10
8
Illustration 3.10 Connection View Inside the Lower Front Panel
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11 9, 10 12
130BT254.10
Illustration 3.11 One-drive Configuration
130BT255.10
9 9
11
11
12 13 18 19 27 29 32 33 20 33
64
LifeStop
55
12 13 18 19 27 29 32 33 20 33
64
LifeStop
55
Illustration 3.12 Two Independent Drive Configuration
M750-2267-GA TRANSFORMEA
130BT256.10
Illustration 3.13 Outside View and Cabinet Skeleton
3.2.4 MDCIC Connector Configuration
The MDCIC board has the four connectors. The ribbon cables
from the power units will be connected from FK100 to FK102
in this order. FK103 is reserved for the future use.
For one power unit configuration, the special part which
consists of the DC/DC converter and the ribbon cable is
connected to FK101. It generates an isolated 5V from an
internal 24V for the RS-485 port located at the control card.
MDCIC Port Layout
FK100 (Master) FK102 (Slave 2)
FK101 (Slave 1) FK103 (Empty
3.3 First Power Up/Commissioning Check
List
The following measurement equipment are recommended:
•Voltage meter (1kA AC/DC env. Cat III)
•Current clamp min. 2kA
•Harmonic analyzer, only for commissioning
Check list
•Check fan voltage supply (3x400V).
•Verify that system is not powered.
•Verify the system is grounded to earth.
1. all AFEs and frequency converters
2. all motors
3. all filters
4. the whole crane construction
5. HT transformer
•Check that there are no earth faults or short circuits
at the motor cables and motors.
•Check that the DC discharge resistor is connected
right and not shorted.
•Verify phase sequence and continuity for the
voltage sensing on the AFE as described below.
1. Make sure that power is not applied.
2. Manually close input contactor (between
AFE and LCL filter).
3. Unplug the MK105 connector on the
MDCIC.
4. Measure MK105 of MDCIC harness to the
input phases.
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4.1 Red wire of MK105 to phase R.
4.2 White wire of MK105 to phase
S.
4.3 Black wire of MK105 to phase T.
4.4 All should be <0.2Ω.
•Open the input contactor between AFE and LCL
filter.
•Verify that the input voltage is balanced three
phase 630V AC line-to-line RMS.
•Apply power to the LCL filter and verify that the
rms current magnitude measured is approximately
same as the calculation using the following
formula:
i =630 × 314 ×
C × 3
3, where C is the LCL filter
capacitance, delta value.
•Leave the AFE main contactors open and disallow
the AFE start signal in the PLC.
•Soft charge the system but do not enable the main
contactor.
•Let the softcharge circuit active for about 5min.
•Check the voltage at the AFE Mains side when the
AFE is powered up by softcharge. The voltage
between all phases should be 0V. Also the voltage
between the phases L1/L2/L3 and earth should be
0V. Please call Danfoss service if you can measure a
voltage greater then 10V here.
Do not switch on the mains contactors if you
measure a voltage more than 10V here.
•Verify that all LCPs read the DC link voltage to
within ±2% of a calibrated voltage meter. The
expected voltage value is:
890 VDC + 5 / −10 % = ( Vmains
_ LL _ RMS
× 2 + 5 / −10 %
= 630 × 1, 414 + 5 / −10 % )
•Download all the AFE and frequency converter
settings with .
1. Capacitance value of output filter must
be star equivalent.
2. Danfoss Drives output filters are always
marked with star equivalent values.
3. Set the right LCL filter values in the AFE,
the capacitance value of the LCL filter
shall be entered in as delta equivalent.
4. Set the right mains values in the AFE.
5. Par. group 4-** Output Limits AFE – use
factory settings.
6. Total system capacitance par. 7-60 must
be programmed with a sum of the DC-
link capacitance x 0,9.
7. Use par. group 7-** Controllers as follows:
•Par. 7-61 DC-Link Reference is
changed from 980V (default) to
975V.
•Par. 7-62 DC-Link PI Proportional
Gain (Kp) is calculated internally
based on the power size and DC
capacitance in par. 7-60.
Recommend to use the default
value. The wrong setting could
cause the unstable DC voltage
regulation.
•Par. 7-63 DC-Link PI Integral Time
(Ti) is changed to 5ms.
•Switch Crane off.
•Program the PLC to the normal start-up sequence.
•Switch Crane on.
•The AFE starts, but not any of the inverters, and
verify that the AFE and inverter LCP readings are
975V DC and that they are within ±2% of a
calibrated voltage meter.
•Check if all fans are running after closing the mains
contactor.
•Start checking inverters and motors.
•Save all parameter settings with .
•For the crane commissioning, measure THDu and
THDi of the 630V and 400V terminals and
document the results in the commissioning
certificate.
•Verify that the THD levels of the 400V terminal are
complied to EN 61000-3 or other country specified
harmonic requirements.
Crane System Design VLT®Active Front End AFE 302 Operating Instructions Liebherr
16 MG.33.X2.02 - VLT®is a registered Danfoss trademark
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3.4 E-House Design
3.4.1 Cables between AFE and LCL Filters
•The cables should be as short as possible.
•The connection must be made with shielded
cables.
The synchronization voltage cable which is connected to the
AFE-MDCIC board MK105 must be separated from all power
cables. The distance needs to be at least 50cm from other
power cables.
3.4.2 Cables to the Damping Resistors
The cables should be as short as possible.
3.5 Test with the Real System Transformer
and Motors
3.5.1 Re-program the Frequency Converter
Parameters
•Set the mains voltage, mains frequency, the
transformer values, LCL filter values, and DC
capacitance.
3.6 On-site Final Test
3.6.1 Change Parameters to Actual
•Set actual cable length.
•Check encoder wiring and encoder direction.
•Optimize ramp time shapes.
•Save parameter settings in the LCPs.
3.6.2 Run with Full Load
•Check that AFE input voltage is stable. The voltage
waveform does not need to be sinusoidal.
•Check that DC-link voltage is stable.
3.7 AFE Emergency and Restore Procedures
3.7.1 Emergency Run with One Slave Unit
Damaged
NOTE
The mains synchronization voltage is always connected to
the MDCIC board. Make sure that the mains power switch is
off before opening the frequency converter cabinet.
NOTE
The power is reduced to two thirds of the original.
1. Switch Crane off.
2. Switch the circuit breaker in front of the damaged
AFE power unit off.
3. Check the DC link voltage with a voltage meter
directly on the DC link bus bar and inside the
damaged module (after the DC link fuses inside the
AFE).
NOTE
Do not touch anything until the DC voltage is below 10V.
4. Disconnect the DC link fuses of the damaged
power unit and AC connection.
5. Disconnect the softcharge connector on the
softcharge board of the damaged power unit.
6. Disconnect the ribbon cable, from the damaged
AFE power unit, on the MDCIC card.
7. If the removed connector is at Inverter 2 position,
move the ribbon cable at Inverter 3 position to
Inverter 2.
8. Turn the key switch to AFE emergency mode.
9. Switch Cane on.
10. Check on the AFE LCP if it is in setup 2. The setup
shift at the AFE is done with terminal 32 at AFE
control card. Terminal 32 = 0 means setup 1,
Terminal 32 = 1 means setup 2.
11. A warning 78 (power unit setup) may come up at
the AFE LCP.
12. Switch Crane off.
13. Wait at least 20s. All LCPs must be completely off.
14. Switch Crane on.
15. The warning 78 will disappear.
16. Now you can run the crane with only two AFE
power units.
Crane System Design VLT®Active Front End AFE 302 Operating Instructions Liebherr
MG.33.X2.02 - VLT®is a registered Danfoss trademark 17
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3.7.2 Restoration after Slave Unit Repaired
1. Switch Crane on but do not run any frequency
converter/motor.
2. Turn the key switch to AFE normal mode.
3. A warning 78 (power unit setup) will come up at
the AFE LCP.
4. Check on the AFE LCP if it is in setup 1. The setup
shift at the AFE is done with terminal 32 at AFE
control card. Terminal 32 = 0 means setup 1,
Terminal 32 = 1 means setup 2.
5. Switch Crane off.
6. Check the DC link voltage with a voltage meter
directly on the DC link bus bar and inside the
repaired AFE module (after the DC link fuses inside
the AFE).
NOTE
Do not touch anything until the DC voltage is below 10V
7. Bring back the ribbon cables on the MDCIC card in
the original setup (AFE Master to Inverter 1, AFE
Slave left to Inverter 2, AFE Slave right to Inverter
3).
8. Connect the softcharge connector on the
softcharge board.
9. Connect the DC link fuses and AC connection.
10. Switch on the circuit breaker in front of the AFE.
11. Switch Crane on.
12. The AFE runs now with all 3 power units.
3.7.3 Emergency Run with Master Unit
Damaged
NOTE
The power is reduced to two thirds of the original.
1. Switch Crane off.
2. Switch the circuit breaker in front of the damaged
AFE power unit off.
3. Check the DC link voltage with a voltage meter
directly on the DC link bus bar and inside the
damaged module (after the DC link fuses inside the
AFE).
NOTE
Do not touch anything until the DC voltage is below 10V
4. Disconnect the DC link fuses of the damaged
power unit and AC connection.
5. Disconnect the softcharge connector on the
softcharge board of the damaged power unit.
6. Disconnect the ribbon cable from the Inverter 1
position at the MDCIC.
7. Unplug the ribbon cable at Inverter 3 position on
the MDCIC card and plug it at Inverter 1 position.
8. Plug this ribbon cable (what you plugged out from
Inverter 3) on the connector Inverter 1. Now the
right power unit will be the AFE Master.
9. Turn the key switch to AFE emergency mode.
10. Switch Crane on.
11. Check on the AFE LCP if it is in setup 2.
12. A warning 78 (power unit setup) may come up at
the AFE LCP.
13. Switch Crane off.
14. Wait at least 20s. All LCPs must be completely off.
15. Switch Crane on.
16. The warning 78 will disappear.
17. Now you can run the crane with only two AFE
power units.
3.7.4 Restoration after Master Unit Repaired
1. Switch Crane on but do not run any frequency
converter/motor.
2. Turn the key switch to AFE normal mode.
3. A warning 78 (power unit setup) will come up at
the AFE LCP.
4. Check on the AFE LCP if it is in setup 1 (see
attached file LCP.pdf). The setup shift at the AFE is
done with terminal 32 at AFE control card. Terminal
32 =0means setup 1, Terminal 32 =1means setup
2.
5. Switch Crane off.
6. Check the DC link voltage with a voltage meter
directly on the DC link bus bar and inside the
repaired AFE module (after the DC link fuses inside
the AFE).
NOTE
Do not touch anything until the DC voltage is below 10V
7. Bring back the ribbon cables on the MDCIC card in
the original setup (AFE Master to Inverter 1, AFE
Slave left to Inverter 2, AFE Slave right to Inverter
3).
8. Connect the softcharge connector on the
softcharge board.
9. Connect the DC link fuses an AC connection.
10. Switch on the circuit breaker in front of the AFE.
11. Switch Crane on.
12. The AFE runs now with all 3 power units.
Crane System Design VLT®Active Front End AFE 302 Operating Instructions Liebherr
18 MG.33.X2.02 - VLT®is a registered Danfoss trademark
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3.8 Manual Shut Down Sequence
•Stop all motor drives.
•switch off the AFE start signal.
•Delay one second.
•Open the mains contactor
•Switch off the HT transformer if necessary
•In emergency, command the AFE to stop and open
the AFE contactor, or pull the safe stop and open
the AFE contactor.
3.9 Start-up Sequence
The following figure shows the system start-up sequence
flow chart. The flow chart describes the interaction among
Auxiliary Hardware, AFE Frequency Converters, and Liebherr
Control PLC. The arrowed lines indicate the flow of the
actions. The Liebherr PLC expects to receive the “Control
Ready” and “Ready” signals from the AFE frequency
converter and it will send “Run” signal to AFE frequency
converter. The waiting periods and the number of tries are
tentative. The “Control Ready” signal is on when the power
in Control Card (CC) is on. The meaning of the "Ready" signal
in the AFE frequency converter is different from the one in
the standard frequency converter. The “Ready” signal in the
AFE frequency converter is on when the DC voltage is
boosted to the level within the AFE regulation range.
Crane System Design VLT®Active Front End AFE 302 Operating Instructions Liebherr
MG.33.X2.02 - VLT®is a registered Danfoss trademark 19
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