afe basics danfoss

8/16/2019 AFE Basics Danfoss

1/49

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 1

AFE Basics


2/49


3/49


AFE Bene$its

! *ow +ar&onics and low "+, -"otal +ar&onic,istortion

! /o rae circ'it and rae resistors (

/o rae resistor cooling s%ace is needed.! Constant ,C voltage ( ood $or te $l') control

! M'lti drive rigid o%eration (

Eac drives will e inde%endent o$ eac otereca'se te ,C voltage is constant. ( Energ saving i$ te drives r'n in &otoring and

raing at te sa&e ti&e.


4/49


+ow te &ains voltage is

selected

A F E 4 / V M

* C * F i l t e r

650V Motor 57V8910: Voltage ,ro% tro'g*C* and "rans$or&er

630V

StartSelection


5/49


A F E 4 / V M

* C * F i l t e r

M a i n s

AFE Control Basics

Motoring

Braking

Vdc goes down.

Vdc goes up.

Control Block

! ;eg'late Vdc

! enerate te AFE voltage wic is

sncroni


6/49


Si&%le Circ'it ,iagra&

V 0 V a $ e

A F E

4 a

* & * c

* a ? * r @ * & @ * c; a ? ; r @ ; & @ ; c

M a i n s

V d c

C $

* C * F i l t e r

* r

* r

M a i n s " r a n s $ o r & e r i n d ' c t a n c e

V a $ e ? V 0 9 - ; a @ >w * a 4 a

! *a -?*r@*&@*c $or%ower trans$er at$'nda&ental $re='enc

( *c and C$ is $or low%ass $ilter -700 to00+


7/49


Vector ,iagra&

! 4a? 4=@4d

( 4d re$ ?0 -P$?0

! Va$e Voltage *i&it Factors

( "e &ains voltage level

! 910 to @7: o$ 630V

( ,C voltage level! Va$e &a) VdcDs=-2%w&

( "otal 4nd'ctance

! 8 to 10: %'

( P ase

! 630V and 1.2M

" # e r a d i ' s o $ V a $ e - & a ) V d c D S G ; " - 2 M % w &

V 0 > w * a 4 a

; a 4 a

9 ; 1 4 a

V a $ ei n & o t o r i n g

e n e r a t i o n- 4 n v e r t e r B r a i n g

9 >w * a 4 a

* o a d i n g- 4 n v e r t e r M o t o r i n g

4 a

V a $ ei n r a i n g

V e c t o r , i a g r a &

V a $ e ? V 0 9 - ; a @ >w * a 4 a

arning Message

6H -Voltage *i&it ( Va$e &agnit'de is

at its li&it.


8/49


AFE Control Bloc ,iagra&

! "e %rogra& is i&%le&ented in ,SP -,igital Signal Processor.

Vector Control Bloc

AFE Mod'le and

*C* Filter


9/49


10/49


*C* Filter


11/49


*C* Filter ,esign

! F'nction

( or $or te %ower $low.

! "e total ind'ctance is 8 to 10: %'.

( ;ed'ce te ar&onics.

! *c and C$ is te low %ass $ilter wit 700 to 00+<

to red'ce te 1.7+< ar&onic c'rrent into te

&ains and to lower te voltage distortion at H00V.

! ;$ -da&%ing resistor li&its te ar&onic c'rrent

&agnit'de.


12/49


*C* Filter 9 ;esonance Fre='enc

! ,esign o$ te *C* $ilter is to%rovided di$$erential &ode

$iltering o$ te switcing

$re='enc.

! ,esired resonance $re='enc is

etween te c'rrent reg'latorandwidt and te switcing

$re='enc o$ te AFE.

-4JBFresFsw

! ,a&%ing resistors control te

a&%lit'de o$ te $ilterresonance. "e sste& level

trade o$$ is losses vers's

da&%ing.

-40

-30

-20

-10

0

10

M a g n i t u d e ( d B )

101

102

103

104

-180

-135

-90

-45

0

P h a s e ( d e g )

Converter Side Vcap/Vconv, fres = 728.281Hz

So'rce

4&%edance

R t Lt E rn

E sn

E tn

I r

n

Converter

Side Filter

R c Lc

R c Lc

R c Lc

Main Side

Filter

R m Lm

R m Lm

R m Lm

R t Lt

R t Lt

R cf Ccf


13/49


"%ical ,rive ;'n ,ata


14/49


630VAC Mains Voltage

! "e %lot on te le$t is te &ains voltage e$ore te

active $ront9end is t'rned on.

! "e %lot on te rigt is te &ains voltage wit te

active $ront9end r'nning wit load.


15/49


16/49


1.2 M AFE C'rrent Stead9State


17/49


18/49


Mains C'rrent 9 Motoring

( Pase C'rrents K500 Ar&s -K00 Motoring ( C'rrent "+, H: ( ,C *in Voltage ;i%%le KL3:


19/49


Mains C'rrent D AFE C'rrent 9 Motoring

! Co&%arison o$ te active $ront9end c'rrent e$ore and a$ter te

*C* $ilter


20/49


! "ransient ti&e

K120&sec

! Voltage

reg'lation isKH:

'ndersoot

-533 Vdc

AFE "ransient $ro& enerating to Motoring

M a i n s I n p u t

C u r r e n t s

H o i s t # 1 M o t o r

C u r r e n t s

D C

L i n k

Generating Motoring

R1

1.250 kAMP

-1.250 kAMP

S1

1.250 kAMP

-1.250 kAMP

T1

1.250 kAMP

-1.250 kAMP

U1

1.250 kAMP

-1.250 kAMP

V1

1.250 kAMP

-1.250 kAMP

W1

1.250 kAMP

-1.250 kAMP

VDC_2

1.050 kVolt

00.0 Volt

100.0 !"#$i%1&'10.(11 1&'11.(11

.

Power $lowing to te

grid -9H30

Power $lowing $ro& te

grid -@H67


21/49


AFE "ransient $ro& Motoring to enerating

! "ransient ti&e

K120&sec

! Voltage

reg'lation isKH:

oversoot

-1008 Vdc

M a i n s I n p u t

C u r r e n t s

H o i s t # 1 M o t o r

C u r r e n t s

D C

L i n k

R1

1.250 kAMP

-1.250 kAMP

S 1

1.250 kAMP

-1.250 kAMP

T1

1.250 kAMP

-1.250 kAMP

U1

1.250 kAMP

-1.250 kAMP

V1

1.250 kAMP

-1.250 kAMP

W1

1.250 kAMP

-1.250 kAMP

VDC_2

1.050 kVolt

00.0 Volt

100.0 !"#$i%12'55.*+ 12'5+.*

Motoring Generating

Power $lowing o$$ te

grid -@H67

Power $lowing to te

grid -9H30


22/49


,rive ,esigns


23/49


1. ,rive Con$ig'ration

1. Standalone and Parallel Mod'les Cainet

2. VSnc

3. M,C4C

H. Bloc ,iagra&s1. 3 %arallel9connected drive

2. 3 inde%endent drives

3. 2 %arallel9connected drive and 1 standalone drive

H. 4nverter &od'le

7. ,9$ra&e drive cainet wiring


24/49


1. ,rive Con$ig'ration

-Standalone and Parallel ,rive

Standalone ,riveParallel ,rives

*CP

CC

*CP

Mod1 Mod2M1 S1 S2

CC M,C4C


25/49


Stand Alone ,rive Bloc ,iagra&

! Standalone " ,rive -760

* C PC o n t r o l C a r d- C C .

P o w e r C a r d- P C .

a t e , r iv e- , .

4 B " 1

4 B " 2

4 B " 3

S c a l i n g C a r d

M o d ' l e

CC Functions

! ,rive control ( Fl') controlD AFE

control! 4nter$ace to P*C Encoder etc.

!Nverall %rotection ( 4&a)2

PC Functions

! *ocal controls ( Fan control ;ec Control -not $or AFE ased drives

! ,ata ac='isition ( C'rrent $eedac 4B" /"C reading

! C'rrent %rotection ( 4&a)1 -Move to M,C4C $or %arallel drives! EEP;NM -Basics


26/49


* C PC o n t r o l C a r d- C C

P o w e r C a r d- P C

a t e , r i v e- , 4 B " 1 9 3


a t e , r i v e- , 4 B " 1 9 3


a t e , r i v e- , 4 B " 1 9 3

M a s t e r

S l a v e 1

S l a v e 2

M o d ' l e * e $ t

M o d ' l e M i d d l e

M o d ' l e ; i g # t

2 31

1

2

3

S c a l in g C a r d

H H

H H

H H

Parallel ,rive Bloc ,iagra& 9M,C4C

! CA/ 's co&&'nication ( "e &od'le identi$ier is ased on te HH9%in connector ter&inal location.

! M,C4C -M'lti ,rive Control 4nter$ace Card F'nctions ( S'& '% tree c'rrent signals and its s'& to CC

! 4&a)1 detection and c'rrent alance detection ( ,istri'te te gate signals into tree &od'les. ( Vsnc detection

M,C4C

arning Messages

! A0 -4llegal FC Con$ig

! Possile ca'ses rong CC -AFE vs 4/V rong PC -AFE and 4/V

PC are di$$erent rong EEP;NM a&ong te &od'les

! A5 -4llegal Power Section Con$ig

! Possile Ca'ses Mis&atc etween te setting and # o$ &od'les

connected s'c as i&%ro%er M,C4C connector connection


27/49


2. VSnc -Voltage Sncroni


28/49


3. M,C4C Board

Feat'res! PC ter&inals

( #1 $or Master ( /o si% ( Can 's 4, is

associated wit tePC ter&inal.

! Scaling ter&inals 1 toH corres%onding toPC ter&inals.

! Vsnc circ'it

! Master %rovides CC%ower Vdc&eas're&ent andEEP;NM

( /ote /eeds te correctEEP;NM in slaves.

! ;SH87 4solated 7Vvoltage $ro& 2nd PCconnector

! C'rrent scale cange

"o CC"est Connector

1 2 3 H

Scaling Card "er&inals

"o PC

1 -M

2 -S1

3 -S2

H -S3

Vsnc Connector


29/49


H. Bloc ,iagra&s

Bloc ,iagra&s witin Cainet

! 3 Parallel9Connected ,rive

! 3 4nde%endent ,rives! 2 Parallel9Connected ,rive and 1 Standalone

,rive

! 4nverter Mod'le

! ,9$ra&e ,rive Cainet iring


30/49


1. 3 Parallel9Connected ,rive

AC N't

,C 4n

*CP CC M,C4C

Fan So'rce

So$t

Carge

A') ;ela

Vsnc

,oor Fan

"7 A'to

"rans$or&er


31/49


32/49


3. 2 Parallel ,rive and Nne Standalone ,rive


33/49


H. 4nverterDAFE Mod'le


34/49


7. ,9$ra&e ,rive Cainet


35/49


,esign Basics


36/49


AFE Basics ( Prod'ct

,esign ,etails

1. Start Se='ence

2. F'se Coordination

3. 4nverterDAFE Mod'le

H. Fan Circ'it7. So$t Carge Circ'it

6. Co&%onent *ao't witin Cainet

. E&ergenc ;'n8. 4B" Circ'it St'd

5. CE Certi$ication


37/49


1. Start Se='ence

AC

Contactor I r

I s

I t

ConverterSide Filter

R c Lc

R c Lc

R c Lc

Main SideFilter

R m Lm

R m Lm

R m Lm

Power Stage #3

V rn V sn V tn

Power Stage #2

V rn V sn V tn

Power Stage #1

V rn V sn V tn

R cf Ccf

4nverter #1

+oist#1

T,ω So$t9Carge

AC

Contactor

4nverter #2

+oist#2

T,ω

4nverter #3

"rolleD

Boo&

T,ω

4nverter #H

"raction

T,ω

630VACMains

1. 4n%'t %ower is a%%lied

2. Container Crane P*C closes so$t carge AC contactor

3. AFE and &otor drive controllers are %owered '% $ro&te ,C lin tro'g SMPS -switcing &ode %owers'%%l

H. AFE read signal is received te P*C and te &ain AC contactor is closed and so$t carge AC contactor iso%ened

7. AFE receives te r'n co&&and $ro& te P*C and tecontainer crane sste& is read $or 'se


38/49


2. F'se Coordination

! F'se Coordination Basics ( 4solate te ad %ower &od'le.

( Mae s're to ave ealt %ower &od'les in circ'it.

! Strateg ( All te $'ses are selected $or te largest %ower &od'le. 4t is inde%endent o$ te drive

%ower si


39/49


3. 4nverterDAFE Mod'le

Front View

Side View

ate ,rive Board

Power Card

Scaling Card

Mounted on t%e

"odule &or

standalone dri'es

and on M(CIC &or

parallel dri'es

4nverter and AFE

&od'les 'se te

sa&e ardwaree)ce%t $or te PC.


40/49


H. Fan Circ'it

S

"3 8 0 9 7 0 0 VS i n g l e 9 % # a s e

2 3 0 V @A l % # a

, o o r F a n

+ e a t S i n F a n

2 3 0 V

A ' t o " r a n s $ o r & e r

C # o e o n l $ o r l a r g e $ a n

! Single9%ase -S and " %ase So'rce Voltage

! "e a'to trans$or&er is $or "7 -380 to 700V.

! "e door $an and eat sin $ans r'n togeter.

! "e coe is installed onl in E9$ra&e 700 and 760 drives.


41/49


,oor Fan Strateg

! Module )a*out ( Master is in te &ost le$t %osition. ( 4nde%endent drive will e at te rigt o$ te Master and Slave

! Fan Control Module C%oice ( Master $or %arallel drive

( Parallel and 4nd co&ination or All ind ( *e$t and ;igt Ends! /o control $ro& te &iddle in case #3 ( Ass'&e tat 4nd1 and 4nd2 are +oistMaster and Slave co&ination.

2

1

3


42/49


7. So$t Carge Circ'itD Sce&e

! Eac %ower &od'le as te so$t carge -SC circ'it e)ce%t $or te ,9$ra&e drives. ( # o$ SC circ'it is e='al to # o$ %ower &od'les.

( /o SC circ'it is wit ,9$ra&e drives.

! "e SC resistors are in %ositive and negative %ats. ( ;-SC neg is added to eli&inate te SC $'se lowing wen te inverter &otor is gro'nded.

! Eac cainet as one set o$ SC $'ses.

S C B o a r d

4 M

* C * F i l t e r

* & ? 2 5 ' +* c ? 1 0 0 ' +C $ ? 2 H 0 ' F; $ ? 0 . 0 5 N # &

* & * c

C $ ; $

P " C

; - s c % o s

; - s c n e g

A F E P o w e r M o d ' l e 4 n v P o w e r M o d ' l e

S C B o a r d a n d S C ; e s i s t o r s

- P o s i t i v e " e & %C o e $ $ ic i e n t ; e s i s t o r

Fault Current &ro"

egati'e Fault Voltage

IM Ground

Fault

+sc,pos- and PTC li"it t%e &ault

current &ro" t%e positi'e 'oltage.


43/49


Eart Fa'lt -Alar& 1H

! ,etection Sce&e ( Calc'late a s'& o$ tree c'rrents.

( 4$ it e)ceeds te tresold generate te $a'lt&essage and sto% te o%eration.

! Fa'lt Cases1. en te $a'lt a%%ens d'ring te inverter

o%eration it sto%s i&&ediatel.

2. en te $a'lt a%%ens a$ter te inverter sto%s and

e$ore te sste& starts te SC carges te ,C's. 4t activates te AFE. en te inverter is t'rnedon te inverter so'ld detect te $a'lt i&&ediatel.


44/49


6. Co&%onent *ao't witin Cainet

Fan S'%%l

Board -FSB

FSB F'se

So$t Carge

Board -SCB

and SC

;esistors

SC F'se

!T#

T%e &an 'oltagec%oice per

"odule is

s%i&ted to

reduce t%e &use

stress.

!T#

Pre'ent t%e spike

'oltage &ro"

going t%roug%.


45/49


Magni$ied View o$ FSB and

SC Board

SC ;esistor

SC Board

FSB


46/49


,9$ra&e ,rive Cainet

! 600&& Cainet

! 500A ,C F'se

! ;evisions ( ;e&oved te door $an and

associated trans$or&er.! "e ,9$ra&e drive internal

cooling is done wit te to%$an.

( Moved te FSB 'nder tecontrol card -CC %osition.,C F'ses

FSBCC


47/49


. E&ergenc ;'n

! "e&%oraril red'ce te n'&er o$ %ower &od'les and r'n te drive wit a red'ced%ower.

( ( ;ed'ced Power Mode! Correct r'nning condition wit a li&ited %ower -;ated %ower divided a ratio o$ te &od'le cange

( 8 ( Power nit Set'%! Condition to disale te o%eration d'e to te &is&atc etween # o$ setting and # o$ act'al &od'les

connected

! Proced're ( Psical Canges

! 3 to 2 Power Mod'le Cange ( ,isconnect te %ower &od'le %sicall.

Be$ore start dis&o'nting &ae s're to ave te ,C ca%acitor discarged. ( Cange te HH9%in connector location in M,C4C. ( Mo'e /u$ rela* signal &ro" t%e new Master power "odule.

ote T%e door &an is run &ro" t%e original Master power "odule. Since it is di&&icult to reroute t%ewire &ro" t%e new Master1 t%e door &an is te"poraril* inoperati'e.

! 2 to 1 Power Mod'le Cange ( ,o te %rocesses aove. ( 4$ ;SH87 inter$ace is 'sed need to connect a s%ecial asse&l to #2 ter&inal at M,C4C. "e asse&l generates

te isolated 7V $or ;SH87 co&&'nication.

( P*C co&&and! Cange te %ara&eter setting $ro& Set'% #1 to Set'% #2. -Par. 0910

( /ote ;eview te P4 gains.


48/49


8. 4B" Circ'it St'd

! 4B" ,esign ( 4B" circ'it is designed to

&aintain te over9voltage levelwitin its rating

( 4B" te&%erat're rise d'e tote worst r'nning condition iswitin its te&%erat're ca%ailit

( 4B" c'rrent is li&ited to itsailit. -4MAQ1 and 4MAQ2

! Co&%onents ( 4B" ( ,C Ca% ans ( Sn'er Ca% ( Sandwiced B's Asse&l to

Ca% Ban -B's1 ( Sandwiced B's Asse&l to

,C -B's2

C a % B a n 1

C a % B a n 2

, C

A C 2

4 B " 2

S n ' e r C a %6 1 ' Fi n e a c # t e r & i n a l s

4 B " 1

4 B " 3

A C 1

A C 3

B ' s 1

B ' s 2

" o t a l C a % a c i t a n c e1 1 . 2 & F $ o rP H 0 0 t o P 7 6 0


49/49

1. 4" Mains Crane Sste&! ,rive N%eration wit Nne9%oint and "wo9%oint ro'nd Fa'lt

! +F -+ig Fre='enc Board ( /oise %at es%eciall $or 4B" switcing noise contain&ent

! 4so9&eter F'nction wit te AFE ,rive

4 M

* C * F i l t e r

A F E

A F E

A F E 3 0 2 P 8 0 0 "

* B 9 3 0 2 P 7 6 0 "

2 . 7 M V A 6 3 0 V1 7 0 0 # %6 5 0 V

* & ? 2 5 ' +* c ? 1 0 0 ' +

C $ ? 2 H 0 ' F; $ ? 0 . 0 5 N # &

* & * c

C $ ; $

F a ' l t

A 1 D @ A 1 D 9 * 1 * 2 A E

" 1 " 2 ; 1 ; 2 F 1 F 2 M @ M 9 A B 1 1 1 2 1 H 2 1 2 2 2 H

@ 9

A 1 6 0

B e n d e r 4 s o & e t e r

4 ; , + 2 7 A + 1 7 0

+ F B o a r d

P , " e s t S e t ' % +F Board

afe basics danfoss

Documents