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AFE Basics

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

1.2 MW AFE
The AFE consists of three power modules in
parallel.

Power Stage #1

The AFE and inverter have the same hardware


except for the PC firmware.
The AFE uses the AFE SW.
AC
Contactor

630VAC
Mains

Main Side
Filter

Converter
Side Filter

Vrn

Lm

Rc

Lc

Ir

Rm

Lm

Rc

Lc

Is

Lc

It

Lm

Rc
Ccf

Vtn

Power Stage #2

Rm

Rm

Vsn

Vrn

Vsn

Vtn

Rcf
Power Stage #3

Vrn

Vsn

Vtn

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 2

AFE Benefits

Low Harmonics and low THD (Total Harmonic


Distortion)
No brake circuit and brake resistors

Constant DC voltage

No brake resistor cooling space is needed.


Good for the flux control

Multi drive rigid operation

Each drives will be independent of each other


because the DC voltage is constant.
Energy saving if the drives run in motoring and
braking at the same time.

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 3

How the mains voltage is


selected
L C L F ilt e r
AFE

630V

Selection

8-10% Voltage Drop through


LCL and Transformer

IN V

975V

690V Motor

Start
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 4

AFE Control Basics


Control Block
Regulate Vdc
Generate the AFE voltage which is
synchronized with the Mains.
Same frequency as the Mains one
Adjust the AFE voltage magnitude
and phase

Vdc goes down.


Vdc goes up.

IGBT Gating

L C L F ilte r

Motoring
Vdc

AFE

IN V

Measure Vdc

M a in s

Braking

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 5

Simple Circuit Diagram

Point of PF
Control

V a fe = V 0 - ( R a + jw L a ) * Ia
Ia
M a in s

AFE
V0

Lr

La (=Lr+Lm+Lc) for
power transfer at
fundamental frequency

Lm

Lc

L r:
M a in s T r a n s fo r m e r
in d u c ta n c e

Cf

L a = L r+ L m + L c
R a = R r+ R m + R c

L C L F il t e r

Vdc

V a fe

Lc and Cf is for low


pass filter (500 to
700Hz) Ignore its
harmonic function for
power flow calculation

The positive current


direction is for motoring
The power factor is
controlled at the primary
side of the transformer.

Ignore Cf for
Power Flow
Calculation

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 6

Vector Diagram
V e c to r D ia g r a m

G e n e r a t io n
( I n v e r t e r B r a k in g )

Ia= Iq+Id

T h e r a d iu s o f V a fe ( m a x ) :
V d c /S Q R T (2 )* M p w m

R a * Ia

Id ref =0 (Pf=0)

Vafe Voltage Limit Factors

The mains voltage level

V a fe
in b r a k in g

DC voltage level

V0

jw L a * Ia

-10 to +5% of 630V

Vafe max <Vdc/sq(2)*Kpwm

Total Inductance

8 to 10% pu

Ia
- jw L a * Ia

PU base:

V a fe
in m o to r in g

630V and 1.2MW

Warning Message:
L o a d in g
( I n v e r t e r M o to r in g )

-R 1 * Ia

V a fe = V 0 - ( R a + jw L a ) * Ia

* W64 (Voltage Limit) Vafe magnitude is


at its limit.

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 7

AFE Control Block Diagram

AFE Module and


LCL Filter

Vector Control Block

The program is implemented in DSP (Digital Signal Processor).


| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 8

DQ Control Block

Q Axis for Real Power

DC Voltage Regulation
PI Control

P gain: Par. 7-62 (Vary)

DC capacitance (Par. 7-60) influences


the P gain.

I time: Par. 7-63 (Default 5ms)

D Axis for Reactive Power

Zero reference

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 9

LCL Filter

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LCL Filter Design

Function
Work for the power flow.

The total inductance is 8 to 10% pu.

Reduce the harmonics.

Lc and Cf is the low pass filter with 500 to 700Hz


to reduce the 1.5kHz harmonic current into the
mains and to lower the voltage distortion at 400V.
Rf (damping resistor) limits the harmonic current
magnitude.

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 11

LCL Filter - Resonance Frequency


Converter Side Vcap/Vconv, fres = 728.281Hz

10

Magnitude (dB)

0
-10
-20
-30

Phase (deg)

-40
0
-45
-90
-135
-180

10

Source
Impedance

10
Main Side
Frequency (Hz)
Filter

10

Converter
Side Filter

Ern

Rt

Lt

Rm

Lm

Rc

Lc

Esn

Rt

Lt

Rm

Lm

Rc

Lc

Etn

Rt

Lt

Rm

Lm

Rc

Lc

Ccf

Rcf

10

Ir

Design of the LCL filter is to


provided differential mode
filtering of the switching
frequency.
Desired resonance frequency is
between the current regulator
bandwidth and the switching
frequency of the AFE.
(I_BW<Fres<Fsw)
Damping resistors control the
amplitude of the filter
resonance. The system level
trade off is losses versus
damping.

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 12

Typical Drive Run Data

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 13

630VAC Mains Voltage

The plot on the left is the mains voltage before the


active front-end is turned on.
The plot on the right is the mains voltage with the
active front-end running with load.
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 14

1.2 MW AFE Current Steady-State


Transient imbalance is <8% peak
and <3% RMS (~30Amps)

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 15

1.2 MW AFE Current Steady-State

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 16

AFE Current - Motoring

Phase Currents ~900 Arms (~700kW Motoring)


DC Link Voltage Ripple ~3%
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 17

Mains Current - Motoring

Phase Currents ~900 Arms (~700kW Motoring)


Current THD <4%
DC Link Voltage Ripple ~3%
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 18

Mains Current / AFE Current - Motoring

Comparison of the active front-end current before and after the


LCL filter
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 19

AFE Transient from Generating to Motoring


Power flowing to the
grid (-430kW)

Power flowing from the


grid (+465kW)

00:13:11.20 42348 1

1.250 kAMP

Mains Input
Currents

R1

Transient time
~120msec
Voltage
regulation is
~4%
undershoot
(933 Vdc)

-1.250 kAMP
1.250 kAMP
S1
-1.250 kAMP
1.250 kAMP
T1
-1.250 kAMP
1.250 kAMP

Hoist#1 Motor
Currents

U1
-1.250 kAMP
1.250 kAMP
V1
-1.250 kAMP
1.250 kAMP
W1
-1.250 kAMP

DC
Link

Motoring

Generating

1.050 kVolt
VDC_ 2
900.0 Volt
13:10.811

100.0 ms/div

13:11.811

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 20

AFE Transient from Motoring to Generating


Power flowing off the
grid (+465kW)

Power flowing to the


grid (-430kW)

1.250 kAMP

Mai ns Input
Currents

R1

Transient time
~120msec
Voltage
regulation is
~4%
overshoot
(1008 Vdc)

-1.250 kAMP
1.250 kAMP
S1
-1.250 kAMP
1.250 kAMP
T1
-1.250 kAMP
1.250 kAMP

Hoist#1 Motor
Currents

U1
-1.250 kAMP
1.250 kAMP
V1
-1.250 kAMP
1.250 kAMP
W1
-1.250 kAMP

Motoring

DC
Link

1.050 kVolt

Generating

V DC_2
900.0 Volt
12:55.796

100.0 ms /div

12:56.796

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

Drive Designs

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 22

1. Drive Configuration
1.
2.
3.
4.

Standalone and Parallel Modules Cabinet


VSynch
MDCIC
Block Diagrams
1.
2.
3.
4.
5.

3 parallel-connected drive
3 independent drives
2 parallel-connected drive and 1 standalone drive
Inverter module
D-frame drive cabinet wiring
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 23

1.
Drive Configuration
(Standalone and Parallel Drive)
Standalone Drive

CC

Parallel Drives
MDCIC

CC

Mod1
LCP

Mod2
LCP

M1

S1

S2

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 24

Stand Alone Drive Block Diagram

Standalone T7 Drive (<560kW)


PC Functions

CC Functions

Local controls Fan control, Rec Control (not for AFE based drives)

Drive control Flux control/ AFE


control

Data acquisition Current feedback, IGBT NTC reading

Interface to PLC, Encoder, etc.

EEPROM (Basics)

Current protection Imax1 (Move to MDCIC for parallel drives)

Overall protection Imax2

M o d u le
IG B T 1

LC P

C o n tro l C a rd
(C C )

P o w e r C a rd
(P C )

G a te D r iv e
(G D )

IG B T 2

S c a lin g C a r d
IG B T 3

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 25

Parallel Drive Block Diagram -MDCIC

CAN bus communication

The module identifier is based on the 44-pin connector terminal location.

MDCIC (Multi Drive Control Interface Card) Functions

Sum up three current signals and its sum to CC


Imax1 detection and current balance detection
Distribute the gate signals into three modules.
Vsync detection

M o d u le L e ft

MDCIC
S c a lin g C a r d

LCP

C o n tr o l C a rd
(C C )

P o w e r C a rd
(P C )

3
44

1
2

Warning Messages

IG B T 1 - 3

M a s te r

44

44

G a te D r iv e
(G D )

M o d u le M id d le
P o w e r C a rd
(P C )

G a te D r iv e
(G D )

IG B T 1 - 3

S la v e 1

A70 (Illegal FC Config)

M o d u le R ig h t

Possible causes: Wrong CC (AFE vs INV), Wrong PC (AFE and INV


PC are different), Wrong EEPROM among the modules

A79 (Illegal Power Section Config)


Possible Causes: Mismatch between the setting and # of modules
connected such as improper MDCIC connector connection

P o w e r C a rd
(P C )

G a te D r iv e
(G D )

IG B T 1 - 3

S la v e 2

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 26

2. VSynch (Voltage Synchronization)

Vsync circuit is a part of MDCIC


board.
Function

Measure the mains voltage, in


front of the LCL filter.
Detect the zero crossing.
Send the zero crossing signal to
CC.

Control in CC

O p t o c o u p le r
Is o la tio n

V o lta g e D iv id e r

Z e ro C ro s s
D e te c to r

It is only used once.

Generate Vafe based on the


mains voltage and frequency
information (Par. 40-00 and 4001).

Fault investigation, if AFE fails at


the start up

L C L F il t e r

Common Alarms:

CC
DSP

Synchronize the Vafe according to


the zero crossing signal.

V s y n c C ir c u it
(A p a rt o f M D C IC )

Over Current (A13)


Output Frequency Limit (W62)
Output Voltage Limit (W??)

AFE

IN V

Questions to be investigated
1.
2.
3.

Are RST connected correctly?


Are the parameter setting (40-00
and 40-01) correct?
Are PI gains correct?
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 27

3. MDCIC Board
To CC

Scaling Card Terminals

Test Connector
Features:

PC terminals

Scaling terminals 1 to
4 corresponding to
PC terminals.
Vsync circuit

1 (M)

3 (S2)

Master provides CC
power, Vdc
measurement, and
EEPROM

2 (S1)

To PC

4 (S3)

#1 for Master
No skip
Can bus ID is
associated with the
PC terminal.

Note: Needs the correct


EEPROM in slaves.

RS485 Isolated 5V
voltage from 2nd PC
connector

Current scale change

Vsync Connector
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 28

4. Block Diagrams
Block Diagrams within Cabinet

3 Parallel-Connected Drive
3 Independent Drives
2 Parallel-Connected Drive and 1 Standalone
Drive
Inverter Module

D-frame Drive Cabinet Wiring


| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 29

1. 3 Parallel-Connected Drive
LCP

CC

MDCIC

Vsync

Aux Relay

Soft
Charge

DC In
T5 Auto
Transformer

Door Fan

Fan Source

AC Out
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 30

2. 3 Independent Drives

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 31

3. 2 Parallel Drive and One Standalone Drive

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 32

4. Inverter/AFE Module

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 33

5. D-frame Drive Cabinet

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 34

Design Basics

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 35

AFE Basics Product


Design Details
1.
2.
3.
4.
5.
6.
7.
8.
9.

Start Sequence
Fuse Coordination
Inverter/AFE Module
Fan Circuit
Soft Charge Circuit
Component Layout within Cabinet
Emergency Run
IGBT Circuit Study
CE Certification
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 36

1. Start Sequence
Power Stage #1

Inverter #1
Hoist#1

Soft-Charge

Vrn

AC
Contactor

AC
Contactor

630VAC
Mains

Main Side
Filter

Converter
Side Filter

Lm

Rc

Lc

Ir

Rm

Lm

Rc

Lc

Is

Rm

Lm

Rc

Lc

It

T,

Vtn

Power Stage #2

Rm

Ccf

Vsn

Inverter #2
Hoist#2

Vrn

Vsn

T,

Vtn

Rcf
Power Stage #3

1. Input power is applied


2. Container Crane PLC closes soft charge AC contactor
3. AFE and motor drive controllers are powered up from
the DC link through SMPS (switching mode power
supply)
4. AFE ready signal is received by the PLC and the main
AC contactor is closed and soft charge AC contactor is
opened

Inverter #3
Trolley/
Boom

Vrn

Vsn

T,

Vtn

Inverter #4
Traction

T,

5. AFE receives the run command from the PLC and the
container crane system is ready for use

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 37

2. Fuse Coordination

Fuse Coordination Basics

Isolate the bad power module.


Make sure to have healthy power modules in circuit.

Strategy

All the fuses are selected for the largest power module. It is independent of the drive
power size.

Power module Failure Example

Must NOT open

Must open

Must NOT Open

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 38

3. Inverter/AFE Module
Front View
Side View
Inverter and AFE
modules use the
same hardware
except for the PC.
Power Card

Gate Drive Board

Scaling Card
Mounted on the
module for
standalone drives
and on MDCIC for
parallel drives

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 39

4. Fan Circuit

Single-phase (S and T phase) Source Voltage


The auto transformer is for T5 (380 to 500V).
The door fan and heat sink fans run together.
The choke is installed only in E-frame 500 and 560kW drives.

230V+
A lp h a

D oor Fan
230V
C h o k e o n ly
fo r la r g e fa n

T
380 - 500V
S in g le - p h a s e

A u to T ra n s fo rm e r

H e a t S in k F a n
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 40

Door Fan Strategy

Module Layout

Master is in the most left position.


Independent drive will be at the right of the Master and Slave

Fan Control Module Choice

Master for parallel drive


Parallel and Ind combination or All ind Left and Right Ends

No control from the middle in case #3 Assume that Ind1 and Ind2 are Hoist
Master and Slave combination.

2
1

3
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 41

5. Soft Charge Circuit/ Scheme

Each power module has the soft charge (SC) circuit except for the D-frame drives.

The SC resistors are in positive and negative paths.

# of SC circuit is equal to # of power modules.


No SC circuit is with D-frame drives.
R(SC neg) is added to eliminate the SC fuse blowing when the inverter motor is grounded.

Each cabinet has one set of SC fuses.


S C B o a r d a n d S C R e s is to r s

S C B o a rd

R (s c p o s )

Rsc(pos) and PTC limit the fault


current from the positive voltage.

PTC

( P o s it iv e T e m p
C o e f f i c i e n t R e s is t o r )

Fault Current from


Negative Fault Voltage
R (s c n e g )

IM Ground
Fault

L C L F ilt e r
Lm

Lc
IM

Rf Cf

Lm =29uH
Lc=100uH
C f= 2 4 0 u F
R f= 0 .0 9 O h m

A F E P o w e r M o d u le

I n v P o w e r M o d u le

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 42

Earth Fault (Alarm 14)

Detection Scheme

Calculate a sum of three currents.


If it exceeds the threshold, generate the fault
message and stop the operation.

Fault Cases
1. When the fault happens during the inverter
operation, it stops immediately.
2. When the fault happens after the inverter stops and
before the system starts, the SC charges the DC
bus. It activates the AFE. When the inverter is turned
on, the inverter should detect the fault immediately.

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 43

6. Component Layout within Cabinet


Fan Supply
Board (FSB)
NOTE:
Prevent the spike
voltage from
going through.

Soft Charge
Board (SCB)
and SC
Resistors

FSB Fuse
NOTE:
The fan voltage
choice per
module is
shifted to
reduce the fuse
stress.

SC Fuse

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 44

Magnified View of FSB and


SC Board
FSB

SC Board

SC Resistor

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 45

D-frame Drive Cabinet

CC

FSB

600mm Cabinet
900A DC Fuse
Revisions

Removed the door fan and


associated transformer.

DC Fuses

The D-frame drive internal


cooling is done with the top
fan.

Moved the FSB under the


control card (CC) position.

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 46

7. Emergency Run

Temporarily reduce the number of power modules and run the drive with a reduced
power.

W77 Reduced Power Mode

W78 Power Unit Setup

Correct running condition with a limited power (Rated power divided by a ratio of the module change)
Condition to disable the operation due to the mismatch between # of setting and # of actual modules
connected

Procedure

Physical Changes

3 to 2 Power Module Change

2 to 1 Power Module Change

Disconnect the power module physically.

Before start dismounting, make sure to have the DC capacitor discharged.


Change the 44-pin connector location in MDCIC.
Move Aux relay signal from the new Master power module.

Note: The door fan is run from the original Master power module. Since it is difficult to re-route the
wire from the new Master, the door fan is temporarily inoperative.
Do the processes above.
If RS485 interface is used, need to connect a special assembly to #2 terminal at MDCIC. The assembly generates
the isolated 5V for RS485 communication.

PLC command

Change the parameter setting from Setup #1 to Setup #2. (Par. 0-10)

Note: Review the PI gains.

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 47

8. IGBT Circuit Study

IGBT Design

IGBT circuit is designed to


maintain the over-voltage level
within its rating
IGBT temperature rise due to
the worst running condition is
within its temperature capability
IGBT current is limited to its
ability. (IMAX1 and IMAX2)

Snubber C ap
6* 1uF
in e a c h te r m in a ls

IG B T 1

AC1

Cap Bank 1

IG B T 2
B us1

AC2

Components

IGBT
DC Cap banks
Snubber Cap
Sandwiched Bus Assembly to
Cap Bank (Bus1)
Sandwiched Bus Assembly to
DC (Bus2)

IG B T 3
Cap Bank 2
T o ta l C a p a c ita n c e
1 1 .2 m F fo r
P 4 0 0 to P 5 6 0

AC3

B us2

DC

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 48

1. IT Mains Crane System

Drive Operation with One-point and Two-point Ground Fault


HF (High Frequency) Board

Noise path especially for IGBT switching noise containment

Iso-meter Function with the AFE Drive


AFE302P800T7

P D T e s t S e tu p

HF Board

AFE

L B -3 0 2 P 5 6 0 T 7
L C L F ilte r
Lm

Lc

AFE
IM

2 .5 M V A 6 3 0 V
Rf Cf

1500hp
690V

Lm =29uH
Lc=100uH
C f= 2 4 0 u F
R f= 0 .0 9 O h m

H F B o a rd

F a u lt

B e n d e r Is o m e te r
A 1 /+ A 1 /-

L1

L2

AK

KE

AK160
T1

T2

R1 R2 F1

F2

M + M - A

IR D H 2 7 5

11

12

14

21

22

24

AG H150W
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 49

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