Danfoss VLT AAF006, Service Manual

Page 1: ...MAKING MODERN LIVING POSSIBLE VLT Advanced Active Filter AAF006 D and E Frame Service Manual www danfoss com drives MG90Z122 130R0268 MG90Z122 Rev 2012 04 20...

Page 2: ...2 1 LCP Layout 2 1 2 2 2 Setting LCP Display Values 2 2 2 2 3 Display Menu Keys 2 2 2 2 4 Navigation Keys 2 3 2 2 5 Operation Keys 2 3 2 2 6 Tips and Tricks 2 4 2 3 Status Messages 2 4 2 3 1 Status M...

Page 3: ...ult Symptoms 4 3 4 4 1 No Display 4 3 4 4 2 Intermittent Display 4 3 4 5 Warning Alarm Messages 4 4 4 5 1 Warning Alarm Code List 4 4 4 6 After Repair Tests 4 12 5 Active Filter and the Power Grid 5 1...

Page 4: ...use Test 6 4 6 2 5 2 Ohm Test of Transformer 6 4 6 2 5 3 Ohm Test of Fans 6 4 6 2 6 AC Line power Contactor and Soft Charge Contactor Tests 6 5 6 3 Dynamic Test Procedures 6 5 6 3 1 No Display Test 6...

Page 5: ...3 8 IGBT Current Sensors CT1 CT2 and CT3 7 14 7 3 9 Damping Resistors 7 14 7 3 10 Fan Transformer 7 14 7 3 11 Fan 7 14 8 E Frame Sizes Disassembly and Assembly Instructions 8 1 8 1 Electrostatic Disch...

Page 6: ...or Bank Assembly 8 14 8 3 6 IGBT Modules 8 15 8 3 7 IGBT Current Sensors CT1 CT2 and CT3 8 17 8 3 8 Fan Transformer 8 18 8 3 9 Fan 8 18 8 3 10 Damping Resistors 8 18 9 Special Test Equipment 9 1 9 1 T...

Page 7: ...Contents VLT Advanced Active Filter AAF006 D and E Frames Service Manual MG90Z122 VLT is a registered Danfoss trademark...

Page 8: ...1 2 1 Warnings CAUTION Active filters contain dangerous voltages when connected to line power The connected current transducers may also hold dangerous voltages when connected Only a competent techni...

Page 9: ...15 355 E9 1490 676 A210 500 550 355 400 E9 1490 676 A210 550 600 400 450 E9 1490 676 A330 450 500 630 700 F18 4409 2000 Table 1 1 Active Filter Ratings Frame designation Depth in mm Width in mm Height...

Page 10: ...239 115 239 115 239 115 Table 1 3 Product Related Specifications The filter will automatically limit output to avoid overcurrent tripping Typical average switching frequency 3 0 4 5 kHz Excessive swi...

Page 11: ...t in various locations in the filter Three current transducers on the output phases bus bars induce counter harmonics onto line power There are also three current transformers on the line power bus ba...

Page 12: ...Metric socket set 7 19 mm Socket extensions 100 mm 150 mm 4 in and 6 in Torx driver set T 10 T 50 Torque wrench 0 675 19 Nm 6 170 in lbs Needle nose pliers Magnetic sockets Ratchet Screwdrivers Standa...

Page 13: ...Line power disconnect option 19 Damping resistors 7 Input terminal mounting plate 20 Cross bus bar 8 Line power contactor 21 DC link inductor 9 Lower capacitor bank assembly 22 DC link inductor 10 LC...

Page 14: ...y adjusts to assure operation is not disrupted Warnings usually indicate that the filter is running at its maximum capability Familiarity with the information provided on the display is important Diag...

Page 15: ...u Alarm Log Figure 2 3 Key Function Status Press to show operational information In Auto mode press and hold to toggle between status readout displays Press repeatedly to scroll through each status di...

Page 16: ...rea identifying the problem Red ALARM A fault condition causes the red alarm light to flash and an alarm text is displayed Table 2 4 2 2 5 Operation Keys Operation keys are found at the bottom of the...

Page 17: ...urrent transformer detection is finished Press OK to accept the settings found or cancel to discard Location polarity or ratio errors may be caused when running with large grid load changes If errors...

Page 18: ...nput signals are wired to the CT terminal Incorrect CT settings or improper wiring are the primary reasons for the filter not starting or causing the unit to trip or malfunction Setting CTs is describ...

Page 19: ...0 Table 2 8 External CT settings are programmed in parameter group 300 2 The automatic CT detection is only possible with CT installed on the PCC side 130BP093 10 0 0 300 29 Start Auto CT Detection 1...

Page 20: ...receive an external signal for filter sleep mode For the LHD units terminals 18 and 20 are wired to the drive terminal 29 and 20 to allow the drive to start and stop the filter when drive goes into st...

Page 21: ...on of the terminal It is important to confirm that the control terminal is programmed for the correct function Parameter settings are displayed by pressing the Status key on the LCP 130BP045 10 Status...

Page 22: ...input for controlling the filter R 2 Kohm Less than 5 V logic 0 open Greater than 10 V logic 1 closed Wired and programmed for feedback from line power 37 0 24 V DC input for safety stop some units J...

Page 23: ...MK103 69 61 68 RS 485 Interface 91 L1 92 L2 93 L3 95 Fuse Option Manual disconnect Switch mode Power supply 10V DC 15mA 24V DC 200mA MK102 12 13 18 19 27 29 32 33 20 37 130BB507 11 Figure 2 14 AFC Ca...

Page 24: ...that can disrupt the entire system This can be resolved by fitting an equalizing cable next to the control cable Minimum cable cross section is 8 AWG 50 60 Hz ground loops When using very long contro...

Page 25: ...Operator Interface and Acti VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 12 MG90Z122 VLT is a registered Danfoss trademark 2 2...

Page 26: ...igure 3 1 AAF Internal Circuitry 1 Line power option plate 6 Power module 2 HI Lm reactor 7 DC capacitors 3 Line power contactor 8 Damping resistors 4 Power card 9 AC capacitor 5 Inverter side reactor...

Page 27: ...ounted in the customer electrical supply system In the LHD the external CTs are mounted in front of the Adjustable frequency drive The customer supplied external CT secondary coil can be rated with no...

Page 28: ...eep It is only closed when the filter is ON thereby minimizing standby losses When the line power contactor is open active filter control is maintained by the soft charge circuit The status of the mai...

Page 29: ...sensor CT6 Hall Effect AC capacitor current sensor CT7 Current Transformer External current transformer CT8 Current Transformer External current transformer CT9 Current Transformer External current t...

Page 30: ...filter section is the same as the stand alone AAF active filter 1 2 3 4 5 6 7 8 9 10 140BX433 Figure 3 3 LHD Internal Circuitry 1 Line power option plate 6 Power module 2 HI Lm reactor 7 DC capacitor...

Page 31: ...Internal Active Filter Oper VLT Advanced Active Filter AAF006 D and E Frames Service Manual 3 6 MG90Z122 VLT is a registered Danfoss trademark 3 3...

Page 32: ...e filter has been designed to operate within certain specifications Incorrect parts may affect tolerances and result in further damage to the unit 5 Read the instruction and service manuals A thorough...

Page 33: ...as well Check the voltage source of the signals Check that the maximum CT burden is not exceeded through long wiring or small square section Though not always necessary depending on the installation c...

Page 34: ...phanumeric display The other is three LEDs near the bottom of the LCP If the power on LED is illuminated green but the backlit display is dark this indicates that the LCP itself is defective and must...

Page 35: ...has appeared The trip removes power injection to the grid and can be reset after the condition has been cleared by pressing the reset button or through a digital input parameter 5 1 The event that cau...

Page 36: ...fault X 24 External fan fault X 29 Heatsink temp X X X 33 Inrush fault X X 34 Fieldbus communication fault X X 38 Internal fault X X 39 Heatsink sensor X X 40 Overload of Digital Output Terminal 27 X...

Page 37: ...is dependent on the filter voltage rating The unit is still active See rating Table 1 4 in for the voltage limits WARNING 6 DC link voltage low The intermediate circuit voltage DC is lower than the lo...

Page 38: ...oss supplier 15 40 FC Type 15 41 Power Section 15 42 Voltage 15 43 Software Version 15 45 Actual Typecode String 15 49 SW ID Control Card 15 50 SW ID Power Card 15 60 Option Mounted 15 61 Option SW Ve...

Page 39: ...Service Department 2820 LCP stack overflow 2821 Serial port overflow 2822 USB port overflow 3072 5122 Parameter value is outside its limits 5123 Option in slot A Hardware incompatible with control boa...

Page 40: ...cards to check compatibility ALARM 79 Illegal power section configuration The scaling card is the incorrect part number or not installed Also MK102 connector on the power card could not be installed A...

Page 41: ...ng current The active filter utilizes a phase locked loop PLL to track the AC line voltage frequency When the active filter starts the PLL uses the LCL filter AC capacitor currents from the current tr...

Page 42: ...ect polarity of the CTs Program the CT parameters manually if auto CT detection fails WARNING 318 CT ratio error The auto CT function could not determine the correct primary rating of the CTs Program...

Page 43: ...n the following parameters Primary Rating 300 20 CT Primary Rating Sequence 300 24 CT Sequence Polarity 300 25 CT Polarity 8 Mount the CT short at all three CT inputs on the CT input terminal factory...

Page 44: ...d based drives or other active input devices are present on the same grid the high switching noise can overload the damping resistor of the LCL filter The amplitude of voltage harmonics above 25th ord...

Page 45: ...e load side resonant conditions occurring within the electrical power system between the active filter and the load don t interfere with active filter functioning At light grid loads the grid resonanc...

Page 46: ...y feeling the outside of the unit if the overtemperature condition is still present If not the temperature sensor must be checked This can be done with the use of an ohmmeter in accordance with the th...

Page 47: ...eration are uncommon the following detrimental EMI effects may be seen Serial communication transmission errors CPU exception faults Unexplained filter trips Disturbance resulting from other nearby eq...

Page 48: ...ices and power supplies connected to line power are energized at rated voltage Use extreme caution when conducting tests on a powered filter Contact with powered components could result in electrical...

Page 49: ...ed of six IGBTs Depending on the size of the unit either one two or three IGBT modules are present The filter also has three snubber capacitors on each IGBT module Before starting tests ensure that me...

Page 50: ...Pin 2 is common 1 With ohmmeter measure pins 1 and 2 of each test connector Reading should indicate 7 8 K for D frames and 3 9 K for E frames Incorrect reading An incorrect reading indicates that eit...

Page 51: ...function and setting the measurement manually To aid in making the measurements unplug the MK107 from the power card Checking continuity of connections For the following tests read connector MK107 on...

Page 52: ...ures in this section are numbered for reference only Tests need not be performed in this order Perform tests only as necessary WARNING Electrical Hazard Never disconnect the input cabling to the filte...

Page 53: ...l then continue Remember to check the customer connections If still unsuccessful proceed to the SMPS test A correct reading of both control card voltages would indicate the LCP or the control card is...

Page 54: ...control terminals Verify the control voltage power supply is correct as follows 1 With a voltmeter measure voltage at control card terminal 12 and 13 with respect to terminal 20 The meter should read...

Page 55: ...ut installation and configuration for faults again 7 Program step by step the filter for compensation other harmonics and monitor the AC output filter current indicated on the LCP or by direct measure...

Page 56: ...is lower than 15 of the nominal filter current If higher conduct a hardware fault inspection 11 Stop the active filter and remove all three CT short lugs 12 Check the filter parameters according to a...

Page 57: ...Test Procedures VLT Advanced Active Filter AAF006 D and E Frames Service Manual 6 10 MG90Z122 VLT is a registered Danfoss trademark 6 6...

Page 58: ...low that they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic components CAUTION Use proper electrostatic discharge ESD procedures to pre...

Page 59: ...g Plate 1 Control card terminal block 6 FU4 2 Control card 7 Power card mounting plate 3 Active filter AAF card 8 Power card 4 Control card mounting plate 9 Mounting nut 5 FU5 10 Control card assembly...

Page 60: ...t 1 Remove the control card mounting plate in accordance with the procedure 2 Remove the 5 mounting nuts 0 39 in 10 mm 3 Remove the control assembly support bracket Reinstall in the reverse order of t...

Page 61: ...g card controls signals operating with this specific filter The scaling card is not part of the replacement power card 6 Retain power card insulation for reassembly Reinstall in the reverse order of t...

Page 62: ...isconnect the red wires from the AC input contactors by removing the retaining nut 0 32 in 8 mm 7 Remove the cables from the top side of fuses FU6 FU14 and FU15 and disconnect the inline connector goi...

Page 63: ...the control assembly support bracket in accordance with the procedure 2 Remove the power card mounting plate in accordance with the procedure 3 Remove the nut 0 43 in 11 mm from each side of the AC ca...

Page 64: ...r Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 7 2 8 AC Contactors Prior to removing cables from the AC contactors note the mounting orientation of the A...

Page 65: ...orque tightening values 7 2 10 Discharge Card 1 Disconnect MK100 from the discharge card 2 Remove the discharge card by removing the four screws T 25 Reinstall in the reverse order of this procedure S...

Page 66: ...ns The fused disconnect option is shown 1 Disconnect the line power input wiring from terminals L1 L2 L3 and the ground connector 2 Remove the 3 cross bus bars between the input terminals and the inpu...

Page 67: ...inal 7 L3 3 Cross bus bar terminal 8 L2 4 Cross bus bar terminal 9 L1 5 Line power disconnect fuse optional Table 7 6 Reinstall in the reverse order of this procedure See Table 1 7 for torque tighteni...

Page 68: ...Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 7 3 3 Contactor Transformer 1 Remove the input terminal mounting plate in accordance with the procedure 2 D...

Page 69: ...er when leaving the filter attached 1 Note the color of the wires attached to the DC bus terminals on the right side of the capacitor bank assembly for proper reassembly 2 Remove the two nuts 0 39 in...

Page 70: ...0 Fan Molex connector 3 Current sensor standoff 11 Fan 4 IGBT intermediate bus bar 12 Retaining screw 5 Current sensor bus bar 13 DC bus assembly 6 Current sensor 14 Snubber capacitor 7 Damping resist...

Page 71: ...late in accordance with the procedure 2 Remove the nuts 0 51 13 mm from both ends of the current sensor bus bar 3 Remove the retaining nut 0 32 8 mm from the current sensor standoff 4 Disconnect the c...

Page 72: ...ctricity Voltages so low that they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic components CAUTION Use proper electrostatic discharge...

Page 73: ...trol card terminal block 6 FU4 2 Control card 7 Power card mounting plate 3 Active filter AAF card 8 Power card 4 Control card mounting plate 9 Mounting nut 5 FU5 10 Control card assembly support brac...

Page 74: ...t 1 Remove the control card mounting plate in accordance with the procedure 2 Remove the 5 mounting nuts 0 39 in 10 mm 3 Remove the control assembly support bracket Reinstall in the reverse order of t...

Page 75: ...g card controls signals operating with this specific filter The scaling card is not part of the replacement power card 6 Retain power card insulation for reassembly Reinstall in the reverse order of t...

Page 76: ...ttaching the MK102 ring lug to the power card mounting plate 5 Note the position of the red and white cables from the FU4 and FU5 fuse block for reassembly Unplug the cables 6 Remove the power card mo...

Page 77: ...edure 3 Remove the nut 0 43 in 11 mm from each side of the AC capacitor and the lug wires 4 Remove the AC capacitor by removing the nut 0 32 in 8 mm from each side of the AC capacitor mounting bracket...

Page 78: ...CT5 CT6 1 2 130BX442 10 Figure 8 5 1 AC capacitor current sensor 2 Retaining nut Table 8 5 E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual MG90Z122 VLT is a...

Page 79: ...per reinstallation Direction of the cable is phase sensitive to the sensor function 2 Remove the nut 0 43 in 11 mm from the corresponding capacitor in order to remove the lug cable which goes through...

Page 80: ...actor L3 10 MOV retaining nut 3 AC contactor L1 11 MK107 4 Differential mode RFI card 12 MK106 5 Discharge card PCA16 13 MK1 6 Soft charge resistor 14 Common mode RFI card 7 Fuses FU6 FU14 FU15 15 Pow...

Page 81: ...is procedure See Table 1 7 for torque tightening values 8 2 12 Discharge Card 1 Disconnect MK100 from the discharge card 2 Remove the discharge card by removing the four screws T 25 Reinstall in the r...

Page 82: ...inal 7 L3 3 Cross bus bar terminal 8 L2 4 Cross bus bar terminal 9 L1 5 Line power disconnect fuse optional Table 8 8 Reinstall in the reverse order of this procedure See Table 1 7 for torque tighteni...

Page 83: ...ing plate by removing two screws 0 32 in 8 mm in the front of the plate and two screws 0 32 in 8 mm at the back of the plate on the vertical mounting tabs not shown Disconnect cables MK102 MK103 and M...

Page 84: ...39 in 10 mm 3 The capacitor bank connection to the DC bus bars can be seen recessed in the gap between the upper and lower capacitor banks A minimum extension of 6 in 150 mm is required Remove the 6...

Page 85: ...0 39 in 10 mm 3 The capacitor bank connection to the DC bus bars can be seen recessed in the gap between the upper and lower capacitor banks A minimum extension of 6 in 150 mm is required Remove the...

Page 86: ...ntermediate IGBT output bus bar step 7 8 Top IGBT module retaining screw step 6 4 Intermediate IGBT output bus bar retaining nut step 7 9 IGBT bus bar assembly 5 Bottom retaining nuts IGBT bus bar ass...

Page 87: ...nut 0 32 in 8 mm from the three intermediate IGBT output bus bars to provide access to IGBTs 8 Remove the screw T 30 on the top end of the intermediate IGBT bus bar to allow access to the IGBT module...

Page 88: ...Intermediate IGBT bus bar top 13 Fan transformer 7 Current sensor retaining screw 14 Fan assembly Table 8 13 1 Remove the input terminal mounting plate in accordance with the procedure 2 Remove the u...

Page 89: ...he line power input cabling from terminals L1 L2 L3 and the ground connector 2 Disconnect the Molex connector from the fan assembly 3 Remove the fan assembly by removing six nuts 0 39 in 10 mm Reinsta...

Page 90: ...C bus enabled and operating a load to verify some test signals The following is a description of the signals available on the signal test board 6 Test Proceduresof this manual describes when these tes...

Page 91: ...l to 25C 6 FANO Control Card signal Signal from the control card to turn the fans on and off 0 V DC ON command 5 V DC OFF command 7 INRUS H Control Card signal Signal from the control card to start ga...

Page 92: ...to gate SCR s for fan voltage control In sync with line freq 8 00 6 00 4 00 2 00 0 00 V 2 00 4 00 6 00 8 00 4 0ms 2ms Div Input A 130BX152 10 7 trigger pulses at 3 kHz 5 V DC fans off 18 HI_LO W Cont...

Page 93: ...00 0 00 V 2 00 4 00 6 00 8 00 4 0ms 50Us Div Input A 130BX153 10 2v div 100us div Run 10 Hz 2 2 2 5 V DC Equal on all phases TP25 TP30 27 GVP_T IGBT gate signal buffered V phase positive Signal origi...

Page 94: ...v 100us div Run 10 Hz 2 2 2 5 V DC Equal on all phases TP25 TP30 30 GWN_ T IGBT gate signal buffered W phase negative Signal originates on the control card 8 00 6 00 4 00 2 00 0 00 V 2 00 4 00 6 00 8...

Page 95: ...Special Test Equipment VLT Advanced Active Filter AAF006 D and E Frames Service Manual 9 6 MG90Z122 VLT is a registered Danfoss trademark 9 9...

Page 96: ...MK1703 1 24 MK107 CBL2 1 24 CAP CT INPUT MK103 12 13 M CT3 M CT2 M CT1 SW1 14 DISCONNECT MANUAL C3 CT4 CT5 C4 CT6 C5 LC1 FK104 1 16 IND1 CBL26 CBL30 SW3 3 5 8 4 4A 15A X4 X2 X1 H4 H2 H3 H1 M 1 9 6 7 2...

Page 97: ...HITE BLACK RED WHITE BLACK WHITE RED BLACK RED BLACK WHITE RED BLACK WHITE PCA15 1 2 3 MK1 RFI CARD HF SWITCH CBL5 PCA13 PCA14 7 8 SHIELD GND 37 JUMPER GND TMP 3 1 2 18 PULSE NTC MK103 CBL22 CN6 1 1 2...

Page 98: ...MAKING MODERN LIVING POSSIBLE VLT Advanced Active Filter AAF006 D and E Frame Service Manual www danfoss com drives MG90Z122 130R0268 MG90Z122 Rev 2012 04 20...