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VLT Advanced Active Filter AAF006 D and E Frame Service Manual

1. VLT Advanced Active Filter AAF006 D and E Frames Service Manual OL SEVXAOEL Block Diagrams
2. Operator Interface and Acti VLT Advanced Active Filter AAF006 D and E Frames Service Manual E o wn ca ca Fuse Manual E Option disconnect T e e CN aaa e AVY s 91 L1 et el A i l L fe anne NANM WA 92 L2 d il Or AN a L fi 2 MAA PADE 93 3 si a b e LE 95 O 0 O E I 9 Switch mode Power supply 10V DC 24V DC 15mA 200mA S 5V RS 485 Interface 13 69 18 24V NPN 0V PNP a 2 68 19 24V NPN 8 2 ov PNP spe 24V NPN 3 0 L 0V PNP 424 L N pey ov 29 24V NPN d 1 OV PNP 424V B 2 3 24V NPN ov TL OV PNP 33 24V NPN TL OV PNP 20 24V NPN 3 OV PNP 37 MK108 1A MK101 5A O Illustration 2 7 AFC Card Connections MG90Z102 VLT is a registered Danfoss trademark 21 Denpi Operator Interface and Acti VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 8 Earthing Screened Control Cables NOTE CT wires must be screened or twisted pair to reduce noise Screen all control cables and connect the screen with cable impact o
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4. VLT Advanced Active Filter AAFO06 D and E Frames Service Manual OL v VXg8OEL Block Diagrams FOLIMS HY I MS WH3HLL891 x s F 2 g E ales FB d A ipis puis egol KAZAA 9D Ej 5 semua STNGOW 9DVIONODS
5. 40 5 3 2 Current Feedback Problems sna 40 A uan 4 5 3 4 Effect of EMI 41 2 MG90Z102 VLT is a registered Danfoss trademark Contents VLT Advanced Active Filter AAF006 D and E Frames Service Manual 6 Test Procedures 42 MG90Z102 VLT is a registered Danfoss trademark Contents VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 2 10 Discharge Card msn 37 7 2 11 Soft Charge Resistor 7 0 5070 37 7 3 Active Side Bottom Instructions se 58 7 3 1 Input Terminal Mounting Plate 58 7 3 2 Gate Drive Card sss 59 7 371GBTModules mmm 61 7 3 8 IGBT Current Sensors CTI CT2 and CT3 62 7 3 9 Damping Resistors U ss 62 7310FanTransformer msn 62 7 3 11 Fan 62 MG90Z102 VLT is a registered Danfoss trademark Contents VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8339 A sss 79 8 3 10 Damping Resistors nin 79 9 Special Test Equipment sss 8 9 1 Test Equipment IA 9 1 1 Signal Test Board p n 176F8437 OO 9 1 2 Signal Test Board Pin Outs Description and Voltage Levels 80 MG90Z102 VLT is a registered Danfoss trademark Introduction 1 Introduction The purpose of this manual is to provide detailed technical information and instructions to enable a qualified technician to identify faults and perform repairs on VLT Advanced Active Filters in D and E frame sizes It covers both the stand alone active filter AAF and the filter p
6. 165 of CT current rating AC waveform 2000 0 1500 0 1000 0 500 0 0 0 mV k t Fi 500 0 V phase not conditioned 130BX148 10 output frequency of the filter 1000 0 1500 0 2000 0 200 ms Approx 400 mV RMS 100 loa 3 IW1 Current sensed W phase not 937 V ACpeak 165 of CT current rating AC waveform 2000 0 1500 0 1000 0 500 0 0 0 mV k f 500 0 1000 0 1500 0 2000 0 conditioned output frequency of the filter 130BX148 10 200 ms ms Div Approx 400 mV RMS 100 load 4 COMM Logic common This common is for all signals ON 5 AMBT Ambient temp Used to control FAN high and low fan speeds 1 V DC approximately equal to 25C FANO Control Card Signal from the control card to turn the fans on and off 0 V DC ON command 7 INRUS Control Card Signal from the control card to start gating the SCR front end 3 3 V DC SCRs disabled 8 RL1 Control Card Signal from Control Card to provide status of Relay 01 0 V DC Relay active Maud SSSSSCSCSOSOSOSCCCC C r Wwe SSCS 18 V DC The red LED indicates voltage is present between VPOS and VNEG 18 V DC regulated supply regulated terminals 16 5 to 19 5 V DC supply 16 5 to 19 5 V DC 18 V DC The red LED indicates voltage is present between VPOS and VNEG 18 V DC regulated supply regulated terminals 16 5 to 1
7. 6 00 130BX153 10 W phase 4 00 positive Signal 200 originates on 0 00 V Control Card 2 00 4 00 6 00 8 00 4 0ms 50Us Div 2v div 100us div Run 10 Hz 2 2 2 5 V DC Equal on all phases TP25 TP30 30 IGBT gate signal buffered W phase 130BX153 10 negative Signal originates on Control Card 4 0ms 50Us Div 2v div 100us div Run 10 Hz 84 MG90Z102 VLT is a registered Danfoss trademark ureibelq pojg 1E2417 avv LOL uoneasnyll
8. Measure the resistance to earth of the LCL filter components leads with a megohmmeter to check for earth faults e Perform AC capacitors and current transducers test 6 Test Procedures Check that the connectors on current transducers and on the AFC card are pinned properly Check AC capacitors current transducers cables Replace the AFC card Automatic switching between the grid and a generator based on certain events can cause mains loss leading to this alarm Use auto reset if this is the cause ALARM 306 Compensation limit The compensation current exceeds unit capability Unit is running at full compensation Warning 306 is informational in nature and does not indicate a malfunction WARNING ALARM 308 Resistor temp Excessive resistor heatsink temperature detected A temperature feedback is implemented using an NTC thermistor mounted on the damping resistor heat sink The temperature is calculated and compared to a power unit dependent PUD alarm level Warning 308 is displayed when the PUD warning level is reached This indicates the resistor temperature is close to the alarm level Troubleshooting Verify if Ambient temperature is too high Incorrect clearance above and below the unit p VLT Advanced Active Filter AAF006 D and E Frames Service Manual Dirty heatsink Blocked air flow around the unit Damaged heatsink fan WARNING ALARM 309 Mains earth fault An earth ground fault was
9. Operator Interface and Acti 2 3 Status Messages Status messages appear in the bottom of the display The left part of the status line indicates the active operation model of the filter The right part of the status line gives the operation status e g Run Stop Trip Operation Mode Off The device does not react to any control signal until Auto On or Hand On on the LCP are pressed Auto On The filter is controlled via the control terminals and or the serial communication Hand On The operator is able to adjust the local reference manually Stop commands alarm reset and set up selection signals can be applied to the control terminals p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 3 1 Status Message Definitions Operation Status Auto CT ready The automatic current transformer detection is ready for operation Press Hand On to begin the process Auto CT The automatic current transformer detection is running running Auto CT The automatic current transformer detection is finished 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 occurs set the polarity location and ratio manually PowerUnit Off Available only with an optional device installed for example a 24 V supply The mains supply to the unit is removed but the control card is still supplied wi
10. Remove the IGBT bus bar assembly 76 MG90Z102 VLT is a registered Danfoss trademark p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 6 At the top end of the IGBT module remove the 12 T 25 retaining screws 4 each for the U V and W intermediate IGBT output bus bars 7 Loosen the retaining nut 8 mm from the 3 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 for removal 9 Note that a Mylar shield covers lower 8 retaining screws Take proper care to avoid damage to the shield Remove the 2 IGBT modules by removing the 16 T 25 screws 8 per module and sliding the modules free from under the bus bars 10 Clean the heatsink surface with a mild solvent or alcohol solution Reassembly 1 Replace the IGBT module in accordance with the instructions provided with the replacement kit Note that tightening pattern and torque values described in kit must be complied with 2 Reassemble the remaining parts in reverse order of their removal See Table 1 7 for torque tightening values MG90Z102 VLT is a registered Danfoss trademark 77 p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 3 7 IGBT Current Sensors CT1 CT2 and CT3 3 4 5 1 2 6 5
11. VLT is a registered Danfoss trademark p Internal Active Filter Oper VLT Advanced Active Filter AAF006 D and E Frames Service Manual 3 3 7 Low Harmonic Drive generated on the mains by the frequency converter Apart from that the functionality of the active filter section is the The low harmonic drive LHD consists of an active filter same as the stand alone AAF active filter AAF section and a frequency converter section The AAF section actively compensates for harmonic distortion Romo 2 SET YA vm j i iie E LI rT tn i i l qp E ld Jo mmm Illustration 3 3 LHD Internal Circuitry 1 Mains option plate 6 Power module 2 HI Lm reactor 7 DC capacitors 3 Mains contactor 8 Damping resistors 4 Power card AC capacitor 5 Inverter side reactor Lc Frequency converter interconnect MG90Z102 VLT is a registered Danfoss trademark 27 Troubleshooting 4 Troubleshooting 4 1 Troubleshooting Tips Before attempting to repair a filter here are some tips to follow to make the job easier and possibly prevent unnecessary damage to functional components 1 Note all warnings concerning voltages present in the filter Always check for the presence of AC input voltage and DC bus voltage before working on the unit Some points in the filter are
12. 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 low voltage warning limit The limit is dependent on the filter voltage rating The unit is still active See rating Table 1 4 in for the voltage limits WARNING ALARM 7 DC overvoltage If the intermediate DC link voltage exceeds the limit the filter trips after a time See rating Table 1 4 in for the voltage limits There are two different procedures for troubleshooting alarm 7 depending upon the time the alarm occurs Alarm 7 DC overvoltage occurs immediately after starting run the active filter e Turn off the active filter Measure the resistance to earth of the LCL filter AC capacitors and damping resistors leads with a megohmmeter to check for earth faults Perform AC capacitors current transducers test e Check if the connectors on the current transducers and on the AFC card are pinned properly Check AC capacitors current transducers cables Replace the AFC card Alarm 7 DC overvoltage occurs during the active filter operation Perform the Mains Resonance Test 6 3 7 Mains Resonance Test WARNING ALARM 8 DC under voltage If the intermediate circuit voltage DC link drops below the undervoltage limit the filter checks if a 24 V backup supply is connected If no 24 V backup supply is connected the filter t
13. scaling of current and voltage feedbacks The power card contains a switch mode power supply SMPS which provides the unit with 24 V DC 18 V DC 18 V DC and 5 V DC operating voltages The control and interface circuitry is powered by the SMPS The SMPS is supplied by the DC bus voltage The filter can be purchased with an optional secondary SMPS which is powered from a customer supplied 24 V DC source This secondary SMPS provides power to the control circuitry when the mains input is disconnected and can maintain communication options when the filter is not powered from the mains Circuitry for controlling the cooling fans is also provided on the power card The gate signals from the control card to the transistors IGBTs are isolated and buffered on the gate drive card 3 2 5 Filter Power Section Mains power enters though the input terminals or the disconnect and or the RFI option depending on the unit s configuration If the unit is equipped with optional fuses these fuses limit damage caused by a short circuit in the power section The three mains phases are fed to a Harmonics Isolation reactor HI reactor that distributes mains power to the inverter or the frequency converter for the LHD If the filter is used as a stand alone AAF unit the HI reactor is considered a mains side filter containing only the mains side reactor Lm The mains power will not be applied to the inverter until the intermediate circuit DC bus has b
14. 7 t gc 9 E 1 8 LI e e e h A j A M ER BI 2 fy 5 5 10 0 0 0 11 e 99 e 88 e Of OOODODQODOOOODOODOA 13 14 Illustration 8 12 IGBT Current Sensor Fan and Fan Transformer and Damping Resistors 130BX413 Damping resistor 8 Intermediate current sensor bus bar Damping resistor bus bar 9 Intermediate IGBT bus bar standoff Damping resistor retaining nut T 20 1 Intermediate IGBT bus bar retaining screw 1 2 3 0 Intermediate IGBT bus bar bottom 1 Remove the input terminal mounting plate in 7 Remove the current sensor by removing the nut accordance with the procedure 8 mm one on each side of the current sensor 2 Remove the upper capacitor bank in accordance Reinstall in the reverse order of this procedure See with the procedure Table 1 7 for torque tightening values 3 Remove 4 screws T 30 attaching the IGBT intermediate bus bars to the IGBT module 4 On the other end of the IGBT intermediate bus bar remove the retaining screw T 30 5 Remove the standoff nuts 8 mm from IGBT intermediate bus bar 6 Disconnect the current sensor cable not shown 78 MG90Z102 VLT is a registered Danfoss trademark p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 3 8 Fan Transformer 1 Disconnect the mains input cabling from terminals L1 L2 L3 and the earth ground connector 2 Disconnect the in line conn
15. If this test is successful then continue Remember to check the customer connections If still unsuccessful proceed to the Switch Mode Power Supply SMPS test 2 Measure the 10 V DC control voltage at terminal 50 with respect to terminal 55 The meter should read between 9 2 and 11 2 V DC An incorrect reading here could indicate the supply is loaded down by a fault in the customer connections Unplug the terminal strip and repeat the test If this test is successful 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 defective Replace the LCP with a known good one If the problem persists replace the control card in accordance with the disassembly procedures in 7 D Frame Sizes Disassembly and Assembly Instructions or 8 E Frame Sizes Disassembly and Assembly Instructions 6 3 4 Switch Mode Power Supply SMPS Test For this procedure provide 650 V using the split bus power supply The SMPS derives its power from the DC bus The first indication that the DC bus is charged is the DC bus charge indicator light located on the power card being lit This LED however can be lit at a voltage still too low to enable the power supplies First test for the presence of the DC bus 1 Insert the signal test board into the power card connector MK104 2 Connect the negative meter lead
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17. and remove the cabling from each a 3 Disconnect the wires from the auxiliary contactors by loosening the retaining screw 70 MG90Z102 VLT is a registered Danfoss trademark p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 4 Remove the AC contactor by removing the 4 mounting nuts 10 mm Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 8 2 9 Common Mode CM RFI Filter Card 1 Disconnect the cables from MK1 MK5 MK6 and MK7 2 Remove the common mode RFI filter card by removing the 4 screws T 25 from the standoffs Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 8 2 10 Differential Mode DM RFI Filter Card 1 Disconnect the cables from MK105 MK106 and MK107 2 Remove the differential mode RFI filter card by removing the 4 screws T 25 from the standoffs Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 8 2 11 MOVs 1 Disconnect the wires from the terminals on the top and bottom of the MOV by loosening the retaining screws 2 Remove the MOV by removing the 2 screws T 20 top and bottom Reinstall in the reverse order of this 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 4 screws
18. binary 0 or 1 which in effect act as a switch Digital signals are controlled by a 0 to 24 V DC signal A voltage signal lower than 5 V DC is a logic 0 open A voltage higher than 10 V DC is a logic 1 closed Digital inputs to the filter are switched commands such as start stop and reset e Digital inputs to connection MK102 18 19 20 27 and or 29 can be programmed for external start stop and or reset of the unit or to receive an external signal for filter sleep mode e 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 standby or off modes The LHD filter should be in Hand On local mode for proper operation Digital input terminal 32 and 33 are pre wired and configured for feedback from the mains contactor CBL28 These are not for external use and can not be reconfigured Digital output signals on terminal 27 and 29 can be used for external THDi or THDv readout to an external controller or system To allow for this option pulse reference signals need to be programmed for terminals 27 and 29 Terminals 12 and 13 provide 24 V DC low voltage power often used to supply power to the digital input terminals 18 33 The terminal 37 safe stop function can be used to stop the filter in emergency stop situations In the normal operating mode when safe stop is not reguired the regular stop function is used Use of
19. can be uploaded into an EEPROM located in the LCP This function is useful for maintaining a backup parameter set It can also download programming to the filter to restore programming to a repaired unit or to program multiple units by downloading from a programmed master LCP The LCP is removable to prevent undesired program changes With an optional remote mounting kit the LCP can be mounted in a remote location of up to 3 meters away Control terminals which are programmable for specific functions are provided for input In addition output terminals provide signals to control peripheral devices or MG90Z102 VLT is a registered Danfoss trademark 23 Internal Active Filter Oper for reporting the status of monitored filter functions The control card logic is also capable of communicating through its serial link with outside devices such as personal computers or programmable logic controllers PLC The control card can also provide two voltage supplies for use from the control terminals The 24 V DC is used for switching functions such as start and stop The 24 V DC supply also provides 200 mA of power part of which may be used to power external devices A 10 V DC supply on terminal 50 is rated at 17 mA is also available for use 3 2 3 Active Filter Card The active filter card AFC performs calculations based on internal currents from IGBT current transducers external currents from customer supplied current transf
20. constrained air passages inside the enclosure and in the back channel Check that required top clearance of 225 mm 8 5 in is present to ensure proper air flow for cooling Warnings alarms filter status fault history and many other important items are available via the local control panel display on the filter The active filter must be free of dirt metal chips moisture and corrosion Check for burnt or damaged power components or carbon deposits resulting from catastrophic component failure Check for cracks or breaks in the housings of power semiconductors and pieces of broken component housings loose inside the unit Check for proper installation regarding electromagnetic compatibility Refer to the active filter operating instructions and 5 Active Filter and the Power Grid of this manual for further details Under specific conditions these units can be operated within a maximum ambient of 45 C 113 F Humidity levels must be less than 9596 non condensing Check for harmful airborne contaminates such as sulphur based compounds This unit requires a dedicated earth wire from its chassis to the building earth Check for good earth connections that are tight and free of oxidation The use of a conduit or mounting the filter on to a metal surface is not a suitable earth Check for loose connections Check for blown fuses Check for proper fusing Check the grid connected loads Check that th
21. detected measured by the CT mains currents The sum current from three mains CTs is too high The earth fault must be detected at every sample during a period of 400 ms for Alarm 309 to be reported Troubleshooting Check the installation mains CTs and wiring Replace the AFC card ALARM 311 Switch freq limit The average switching frequency of the unit exceeded the limit If the actual switching frequency exceeds 6 kHz for 10 electrical cycles Alarm 311 is reported Service parameter 98 21 displays the actual switching frequency NOTE Do not change any service parameters unless directed to do so in this service manual Troubleshooting Perform the Mains Resonance Test 6 3 7 Mains Resonance Test ALARM 314 Auto CT interrupt Auto CT detection was interrupted by the user ALARM 315 Auto CT error An error was detected while performing auto CT detection Auto CT detection does not work under the following conditions if any sum current transformers are installed when the active filter is supplied through a step up or step down transformers or when the filter is lt 10 of the CT primary Program the CT parameters manually if auto CT detection fails WARNING 316 CT location error The auto CT function could not determine the correct locations of the CTs Program the CT parameters manually if auto CT detection fails WARNING 317 CT polarity error The auto CT function could not determine the correct polarity of t
22. filter parameters according to application requirements in the following parameters Priority 300 01 Compensation Priority Harmonic Selection Mode 300 00 Harmonic Cancellation Mode and 300 30 Compensation Points and Cos fi Reference 300 35 Cosphi Reference Provide the active filter with a run command Monitor that the total harmonic current and voltage distortion is reduced If not check CT input installation for faults or configuration errors Copy parameter settings to the LCP memory 0 50 LCP Copy for back up MG90Z102 VLT is a registered Danfoss trademark 49 p D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 D Frame Sizes Disassembly and Assembly Instructions 7 1 Electrostatic Discharge ESD CAUTION Filters contain dangerous voltages when connected to mains voltage No disassembly should be attempted with power applied Remove power to the filter and wait at least 20 minutes to let the filter capacitors fully discharge Only a competent technician should carry out service ELECTROSTATIC DISCHARGE ESD Many electronic components within the filter are sensitive to static electricity 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 ESD procedures to prevent damage to sensitive components when servicing the fil
23. for all stand alone filters in 300 29 Start Auto CT Detection The following conditions must be met Active filter bigger than 10 of CT RMS rate Illustration 2 5 External CT Wiring CTs installed on the PCC side Auto CT not possible for load side CT installation The filter supports all standard CTs with 1 Aor5A secondary rating CTs should have an accuracy of 0 5 or better to reassure sufficient accuracy Only one CT per phase Auto CT not possible for summation CTs CTs are part of standard range eo mn 0 096 0 00 10 F Unsuccessful Auto CT Detection can indicate an incorrect 3002 8 CT installation Check the CT installation and program the S 300 21 CT Secondary m CTs by hand Rating 1 5A Illustration 2 6 CT Secondary Rating MG90Z102 VLT is a registered Danfoss trademark 17 Operator Interface and Acti 2 5 3 Control Wiring Input Output The active filter allows external control signals for either input control to the filter or to receive feedback from the filter Control wiring to the active filter depending on type can connect to the following e FC control board AFC CT input terminal Power card The active filter supports the following 3 inputs terminal 18 19 20 2 programmable in output terminal 27 29 External control signals are all wired to the FCA terminal MK102 Digital inputs and outputs Digital signals are a simple
24. in this section are numbered for reference only Tests need not be performed in this order Perform tests only as necessary AWARNING Electrical Hazard Never disconnect the input cabling to the filter with power applied due to danger of severe injury or death CAUTION Take all the necessary safety precautions for system start up before applying power to the filter 6 3 1 No Display Test A filter with no display can be the result of several causes A single character in the display or a dot in the upper corner of the display indicates a communication error and is typically caused by an option card not properly installed p VLT Advanced Active Filter AAF006 D and E Frames Service Manual When this condition occurs the green power on LED is illuminated If the LCD display is dark and the green power on LED is not lit proceed with the following tests First test for proper input voltage 6 3 2 Input Voltage Test 1 Apply power to filter 2 Use the DVM to measure the input mains voltage between the filter input terminals in seguence L1 to L2 L1 to L3 L2 to L3 All measurements must be within the range of 342 550 V AC Readings of less than 342 V AC indicate problems with the input mains voltage In addition to the actual voltage reading the balance of the voltage between the phases is also important The filter can operate within specifications as long as the imbalance of supply voltage is not more than 3
25. of the UPS unit can be irritated by high frequency switching harmonics in the mains voltage As a result the UPS could remain on battery power unable to reconnect the mains supply voltage An option to avoid this problem is tuning the power failure detector of the UPS unit by changing setup parameters Another option is replacing the UPS with a unit not sensitive to high frequency switching harmonics 5 2 4 Mains Resonances In most common cases active filters do not affect the load in the form of a resonance condition The active filters are capable to operate in a resonance condition to a minimum of the 31st harmonics order With CTs on the 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 resonance frequency changes with grid loads and can interfere with the active filter Filters with CTs installed on the PCC side light loaded might get unstable or experience runaway uncontrollable compensation To avoid this use either the sleep mode function to deactivate the filter at light loads or use Denpi VLT Advanced Active Filter AAF006 D and E Frames Service Manual selective harmonic compensation to omitting harmonic compensation near the light load resonance point In the case of mains resonances the following trips can occur e WARNING ALARM 7 DC overvoltage e WARNING ALARM 30
26. on lines 3 and 4 Included in the data are total operating hours power ups and trips and fault logs that store status values present at the 20 most recent trips The service information is accessed by displaying items in parameter group 15 42 amp 3968 Wn 15 0 15 04 Over Temp s 130BX173 10 Parameter group 15 also displays software versions for various components hardware identification numbers and other useful information and to determine revision status 0 096 0 00 10 15 4 130BP095 10 15 43 Software Version 99 52 2 5 Filter Inputs and Outputs 2 5 1 Current Transformers The active filter monitors internal current harmonics and receives input from external current transformers A current transformer CT measures electrical current The CT has a primary circuit and a secondary circuit The secondary circuit duplicates the primary exactly but with a reduced current load The AAF receives signals from the external CT secondary circuit and actively generates an output wave pattern to compensate for current irregularities Internally the AAF monitors harmonics of the IGBT output along with the LCL capacitor banks 2 5 2 Filter CT Input The active filter operates by receiving signals from the current transformers CTs The signals are processed and the filter reacts accordingly to programmed instructions Invalid signals cause the filter malfunctions or for the filter to trip Input sig
27. s current transformers CT is very important for the correct operation of the active filter Most issues during active filter commissioning are related to the incorrect installation or wiring of customer s current transformers It is strongly recommended prior to commissioning the active filter to perform visual inspection of the CT instal lation and wiring as described in Table 4 1 If the visual proof is not possible measure the CT s current feedback signals on the current transformer input terminals with a current probe rated for 1 A or 5 A corresponding to the secondary rating of the current transformers Monitoring the DC link voltage and the filter output current on the LCP while operating the filter gives suitable information about CT current feedback signals The indicated value of the DC link voltage should be nearly constant with variations less then 20 V Acoustic noise from LCL filter reactors can indicate improper CT installation and operation of the active filter The noise should be fairly even without crashes which indicate instability of the active filter operation Low frequency noise oscillations usually indicate oscillations in the mains or the load To ensure the proper operation of customer s current transformers it is useful to monitor the waveform of the current feedback signals This can be done by using a current probe rated for 5A and an oscilloscope Measure the current of the CTs and line current The
28. shape of the signal should be the same with different values 40 MG90Z102 VLT is a registered Danfoss trademark p Active Filter and the Power VLT Advanced Active Filter AAFO06 D and E Frames Service Manual 5 3 3 Noise On CT Input The control logic of the active filter provides robustness against noise on CT inputs High frequency noise above 3 kHz does not affect the active filter performance But if the amplitude of this noise is twice that of the real signal the input analog circuitry can be saturated As a result the compensation quality of harmonics on the mains can be adversely affected Noise on CT inputs with high amplitude in practical terms is not realistic and usually indicates CT or wiring damage 5 3 4 Effect of EMI 5 While Electromagnetic Interference EMI related distur bances to filter operation are uncommon the following detrimental EMI effects may be seen Serial communication transmission errors e CPU exception faults e Unexplained filter trips Disturbance resulting from other nearby equipment is more common Generally other industrial control equipment has a high level of EMI immunity However non industrial commercial and consumer equipment is often susceptible to lower levels of EMI Detrimental effects to these systems may include the following e Pressure flow temperature signal transmitter signal distortion or aberrant behaviour Radio and TV interference Telephone int
29. sheet is connectors installed behind the power card See Table 1 7 for torque 3 Remove the 7 mounting screws T 25 from the tightening values power card 4 Remove the power card from the plastic standoff at the top right of the power card 130BX172 10 WA 7h 3 Illustration 7 3 Power Card Terminals and Scaling Card Power card PCA3 9 MK106 FK103 16 Current scaling card standoff COIPNI AMI ARPWInNi MG90Z102 VLT is a registered Danfoss trademark 53 D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 2 5 Power Card Mounting Plate 1 Remove the control assembly mounting bracket in accordance with procedure 2 The power card mounting plate can be removed with the power card still mounted if so desired If the power card is to be removed remove it in accordance with the power card procedure 3 To remove the power card mounting plate with the power card attached unplug power card connectors MK102 MK103 MK105 MK106 MK107 MK109 MK110 and FK112 4 Remove the nut 7 mm attaching the MK102 ring lug to the power card mounting plate 5 Note the position of the red and white cables from the FUA and FUS5 fuse block for reassembly Unplug the cables 6 Disconnect the red wires from the AC input contactors by removing the retaining nut 8 mm 7 Remove the cables from the top side of fuses FU6 FU14 and FU15 and di
30. the 4 screws T 30 Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 74 MG90Z102 VLT is a registered Danfoss trademark Darfi E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 3 5 Lower Capacitor Bank Assembly 130BX411 m P er E Pd e p HH amp o le m di eT Illustration 8 10 Lower Capacitor Bank Assembly 1 Upper capacitor bank 4 Lower capacitor bank electrical connection nut Upper capacitor bank retaining nut Lower capacitor bank Upper capacitor bank electrical connection nut le Lower capacitor bank retaining nut 1 Remove the input terminal mounting plate in Reinstall in the reverse order of this procedure See accordance with the procedure Table 1 7 for torque tightening values 2 Remove the input terminal mounting plate support bracket by removing 4 nuts 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 150 mm 6 in is re
31. the fan terminals b Read across the fan terminals on each fan A reading of 400 O is expected Replace any defective fans 130BX184 10 Power card 4 Bate MG90Z102 VLT is a registered Danfoss trademark 45 Test Procedures 6 2 6 AC Mains Contactor and Soft Charge Contactor Tests The AC mains contactor and soft charge contactor can be tested for continuity using an ohmmeter set to Rx1 scale Measure resistance across each set of contacts in both the energized and non energized state 1 Place meter leads across the contact sets L1 T1 L2 T2 L3 T3 in turn The non energized state should read open infinite resistance 2 Repeat step 1 in the energized state NOTE In most cases depressing the plunger on the top of the contactor does not allow closing the contacts The energized state should read 0 or near 0 3 Using meter leads measure resistance across each set of auxiliary contacts Aux 1 Aux 2 Reading values for the non energized state should be infinite resistance and near 0 O for energized state of the AC mains contactor and soft charge contactor NOTE The AC mains contactor and soft charge contactor have an electronic coil therefore using an ohmmeter to test the coil by measuring the resistance across the coil is not possible In general the ohmmeter should measure 1 5 M 0 Low values indicate on coil damaging 6 3 Dynamic Test Procedures NOTE Test procedures
32. 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 Disconnect CM4 not shown 3 Remove the contactor transformer by removing 4 screws 10 mm Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values Differential mode RFI filter 7 3 4 Common Mode CM RFI Filter Card 1 Disconnect the cables from MK1 MK5 MK6 and MK7 2 Remove the common mode PFI filter card by removing the 4 screws T 25 from the standoffs Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 7 3 5 Differential Mode DM RFI Filter Card 1 Disconnect the cables from MK105 MK106 and MK107 2 Remove the differential mode RFI filter card by removing the 4 screws T 25 from the standoffs Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values MG90Z102 VLT is a registered Danfoss trademark p D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 3 6 Capacitor Bank Assembly Note that the RFI filter can remain attached to the cover plate when removing the capacitor bank assembly Disconnect the wiring from the RFI filter when leaving the filter attached 1 Note the color of the wires attached to the DC bus terminals on
33. to terminal 4 common of the signal board With a positive meter lead check the following terminals on the signal board Terminal Supply V Voltage Range V DC 11 16 5 19 5 12 16 5 19 5 23 23 25 24 4 75 5 25 In addition the signal test board contains three LED indicators that indicate the presence of voltage as follows Red LED 18 V DC supplies present Yellow LED 24 V DC supply present Green LED 5 V DC supply present The lack of any one of these power supplies indicates the low voltage supplies on the power card are defective This assumes that the proper DC bus voltage was read at power card connector MK105 A and B Replace the power card in accordance with the disassembly procedures in 7 D Frame Sizes Disassembly and Assembly Instructions or 8 E Frame Sizes Disassembly and Assembly Instructions 6 3 5 Current Sensors Test CT1 CT2 CT3 For this procedure provide 650 V using the split bus power supply Testing current feedback with the signal test board 1 Remove power to filter Make sure the DC bus is fully discharged 2 Install the signal test board into power card connector MK104 3 Apply power to the filter with the 650 V split bus power supply 4 Using a DVM connect the negative meter lead to terminal 4 common of the signal test board 5 Measure the AC voltage at terminals 1 2 and 3 of the signal test board in sequence These terminals correspond with cu
34. trigger this warning Troubleshooting The heatsink temperature measured as 0 C could indicate that the temperature sensor is defective thereby causing the fan speed to increase to the maximum If the sensor wire between the IGBT and the gate drive card is discon nected this warning is produced Also check the IGBT thermal sensor see 6 2 3 Intermediate Section Tests 34 MG90Z102 VLT is a registered Danfoss trademark Troubleshooting ALARM 67 Option module configuration has changed One or more options have either been added or removed since the last power down Check that the configuration change is intentional and reset the unit ALARM 68 Safe stop activated Loss of the 24V DC signal on terminal 37 has caused the filter to trip To resume normal operation apply 24V DC to terminal 37 and reset the filter ALARM 70 Illegal frequency converter configuration The control card and power card are incompatible Contact your supplier with the type code of the unit from the nameplate and the part numbers of the 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 ALARM 80 Drive initialised to default value Parameter settings are initialised to default settings after a manual reset Reset the unit to clear the alarm WARNING 250 New spare part The power or switch mode
35. 2 Cap over current e WARNING ALARM 304 DC over current e ALARM 311 Switch freq limit In general power supply grids with long cables above 500 5 m have a higher probability of resonance issues compare to grids with short cables 5 2 5 Control Logic Problems Problems with control logic can often be difficult to diagnose since there is usually no associated fault indication The typical complaint is simply that the filter does not respond to a given command The filter is designed to accept a variety of signals For troubleshooting first determine what types of signals the filter is receiving There are six digital inputs terminals 18 19 27 29 32 33 and two analog inputs 53 and 54 See Filter Inputs and Outputs Using the status information displayed by the unit is the best method of locating problems of this nature By selecting within parameter group 0 2 Display line 2 or 3 of the display can be set to indicate the signals coming in The presence of a correct reading indicates that the desired signal is detected by the microprocessor This data also may be read in parameter group 16 6 If there is not a correct indication the next step is to determine whether the signal is present at the input terminals of the filter This can be performed with a voltmeter or oscilloscope in accordance with the Input Terminal Signal Test see 6 Test Procedures If the signal is present at the terminal the control card is def
36. 9 5 V DC supply 16 5 to 19 5 V DC fon 10 11 v lt 3 O Nn S z zZ m 2 MG90Z102 VLT is a registered Danfoss trademark 81 p Special Test Equipment VLT Advanced Active Filter AAF006 D and E Frames Service Manual Pin Sche Function Description Reading Using a Digital No matic Voltmeter Acron ym 13 DBGAT Brake IGBT gate Voltage drops to zero when 20 0 15 0 10 0 5 0 0 0V 5 0 10 0 15 0 brake is turned off Voltage increases to 4 04 V DC as brake duty cycle reaches max pulse train 130BX150 10 20 0 400 0 us 20 us Div Varies w brake duty cycle 5 10 V DC level with the brake 14 BRT_O Brake IGBT 5V o logic level Run i turned off Voltage decreases signal i50 z S to zero as brake duty cycle 50 E Bn reaches max 0 0V TPAR 5 0 10 0 15 0 20 0 400 0 us 20 us Div Varies w brake duty cycle 5 aue 7 16 FAN T Control signal Indicates Fan Test switch is activated to force the fans on high 15V DC disabled ST for fans 0 V DC fans on high 17 FAN O Pulse train to Input A z 5 V DC fans off N gate SCR s for S fan voltage
37. A F pannonan E Mud R H waws semi wd aa E LH H pe ER N ASA SOD ww pos gt rm ELZMS 5 sivod mea KITENGE NDI us M Li HINS m frm Eun m s dup sasapaan tlale lel 1a Jezi o dd sxeid nduy si 7g E maa 4I 2 d m e 908 ICD ST Ts epp Te eT AT Tate s oy J iom 1199 of E zov t4 aste B waa aol is Ta alaa alala ya m EE mwaa ZOD wH 91ND vouassn SW m ALON NOLLD3NNOD 1 aly aly Tusc SINdNI TYLIDIO rm 19 ir i E HB 3T ti ri FOUNS 3 m 5 r pas xw 204 i s u sis ete elais p B sce a E ow soo E nom era i a aay puw E TE ses md Rod JN E m l PA oon uow m viona JOMINOD p aji m a al i T1 l q WD zhvos i P z z o 8 B amp I oco i ET HS stu Evd Jaw f j ii 5 wanan E a i QuV2 YMOd eLt HJE ew wa OUVI YI BALDY n S Tl id A QV 1081N02 24 Asia at TER Ty E 5 5 n amp amp VD FE sm Sin m d no jJ z via SN 5 y sag ESESES ET E LI 101 f 5 fe cb 91919 alele N H KAEA ilele elel mme c LLL 2a A Jow aoswana OLD ZND y D A9 aa rouns aa Er al Du vedi g gt gt i Pn 9 85 MG90Z102 VLT is a registered Danfoss trademark www danfoss com drives Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes b
38. Danfoss calculates mains imbalance per an IEC specifi cation Imbalance 0 67 X Vmax Vmin Vavg For example if three phase readings were taken and the results were 500 V AC 478 5 V AC and 478 5 V AC then 500 V AC is Vmax 478 5 V AC is Vmin and 485 7 V AC is Vavg resulting in an imbalance of 396 Although the filter can operate at higher mains imbalances the lifetime of components such as DC bus capacitors will be shortened Incorrect reading ACAUTION Open blown input fuses or tripped circuit breakers usually indicate a more serious problem Before replacing fuses or resetting breakers perform static tests described in 6 Test Procedures An incorrect reading here requires checking the mains supply Typical items to check would be Open blown input fuses or tripped circuit breakers Open disconnects or line side contactors Problems with the power distribution system 46 MG90Z102 VLT is a registered Danfoss trademark Test Procedures Denpi VLT Advanced Active Filter AAF006 D and E Frames Service Manual If the Input Voltage Test was successful check for voltage to the control card 6 3 3 Control Card Basic Voltage Test 1 Measure the control voltage at terminal 12 with respect to terminal 20 The meter should read between 21 and 27 V DC An incorrect reading could indicate the supply is loaded down by a fault in the customer connections Unplug the terminal strip and repeat the test
39. E control In sync v t with line freq E 4 0ms 2ms Div 7 trigger pulses at 3 kHz 18 HI LO Control signal Signal to switch fan speeds between high and low 5 V DC fans on high W from Power Otherwise 0 V DC Card 19 SCR DI Control signal Indicates SCR front end is enabled or disabled 0 6 to 0 8 V DC SCRs enabled S for SCR front 0 V DC SCR disabled end 20 INV DI Control signal Disables IGBT gate voltages 5 V DC inverter disabled S from Power 0 V DC inverter enabled Card a es S 22 UINVE Bus Voltage Signal proportional to UDC O V switch must be off X scaled down 1 V DC 450 V DC T4 T5 1V DC 610 V DC T7 23 VDD 24V DC Yellow LED indicates voltage is present 24 V DC regulated supply 82 MG90Z102 VLT is a registered Danfoss trademark p Special Test Equipment VLT Advanced Active Filter AAF006 D and E Frames Service Manual Pin Sche Function Description Reading Using a Digital No matic Voltmeter Acron ym 24 VCC 5 0 V DC The green LED indicates voltage is present 5 0 V DC regulated supply regulated 4 75 to 5 25 V DC supply 4 75 5 25 V DC 25 GUP T IGBT gate signal buffered 2 2 2 5 V DC Equal on all phases TP25 TP30 130BX153 10 U phase positive Signal originates on Control Card 4 0ms 50Us Div 2v div 100us div Run 10 Hz IGBT gate Inp
40. Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the filter being charged by the meter Incorrect reading An incorrect reading in any inverter test indicates a failed IGBT module Replace the IGBT module according to the disassembly instructions in 7 D Frame Sizes Disassembly and Assembly Instructions or 8 E Frame Sizes Disassembly and Assembly Instructions It is further recommended for units with two IGBT modules that both modules be replaced even if the second module tests correctly 6 2 2 Gate Resistor Test Indications of a failure in this circuit IGBT failures may be caused by the filter being exposed to repeated earth faults or by extended filter operation outside of its normal operating parameters Mounted to each IGBT module is an IGBT gate resistor board containing among other components the gate resistors for the IGBT transistors Based on the nature of the failure a defective IGBT can produce good readings from the previous tests In nearly all cases the failure of an IGBT will result in the failure of the gate resistors Located on the gate drive card near each of the gate signal leads is a 3 pin test connector These are labeled MK 250 350 450 550 650 750 850 For the sake of clarity refer to the 3 pins as one two and three reading left to right Pins 1 and 2 of each connector are in parallel with the gate drive signal sent to th
41. External current transformer Transformer Table 3 4 Power Card Ambient Temperature Sensor 3 Control card thermal sensor measured temperature The fan can be off or low speed based on this temperature CT9 Current External current transformer Transformer Table 3 2 Current Transducers 3 3 5 Cooling Fans All active filters are equipped with cooling fans to provide airflow along the heatsink and through the doors All fans are powered by mains voltage which is stepped down by an autotransformer and regulated to 200 or 230 V AC by circuitry provided on the power card On off and high low speed control of the fans is provided to reduce overall acoustical noise and extend the life of the fans 3 3 6 Fan Speed Control The cooling fans are controlled with sensor feedback which regulates fan operation and speed control as described below 1 IGBT thermal sensor measured temperature The fan can be off low speed or high speed based on this temperature IGBT Thermal Sensor Temperature Fan turn ON low speed Fan high speed to low speed Fan low speed to high speed Fan turn OFF from low speed Table 3 3 IGBT Thermal Sensor Control Card Ambient Temperature Fan turn ON to low speed Fan turn OFF from low speed Table 3 5 Control Card Thermal Sensor 4 Current value If the current injection is greater than 6096 of rated current the fan will turn on low speed 26 MG90Z102
42. I O function must be thought of as a two step process The desired 1 0 terminal must be wired properly and the corresponding parameter must be set accordingly Control terminals are programmed in the 5 0 and 6 0 parameter groups 5 3 Internal Active Filter Problems The vast majority of problems related to failed filter power components can be identified by performing a visual inspection and the static tests as described in the test section There are however a number of possible problems that must be diagnosed in a different manner The following discusses many of the most common problems 5 3 1 Overtemperature Faults In the event that an overtemperature indication is displayed determine whether this condition actually exists within the filter or whether the thermal sensor is defective p VLT Advanced Active Filter AAF006 D and E Frames Service Manual Of course this can easily be detected by 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 thermal sensor test procedure 5 3 2 Current Feedback Problems CAUTION Incorrect wiring or installation of current transformers will not damage the active filter but can have a very negative influence on the grid and can potentially damage other equipment connected to the grid Providing suitable current feedback signals from customer
43. MAKING MODERN LIVING POSSIBLE VLT Advanced Active Filter AAFO06 D and E Frame Service Manual THE REAL DRIVE Contents VLT Advanced Active Filter AAF006 D and E Frames Service Manual Contents 1 Introduction Oo MG90Z102 VLT is a registered Danfoss trademark Contents VLT Advanced Active Filter AAF006 D and E Frames Service Manual 32 3 Active Filter Card rra 24 3 2 4 Control to PowerInterface sn 24 3 2 5 Filter PowerSection n 24 3 3 Additional Circuitty U mmmsnnnuununnuuuuiiiuiuunnnan 25 BB TAC Contactor a 25 3 3 3 Additional Thermal Protection ss 3 3 6 Fan Speed Control J7 si 26 3 3 7 Low Harmonic Drive ssn 27 4 Troubleshooting ie 28 4 1 Troubleshooting M 28 4 4 2 Intermittent Display nnn ee ne ene nee 30 4 5 Warning Alarm Messages OO 30 45 1 Warning Alarm Code List costes eb dedu 30 4 6 After Repair TE H 37 5 Active Filter and the Power Grid 38 5 1 2 Grid Impedance S 38 5 1 3 Voltage Pre distortions eite NUN ut setate a bean 38 5 2 Basic Troubleshooting Background nnn 38 5 2 1 Mains Phase Loss and Unbalanced Phase Trips 38 5 2 2 Voltage Dips and Flickers l sn 38 5 2 3 Compatibility with Other Equipment on the Same Mains an 38 524MainsResonances sd 39 5 2 5 Control Logic Problems mmm 39 5 2 6 Programming Problems s 40 5 3 Internal Active Filter Problems 00s 40 5 3 1 OvertemperatureFaults
44. Manual 8 2 3 Active Filter Card 130BB950 10 1 MK101 4 MK107 amo s ma CAUTION Mains Primary Side Current Use a shorting connector on the secondary side of customer supplied external current transformers CT whenever current is present on the mains primary side and the AFC card is NOT wired to the external CT terminals When performing service on an active filter use a shorting connector on the secondary side of external CTs for extra safety Failure to short out the secondary side of current transformers when current is present on the primary side and the AFC card is NOT connected could damage the current transformer 1 Note if cable is connected to MK101 5A or MK108 1A for reassembly 2 Remove plugs MK100 MK103 MK107 FK100 and MK101 5A or MK108 1A from AAF card 3 Remove AAF card by removing the 4 mounting screws T 10 Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values MG90Z102 VLT is a registered Danfoss trademark 65 Darfi E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 2 4 Power Card 5 Remove the current scaling card from the power card by pushing in the retaining clips on the The power card may remain attached to power card standoffs KEEP THIS SCALING CARD FOR FUTURE mounting plate if power card mounting plate is to be REINSTALLATION OF ANY REPLACEMEN
45. NING 23 Internal fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in 14 53 Fan Monitor 0 Disabled The regulated voltage to the fans is monitored Troubleshooting e Check fan fuse e Check fan resistance see 6 2 5 Fan Continuity Tests WARNING 24 External fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in 14 53 Fan Monitor 0 Disabled The regulated voltage to the fans is monitored Troubleshooting e Check fan fuse e Check fan resistance see 6 2 5 Fan Continuity Tests ALARM 29 Heatsink temp The maximum temperature of the heatsink has been exceeded The temperature fault will not be reset until the temperature falls below a defined heatsink temperature The trip and reset point are different based on the filter power size See Table 1 4 for trip levels Troubleshooting e Ambient temperature too high Incorrect clearance above and below the unit Dirty heatsink Blocked air flow around the unit Damaged heatsink fan ALARM 33 Inrush fault Too many power ups have occurred within a short time period Let the unit cool to operating temperature WARNING ALARM 34 communication fault The fieldbus on the communication option card is not working ALARM 38 Internal fault When an internal fault occurs a
46. Remove the AC capacitor by cutting the cable tie securing the AC capacitor Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values MG90Z102 VLT is a registered Danfoss trademark 55 p D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 2 7 AC Capacitor Current Sensor CT4 CT5 CT6 1 Remove the control assembly support bracket in accordance with the procedure 2 Remove the power card mounting plate in accordance with the procedure 3 Prior to removing the current sensor cabling note the direction of the cable routing through the current sensor and number of wraps 3 for proper reinstallation The direction of the cable and number of wraps is phase sensitive to the sensor function 4 Remove the nut 11 mm from the top side of the corresponding capacitor in order to remove the lug cable which goes through the current sensor 5 Remove the Molex connector not shown from the current sensor 6 Remove the current sensor by removing the nuts 7 mm one on each side of the current sensor 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 AC contactors and connection of all cables for proper reinstallation 1 Remove the nut 10 mm from the top and bottom of the contactor term
47. T 25 Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 8 2 13 Soft Charge Resistor 1 Disconnect the cable going to fuses FU14 and FU 15 and the AC contactors 2 Remove the soft charge resistor by removing the 4 retaining nuts 7 mm Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values MG90Z102 VLT is a registered Danfoss trademark 71 p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 3 Active Section Bottom Instructions 1 Disconnect the mains input wiring from terminals L1 L2 L3 and the earth ground connector 8 3 1 Input Terminal Mounting Plate 2 Remove the 3 cross bus bars between the input terminals and the input inductor These are CAUTION located above the optional RFI filter if the RFI Two Person Lift filter is present Remove 3 nuts 17 mm not j A shown 3 T 40 screws and 13 mm nuts from The input terminal mounting plate supports various rae the passive side of the unit customer ordered options The input terminal mounting plate with options attached can exceed 35 kg 60 Ibs 3 Remove input terminal mounting plate by Assistance is required for removal Failure to provide removing 8 10 mm retaining nuts from plate assistance when during removal could result in personal injury Note that the input terminal mounting plate provides mou
48. T POWER removed CARD The scaling card controls signals operating with this specific filter The scaling card is not 1 Remove the control assembly support bracket in part of the replacement power card accordance with the procedure 6 Retain power card insulation for reassembly 2 Unplug power card connectors MK102 MK103 Reinstall in the reverse order of this procedure When MK105 MK106 MK107 MK109 and both MK112 installing the power card ensure that the insulator sheet is connectors installed behind the power card See Table 1 7 for torque 3 Remove the 7 mounting screws T 25 from the tightening values power card 4 Remove the power card from the plastic standoff at the top right of the power card 130BX172 10 WA 7h 3 Illustration 8 3 Power Card Terminals and Scaling Card Power card PCA3 9 MK106 FK103 16 Current scaling card standoff COIPNI AMI ARPWInNi 66 MG90Z102 VLT is a registered Danfoss trademark p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 2 5 Power Card Mounting Plate 5 Note the position of the red and white cables from the FU4 and FUS fuse block for reassembly 1 Remove the control assembly mounting bracket Unplug the cables in accordance with procedure 6 Remove the power card mounting plate by 2 The power card mounting plate can be removed removing 7 8 mm nuts with the power card still mou
49. V DC corresponds to a 4 to 20 mA signal Note that a minus sign preceding any reading above indicates a reversed polarity In this case reverse the wiring to the analog terminals 6 3 7 Mains Resonance Test Resonances can occur in systems when the filter is able transfer energy between itself and other energy storage devices with no damping If often occurs between a filter and other non tuned capacitor banks In case of resonance faults investigate if the grid contains other capacitor banks and disconnect these if possible It might also be advisable to de tune the capacitors by adding reactors 1 Check the CT installation wiring 2 Check the voltage imbalance value It should be below 3 3 Mount the CT shorter on all three CT inputs on the CT input terminal Give the active filter a run command If Alarm 7 DC overvoltage occurs go to the troubleshooting procedure for Alarm 7 If no Alarm 7 occurs go to the next step 4 Remove CT short lugs 5 Program the filter for the selective harmonic compensation mode 300 00 Harmonic Cancel lation Mode harmonic selection mode and program the filter for compensation of the 5th and 7th harmonics only 300 30 Compensation Points compensation points for 5th and 7th harmonics set to zero and other harmonics to the maximal value 6 Give the filter a run command and observe whether the voltage distortion is reduced in the 48 MG90Z102 VLT is a registered Danfoss trad
50. an reduce the longevity and performance of the AAF or completely destroy sensitive electronic components 6 MG90Z102 VLT is a registered Danfoss trademark Dafoe Introduction VLT Advanced Active Filter AAF006 D and E Frames Service Manual 1 4 Frame Size Definitions 380 480 V AC Active Filter current Weight of unit ka A210 355 400 E9 676 A210 676 Table 1 1 Active Filter Ratings Frame designation Depth mm Width mm Height mm D13 1740 D14 1740 E1 2000 E9 2000 F18 2200 Table 1 2 Dimensions Filters are available in IP21 and IP54 MG90Z102 VLT is a registered Danfoss trademark 7 Introduction VLT Advanced Active Filter AAFO06 D and E Frames Service Manual 1 5 Rating Tables p Ratings below are for the active filter Drive related specifications can be found in the respective Low Harmonic Drive Instruction Manual Harmonic compensation values for the LHD filters are approximate Variations due to tuning for frame sizes and associated drives may occur AAF006 AAFO006 Model number ae ot LHD filter AAF006 LHD filter AAF00 AAFO006 AAF006 AAFO006 only A190 only 6A250 A310 A330 A400 Overload 60 s every 10 LHD build in CT s rating 100 150 NA Table 1 3 Product Related Specifications The filter will automatically limit output to avoid over current tripping Typical average switching frequency 3 0 4 5 kHz Excessive switc
51. ary sides The mains contactor is powered within 110 127 V Depending on the mains voltage the mains contactor is powered by one of the two soft charge control transformer secondaries Control is from connector FK100 on the power card PCB3 When the filter is powered on the soft charge circuit the DC link capacitors will be charged to approximately sqrt 2 line to line mains voltage The soft charge time depends on main voltage and filter type Standby current is 0 3 A Table 3 1 lists the soft charge time and RMS current Filter size A Imax RMS Soft charge time s Table 3 1 Soft Charge Electrical Characteristics 3 3 3 Additional Thermal Protection A software temperature protection circuit monitors filter temperature conditions To meet UL requirements additional thermal protection is provided by signals to the mains contactors via the power card PCA3 relay contactor FK101 Signals are generated by a series of thermal switches in each phase of the LM reactors and LC reactors and through single thermal switches mounted on the damping resistors LCL and IGBT module heatsinks Before issuing a fault and opening the contactors the filter will automatically try to reduce its temperature by reducing its compensation The main contactors are rated for 110 127 V and power is supplied from the soft charge control transformer 3 3 4 Current Transducers Current transducers are used to monitor current in vari
52. ate supports various rae the passive side of the unit customer ordered options The input terminal mounting plate with options attached can exceed 35 kg 60 Ibs 3 Remove input terminal mounting plate by Assistance is required for removal Failure to provide removing 8 10 mm retaining nuts from plate assistance when during removal could result in personal injury Note that the input terminal mounting plate provides mounting for various options The fused disconnect option is shown 1308 X409 20 Illustration 7 6 Input Terminal Mounting Plate Input terminal mounting plate 6 Mains disconnect optional 1 Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 58 MG90Z102 VLT is a registered Danfoss trademark D Frame Sizes Disassembly a 7 3 2 Gate Drive Card Darfi VLT Advanced Active Filter AAF006 D and E Frames Service Manual 130BX418 10 Common mode RFI filter Gate drive card alu Capacitor bank Capacitor bank retaining screw Capacitor bank plate 1 2 3 Gate drive card mounting screw 4 Contactor transformer 1 Remove the input terminal mounting plate in accordance with the procedure 2 Disconnect MK100 MK101 MK102 MK103 MK104 and MK106 from the gate drive card 3 Remove the gate drive card by removing the 6 screws T 25 Reinstall in
53. bles through free air Avoid routing mains wiring and signal wiring in parallel If parallel routing is unavoidable try to maintain a separation of 150 200 mm 6 8 in between the cables or separate them with an earthed conductive partition For North American installations control wiring and power wiring must be in separate conduit Check for broken or damaged wires and connections Ensure that the CT polarity is correct If summation CTs are used ensure polarity and sequence is correct Check that CTs have the same rating summation CTs 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 conditions the use of screened cable or a twisted pair is always recommended Ensure the screen is terminated correctly Refer to the section on earthing screened cables in 2 Operator Interface and Active Filter Control For North American installations control wiring and power wiring must be in separate conduit Inspect For Cooling and clearances Display Interior EMC consider ations Environmental conditions Earthing Input power wiring Grid conditions Description Make sure the bottom gland plate is installed Check the operational status of all cooling fans and fan direction Check the door filters Check for blockage or
54. caused by the frequency converter Three other current Transformer transducers in the LCL filter section are used for overload cT9 Current Baena curent tandog protection for the AC capacitors and damping resistors Tema Table 1 6 Current Transducers MG90Z102 VLT is a registered Danfoss trademark 9 Zarfi Introduction VLT Advanced Active Filter AAF006 D and E Frames Service Manual 1 8 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 fastening IGBTs See the instructions included with those replacement parts for correct values Shaft Size Driver Size Torx Hex mm Torque in Ibs Torque Nm M4 1 0 M5 2 3 M6 4 0 M8 9 6 M10 19 2 M12 19 Table 1 7 Torque Values 1 9 Tools Required Operating Instructions for the FC Series Active Filters 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 Standard and cross thread Additional Tools Recommended for Testing Digital volt ohmmeter must be rated for 1200 V DC for 690 V units Analog voltmeter Oscilloscope Megohmmeter Clamp on style amp meter Signal test board p n 176F8437 and extension board p n 130B3147 Split bus power supp
55. ch terminal has specific functions it is capable of performing and a numbered parameter associated with it See Table 2 1 The setting selected in the parameter enables the function 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 Stat Quick Main Alarm atus Menu Menu Log A 130BP045 10 18 MG90Z102 VLT is a registered Danfoss trademark Darfi Operator Interface and Acti VLT Advanced Active Filter AAF006 D and E Frames Service Manual Use the arrow keys 4 Y gt and 4 on the LCP to scroll through parameters B eo N e eo E Quick Main Alarm O Status Lo Menu Menu g OES AC Alarm Consult AAF operating instructions manual for details on changing parameters and the functions available for each control terminal In addition the input terminal must be receiving a signal Confirm that the control and power sources are wired to the terminal Then check the signal Signals can be checked in two ways Digital input can be selected for display by pressing Status as discussed previously or a voltmeter may be used to check for voltage at the control terminal In a few cases the filter can trip before the signal reads on the voltmeter See procedure details at Input Terminal Signal Test in section6 Test Procedu
56. code number defined in Table 4 3 is displayed Troubleshooting Cycle power Check that the option is properly installed Check for loose or missing wiring MG90Z102 VLT is a registered Danfoss trademark 33 Troubleshooting It may be necessary to contact your Danfoss supplier or service department Note the code number for further troubleshooting directions No Tert 0 Serial port cannot be initialised Contact your Danfoss supplier or Danfoss Service Department 256 258 Power EEPROM data is defective or too old 512 519 Internal fault Contact your Danfoss supplier or Danfoss Service Department 783 Parameter value outside of min max limits 1024 1284 Internal fault Contact your Danfoss supplier or the Danfoss Service Department 1299 Option SW in slot A is too old 1300 Option SW in slot B is too old 1302 Option SW in slot C1 is too old 1315 Option SW in slot A is not supported not allowed 1316 Option SW in slot B is not supported not allowed 1318 Option SW in slot C1 is not supported not allowed 1379 2819 Internal fault Contact your Danfoss supplier or Danfoss 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 board hardware 5124 Option in slot B Hardware incompatible with control board hardware 5125 Option in slot CO Hardware incompatible wit
57. contactors between the input terminal and output terminals If continuity is detected replace the contactor fuse There should also be no continuity between any two test points of the 3 phases for either the input or the output Loss of mains A loss of mains voltage will cause the contactors to open Check the mains supply Consider use of auto reset Other If none of the above tests have identified the problem replace the power card WARNING ALARM 302 Cap over current Excessive current was detected through the AC capacitors of the LCL filter See for current trip points Troubleshooting Check that the nominal voltage parameter 300 10 is set correctly If the nominal voltage parameter is set to Auto change this parameter to nominal voltage of the installation Check that the CT parameter placement parameter 300 26 corresponds to the installation e Perform the Mains Resonance Test 6 3 7 Mains Resonance Test WARNING ALARM 303 Car earth fault An earth ground fault was detected in the LCL filter AC capacitor currents The summed currents in the LCL filter CTs exceeds the power unit dependent PUD level Troubleshooting Turn off the filter Measure the resistance to earth of the LCL filter components leads with a megohmmeter to check for earth faults Check the AC capacitors and current transducers Check that the connectors on current transducers and on the AFC card are pinned properly Chec
58. d two diode drops as the meter charges the capacitors in the reverse direction Although the test does not ensure the capacitors are fully functional it ensures that no short circuits exist in the intermediate circuit Incorrect reading A short circuit could be caused by a short in the soft charge or inverter section Be sure that the tests for these circuits have already been performed successfully A failure in one of these sections could be read in the intermediate section since they are all routed via the DC bus The only likely cause would be a defective capacitor within the capacitor bank There is not an effective test of the capacitor bank when it is fully assembled Although it is unlikely that a failure within the capacitor bank would not be indicated by a physically damaged capacitor if suspect the entire capacitor bank must be replaced Replace the capacitor bank in accordance with the disassembly procedures in 7 D Frame Sizes Disassembly and Assembly Instructions or 8 E Frame Sizes Disassembly and Assembly Instructions 6 2 4 Heatsink Temperature Sensor Test The temperature sensor is an NTC negative temperature coefficient device As a result high resistance means low temperature As temperature decreases resistance increases Each IGBT module has a temperature sensor mounted internally The sensor is wired from the IGBT module to the gate drive card connector MK100 For filters with two IGBTs the sensor on the rig
59. d voltage levels are provided Details on performing tests using the test fixture are provided in 6 Test Procedures of this manual Other than power supply measurements most of the signals being measured are made up of waveforms Although in some cases a digital voltmeter can be used to verify the presence of such signals it cannot be relied upon to verify that the waveform is correct An oscilloscope is the instrument prefered However when similar signals are being measured at multiple points a digital voltmeter can be used with some degree of confidence By comparing several signals to each other such as gate drive signals and obtaining similar readings it can be concluded each of the waveforms match one another and are therefore correct Values are provided for using a digital voltmeter for testing as well 80 MG90Z102 VLT is a registered Danfoss trademark Darfi Special Test Equipment VLT Advanced Active Filter AAF006 D and E Frames Service Manual Pin Sche Function Description Reading Using a Digital No matic Voltmeter Acron IU1 Current sensed 937 V ACpeak 165 of CT current rating AC waveform 2000 0 1500 0 1000 0 500 0 0 0 mV i t 7 500 0 1000 0 1500 0 2000 0 U phase not 130BX148 10 conditioned output frequency of the filter 200 ms ms Div Approx 400 mV RMS 100 load lt EN 2 IVI Current sensed 937 V ACpeak
60. de a safe and sure location for making necessary measurements Test equipment described in this section is available from Danfoss ACAUTION Using the test cable allows powering the filter without having to charge DC bus capacitors Main input power is required and all devices and power supplies connected to mains are energised at rated voltage Use extreme caution when conducting tests on a powered filter Contact with powered components could result in electrical shock and personal injury 9 1 1 Signal Test Board p n 176F8437 The signal test board provides access to a variety of signals that can be helpful in troubleshooting the filter The signal test board is plugged into power card connector MK104 Points on the signal test board can be monitored with or without the DC bus disabled In some cases the filter will need the DC 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 tests would be called for and what the signal should be at that given test point p VLT Advanced Active Filter AAF006 D and E Frames Service Manual o Ke Ke x lt a o m Illustration 9 1 Signal Test Board 9 1 2 Signal Test Board Pin Outs Description and Voltage Levels The tables on the following pages list the pins located on the signal test board For each pin its function description an
61. e IGBTs Pin 1 is the signal and Pin 2 is common 1 With ohmmeter measure pins 1 and 2 of each test connector Reading should indicate 7 8 K O for D frames and 3 9 K Q for E frames Incorrect reading An incorrect reading indicates that either the gate signal wires are not connected from the gate drive card to the gate resistor board or the gate resistors are defective Connect the gate signal wires or if the resistors are defective the entire IGBT module assembly requires replacement Replace the IGBT module according to the disassembly procedures in 7 D Frame Sizes Disassembly and p VLT Advanced Active Filter AAF006 D and E Frames Service Manual Assembly Instructions or 8 E Frame Sizes Disassembly and Assembly Instructions 6 2 3 Intermediate Section Tests The intermediate section of the filter is made up of the DC bus capacitors and the balance circuit for the capacitors 1 Test for short circuits with the ohmmeter set on Rx100 scale or for a digital meter select diode 2 Measure across the positive DC terminal A and the negative DC terminal B on connector MK105 on the power card Observe the meter polarity 3 The meter will start out with low ohms and then move towards infinity as the meter charges the capacitors 4 Reverse meter leads on connector MK105 on the power card 5 The meter will peg at zero while the capacitors are discharged by the meter The meter then begins moving slowly towar
62. e PF capacitor banks are installed and tuned Verify AC coils are in front of non linear loads MG90Z102 VLT is a registered Danfoss trademark 29 Troubleshooting Inspect For Vibration Description e Look for any unusual amount of vibration that the unit may be subjected to e The filter should be mounted solidly and subject to vibrations of less then 1G e If shock mounts are employed for higher vibrations check these for cracks or malfunction Table 4 1 Visual Inspection 4 4 Fault Symptoms 4 4 1 No Display The LCP display provides two display indications One by means of the backlit LCD alphanumeric display The other is three LED indicators lights 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 be replaced 130BP044 10 On Warn Alarm Be certain however that the display is completely dark Having a single character in the upper corner of the LCP or just a dot indicates that communications may have failed with the control card This is typically seen when a serial bus communication option has been installed in the filter and is either not connected properly or is malfunctioning If neither indication is available then the source of the problem may be elsewhere Proceed to 6 3 1 No Display Test to carry out further troubleshooting st
63. e from the control card CAUTION Mains Primary Side Current Use a shorting connector on the secondary side of customer supplied external current transformers CT whenever current is present on the mains primary side and the AFC card is NOT wired to the external CT terminals When performing service on an active filter use a shorting connector on the secondary side of external CTs for extra safety Failure to short out the secondary side of current transformers when current is present on the primary side and the AFC card is NOT connected could damage the current transformer 3 Remove capacitors CT cable from terminal MK103 of AAF card 4 Remove the external CT cable from terminal MK101 or MK108 in the AAF card 5 Remove ribbon cables from FC100 and MK100 on the AAF card 6 Remove the control card terminal blocks 7 Remove the 4 screws T 20 securing the control card mounting plate to the control assembly support bracket 8 Remove the control card mounting plate Reinstall in reverse order of this procedure See Table 1 7 for torque tightening values 8 2 2 Control Assembly Support Bracket 1 Remove the control card mounting plate in accordance with the procedure 2 Remove the 5 mounting nuts 10 mm 3 Remove the control assembly support bracket Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values p VLT Advanced Active Filter AAF006 D and E Frames Service
64. e short circuit impedance impedance voltage of the transformer or the power supply generator corresponds to a minimal value of the grid impedance on the point of common coupling PCC The maximal value depends on low voltage grid wiring type length and upper voltage level grid impedance In the case of unknown values the maximum is estimated as double the supply transformer short circuit impedance value The correct current of the filter depends on the grid impedance For higher grid impedance the 10 filter correction current is reduced Active filters have no limitations to the lowest grid impedance But from the installation point of view it is important that the available short circuit current of the grid is less than potential capacitor overcurrent of 3 of the filter rating 5 1 3 Voltage Pre distortions Active filters are suitable for operation under non sinusoidal voltages A total harmonic voltage distortion of up to 10 should not affect the active filter performance If active front end 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 p VLT Advanced Active Filter AAF006 D and E Frames Service Manual The amplitude of voltage harmonics above 25th order should be not higher than 3 WARNING ALARM 302 Cap over current usually indicates high voltage pre distortions or high grid impedances 5 2 Basic Troublesho
65. e used to test circuitry within the filter and provides easy access to test points The test board plugs into connector MK104 on the power card Its use is described in the procedures where called out See 9 1 1 Signal Test Board p n 176F8437 in 9 1 1 Test Equipment for detailed pin descriptions o Ke Ne gt a o m Illustration 6 2 Signal Test Board 6 2 Static Test Procedures 6 2 1 Inverter Section Tests The inverter section is contains the IGBTs for two functions first provide power to the DC line capacitors and second to inject current back into the power grid IGBTs are grouped into modules comprised of six IGBTs Depending on the size of the unit either one two or three IGBT modules are present The filter also has 3 snubber capacitors on each IGBT module p VLT Advanced Active Filter AAF006 D and E Frames Service Manual Before starting tests ensure that meter is set to diode scale If removed previously reinstall the soft charge card and power cards Do not disconnect the cable to connector MK105 on the power card since the path for continuity would be broken 6 2 1 1 Inverter Test Part 1 Connect the positive meter lead to the positive DC bus connector MK105 A on the power card 2 Connect the negative meter lead to LC inductor secondary side terminals L1 L2 and L3 in sequence Each reading should show infinity The meter will start at a low value and slowly climb toward inf
66. earth through an internal RC link It is recommended to use twisted pair cables to reduce the differential mode interference between conductors Table 2 3 Earthing Screened Control Cables 22 MG90Z102 VLT is a registered Danfoss trademark Internal Active Filter Oper 3 Internal Active Filter Operation 3 1 General This section is intended to provide an operational overview of the filter s main assemblies and circuitry With this information a repair technician should have a better understanding of the unit s operation and aid in the troubleshooting process 3 2 Description of Operation 3 2 1 Introduction The AAF consists of an inverter section active and an LCL filter passive The inverter section actively compensates for harmonic distortion on the mains to maintain minimal influence on the supply transformer load The harmonic p VLT Advanced Active Filter AAF006 D and E Frames Service Manual suppression is designed to comply with customer requirements and local standards The LCL passive filter section ensures trouble free connection of the active inverter section to the mains along with suppressing the inverter switching frequency In the filter section are three capacitors located between two reactors to form an LCL circuit The LCL circuit is arranged in a common mode CM and differential mode DM configuration Connected in series with the capacitors are three damping resistors to
67. ective and must be replaced If the signal is not present the problem is external to the filter The circuitry providing the signal along with its associated wiring must then be checked MG90Z102 VLT is a registered Danfoss trademark 39 Active Filter and the Power 5 2 6 Programming Problems CAUTION Incorrect parameter settings will not damage the active filter but can have a very negative influence on the grid and can potentially damage other eguipment connected to the grid Difficulty with active filter operation can be a result of improper programming of the filter parameters Three areas where programming errors may effect the filter performance are CT settings References and limits 1 0 configuration Any references or limits set incorrectly will result in less than optimal filter performance For instance if the reference for the Cos Phi parameter is set too low the unit will be unable to reach full compensation of reactive currents Parameters must be set according to the requirements of the particular installation References are set in the parameter group 300 0 Incorrectly set I O configuration usually results in the filter not responding to the function as commanded It must be remembered that for each control terminal input or output there are corresponding parameters settings These settings determine how the filter responds to an input signal or the type of signal present at that output Using an
68. ector from the fan transformer not shown 3 Remove the fan transformer by removing the nut 13 mm in the centre of the fan transformer Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 8 3 9 Fan 1 Disconnect the mains input cabling from terminals L1 L2 L3 and the earth ground connector 2 Disconnect the Molex connector from the fan assembly 3 Remove the fan assembly by removing 6 nuts 10 mm Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 8 3 10 Damping Resistors 1 Remove the input terminal mounting plate in accordance with the procedure 2 Remove the damping resistor bus bars by removing the screws T 20 3 Remove the damping resistor by removing the screws T 20 on either side of the damping resistor Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values MG90Z102 VLT is a registered Danfoss trademark 79 Special Test Eguipment 9 Special Test Eguipment 9 1 Test Eguipment Test tools have been developed to aid in troubleshooting these products It is highly recommended for repair and servicing this equipment that these tools be available to the technician Without them some troubleshooting procedures described in this manual cannot be carried out Although some test points can be found inside the filter to probe for similar signals the test tools provi
69. ee CT inputs on the CT input terminal factory pre mounted 9 Provide the active filter with a run command 10 Check that the filter current shown on the LCP is lower than 1596 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 application requirements in the following parameters Priority 300 01 Compensation Priority Harmonic Selection Mode 300 00 Harmonic Cancellation Mode and 300 30 Compensation Points and Cos fi Reference 300 35 Cosphi Reference 13 Provide the active filter with a run command 14 Monitor that the total harmonic current and voltage distortion is reduced If not check CT input installation for faults or configuration errors 15 Copy parameter settings to the LCP memory 0 50 LCP Copy for back up MG90Z102 VLT is a registered Danfoss trademark 37 Active Filter and the Power 5 Active Filter and the Power Grid 5 1 Grid Variations 5 1 1 Grid Configurations Active filters operate with all typical grid configurations such as 3 phase 3 wire 3 phase 4 wire Grounded wye Ungrounded isolated wye Delta wire 50 Hz 10 tolerance e 60 Hz 10 tolerance 5 1 2 Grid Impedance The short circuit impedance or percent impedance of the power supply represents the grid impedance In supply systems with short cables below 500 m th
70. een charged and the AC contactors have cut in This happens after the soft charge circuit has charged the intermediate circuit capacitors in the inverter By turning the filter on the inverter connects to the mains through the inverter side reactor Lc the AC contactors and the HI Lm reactor At this stage the DC voltage is boosted the amount depending on the mains voltage 24 MG90Z102 VLT is a registered Danfoss trademark Internal Active Filter Oper 3 3 Additional Circuitry 3 3 1 AC Contactor Because the main contactor circuit ties into the soft charge circuit understanding both is necessary to understand the working principles of the mains contactor The filters contain two three phase normally open contactors These are used as single phase by shortening all input terminals together and all output terminals together This is done to reduce the size of the contactors Since the DC link is floating this guarantees that there is no current flow when only two phases are opened The two virtual single phase contactors are in front of phase R and T respectively The mains contactors connect or disconnect the active filter inverter from the mains These contactors are commanded to close after the soft charged period has passed and before operation of the filter begins The contactor is commanded open if the filter stops for any reason such as when an alarm condition is detected or when the filter is commanded to stop or sl
71. eep It is only closed when the filter is ON thereby minimizing standby losses When the mains contactor is open active filter control is maintained by the soft charge circuit The status of the main contactors is monitored via an auxiliary contact reporting to terminals 32 and 33 on the FC control card PCA1 3 3 2 Soft Charge Circuit Because the soft charge circuit ties into the main contactor circuit understanding both is necessary to understand the working principles of the soft charge circuit The purpose of the soft charge circuit is to e Limit inrush current when DC link capacitors are charged e Provide control power when the mains contactor is open due to faults or when the filter is in sleep mode The soft charge circuit contains MOVs fuses resistors and a control transformer Three fuses on the grid side protect the circuit Three delta connected MOVs suppress transient when present on the incoming mains Resistors in series with the L1 L3 phases limit the inrush current during start up when the DC link capacitors are not charged When the capacitors are charged and the filter is commanded to operate the contactors across the Denpi VLT Advanced Active Filter AAF006 D and E Frames Service Manual resistors energize and short circuit the resistors Voltage for the coils of these contactors is supplied by the soft charge control transformer The soft charge control transformer has one primary and two second
72. eing necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved v NEM DII E M G 9 8 Z 1 8 2 wes6elg xolg 22139213 AHT Z 0L Uonenshiji
73. emark Test Procedures 5th and 7th harmonics If not check CT input 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 measurements with a current probe A high current indicates possible resonance points in the power supply Ground these points by changing the order of compensated harmonics and disable by programming the active filter 6 3 8 Control Card Digital Inputs Outputs Test Control card test digital inputs outputs test Use the following procedure to test the control card and replace the control card if a problem is found 1 Power the control card from a 24 V DC backup Do not power the active filter from mains voltage 2 Program the digital inputs for PNP using parameter 5 00 3 Verify the voltage across T12 and T20 is 24V DC using a multi meter Verify that T32 is 0 using parameter 16 60 Use a jumper wire to connect T12 and T32 4 5 6 Verify that T32 is 1 using parameter 16 60 7 Remove the jumper wire 8 Verify that T33 is 0 using parameter 16 60 9 Use a jumper wire to connect T12 and T33 10 Verify that T33 is 1 using parameter 16 60 11 Remove the jumper wire 12 Change parameter 5 00 back to the previous value if changed earlier 6 4 After Repair Tests After any repair to a filter or after any testing of a filter suspected of being
74. ensure that the filter prevents resonance Soft charge circuitry limits the inrush current during power up The control card along with the active filter control AFC card provide the logic for controlling the active filter 1308X432 Illustration 3 1 AAF Internal Circuitry 3 Jo LU areal e Em O Mains option plate 1 HI Lm reactor Power module DC capacitors e o Aem SSCS Inverter side reactor Lc 3 2 2 Control Card The primary logic element of the control card is a microprocessor which supervises and controls all functions of filter operation In addition separate PROMs contain programmable parameters to provide the user with customized control performance These parameters are programmed to enable the filter to meet application requirements and to allow for changing the operational characteristics of the filter The programmed instructions are then stored in an EEPROM which provides security during power down A custom integrated circuit generates a pulse width modulation PWM waveform which is sent to the interface circuitry located on the power card Another part of the control section is the local control panel LCP This is a removable keypad display mounted on the front of the filter The LCP provides the user interface with the unit All the filter s programmable parameter settings
75. eps 4 4 2 Intermittent Display Cutting out or flashing of the entire display and power LED indicates that the power supply SMPS is shutting down as a result of being overloaded This may be due to improper control wiring or a fault within the filter itself The first step is to rule out a problem in the control wiring To do this disconnect all control wiring by unplugging the control terminal blocks from the control card p VLT Advanced Active Filter AAF006 D and E Frames Service Manual If the display stays lit then the problem is in the control wiring external to the filter All control wiring should be checked for shorts or incorrect connections If the display continues to cut out follow the procedure for No Display as though the display were not lit at all 4 5 Warning Alarm Messages 4 5 1 Warning Alarm Code List A warning or an alarm is signalled by the LEDs on the front of the filter and by a code on the display A warning indicates a condition that may require attention or a trend that may eventually require attention A warning remains active until the cause is no longer present Under some circumstances operation may continue A trip is the action when an alarm 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 caused an alarm cannot damage the filter or ca
76. erference e Computer network data loss Digital control system faults MG90Z102 VLT is a registered Danfoss trademark 41 Test Procedures 6 Test Procedures 6 1 Introduction AWARNING Electrical Hazard Touching electrical parts of filter may be fatal even after eguipment has been disconnected from AC power Wait 20 minutes for D frame sizes 30 minutes for E frame sizes after power has been removed before touching any internal components to ensure that capacitors have fully discharged See label on front of filter door for specific discharge time This section contains detailed procedures for testing filters Previous sections of this manual provide symptoms alarms and other conditions which reguire additional test procedures to further diagnose the filter The results of these tests indicate the appropriate repair actions Again because the filter monitors input and external signals the source of fault conditions may exist outside of the filter itself Testing described here isolates many of these conditions as well The Disassembly and Assembly Instructions describe detailed procedures for removing and replacing filter components Filter testing is divided into Static Tests Dynamic Tests and After Repair Tests Static tests are conducted without power applied to the filter Most filter problems can be diagnosed simply with these tests Static tests are performed with little or no disassembly The purpose of static tes
77. erform the AC capacitors current transducers test 6 Test Procedures Check if the connectors on current transducers and on the AFC card are pinned properly e Check the AC capacitors current transducers cables e Replace the AFC card p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 4 6 After Repair Tests After any repair to a filter or after any testing of a filter suspected of being faulty follow this procedure to ensure that all circuitry is functioning properly before returning the unit to operation 1 Perform visual inspection procedures as described in Table 4 1 2 Perform the static test procedures to ensure that the unit is safe to start 3 Apply AC power to the unit 4 Copy parameter settings to the LCP memory 0 50 LCP Copy for back up 5 Program the filter according to CT installation in the following parameters Location 300 26 CT Placement CT Primary Voltage 300 22 CT Nominal Voltage 6 Perform an Auto CT detection 300 29 if the following conditions are met the CTs are installed on the PCC side towards the transformer CTs do not use sum transformers the filter is not supplied through a transformer and the filter is gt 10 of the CT primary 7 Check the filter parameters according to CT installation in 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 thr
78. f external CTs for extra safety Failure to short out the secondary side of current transformers when current is present on the primary side and the AFC card is NOT connected could damage the current transformer 1 Note if cable is connected to MK101 5A or MK108 1A for reassembly 2 Remove plugs MK100 MK103 MK107 FK100 and MK101 5A or MK108 1A from AAF card 3 Remove AAF card by removing the 4 mounting screws T 10 Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 52 MG90Z102 VLT is a registered Danfoss trademark p D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 2 4 Power Card 5 Remove the current scaling card from the power card by pushing in the retaining clips on the The power card may remain attached to power card standoffs KEEP THIS SCALING CARD FOR FUTURE mounting plate if power card mounting plate is to be REINSTALLATION OF ANY REPLACEMENT POWER removed CARD The scaling card controls signals operating with this specific filter The scaling card is not 1 Remove the control assembly support bracket in part of the replacement power card accordance with the procedure 6 Retain power card insulation for reassembly 2 Unplug power card connectors MK102 MK103 Reinstall in the reverse order of this procedure When MK105 MK106 MK107 MK109 and both MK112 installing the power card ensure that the insulator
79. faulty follow this procedure to ensure that all circuitry is functioning properly before returning the unit to operation 1 Perform visual inspection procedures as described in Table 4 1 2 Perform the static test procedures to ensure that the unit is safe to start 3 Apply AC power to the unit 4 Copy parameter settings to the LCP memory 0 50 LCP Copy for back up 11 12 13 14 15 p VLT Advanced Active Filter AAF006 D and E Frames Service Manual Program the filter according to CT installation in the following parameters Location 300 26 CT Placement CT Primary Voltage 300 22 CT Nominal Voltage Perform an Auto CT detection 300 29 if the following conditions are met the CTs are installed on the PCC side towards the transformer CTs do not use sum transformers the filter is not supplied through a transformer and the filter is gt 10 of the CT primary Check the filter parameters according to CT installation in the following parameters Primary Rating 300 20 CT Primary Rating Sequence 300 24 CT Sequence Polarity 300 25 CT Polarity Mount the CT short at all three CT inputs on the CT input terminal factory pre mounted Provide the active filter with a run command Check that the filter current shown on the LCP is lower than 1596 of the nominal filter current If higher conduct a hardware fault inspection Stop the active filter and remove all three CT short lugs Check the
80. g plate MOV Fuse block l6 Discharge card 1 Disconnect the wires from the terminals on the 7 2 11 Soft Charge Resistor right and left of the MOV by loosening the retaining screws 1 Disconnect the cable going to fuses FU14 and FU 2 Remove the MOV by removing the 2 screws 15 and the AC contactors T 20 right and left 2 Remove the soft charge resistor by removing the Reinstall in the reverse order of this procedure See 4 retaining nuts 7 mm Table 1 7 for torque tightening values Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 7 2 10 Discharge Card 1 Disconnect MK100 from the discharge card 2 Remove the discharge card by removing the 4 screws T 25 Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values MG90Z102 VLT is a registered Danfoss trademark 57 p D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 3 Active Side Bottom Instructions 1 Disconnect the mains input wiring from terminals L1 L2 L3 and the earth ground connector 7 3 1 Input Terminal Mounting Plate 2 Remove the 3 cross bus bars between the input terminals and the input inductor These are CAUTION located above the optional RFI filter if the RFI Two Person Lift filter is present Remove 3 nuts 17 mm not j A shown 3 T 40 screws and 13 mm nuts from The input terminal mounting pl
81. generated by the switch mode power supply SMPS on the power card 24 V 5 V 18 V When powered with 24 V DC with the MCB 107 option only the 24 V and 5 V supplies are monitored When powered with three phase mains voltage all three supplied are monitored WARNING 47 24V supply low The 24 V DC is measured on the control card The external 24 V DC backup power supply may be overloaded otherwise contact your Danfoss supplier WARNING 48 1 8V supply low The 1 8 V DC supply used on the control card is outside of allowable limits The power supply is measured on the control card Check for a defective control card If an option card is present check for an overvoltage condition WARNING 60 External interlock A digital input signal is indicating a fault condition external to the frequency converter An external interlock has commanded the frequency converter to trip Clear the external fault condition To resume normal operation apply 24V DC to the terminal programmed for external interlock Reset the frequency converter WARNING ALARM 65 Control card over temperature The cutout temperature of the control card is 80 C Troubleshooting Check that the ambient operating temperature is within limits Check for clogged filters Check fan operation e Check the control card WARNING 66 Heatsink temperature low This warning is based on the temperature sensor in the IGBT module See for the temperature reading that will
82. h control board hardware 5126 Option in slot C1 Hardware incompatible with control board hardware 5376 6231 Internal fault Contact your Danfoss supplier or Danfoss Service Department Table 4 3 Internal Fault Codes ALARM 39 Heatsink sensor No feedback from the heatsink temperature sensor The signal from the IGBT thermal sensor is not available on the power card The problem could be on the power card on the gate drive card or the ribbon cable between the power card and gate drive card WARNING 40 Overload of digital output terminal 27 Check the load connected to terminal 27 or remove short circuit connection Check 5 00 Digital I O Mode and 5 01 Terminal 27 Mode WARNING 41 Overload of digital output terminal 29 Check the load connected to terminal 29 or remove short circuit connection Check 5 00 Digital I O Mode and 5 02 Terminal 29 Mode p VLT Advanced Active Filter AAF006 D and E Frames Service Manual WARNING 42 Overload of digital output on X30 6 or overload of digital output on X30 7 For X30 6 check the load connected to X30 6 or remove the short circuit connection Check 5 32 Term X30 6 Digi Out MCB 101 For X30 7 check the load connected to X30 7 or remove the short circuit connection Check 5 33 Term X30 7 Digi Out MCB 101 ALARM 46 Power card supply The supply on the power card is out of range There are three power supplies
83. he 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 the CT parameters manually if auto CT detection fails 36 MG90Z102 VLT is a registered Danfoss trademark Troubleshooting ALARM 319 Runaway follower A follower AF was not commanded to run but the feedback indicates it is running The report value indicates the follower ID Troubleshooting Check the follower unit Check the control wiring WARNING 320 AC res HS fault AC resistor heatsink temperature feedback is not connected or low temperature WARNING 321 Volt imbalance gt 3 Possible causes are a phase is missing on the supply side or the mains voltage imbalance is too high Troubleshooting Check the supply voltage imbalance and main fuses of the filter ALARM 322 5V pwr card low 5 V power supply from power card is low Troubleshooting Replace the AFC card Replace the power card ALARM 323 15V neg supply low The negative 15 V power supply is low Troubleshooting Perform the AC capacitors current transducers test 6 Test Procedures Check if the connectors on current transducers and on the AFC card are pinned properly Check the AC capacitors current transducers cables Replace the AFC card ALARM 324 15V pos supply low The positive 15 V power supply is low Troubleshooting P
84. hing frequency trip limit 6 0 kHz Voltages DC voltage maximum reference 790 V DC Inrush circuit enabled 370 V DC Inrush circuit disabled 395 V DC Under voltage disable 402 V DC Under voltage warning 423 V DC Under voltage re enable reset 442 V DC Start permissive 821 V DC Over voltage warning 850 V DC Over voltage trip 855 V DC Temperatures Heatsink over temperature enable Automatic derating begins 85 C Heatsink over temperature trip 105 C Heatsink under temperature warning 0 C Damping resistor heatsink over temperature enable Automatic derating begins 105 C Damping resistor heatsink over temperature trip 115 C Power card over temperature 68 C Power card under temperature 20 C Earth fault alarm 50 Table 1 4 Trip Points 8 MG90Z102 VLT is a registered Danfoss trademark Denpi Introduction VLT Advanced Active Filter AAF006 D and E Frames Service Manual 1 6 Fuses Table 1 5 provides the types and ratings and function of various fuses for the AAF Identification Type Current rating Function If blown check for short in FU5 KLK DC Bus plus to Power Card for SMPS SMPS on Power Card FU6 FNQ R3 Primary of contactor transformer Transformer FU8 Mains Input Fuse Optional Power Component FU9 Mains Input Fuse Optional Power Component FU10 Mains Input Fuse Optional Power Component FU11 KLK 15A Mains Supply to Power Card for Fans amp S
85. ht module is used 44 MG90Z102 VLT is a registered Danfoss trademark Test Procedures For filters with three IGBT modules the centre module is used On the gate drive card the resistance signal is converted to a freguency signal The freguency signal is sent to the power card for processing The temperature data is used to regulate fan speed and to monitor for over and under temperature conditions 1 Use ohmmeter set to read ohms 2 Unplug connector MK100 on the gate drive card and measure the resistance across the cable leads The relationship between temperature and resistance is nonlinear At 25 C the resistance will be approximately 5 k Q At 0 C the resistance will be approximately 13 7 k O At 60 C the resistance will be approximately 1 5 k O The higher the temperature the lower the resistance 6 2 5 Fan Continuity Tests Make all continuity checks using an ohmmeter set to Rx1 scale A digital or analog ohmmeter can be used Some instability may result when measuring resistance of a transformer with a multimeter This can be reduced by turning off the auto ranging 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 the power card 1 Measure from L3 T to MK107 terminal 16 Reading of 1 Q should be indicated 2 Measure from L2 S to MK107 ter
86. ightening values 7 3 9 Damping Resistors 1 Remove the input terminal mounting plate in accordance with the procedure 2 Remove the damping resistor bus bars by removing the screws T 20 3 Remove the damping resistor by removing the screws T 20 on either side of the damping resistor Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 7 3 10 Fan Transformer 1 Disconnect the mains input cabling from terminals L1 L2 L3 and the earth ground connector 2 Disconnect the in line connector from the fan transformer not shown 3 Remove the fan transformer by removing the nut 13 mm in the centre of the fan transformer Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 7 3 11 Fan 1 Disconnect the mains input cabling from terminals L1 L2 L3 and the earth ground connector 2 Disconnect the Molex connector from the fan assembly 3 Remove the fan assembly by removing 6 nuts 10 mm Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 62 MG90Z102 VLT is a registered Danfoss trademark p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 E Frame Sizes Disassembly and Assembly Instructions 8 1 Electrostatic Discharge ESD CAUTION Filters contain dangerous voltages when connected to mains voltage No disassembly sh
87. inal bracket 2 Loosen the 3 screws on the main contactor terminals to allow removal of the contactor terminal bracket 3 Disconnect the coil wires from terminals A1 and A2 by loosening the retaining screws not shown 4 Disconnect the wires from the auxiliary contactors by loosening the retaining screw bi Remove the AC contactor by removing the 4 mounting nuts 8 mm Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 56 MG90Z102 VLT is a registered Danfoss trademark D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 2 9 MOVs Sd Ola ag Oa OO LL e 9 5 JL m all le MN n H T o 9 i o 9 o C Y Illustration 7 5 MOVs Discharge Card and Soft Charge Resistor 1 Power card 4 Soft charge resistor Power card mountin
88. inity due to capacitance within the filter being charged by the meter 6 2 1 2 Inverter Test Part Il 1 Reverse the meter leads by connecting the negative meter lead to the positive 4 DC bus connector MK105 A on the power card 2 Connect the positive 4 meter lead to LC inductor secondary side terminals L1 L2 and L3 in sequence Each reading should show a diode drop Incorrect reading An incorrect reading in any inverter test indicates a failed IGBT module Replace the IGBT module according to the disassembly instructions in 7 D Frame Sizes Disassembly and Assembly Instructions or 8 E Frame Sizes Disassembly and Assembly Instructions It is further recommended for units with two IGBT modules that both modules be replaced even if the second module tests correctly 6 2 1 3 Inverter Test Part Ill 1 Connect the positive meter lead to the negative DC bus connector MK105 B on the power card 2 Connect the negative meter lead to LC inductor secondary side terminals L1 L2 and L3 in sequence Each reading should show a diode drop MG90Z102 VLT is a registered Danfoss trademark 43 Test Procedures 6 2 1 4 Inverter Test Part IV Inverter test part IV 1 Reverse the meter leads by connecting the negative meter lead to the negative DC bus connector MK105 B on the power card 2 Connect the positive 4 meter lead to LC inductor secondary side terminals L1 L2 and L3 in sequence
89. k for earth faults Measure line to line voltages on mains active filter terminals All three voltages should be egual to the nominal voltage of the installation ALARM 15 Hardware mismatch A fitted option is not operational with the present control board hardware or software Check any replacement parts and their programming Record the value of the following parameters and contact your Danfoss 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 Version for each option slot ALARM 16 Short circuit There is short circuiting in the IGBT inverter or on the inverter terminals Trip level equals approximately 120 of the over current trip levels see Table 7 3 Troubleshooting Check the IGBTs Replace the power card WARNING ALARM 17 Control word timeout There is no communication to the filter The warning will only be active when 8 04 Control Word Timeout Function is NOT set to OFF If 8 04 Control Word Timeout Function is set to Stop and Trip a warning appears and the filter ramps down until it trips while giving an alarm Troubleshooting e Check connections on the serial communication cable e Increase 8 03 Control Word Timeout Time Check the operation of the communication eguipment Verify a proper installation based on EMC requirements WAR
90. k AC capacitors current transducers cables Replace the AFC card WARNING ALARM 304 DC over current Excessive current through the DC link capacitor bank was detected in the IGBT current sensors Troubleshooting Check the mains fuses and ensure that all three mains phases are powered Check that the CT parameter placement 300 26 CT Placement corresponds to the instal lation e Perform the Mains Resonance Test 6 3 7 Mains Resonance Test MG90Z102 VLT is a registered Danfoss trademark 35 Troubleshooting ALARM 305 Mains freg limit The mains frequency was outside the limits 50 Hz 60 Hz 10 Verify that the mains frequency is within product specification The alarm may also indicate loss of mains for 1 3 electrical cycles The active filter must synchronize to the mains voltage in order to regulate the DC link voltage and inject compen sating current The active filter utilizes a phase locked loop PLL to track the mains voltage frequency When the active filter starts the PLL uses the LCL filter AC capacitor currents from the current transducers to initialize for a period of 200 ms After the PLL initialization period the active filter inverter will then start switching the mains estimated voltage is used instead of the capacitor currents as input to the PLL The PLL is not tolerant of incorrect wiring or placement of the AC capacitor current transducers Troubleshooting Turn off the filter
91. ly p n 130B3146 Power quality analyses Fluke 435 p n 130BB3173 Dranetz 4300 4400 or similar 10 MG90Z102 VLT is a registered Danfoss trademark p Introduction VLT Advanced Active Filter AAF006 D and E Frames Service Manual 1 10 Exploded Views 1 10 1 Exploded Views E Frame 130BB925 10 Control card not shown 14 Fan transformer Active filter card Gate drive card Input RFI option IGBT module Mains input fuse option fis IGBT current sensor Mains disconnect option n9 Damping resistors COINIADA MIRE WIN Input terminal mounting plate 20 Cross bus bar 13 Fan Bus bar retaining nut MG90Z102 VLT is a registered Danfoss trademark 11 p Operator Interface and Acti VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 Operator Interface and Active Filter Control 2 2 1 LCP Layout 2 1 Introduction m l The LCP display is divided into three functional groups The advanced active filter AAF monitors external and see Illustration 2 1 internal harmonic current conditions When an alarm is issued and the filter trips it cannot be assumed that the fault lies within the active filter itself Most alarms that the AAF displays are generated by conditions outside of the Jouet active filter This service manual provides techniques and
92. minal 1 Reading of 1 O should be indicated Incorrect reading An incorrect reading would indicate a faulty cable connection Replace the cable assembly 6 2 5 1 Fan Fuse Test 1 Test the fan fuses on the soft charge mounting plate by checking the continuity across the fuse An open fuse could indicate additional faults Replace the fuse and continue the fan checks p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 6 2 5 2 Ohm Test of Transformer For the following tests read the plug end of the wire connected to MK107 on the power card 1 Measure between MK107 terminals 1 and 16 Should read approximately 4 0 2 Measure between MK107 terminals 16 and 12 Should read approximately 3 0 3 Measure between MK107 terminals 1 and 12 Should read approximately 1 0 Incorrect reading An incorrect reading would indicate a defective fan transformer Replace the fan transformer When finished reconnect the MK107 6 2 5 3 Ohm Test of Fans Ohm test of fans Measure between terminals 11 and 13 of power card connector MK107 Incorrect reading Disconnect CN5 and measure the resistance between pins 1 and 2 on the fan side of the connector Reading should be approximately 4 Q If incorrect replace fan F2 Disconnect CN4 Measure the resistance across 1 and 2 on the fan side Reading should be approximately 200 O Incorrect reading Isolate the faulty fan as follows a Disconnect the wiring from
93. mponents like power cables 38 MG90Z102 VLT is a registered Danfoss trademark Active Filter and the Power supply transformers and so on The circulation of high freguency current harmonics can produce interaction with other eguipment connected to the same bus increasing the amplitude of neutral currents and activating the operation of zero seguence relays Problems associated with earth ground protections ground fault relays ELCB RCD or GFCI Normally ground faults are eliminated with zero seguence relays connected through ring transformers or to the neutral to ground connection With an active filter connected to the power distribution system high freguency switching current harmonics sink into the ground across parasitic grid capacitances This results in improper operation of ground fault relays Avoid this problem by replacing the fault relay with non sensitive high frequency relay To ensure effective protection and unintended tripping of protective relays all relays must provide protection of 3 phase equipment with active current input and brief discharge at power up It is recommended to use a type with adjustable trip amplitude and time characteristics Use a current sensor with a current sensitivity of more than 200 mA and not less than 0 1 second operating time Problems associated with UPS units A UPS unit can become distorted by active filter switching noise in the mains supply The power failure detector
94. n measured signal clamps at both ends to the metal cabinet Table 2 3 shows earth cabling for optimal results PLC ote a Correct earthing Control cables and cables for serial communication must be fitted with cable a 9 clamps at both ends to ensure the best possible electrical connection Ql PE PE PLC etc AA TZS cen Y OSA e ure ette 6245194941949 9 94 j EE RN een EDS Incorrect earthing Do not use twisted cable ends pigtails since these increase screen impedance at high frequencies PLC etc Earth potential protection When the earth potential between the filter and the PLC or other interface device is different electrical noise may occur that can disturb the entire system This PE PE Mis iimm can be resolved by fitting an equalizing cable next to the control cable Minimum cable cross Equalizing cable section is 8 AWG PLC etc 50 60 Hz earth loops When using very long control cables 50 60 Hz earth loops may occur that can disturb the entire system This can be resolved by connecting one end of the screen with a 100 nF capacitor and keeping the lead short 175ZA165 11 Serial communication control cables Low frequency noise currents between filters can be eliminated by connecting one end of the screened cable to filter terminal 61 This terminal connects to
95. n the reverse order of this procedure See 3 Remove the gate drive card mounting plate by Table 1 7 for torque tightening values removing 2 screws 8 mm in the front of the plate and 2 screws 8 mm at the back of the plate on the vertical mounting tabs not shown Disconnect cables MK102 MK103 and MK104 Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values MG90Z102 VLT is a registered Danfoss trademark 73 p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 3 4 Upper Capacitor Bank Assembly 130BX410 Illustration 8 9 Upper Capacitor Bank Assembly 1 Upper capacitor bank 4 Upper capacitor bank cover plate Input terminal mounting plate support bracket Lower capacitor bank cover plate Retaining nut 10 mm lo Lower capacitor bank 1 Remove the input terminal mounting plate in accordance with the procedure 2 Remove the input terminal mounting plate support bracket by removing 4 nuts 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 150 mm 6 in is required Remove the 6 electrical connection nuts 8 mm for the upper capacitor bank on the DC bus bars 4 Note that the weight of the capacitor bank is approximately 9 kg 20 Ibs 5 Remove the capacitor bank with attached cover plate by removing
96. nals 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 described in 2 5 2 7 External CT Input p VLT Advanced Active Filter AAF006 D and E Frames Service Manual The active filter receives current signal input from three different measure points External mains CT input Internal CT input from IGBT current injection Internal CT input from LCL capacitors AC capacitors All three inputs are 3 phase These are processed individually and the filter reacts according to programmed instructions NOTE Incorrect CT settings or improper wiring are the primary reasons for causing the filter to trip or not starting 2 5 2 1 External CT Input For LHD units CTs are built in LHD CTs are located in the drive section at the input plate and have the following values D frame 500 A E frame 1000 A F frame 1500 A Signals are input at terminal MK101 on the AFC board CAUTION Mains Primary Side Current Use a shorting connector on the secondary side of customer supplied external current transformers CT whenever current is present on the mains primary side and the AFC card is NOT wired to the external CT terminals When performing service on an active filter use a shorting connector on the secondary side of external CTs for extra safety Failure to short out the secondary side of current tra
97. nsformers when current is present on the primary side and the AFC card is NOT connected could damage the current transformer The active filter uses external CT signals to measure the current distortion that the filter is to compensate External CT wires are connected to the CT terminal block The CT terminal block is wired to the AFC board through internal wiring The active filter supports external current transformers with either a 1A and 5A secondary e For 1A CT input the 8 pin connector must be wired to terminal MK108 For 5A CT input connection must be wired to terminal MK101 Primary rating A 16 MG90Z102 VLT is a registered Danfoss trademark Darfi Operator Interface and Acti VLT Advanced Active Filter AAF006 D and E Frames Service Manual 130BB950 10 Illustration 2 3 Active Filter Card 1 MK101 5 A external connector 4 MK107 MK108 1 A external connector MK103 External CT settings are programmed in parameter group 300 2 The automatic CT detection is only possible with USE IU ES Ordine D S CT installed on the PCC side u ki Ku E L2 Ki KU 0 0 0 00 Wa x ad meee t PAKU xo LU a 300 29 Start Auto CT a Detection 1 Enable Auto CT Detect Illustration 2 4 Auto CT Detection LJ e 91 92 93 L1 12 L3 Perform an automatic CT detection
98. nted if so desired If Reinstall in the reverse order of this procedure The ring the power card is to be removed remove it in lug for the wire assembly that connects to power card accordance with the power card procedure connector MK102 attaches to the right mounting stud on 3 To remove the power card mounting plate with the top of the power card mounting plate See Table 1 7 the power card attached unplug connectors for torque tightening values MK102 MK105 MK107 MK109 and MK112 4 Remove the nut 7 mm attaching the MK102 ring lug to the power card mounting plate 8 2 6 AC Capacitors 130BX436 10 um IPS Y i xp A Illustration 8 4 AC Capacitors 1 AC capacitor 3 AC capacitor mounting bracket AC capacitor retaining nut AC capacitor mounting bracket retaining nut MG90Z102 VLT is a registered Danfoss trademark 67 Darfi E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 1 Remove the control assembly support bracket in Note that removing the top most capacitor may require accordance with the procedure removing the center capacitor for ease of access 2 Remove the power card mounting plate in accordance with the procedure Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 3 Remove the nut 11 mm fr
99. nting for various options The fused disconnect option is shown 1308 X409 20 Illustration 8 7 Input Terminal Mounting Plate Input terminal mounting plate 6 Mains disconnect optional 1 Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 72 MG90Z102 VLT is a registered Danfoss trademark p E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 3 2 Gate Drive Card Mounting Plate 130BX408 A v 4 ae IE FFO FE KE XX 4 4 nn e n UBAO ANA nn e o o o y Illustration 8 8 Gate Drive Card and Mounting Plate 1 Gate drive card 3 Retaining screw T 25 2 Gate drive card mounting plate 1 Remove the input terminal mounting plate in 8 3 3 Gate Drive Card accordance with the procedure 2 Disconnect cables from gate drive card 1 Remove the gate drive card mounting plate in connectors MK100 MK101 and MK106 Note that accordance with the procedure cables connected to MK1 02 MK1 03 and MK104 2 Remove the gate drive card by removing 6 can be disconnected easier after removing the mounting plate part way screws T 25 Reinstall i
100. oft Fan Transformer o gt eee FU12 KLK 15A Mains Supply to Power Card for Fans amp Soft Fan Transformer FU13 KLK 15A Mains Supply to Power Card for Fans amp Soft Fan Transformer FU14 FQN R Soft Charge Resistor DC Capacitor Bank IGBT Module FU15 FQN R Soft Charge Resistor DC Capacitor Bank IGBT Module Table 1 5 Fuse Ratings and Functions NOTE Size Dependent AAF190 250 A AAF310 400 A AAF400 500 A 1 7 Current Transducers 1 7 1 Current Transducers Identifi Type Function cation Current transducers are used to monitor current in various cM Hall Effect Output of inverter IGBT current sensor locations in the filter Three current transducers on the CT2 Hall Effect Output of inverter IGBT current sensor output phases bus bars induce counter harmonics onto the CT3 Hall Effect Output of inverter IGBT current sensor mains There are also three current transformers on the CT4 Hall Effect AC capacitor current sensor mains bus bars outside of the active filter The information CT5 Hall Effect AC capacitor current sensor from these three transformers via the active filter card is CT6 Hall Effect AC capacitor current sensor what the filter compensates for on the mains For the LHD CT7 Current External current transformer drive these transformers are on the mains input bus bars Transtomier of the frequency converter for measuring the harmonics CT8 Current Extemal Current transformar
101. om each side of the AC capacitor and the lug wires 4 Remove the AC capacitor by removing the nut 8 mm from each side of the AC capacitor mounting bracket 8 2 7 AC Capacitor Current Sensor CT4 CT5 CT6 130BX442 10 o FASTENER TORQUE MB 96 Na 7 FTLB FASTENER TORQUE MD P Na H FT LB Q R LT 9 S L2 92 T L3 93 ME a p 6 5 1 AC capacitor current sensor 2 Retaining nut 68 MG90Z102 VLT is a registered Danfoss trademark Darfi E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual NOTE Note that AC current sensors are located in different locations in LHD units than AAF All other procedure steps apply 130BX437 10 Illustration 8 5 LHD AC Capacitor Current Sensor Locations 1 AC capacitor current sensor U 3 AC capacitor current sensor W 1 Prior to removing the current sensor cabling 4 Remove the current sensor by removing the nuts note the direction of the cable routing through 7 mm one on each side of the current sen
102. onnected Only a competent technician should carry out service p VLT Advanced Active Filter AAFO06 D and E Frames Service Manual AWARNING For dynamic test procedures mains power is required and all devices and power supplies connected to the mains are energized at rated voltage Use extreme caution when conducting tests in a powered unit Contact with powered components could result in electrical shock and personal injury 1 DO NOT touch electrical parts of the filter or external current transducers when connected to mains After removing power from mains wait 20 minutes for D frame and 40 for E frame units before touching any electrical parts 2 When any repair or inspection is made mains must be disconnected 3 The STOP key on the control panel does not disconnect mains 4 When servicing external current transformers CTs remove power completely from the connection point on both the mains and secondary side of the CTs 5 Use a shorting connector on the secondary side of customer supplied external current transformers CTs whenever current is present on the mains primary side and the AFC card is NOT wired to the external CT terminals 1 3 Electrostatic Discharge ESD CAUTION When performing service use proper ESD procedures to prevent damage to sensitive components Many electronic components within the unit are sensitive to static electricity Voltages so low that they cannot be easily detected c
103. ormers CTs and voltage information from the DC bus These calculations are used to control the output current of the active filter for harmonic suppression on the mains The AFC also interfaces with the power card The power card provides information about the DC bus voltage and the output current from the internal IGBT current transducers in the inverter In addition the AFC receives input from the internal AC capacitor current transducers The external CTs also interface with the AFC and are mounted in the customer electrical supply system In the LHD the external CTs are mounted in front of the frequency converter The customer supplied external CT secondary coil can be rated with nominal currents of 5 A or 1 A depending on the secondary rating of the CT Connectors on the AFC board correspond to these current ratings 130BB950 10 Illustration 3 2 Active Filter Card p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 1 MK101 5 A external 4 MK107 connector 2 MK108 1 A external connector 3 MK103 6 FK100 3 2 4 Control to Power Interface The control to power interface isolates the high voltage components of the power section from the low voltage signals of the control section The interface section consists of the power card and the gate drive card Much of the fault processing is handled by the control card The power card provides conditioning of these signals along with
104. ortion of the VLT Low Harmonic Drive LHD This manual provides the reader with a general view of the filter s main assemblies and a description of the internal processing With this information technicians should have an understanding of AAF operation for troubleshooting and repair This manual provides instructions for the active filter models and voltage ranges described in Table 1 1 1 1 VLT Active Filter Product Overview VLT Active Filter AAF006 is a device for harmonics and reactive current mitigation The unit is designed for instal lation in various applications or combined with a frequency converter as a packaged low harmonic drive solution The AAF measures the current signal via external transducers and counter acts the unwanted elements of the measured current The unwanted elements are programmable via the LCP The active filter can compensate all harmonics until 40t harmonics at the same time in an overall compensation mode or until the 25 harmonics individual selected down to specified value set via the LCP The unit is also capable of correcting reactive currents to harmonize the current and voltage phases creating a displacement power factor close to 1 The AAF also balances the current loads equally on all three phases 1 2 For Your Safety 1 2 1 Warnings ACAUTION Active filters contain dangerous voltages when connected to mains Also the connected current transducers may hold dangerous voltages when ever c
105. oting Background 5 2 1 Mains Phase Loss and Unbalanced Phase Trips The active filter monitors phase loss by measuring the AC capacitors currents If phase loss is detected the filter trips with ALARM 4 Mains phase loss after a time The time response of the phase loss detection is approx 0 5 s When the input voltage becomes unbalanced no phase disappears completely ALARM 4 is not issued However the following trip alarms may occur WARNING ALARM 7 DC overvoltage WARNING ALARM 302 Cap over current WARNING ALARM 304 DC over current ALARM 311 Switch freg limit WARNING 321 Volt imbalance gt 3 Severe imbalance of supply voltage or phase loss can easily be detected with a voltmeter by measuring the line to line voltages 5 2 2 Voltage Dips and Flickers Active filters are suitable for operation on grids with voltage dips and flickers The active behavior depends on the duration depth and affected phase number of the voltage dips When voltage dips threaten possible damage to active filter components the active filter stops operation with following faults WARNING ALARM 4 Mains phase loss ALARM 300 Mains cont fault ALARM 305 Mains freq limit 5 2 3 Compatibility with Other Equipment on the Same Mains Most problems are associated with the circulation of high frequency switching current harmonics generated by active input devices through leakage capacitance of the power distribution system co
106. ould be attempted with power applied Remove power to the filter and wait at least 40 minutes to let the filter capacitors fully discharge Only a competent technician should carry out service ELECTROSTATIC DISCHARGE ESD Many electronic components within the filter are sensitive to static electricity 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 ESD procedures to prevent damage to sensitive components when servicing the filter NOTE Frame size is used throughout this manual where ever procedures or components differ between filters based upon the unit s physical size Refer to 8 E Frame Sizes Disassembly and Assembly Instructions to determine E frame size definitions MG90Z102 VLT is a registered Danfoss trademark 63 Darfi E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 2 Passive Section Top Instructions 130BX405 Illustration 8 1 Control Card and Mounting Plate Support Bracket Power Card and Mounting Plate Control card terminal block 6 FU4 FU5 no Control card assembly support bracket 64 MG90Z102 VLT is a registered Danfoss trademark E Frame Sizes Disassembly a 8 2 1 Control Card and Control Card Mounting Plate 1 Open the front panel door 2 Unplug the LCP ribbon cabl
107. ous locations in the filter Three current transducers on the output phases bus bars induce counter harmonics onto the mains There are also three current transformers on the mains bus bars outside of the active filter The information from these three transformers via the active filter card is what the filter compensates for on the mains For the LHD drive these transformers are on the mains input bus bars of the frequency converter for measuring the harmonics caused by the frequency converter Three other current MG90Z102 VLT is a registered Danfoss trademark 25 Internal Active Filter Oper transducers in the LCL filter section are used for overload protection for the AC capacitors and damping resistors Identifi Type Function cation CT1 Output of inverter IGBT current sensor CT2 Output of inverter IGBT current sensor CT3 Output of inverter IGBT current sensor p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 Power card ambient temperature sensor measured temperature The fan can be off or high speed based on this temperature Power Card Ambient Temperature Fan turn ON to high speed 45 C Fan turn OFF from high speed 40 C Fan turn ON to high speed 10 C CT4 Hall Effect AC capacitor current sensor CT5 Hall Effect AC capacitor current sensor CT6 Hall Effect AC capacitor current sensor CT7 Current External current transformer Transformer CT8 Current
108. power supply has been exchanged The filter type code must be restored in the EEPROM Select the correct type code in 14 23 Typecode Setting according to the label on the unit Remember to select Save to EEPROM to complete WARNING 251 New typecode The power card or other components have been replaced and the typecode changed Reset to remove the warning and resume normal operation ALARM 300 Mains cont fault Mains contactor fault is displayed when the feedback signal indicates that the contactors are not in the expected state i e either of the two contactors could not close or could not open or there is a feedback signal error Troubleshooting Control and feedback wiring check Verify that the control and feedback is wired correctly and there are no loose connections The 24 V DC output of the control card is from terminal 12 and the contactor feedback goes to terminals 32 and 33 The contactor is energized from a control transformer through the power card relay Perform a visual inspection of the control and feedback wiring to verify there is no damage to the wire insulation Perform a continuity check to test for broken wires between the control transformer and terminal 4 on MK112 Perform the Control Card Digital Inputs Outputs Test 6 3 8 Control Card Digital Inputs Outputs Test Contactors test Denpi VLT Advanced Active Filter AAF006 D and E Frames Service Manual Perform a continuity test of the
109. press and hold to toggle Display 2 has an alternate larger display option between status read out displays e The active filter status at the bottom line of the Press repeatedly to scroll through each display is generated automatically and is not status display ub wn See 2 3 Status Messages for definitions e Press and hold Status plus 4 or YT to ana getalfs adjust the display brightness Display Parameter number Default setting e The symbol in the upper right corner of the 1 1 0 20 Power factor display shows whichset up is active This is 1 2 0 21 THD of current 96 not programmable 1 3 0 22 Mains current A Ouick Menu Allows access to programming parameters for 2 0 23 Output current A initial set up instructions and many detailed 3 0 24 Mains freguency Hz application instructions e Press to access Q2 Quick Setup for o sequenced instructions to program the basic 0 096 0 0 orc S setup a G S e Follow the sequence of parameters as 0A presented for the function set up 2 OA GC Main Menu Allows access to all programming parameters G Off Stop e Press twice to access top level index e Press once to return to the last location accessed i Ades l e Press and hold to enter a parameter Illastration 2 2 Defgult Display Values number for direct access to that parameter Alarm Log Displays a list of current warnings the last 10 alarms and the maintenance log e For details about the active filter before it entered the alarm mode select
110. pulse outputs 32 33 Digital input for controlling the filter R 2 Kohm Less than 5 V logic 0 open N o Greater than 10 V logic 1 closed Wired and programmed for feedback from mains 37 0 24 V DC input for safety stop some units Jumper to terminal 13 MK101 39 Common for analog and digital outputs 42 Analog and digital outputs for indicating values such as THD current and power The analog signal is 0 4 to 20 mA at a maximum of 500 Q The digital signal is 24 V DC at a minimum of 500 Q 10 V DC 15 mA maximum analog supply voltage for potentiometer 53 54 Selectable for 0 to 10 V DC voltage input R 10 k Q or analog signals 0 4 to 20 mA NNLLA at a maximum of 200 Q Used for reference or feedback signals Common for terminals 53 and 54 MK103 60 RS 485 common RS 485 interface and serial communication Table 2 1 Terminal Function and Connection Overview Term 18 19 27 29 32 33 37 5 01 5 12 5 02 5 13 Table 2 2 Control Terminals and Associated Parameter Control terminals must be programmed Each control terminal has specific functions it is capable of performing and associated parameter The setting selected in the parameter enables the function of the terminal 20 MG90Z102 VLT is a registered Danfoss trademark p
111. quired Remove the 6 electrical connection nuts 8 mm for the lower capacitor bank on the DC bus bars 4 Note that the weight of the capacitor bank is approximately 9 kg 20 Ibs 5 Remove the capacitor bank with attached cover plate by removing the 4 screws T 30 MG90Z102 VLT is a registered Danfoss trademark 75 Darfi E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 3 6 IGBT Modules 130BX412 10 Illustration 8 11 IGBT Modules Snubber 6 IGBT module Snubber retaining screw step 3 IGBT module retaining screw step 9 1 5 Intermediate IGBT output bus bar iep e Top IGBT module retaining screw ten Intermediate IGBT output bus bar retaining nut step 7 o IGBT bus bar assembly 1 Remove the capacitor banks in accordance with 3 Remove the 12 T 25 retaining screws 6 on each the procedure module on the lower portion of the IGBT modules These screws also attach the snubber capacitors to the IGBT modules Remove the snubber capacitors 2 Note the IGBT signal cables connected between the gate drive card connectors MK100 temperature sensor MK102 U MK103 V and MK104 W and the IGBTs for reassembly not 4 Remove the 4 13 mm retaining nuts at the shown Disconnect the cables at the connectors bottom of the IGBT bus bar assembly on the IGBT modules 5
112. referenced to the negative DC bus and can be at bus potential even though it may appear on diagrams to be a neutral reference Remember that voltage may be present for as long as 40 minutes on E frame size filters or 20 minutes on D frame size filters after removing power from the unit See the label on the front of the filter door for the specific discharge time 2 Never apply power to a unit that is suspected of being faulty Many faulty components within the filter can cause damage to other components when power is applied 3 Never attempt to defeat any fault protection circuitry within the filter That will result in unnecessary component damage and may cause personal injury 4 Always use factory approved replacement parts The 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 understanding of the unit is the best approach When in doubt consult the factory or authorised repair centre for assistance 6 The After Repair Tests should always be performed following a repair to the filter p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 4 2 Fault Symptom Troubleshooting Table 4 1 provides an inspection check list The check list provides guidance through a variety of items to inspect during any filter service process The filter processor monitors inp
113. res In summary for proper functioning the filter input control terminals must be Wired properly Programmed correctly for the intended function Receiving a signal MG90Z102 VLT is a registered Danfoss trademark 19 Dafoe Operator Interface and Acti VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 7 Control Terminal Functions The following describes the functions of the control terminals Many of these terminals have multiple functions determined by parameter settings Connector Terminal Number Function Active filter card MK101 Input from external current transducers 5 amp MK108 1 8 Input from external transducers 1 amp Power Card FK100 01 02 03 Aux relay 1 NC NO used for temperature feedback FK101 04 05 06 Aux relay 2 NO used to set mains contactor Control card MK102 12 13 24 V DC power supply to digital inputs and external transducers The maximum output current is 200 mA Terminal 12 used for internal relay feedback Digital 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 start stop signal from drive in the LHD Common for digital input Wired and programmed for start stop signal from drive in the LHD 19 27 29 Digital inputs for controlling the filter R 2 Kohm Less than 5 V logic 0 open Greater than 10 V logic 1 closed Terminals 27 and 29 are programmable as digital
114. resence of a signal at the desired terminal should correspond to the digital input display readout A reading of 24 V DC indicates the presence of a signal A reading of 0 V DC indicates no signal is present Analog inputs The value of signals on analog input terminals 53 and 54 can also be displayed The voltage or current in mA depending on the switch setting is shown in line 2 of the display 130BB039 10 If the desired signal is not present in the display the problem may be either in the external control wiring to the filter or a faulty control card To determine the fault location use a voltmeter to test for a signal at the control terminals Darfi VLT Advanced Active Filter AAF006 D and E Frames Service Manual Verify the reference voltage power supply is correct as follows 1 With a voltmeter measure the voltage at control card terminal 50 with respect to terminal 55 The meter should read between 9 2 and 11 2 V DC If the 10 V supply voltage is not present conduct 6 3 3 Control Card Basic Voltage Test earlier in this section If the 10 volts is present proceed with checking the individual inputs as follows 2 Connect the negative meter lead to reference terminal 55 3 Connect the positive meter lead to desired terminal 53 or 54 For analog input terminals 53 and 54 a DC voltage between 0 and 10 V DC should be read to match the analog signal being sent to the filter Or a reading of 0 9 to 4 8
115. ress for a definition of the function being displayed Navigation Use the four navigation arrows to move between Keys items in the menu OK Use to access parameter groups or to enable a choice Light Indicator Function Green The ON light activates when the active filter receives power from mains voltage a DC bus terminal or an external 24 V supply Yellow When warning conditions are met the yellow WARN light comes on and text appears in the display area identifying the problem Red A fault condition causes the red alarm light to flash and an alarm text is displayed 2 2 6 Tips and Tricks The AAF default parameter settings ensure that few set up changes are necessary For the majority of applications the Ouick Menu 02 Ouick Set up provides access to all the typical parameters reguired Perform Auto CT for all stand alone filters to set correct current sensor setup Auto CT setup is only possible when CTs are installed at Point of Common Coupling PCC towards the transformer CT setup of LHD units is preset from the factory e Under Quick Menu Q5 Changes Made any parameter changed from factory settings is displayed Press and hold Main Menu for 3 seconds to access any parameter For service purposes it is recommended to backup parameters settings to the LCP see for further information 14 MG90Z102 VLT is a registered Danfoss trademark
116. rews 2 each for the U V and W intermediate IGBT output bus bars 5 Remove the nut 13 mm connecting the current sensor bus bar to the intermediate IGBT bus bar 6 Remove the IGBT intermediate bus bar by removing the retaining nut 8 mm 7 Remove the IGBT module by removing the 8 mounting screws T 25 8 Note that a Mylar shield covers the lower 8 retaining screws Take proper care to avoid damage to the shield Remove the IGBT module by removing the 8 screws T 25 9 Clean the heatsink surface with a mild solvent or alcohol solution Reassembly 1 Replace the IGBT module in accordance with the instructions provided with the replacement kit Note that tightening pattern and torgue values described in kit must be complied with 2 Reassemble the remaining parts in reverse order of their removal See Table 1 7 for torgue tightening values 7 3 8 IGBT Current Sensors CT1 CT2 and CT3 1 Remove the input terminal mounting plate in accordance with the procedure 2 Remove the nuts 13 mm from both ends of the current sensor bus bar 3 Remove the retaining nut 8 mm from the current sensor standoff 4 Disconnect the current sensor cable not shown 5 Remove the current sensor by removing the retaining nuts 8mm one on each side of the current sensor p VLT Advanced Active Filter AAFO06 D and E Frames Service Manual Reinstall in the reverse order of this procedure See Table 1 7 for torque t
117. rips after a fixed time delay The time delay varies with unit size See rating Table 1 4 for the voltage limits Troubleshooting Make sure that the supply voltage matches the filter voltage Perform input voltage test 6 3 2 Input Voltage Test Check the soft charge circuit WARNING ALARM 13 Over current The inverter peak current limit approximately 300 of the rated current is exceeded In general it points to a high error in the current control loop due to damage of the active filter hardware Unexpected high voltage spikes in the mains voltage can cause an overcurrent alarm as well If this alarm occurs again after alarm reset it indicates an active filter hardware defect See Table 1 3 for current trip points Troubleshooting Check the IGBT and LCL filter components Perform input voltage test 6 3 2 Input Voltage Test 32 MG90Z102 VLT is a registered Danfoss trademark Darfi VLT Advanced Active Filter AAF006 D and E Frames Service Manual Troubleshooting ALARM 14 Earth ground fault Sum current measured by internal inverter IGBT current transducers doesn t equal zero There is a discharge from the mains phases to earth either in the cable between the filter and the mains or in the filter itself Trip level equals 50 of filter nominal current Troubleshooting e Turn off the filter e Measure the resistance to earth of the LCL filter components leads with a megohmmeter to chec
118. rrent sensors CT1 CT2 and CT3 respectively Expect a reading near zero volts but no greater than 15 mV A reading of greater than 15 mVv suggests that the corresponding current sensor be replaced 6 3 6 Input Terminal Signal Tests The presence of signals on either the digital or analog input terminals of the filter can be verified on the filter display Digital or analog input status can be selected or read in parameters 16 60 through 16 64 MG90Z102 VLT is a registered Danfoss trademark 47 Test Procedures Digital inputs With digital inputs displayed control terminals 18 19 27 29 32 and 33 are shown left to right with a 1 indicating the presence of a signal 130BB038 10 If the desired signal is not present in the display the problem may be either in the external control wiring to the filter or a faulty control card To determine the fault location use a voltmeter to test for voltage at the 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 between 21 and 27 V DC If the 24 V supply voltage is not present replace the control card If 24 V is present proceed with checking the individual inputs as follows 2 Connect the negative meter lead to reference terminal 20 3 Connect the positive meter lead to the terminals in sequence The p
119. s changed T X s x m _ Wegal PS config Si X 80 Drive initialised to default value hh a 305 Mains frequency limit X MG90Z102 VLT is a registered Danfoss trademark 31 Troubleshooting p VLT Advanced Active Filter AAF006 D and E Frames Service Manual Description Warning Alarm Trip Alarm Trip Lock 2 5 V power card low ae Seer NN ee Table 4 2 Warning alarm code list X Programmable dependent on parameter setting Cannot be auto reset via parameter selection LED indication Trip locked yellow and red WARNING 1 10 Volts low The control card voltage is below 10 V from terminal 50 Remove some of the load from terminal 50 as the 10 V supply is overloaded Max 15 mA or minimum 590 Q This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer Troubleshooting Remove the wiring from terminal 50 If the warning clears the problem is with the customer wiring If the warning does not clear replace the control card WARNING ALARM 4 Mains phase loss A phase is missing on the supply side or the mains voltage imbalance is too high Troubleshooting Check the supply voltage imbalance and main fuses of the filter Check the mains cable connection for tightness WARNING 5 DC link voltage high The intermediate circuit voltage DC is higher than the high voltage warning limit The limit is dependent on the
120. s when current is present on the primary side and the AFC card is NOT connected could damage the current transformer 3 Remove capacitors CT cable from terminal MK103 of AAF card 4 Remove the external CT cable from terminal MK101 or MK108 in the AAF card 5 Remove ribbon cables from FC100 and MK100 on the AAF card 6 Remove the control card terminal blocks 7 Remove the 4 screws T 20 securing the control card mounting plate to the control assembly support bracket 8 Remove the control card mounting plate Reinstall in reverse order of this procedure See Table 1 7 for torque tightening values 7 2 2 Control Assembly Support Bracket 1 Remove the control card mounting plate in accordance with the procedure 2 Remove the 5 mounting nuts 10 mm 3 Remove the control assembly support bracket Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 2 3 Active Filter Card 130BB950 10 1 MK101 4 MK107 apwo js ma CAUTION Mains Primary Side Current Use a shorting connector on the secondary side of customer supplied external current transformers CT whenever current is present on the mains primary side and the AFC card is NOT wired to the external CT terminals When performing service on an active filter use a shorting connector on the secondary side o
121. safe stop on terminal 37 reguires that the user satisfies all provisions for safety including relevant laws regulations and guidelines p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 5 4 Serial Communication Wiring Serial communication to the filter can be supported through different terminals e RS 485 EIA 485 terminal e USB connector e MK103 termination e Optional add on communication protocol connections A serial communication protocol supplies commands and references to the filter can be used to program the filter and reads status data from the filter The serial bus connects to the unit through the RS 485 EIA 485 serial port Commands and references to the filter can be accessed via the USB terminal Connector MK103 allows serial communication to be wired to terminals 4 68 and 69 Terminal 61 is common and may be used for terminating screens only when the control cable run between Danfoss filters or between filters and Danfoss frequency converters Do not use the common screen between filters and other devices For optional add on communication protocols see the operating instructions for the option 2 5 5 Relay Options No relays are available for customer use Additional output relays are available with the MCB105 relay card option This card provides 3 relays of up to 2 A at 240 V resistive load or 0 2 A inductive 2 6 Control Terminals Control terminals must be programmed Ea
122. sconnect the in line connector going to FU12 8 Note the color of the cables red white and black on FU11 FU12 and FU13 for proper reinstallation Remove the cables from the top and bottom of fuses FU11 FU12 and FU13 9 Remove the power card mounting plate by removing 7 8 mm nuts Reinstall in the reverse order of this procedure The ring lug for the wire assembly that connects to power card connector MK102 attaches to the right mounting stud on the top of the power card mounting plate See Table 1 7 for torque tightening values 54 MG90Z102 VLT is a registered Danfoss trademark p Darfi D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 2 6 AC Capacitors 130BX438 10 ai Y li I PS on XY B B i n TET Illustration 7 4 AC Capacitors and AC Contactors AC contactor 5 Auxiliary contactor AC contactor terminal bracket i6 Mains contactor terminal U V W AC contactor terminal bracket retaining nut AC capacitor 1 a Ac contactor mounting screw 8 AC capacitor reining narto O 1 Remove 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 11 mm from each side of the AC capacitor and the lug wires 4
123. sor the current sensor for proper reinstallation Direction of the cable is phase sensitive to the sensor function Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 2 Remove the nut 11 mm from the corresponding capacitor in order to remove the lug cable which goes through the current sensor 3 Remove the Molex connector not shown from the current sensor MG90Z102 VLT is a registered Danfoss trademark 69 Darfi E Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 8 2 8 AC Contactors B S FU15 X a E A 3 Illustration 8 6 AC Contactors CM and DM RFI Filters MOVs Discharge Card and Soft Charge Resistor 1 Power card PCA3 9 MOV 2 AC contactor L3 no o MOV retaining nut 3 AC contactor L1 MK107 4 Differential mode RFI card MK106 5 Discharge card PCA16 13 MK1 6 Soft charge resistor 14 Common mode RFI card 7 Fuses FU6 FU14 FU15 Power card mounting plate 8 Fuses FU11 FU12 FU13 he o Auxiliary contactor Prior to removing cables from the AC contactors note the side of the AC contactor Remove the AC mounting orientation of the AC contactors and connection interconnect bus assembly of all cables for proper reinstallation 2 Disconnect the coil wires from terminals A1 and A2 by loosening the retaining screws not 1 Remove the 5 nuts 10 mm the AC interconnect shown bus assembly
124. ter NOTE Frame size is used throughout this manual where ever procedures or components differ between filters based upon the unit s physical size Refer to the tables in the Introduction Section to determine frame size definitions See for E frame sizes disassembly and assembly instructions 50 MG90Z102 VLT is a registered Danfoss trademark Darfi D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 2 Passive Section Top Instructions 130BX414 Illustration 7 1 Control Card and Mounting Plate Support Bracket Active Filter Card and Power Card and Mounting Plate Control card terminal block 6 FUA 1 Control card mounting plate 9 Mounting nut no Control card assembly support bracket MG90Z102 VLT is a registered Danfoss trademark 51 D Frame Sizes Disassembly a 7 2 1 Control Card and Control Card Mounting Plate 1 Open the front panel door 2 Unplug the LCP ribbon cable from the control card CAUTION Mains Primary Side Current Use a shorting connector on the secondary side of customer supplied external current transformers CT whenever current is present on the mains primary side and the AFC card is NOT wired to the external CT terminals When performing service on an active filter use a shorting connector on the secondary side of external CTs for extra safety Failure to short out the secondary side of current transformer
125. test procedures to isolate a fault condition whether within 10 a or outside of the active filter 0 096 0 096 oC 130BB468 10 111A Active filters have protection circuitry that reduces the filter output current If the reduced output is insufficient 0A or in critical situations a fault is registered and the unit will trip suspend operation to avoid damage When a fault occurs a fault message is displayed to assist in troubleshooting and service The normal operating status of the filter is displayed in real time on the LCP display Virtually every filter operation results in an indication on the LCP display Fault logs are maintained within the active filter for fault history The filter also shows warnings on the LCP display to 2 indicate that the unit has reached a given limit In most cases the AAF automatically adjusts to assure operation is On s not disrupted Warnings usually indicate that the filter is running at its maximum capability Familiarity with the Warm C SS information provided on the display is important Diagnostic data can be accessed through the LCP 2 2 User Interface c 3 me The local control panel LCP is the combined display and keypad on the front of the unit The LCP is the user interface to the active filter Auro Running Quick Main Alarm Status Menus Menu Log Alarm Illustration 2 1 LCP Display a Display mode line sho
126. th 24 V Protection md The filter has detected a critical status e g an over current or over voltage To avoid tripping of the unit alarm protection mode is activated This includes reducing compensation and average switching frequency If possible protection mode ends after approximately 10 s Running The filter is active and compensating Sleeping The energy saving function is enabled This means that the filter mains contactors are open and no harmonic compensation is performed The filter will restart automatically when the wake up condition is met Standby In Auto On mode the filter is active and is waiting for a remote start signal via digital input or serial communication Stop Off was pressed on the LCP or Stop was activated as a function for a digital input terminal The corresponding terminal is not active Trip An alarm has occurred When the cause of the alarm is cleared the filter may be reset via a remote signal through a control terminal or serial communication or by pressing Reset on the LCP Trip lock A serious alarm has occurred When the cause of the alarm is cleared mains power must be cycled on and off before resetting the filter This puts the filter in trip mode and can be reset as described MG90Z102 VLT is a registered Danfoss trademark 15 Operator Interface and Acti 2 4 Service Functions Service information can be displayed
127. the alarm number using the navigation keys and press OK MG90Z102 VLT is a registered Danfoss trademark 13 Operator Interface and Acti Darfi VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 2 4 Navigation Keys Navigation keys are used for programming functions and moving the display cursor Three status indicator lights are also located in this area 130BT117 10 2 2 5 Operation Keys Operation keys are found at the bottom of the control panel Key Function Hand On 130BP046 10 Press to start the active filter in local control e The filter measures distortion and closes the main contactors to start filtering when needed e The other operation keys are still active in hand on mode e An external stop signal by control input or serial communication overrides the local hand on e A remote signal has higher priority than hand on Off Stops the filtering function but does not remove power to the active filter Auto On Puts the system in remote operational mode e Responds to an external start command by control terminals or serial communication Reset Resets the active filter manually after a fault has been cleared Warm Alarm Key Function Back Reverts to the previous step or list in the menu structure Cancel Cancels the last change or command as long as the display mode has not changed Info P
128. the right side of the capacitor bank assembly for proper reassembly 2 Remove the 2 nuts 10 mm from the DC bus terminals not shown 3 Remove the capacitor bank assembly by removing the 4 retaining nuts 10 mm at the bottom of the capacitor bank assembly and 4 retaining nuts T 30 from the top NOTE Reinstall in the reverse order of this procedure See Table 1 7 for torque tightening values 7 60 MG90Z102 VLT is a registered Danfoss trademark Darfi D Frame Sizes Disassembly a VLT Advanced Active Filter AAF006 D and E Frames Service Manual 7 3 7 IGBT Modules 130BX419 eRT Illustration 7 8 IGBT Modules IGBT Current Sensors Damping Resistors Fan and Fan Transformer IGBT module 9 Fan transformer i 16 Damping resistor bus bar MK100 COPNIT AMI RIPWINi MG90Z102 VLT is a registered Danfoss trademark 61 D Frame Sizes Disassembly a NOTE Note that for ease of access the input terminal mounting plate may be removed prior to this procedure 1 Remove the capacitor bank assembly in accordance with the procedure 2 Disconnect the gate leads MK100 MK200 MK300 and the thermal sensor MK10 from the IGBT module 3 Remove the IGBT snubber capacitors and DC bus assembly by removing the 6 retaining screws T 30 from the bottom terminals of the IGBT module 4 At the top of the IGBT module remove the 6 T 25 retaining sc
129. ting is to check for shorted power components or faulty connections Perform these tests on any unit suspected of containing faulty power components before applying power ACAUTION For dynamic test procedures main input power is required All devices and power supplies connected to the mains are energized at rated voltage Use extreme caution when conducting tests on a powered filter Contact with powered components could result in electrical shock and personal injury Dynamic tests are performed with power applied to the filter Dynamic testing traces signal circuitry to isolate faulty components Replace any defective component and retest the filter with the new component before applying power to the filter as described in After Repair Drive Tests Darfi VLT Advanced Active Filter AAF006 D and E Frames Service Manual CAUTION Mains Primary Side Current Use a shorting connector on the secondary side of customer supplied external current transformers CT whenever current is present on the mains primary side and the AFC card is NOT wired to the external CT terminals When performing service on an active filter use a shorting connector on the secondary side of external CTs for extra safety Failure to short out the secondary side of current transformers when current is present on the primary side and the AFC card is NOT connected could damage the current transformer 130BX359 10 Illustra
130. tion 6 1 Shorting Connector 1 Shorting lug 2 Shorting connector Shorting Connector A shorting connector must be placed on the secondary side of customer supplied external CTs whenever current is present on the mains and the AFC card is NOT wired to the external CT terminals Failure to short out the secondary side of the CT could damage the CT The AFC card provides the step down current function when connected When the AFC card is not connected the secondary side must be shorted The shorting connector provided with most customer supplied external CTs should be removed after the AFC card has been wired to the CT and prior to operating the active filter For safety considerations short the secondary side of customer supplied external CTs anytime the AFC card is not wired to the external CT even if current is not present on the mains Customer supplied external CTs connect to the AFC card at MK101 5A or MK108 1A 42 MG90Z102 VLT is a registered Danfoss trademark Test Procedures 6 1 1 Tools Reguired for Testing Digital volt ohmmeter must be rated for 1200 V DC for 690 V units Analog voltmeter Megohmmeter Oscilloscope Clamp on style amp meter Signal test board p n 176F8437 and extension board p n 130B3147 Split bus power supply p n 130B3146 Power quality analyses Fluke 435 p n 130BB3173 Dranetz 4300 4400 or similar 6 1 2 Signal Test Board The signal test board can b
131. use a dangerous condition Alarms must be reset to restart operation once their cause has been rectified This may be done in three ways 1 Pressing the reset button on the LCP 2 A digital reset input 3 Serial communication reset signal NOTE After a manual reset using the Reset button on the LCP the Auto On button must be pressed to restart the unit A trip lock is an action when an alarm occurs which may cause damage to the filter or connected equipment Injection towards grid is stopped A trip lock can only be reset after the condition is cleared by cycling power Once the problem has been rectified only the alarm continues flashing until the filter is reset An X marked in Table 4 2 means that action occurs A warning precedes an alarm 30 MG90Z102 VLT is a registered Danfoss trademark Dafoe Troubleshooting VLT Advanced Active Filter AAF006 D and E Frames Service Manual No Description Warning Alarm Trip Alarm Trip Lock po froveksiow Ai KIA 4 Mains phase loss X X X SA Wi x id a V i w m Geman E X CE m emma X T a ovredoDgmiOmprTemmaz o m Overload of Digital Output emma o 42 Overload of Digital Output on X30 6 or Overload of Digital Output on X Ep UP ES ed 60 External interlock X e Heatsink temperate w Txo id Sd 67 option configuration ha
132. ut A 2 2 2 5 V DC Equal on all phases TP25 TP30 26 GUN T 8 00 signal buffered 6 00 z U phase pli 4 00 130BX153 10 negative Signal 2 00 originates on 0 00V Control Card 2 00 4 00 6 00 8 00 4 0ms 50Us Div 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 8 00 6 00 V phase 130BX153 10 4 00 positive Signal 2 00 originates on 0 00V Control Card 2 00 4 00 6 00 8 00 4 0ms 50Us Div 2v div 100us div Run 10 Hz 2 2 2 5 V DC Equal on all phases TP25 TP30 28 GVN T IGBT gate signal buffered 130BX153 10 V phase negative Signal originates on Control Card 4 0ms 50Us Div 2v div 100us div Run 10 Hz MG90Z102 VLT is a registered Danfoss trademark 83 p Special Test Equipment VLT Advanced Active Filter AAF006 D and E Frames Service Manual Pin Sche Function Description Reading Using a Digital No matic Voltmeter Acron 2 2 2 5 V DC Equal on all phases TP25 TP30 29 IGBT gate signal buffered 8 00
133. uts and outputs as well as internal filter functions so an alarm or warning does not necessary indicate a problem within the unit itself Many times the root cause of the problem is due to interactions between the AAF and other devices connected to the same transformer 5 Active Filter and the Power Grid presents detailed discussions on areas of filter and system trouble shooting that an experienced repair technician should understand in order to make effective diagnoses The After Repair Tests should always be performed following a repair to the filter 28 MG90Z102 VLT is a registered Danfoss trademark Troubleshooting p VLT Advanced Active Filter AAF006 D and E Frames Service Manual 4 3 Visual Inspection Table 4 1 lists a variety of conditions that require visual inspection as part of any initial troubleshooting procedure Inspect For CT feedback and other auxiliary equipment Cable routing Control wiring Description Check the function and installation of current sensors that provide feedback to the active filter Ensure that CT feedback is connected to the AFC card correctly MK101 5 A MK108 1 A Check for auxiliary equipment switches disconnects or input fuses circuit breakers that may reside on the input power side of active filter Check the jumpers on the CT terminal Examine the operation and condition of these items for possible causes of operational faults Avoid routing ca
134. ws which display mode is active and indicates which set up is active and how many set ups are programed 1 1 Pressing The LCP has several user functions e Start and stop the filter when in local control Status changes modes Display operational data status warnings and b Lines 1 3 display user selected operation data cautions see 2 2 2 Setting Display Values Programming active filter functions c Status line displays filter generated status Manually reset the active filter after a fault when messages see 2 3 7 Status Messages auto reset is inactive 12 MG90Z102 VLT is a registered Danfoss trademark p Operator Interface and Acti VLT Advanced Active Filter AAF006 D and E Frames Service Manual 2 2 2 Setting LCP Display Values 2 2 3 Display Menu Keys The display area is activated when the active filter receives Menu keys are used for menu access for parameter set up power from mains voltage a DC bus terminal or an toggling through status display modes during normal external 24 V supply operation and viewing fault log data The information displayed on the LCP can be customized 2 for user application Quick Main Alarm 3 PP Status Menu Menu Log m Each display readout has a parameter associated with it Key Function abe M Options are selected in the main menu 0 Status Press to show operational information Operation Display e In Auto mode
135. ww IJI A Te S p 6 mm A in Tana INDd Le i ILI I ds wa ud pra T T i EA Lane E EM aid i pays ewayy t nsw FREI y ul NS WBHLSD anole MSs i0 ED MS WHHL IH T T 28 T su ka if ons PRR Tw mr L MEN ean ja CJH GH E Eroro 7169 a m f E sn wD an uw sE SH uw mar alelo Onan aem I Wido a e CDINVED E amp ays M sins fc CH a n nous EU RS i g n au Rea T XUIPYT FO mwa T E uo ass XI 5 zam TH Mae H E amp m soe HS CN ara ie E 5 n 1 sus nw 2 Wa 2 ens Fou apu A OUVI yOLsish IVO Y T VV ON Suus RR sea B e el WA d EE aao go Gp Oy H E gt ens _ mem evens HH COD OHH m 3 _ LLL sion LCD msnm LC Naws s a isis z NSWBHLTI aa Taa Teen pn Ten fn fpi orsa ee pilaf ste sm ola 77 VU ZEAEND smahisa 3 Ej Tels Es ea Ie Hee ULIS eae EIS eege sc d il Hl xe liae fue oe Ded lae beo DINERO LATTE dd E Dus seus T wan ees OSSXW OSPXW OSW OSW O0LW HOW i H LHM MS WHHL L891 TTT TE nu een 078 618 gD LND d Ies Er PLNS ol d Kaa Em Ts a ECS L H ELMS E is 13s BE E Gelan mP M M sie l 1MS ER f CY sina DEJES Quvo INYO avo To Ya A ruw ma 3 ed ndu S1799 d 0185 GC Nld Svod Aid J ia od ma 6 18 7 Ect bw BBR S E TR OZ Nid Svodatia can snp 57 inp IAT TIHPEPRET ct pice id 91189 of e a so fol sts v loo IA RRR IND 4 Er 1M Da ND waza PL ME LL 3 2 xu lo1ND 3 844 Lewo Dow FON SINdNI WLISIO 404035 D

VLT Advanced Active Filter AAF006 D and E Frame Service Manual

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