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AFE Basics
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AFE Bene$its
! *ow +ar&onics and low "+, -"otal +ar&onic,istortion
! /o rae circ'it and rae resistors (
/o rae resistor cooling s%ace is needed.! Constant ,C voltage ( ood $or te $l') control
! M'lti drive rigid o%eration (
Eac drives will e inde%endent o$ eac otereca'se te ,C voltage is constant. ( Energ saving i$ te drives r'n in &otoring and
raing at te sa&e ti&e.
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+ow te &ains voltage is
selected
A F E 4 / V M
* C * F i l t e r
650V Motor 57V8910: Voltage ,ro% tro'g*C* and "rans$or&er
630V
StartSelection
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A F E 4 / V M
* C * F i l t e r
M a i n s
AFE Control Basics
Motoring
Braking
Vdc goes down.
Vdc goes up.
Control Block
! ;eg'late Vdc
! enerate te AFE voltage wic is
sncroni
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Si&%le Circ'it ,iagra&
V 0 V a $ e
A F E
4 a
* & * c
* a ? * r @ * & @ * c; a ? ; r @ ; & @ ; c
M a i n s
V d c
C $
* C * F i l t e r
* r
* r
M a i n s " r a n s $ o r & e r i n d ' c t a n c e
V a $ e ? V 0 9 - ; a @ >w * a 4 a
! *a -?*r@*&@*c $or%ower trans$er at$'nda&ental $re='enc
( *c and C$ is $or low%ass $ilter -700 to00+
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Vector ,iagra&
! 4a? 4=@4d
( 4d re$ ?0 -P$?0
! Va$e Voltage *i&it Factors
( "e &ains voltage level
! 910 to @7: o$ 630V
( ,C voltage level! Va$e &a) VdcDs=-2%w&
( "otal 4nd'ctance
! 8 to 10: %'
( P ase
! 630V and 1.2M
" # e r a d i ' s o $ V a $ e - & a ) V d c D S G ; " - 2 M % w &
V 0 > w * a 4 a
; a 4 a
9 ; 1 4 a
V a $ ei n & o t o r i n g
e n e r a t i o n- 4 n v e r t e r B r a i n g
9 >w * a 4 a
* o a d i n g- 4 n v e r t e r M o t o r i n g
4 a
V a $ ei n r a i n g
V e c t o r , i a g r a &
V a $ e ? V 0 9 - ; a @ >w * a 4 a
arning Message
6H -Voltage *i&it ( Va$e &agnit'de is
at its li&it.
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AFE Control Bloc ,iagra&
! "e %rogra& is i&%le&ented in ,SP -,igital Signal Processor.
Vector Control Bloc
AFE Mod'le and
*C* Filter
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*C* Filter
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*C* Filter ,esign
! F'nction
( or $or te %ower $low.
! "e total ind'ctance is 8 to 10: %'.
( ;ed'ce te ar&onics.
! *c and C$ is te low %ass $ilter wit 700 to 00+<
to red'ce te 1.7+< ar&onic c'rrent into te
&ains and to lower te voltage distortion at H00V.
! ;$ -da&%ing resistor li&its te ar&onic c'rrent
&agnit'de.
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*C* Filter 9 ;esonance Fre='enc
! ,esign o$ te *C* $ilter is to%rovided di$$erential &ode
$iltering o$ te switcing
$re='enc.
! ,esired resonance $re='enc is
etween te c'rrent reg'latorandwidt and te switcing
$re='enc o$ te AFE.
-4JBFresFsw
! ,a&%ing resistors control te
a&%lit'de o$ te $ilterresonance. "e sste& level
trade o$$ is losses vers's
da&%ing.
-40
-30
-20
-10
0
10
M a g n i t u d e ( d B )
101
102
103
104
-180
-135
-90
-45
0
P h a s e ( d e g )
Converter Side Vcap/Vconv, fres = 728.281Hz
So'rce
4&%edance
R t Lt E rn
E sn
E tn
I r
n
Converter
Side Filter
R c Lc
R c Lc
R c Lc
Main Side
Filter
R m Lm
R m Lm
R m Lm
R t Lt
R t Lt
R cf Ccf
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"%ical ,rive ;'n ,ata
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630VAC Mains Voltage
! "e %lot on te le$t is te &ains voltage e$ore te
active $ront9end is t'rned on.
! "e %lot on te rigt is te &ains voltage wit te
active $ront9end r'nning wit load.
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1.2 M AFE C'rrent Stead9State
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Mains C'rrent 9 Motoring
( Pase C'rrents K500 Ar&s -K00 Motoring ( C'rrent "+, H: ( ,C *in Voltage ;i%%le KL3:
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Mains C'rrent D AFE C'rrent 9 Motoring
! Co&%arison o$ te active $ront9end c'rrent e$ore and a$ter te
*C* $ilter
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! "ransient ti&e
K120&sec
! Voltage
reg'lation isKH:
'ndersoot
-533 Vdc
AFE "ransient $ro& enerating to Motoring
M a i n s I n p u t
C u r r e n t s
H o i s t # 1 M o t o r
C u r r e n t s
D C
L i n k
Generating Motoring
R1
1.250 kAMP
-1.250 kAMP
S1
1.250 kAMP
-1.250 kAMP
T1
1.250 kAMP
-1.250 kAMP
U1
1.250 kAMP
-1.250 kAMP
V1
1.250 kAMP
-1.250 kAMP
W1
1.250 kAMP
-1.250 kAMP
VDC_2
1.050 kVolt
00.0 Volt
100.0 !"#$i%1&'10.(11 1&'11.(11
.
Power $lowing to te
grid -9H30
Power $lowing $ro& te
grid -@H67
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AFE "ransient $ro& Motoring to enerating
! "ransient ti&e
K120&sec
! Voltage
reg'lation isKH:
oversoot
-1008 Vdc
M a i n s I n p u t
C u r r e n t s
H o i s t # 1 M o t o r
C u r r e n t s
D C
L i n k
R1
1.250 kAMP
-1.250 kAMP
S 1
1.250 kAMP
-1.250 kAMP
T1
1.250 kAMP
-1.250 kAMP
U1
1.250 kAMP
-1.250 kAMP
V1
1.250 kAMP
-1.250 kAMP
W1
1.250 kAMP
-1.250 kAMP
VDC_2
1.050 kVolt
00.0 Volt
100.0 !"#$i%12'55.*+ 12'5+.*
Motoring Generating
Power $lowing o$$ te
grid -@H67
Power $lowing to te
grid -9H30
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,rive ,esigns
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1. ,rive Con$ig'ration
1. Standalone and Parallel Mod'les Cainet
2. VSnc
3. M,C4C
H. Bloc ,iagra&s1. 3 %arallel9connected drive
2. 3 inde%endent drives
3. 2 %arallel9connected drive and 1 standalone drive
H. 4nverter &od'le
7. ,9$ra&e drive cainet wiring
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1. ,rive Con$ig'ration
-Standalone and Parallel ,rive
Standalone ,riveParallel ,rives
*CP
CC
*CP
Mod1 Mod2M1 S1 S2
CC M,C4C
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Stand Alone ,rive Bloc ,iagra&
! Standalone " ,rive -760
* C PC o n t r o l C a r d- C C .
P o w e r C a r d- P C .
a t e , r iv e- , .
4 B " 1
4 B " 2
4 B " 3
S c a l i n g C a r d
M o d ' l e
CC Functions
! ,rive control ( Fl') controlD AFE
control! 4nter$ace to P*C Encoder etc.
!Nverall %rotection ( 4&a)2
PC Functions
! *ocal controls ( Fan control ;ec Control -not $or AFE ased drives
! ,ata ac='isition ( C'rrent $eedac 4B" /"C reading
! C'rrent %rotection ( 4&a)1 -Move to M,C4C $or %arallel drives! EEP;NM -Basics
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* C PC o n t r o l C a r d- C C
P o w e r C a r d- P C
a t e , r i v e- , 4 B " 1 9 3
P o w e r C a r d- P C
a t e , r i v e- , 4 B " 1 9 3
P o w e r C a r d- P C
a t e , r i v e- , 4 B " 1 9 3
M a s t e r
S l a v e 1
S l a v e 2
M o d ' l e * e $ t
M o d ' l e M i d d l e
M o d ' l e ; i g # t
2 31
1
2
3
S c a l in g C a r d
H H
H H
H H
Parallel ,rive Bloc ,iagra& 9M,C4C
! CA/ 's co&&'nication ( "e &od'le identi$ier is ased on te HH9%in connector ter&inal location.
! M,C4C -M'lti ,rive Control 4nter$ace Card F'nctions ( S'& '% tree c'rrent signals and its s'& to CC
! 4&a)1 detection and c'rrent alance detection ( ,istri'te te gate signals into tree &od'les. ( Vsnc detection
M,C4C
arning Messages
! A0 -4llegal FC Con$ig
! Possile ca'ses rong CC -AFE vs 4/V rong PC -AFE and 4/V
PC are di$$erent rong EEP;NM a&ong te &od'les
! A5 -4llegal Power Section Con$ig
! Possile Ca'ses Mis&atc etween te setting and # o$ &od'les
connected s'c as i&%ro%er M,C4C connector connection
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2. VSnc -Voltage Sncroni
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3. M,C4C Board
Feat'res! PC ter&inals
( #1 $or Master ( /o si% ( Can 's 4, is
associated wit tePC ter&inal.
! Scaling ter&inals 1 toH corres%onding toPC ter&inals.
! Vsnc circ'it
! Master %rovides CC%ower Vdc&eas're&ent andEEP;NM
( /ote /eeds te correctEEP;NM in slaves.
! ;SH87 4solated 7Vvoltage $ro& 2nd PCconnector
! C'rrent scale cange
"o CC"est Connector
1 2 3 H
Scaling Card "er&inals
"o PC
1 -M
2 -S1
3 -S2
H -S3
Vsnc Connector
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H. Bloc ,iagra&s
Bloc ,iagra&s witin Cainet
! 3 Parallel9Connected ,rive
! 3 4nde%endent ,rives! 2 Parallel9Connected ,rive and 1 Standalone
,rive
! 4nverter Mod'le
! ,9$ra&e ,rive Cainet iring
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1. 3 Parallel9Connected ,rive
AC N't
,C 4n
*CP CC M,C4C
Fan So'rce
So$t
Carge
A') ;ela
Vsnc
,oor Fan
"7 A'to
"rans$or&er
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3. 2 Parallel ,rive and Nne Standalone ,rive
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H. 4nverterDAFE Mod'le
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7. ,9$ra&e ,rive Cainet
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,esign Basics
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AFE Basics ( Prod'ct
,esign ,etails
1. Start Se='ence
2. F'se Coordination
3. 4nverterDAFE Mod'le
H. Fan Circ'it7. So$t Carge Circ'it
6. Co&%onent *ao't witin Cainet
. E&ergenc ;'n8. 4B" Circ'it St'd
5. CE Certi$ication
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1. Start Se='ence
AC
Contactor I r
I s
I t
ConverterSide Filter
R c Lc
R c Lc
R c Lc
Main SideFilter
R m Lm
R m Lm
R m Lm
Power Stage #3
V rn V sn V tn
Power Stage #2
V rn V sn V tn
Power Stage #1
V rn V sn V tn
R cf Ccf
4nverter #1
+oist#1
T,ω So$t9Carge
AC
Contactor
4nverter #2
+oist#2
T,ω
4nverter #3
"rolleD
Boo&
T,ω
4nverter #H
"raction
T,ω
630VACMains
1. 4n%'t %ower is a%%lied
2. Container Crane P*C closes so$t carge AC contactor
3. AFE and &otor drive controllers are %owered '% $ro&te ,C lin tro'g SMPS -switcing &ode %owers'%%l
H. AFE read signal is received te P*C and te &ain AC contactor is closed and so$t carge AC contactor iso%ened
7. AFE receives te r'n co&&and $ro& te P*C and tecontainer crane sste& is read $or 'se
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2. F'se Coordination
! F'se Coordination Basics ( 4solate te ad %ower &od'le.
( Mae s're to ave ealt %ower &od'les in circ'it.
! Strateg ( All te $'ses are selected $or te largest %ower &od'le. 4t is inde%endent o$ te drive
%ower si
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3. 4nverterDAFE Mod'le
Front View
Side View
ate ,rive Board
Power Card
Scaling Card
Mounted on t%e
"odule &or
standalone dri'es
and on M(CIC &or
parallel dri'es
4nverter and AFE
&od'les 'se te
sa&e ardwaree)ce%t $or te PC.
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H. Fan Circ'it
S
"3 8 0 9 7 0 0 VS i n g l e 9 % # a s e
2 3 0 V @A l % # a
, o o r F a n
+ e a t S i n F a n
2 3 0 V
A ' t o " r a n s $ o r & e r
C # o e o n l $ o r l a r g e $ a n
! Single9%ase -S and " %ase So'rce Voltage
! "e a'to trans$or&er is $or "7 -380 to 700V.
! "e door $an and eat sin $ans r'n togeter.
! "e coe is installed onl in E9$ra&e 700 and 760 drives.
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,oor Fan Strateg
! Module )a*out ( Master is in te &ost le$t %osition. ( 4nde%endent drive will e at te rigt o$ te Master and Slave
! Fan Control Module C%oice ( Master $or %arallel drive
( Parallel and 4nd co&ination or All ind ( *e$t and ;igt Ends! /o control $ro& te &iddle in case #3 ( Ass'&e tat 4nd1 and 4nd2 are +oistMaster and Slave co&ination.
2
1
3
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7. So$t Carge Circ'itD Sce&e
! Eac %ower &od'le as te so$t carge -SC circ'it e)ce%t $or te ,9$ra&e drives. ( # o$ SC circ'it is e='al to # o$ %ower &od'les.
( /o SC circ'it is wit ,9$ra&e drives.
! "e SC resistors are in %ositive and negative %ats. ( ;-SC neg is added to eli&inate te SC $'se lowing wen te inverter &otor is gro'nded.
! Eac cainet as one set o$ SC $'ses.
S C B o a r d
4 M
* C * F i l t e r
* & ? 2 5 ' +* c ? 1 0 0 ' +C $ ? 2 H 0 ' F; $ ? 0 . 0 5 N # &
* & * c
C $ ; $
P " C
; - s c % o s
; - s c n e g
A F E P o w e r M o d ' l e 4 n v P o w e r M o d ' l e
S C B o a r d a n d S C ; e s i s t o r s
- P o s i t i v e " e & %C o e $ $ ic i e n t ; e s i s t o r
Fault Current &ro"
egati'e Fault Voltage
IM Ground
Fault
+sc,pos- and PTC li"it t%e &ault
current &ro" t%e positi'e 'oltage.
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Eart Fa'lt -Alar& 1H
! ,etection Sce&e ( Calc'late a s'& o$ tree c'rrents.
( 4$ it e)ceeds te tresold generate te $a'lt&essage and sto% te o%eration.
! Fa'lt Cases1. en te $a'lt a%%ens d'ring te inverter
o%eration it sto%s i&&ediatel.
2. en te $a'lt a%%ens a$ter te inverter sto%s and
e$ore te sste& starts te SC carges te ,C's. 4t activates te AFE. en te inverter is t'rnedon te inverter so'ld detect te $a'lt i&&ediatel.
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6. Co&%onent *ao't witin Cainet
Fan S'%%l
Board -FSB
FSB F'se
So$t Carge
Board -SCB
and SC
;esistors
SC F'se
!T#
T%e &an 'oltagec%oice per
"odule is
s%i&ted to
reduce t%e &use
stress.
!T#
Pre'ent t%e spike
'oltage &ro"
going t%roug%.
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Magni$ied View o$ FSB and
SC Board
SC ;esistor
SC Board
FSB
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,9$ra&e ,rive Cainet
! 600&& Cainet
! 500A ,C F'se
! ;evisions ( ;e&oved te door $an and
associated trans$or&er.! "e ,9$ra&e drive internal
cooling is done wit te to%$an.
( Moved te FSB 'nder tecontrol card -CC %osition.,C F'ses
FSBCC
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. E&ergenc ;'n
! "e&%oraril red'ce te n'&er o$ %ower &od'les and r'n te drive wit a red'ced%ower.
( ( ;ed'ced Power Mode! Correct r'nning condition wit a li&ited %ower -;ated %ower divided a ratio o$ te &od'le cange
( 8 ( Power nit Set'%! Condition to disale te o%eration d'e to te &is&atc etween # o$ setting and # o$ act'al &od'les
connected
! Proced're ( Psical Canges
! 3 to 2 Power Mod'le Cange ( ,isconnect te %ower &od'le %sicall.
Be$ore start dis&o'nting &ae s're to ave te ,C ca%acitor discarged. ( Cange te HH9%in connector location in M,C4C. ( Mo'e /u$ rela* signal &ro" t%e new Master power "odule.
ote T%e door &an is run &ro" t%e original Master power "odule. Since it is di&&icult to reroute t%ewire &ro" t%e new Master1 t%e door &an is te"poraril* inoperati'e.
! 2 to 1 Power Mod'le Cange ( ,o te %rocesses aove. ( 4$ ;SH87 inter$ace is 'sed need to connect a s%ecial asse&l to #2 ter&inal at M,C4C. "e asse&l generates
te isolated 7V $or ;SH87 co&&'nication.
( P*C co&&and! Cange te %ara&eter setting $ro& Set'% #1 to Set'% #2. -Par. 0910
( /ote ;eview te P4 gains.
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8. 4B" Circ'it St'd
! 4B" ,esign ( 4B" circ'it is designed to
&aintain te over9voltage levelwitin its rating
( 4B" te&%erat're rise d'e tote worst r'nning condition iswitin its te&%erat're ca%ailit
( 4B" c'rrent is li&ited to itsailit. -4MAQ1 and 4MAQ2
! Co&%onents ( 4B" ( ,C Ca% ans ( Sn'er Ca% ( Sandwiced B's Asse&l to
Ca% Ban -B's1 ( Sandwiced B's Asse&l to
,C -B's2
C a % B a n 1
C a % B a n 2
, C
A C 2
4 B " 2
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