AFE Basics Danfoss

AFE Basics
| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 1
1.2 MW AFE
The AFE consists of three power modules in
parallel.
Power Stage #1
The AFE and inverter have the same hardware

except for the PC firmware.
The AFE uses the AFE SW.
AC
Contactor
630VAC
Mains
Main Side
Filter
Converter
Side Filter
Vrn
Lm
Rc
Lc
Ir
Rm
Lm
Rc
Lc
Is
Lc
It
Lm
Rc
Ccf
Vtn
Power Stage #2
Rm
Rm
Vsn
Vrn
Vsn
Vtn
Rcf
Power Stage #3
Vrn
Vsn
Vtn
AFE Benefits
Low Harmonics and low THD (Total Harmonic

Distortion)
No brake circuit and brake resistors
Constant DC voltage
No brake resistor cooling space is needed.

Good for the flux control
Multi drive rigid operation
Each drives will be independent of each other

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

selected
L C L F ilt e r
AFE
630V
Selection
8-10% Voltage Drop through

LCL and Transformer
IN V
975V
690V Motor
Start
AFE Control Basics

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

Vdc goes up.
IGBT Gating
L C L F ilte r
Motoring
Vdc
AFE
IN V
Measure Vdc
M a in s
Braking
Simple Circuit Diagram
Point of PF
Control
V a fe = V 0 - ( R a + jw L a ) * Ia
Ia
M a in s
AFE
V0
Lr
La (=Lr+Lm+Lc) for
power transfer at
fundamental frequency
Lm
Lc
L r:
M a in s T r a n s fo r m e r
in d u c ta n c e
Cf
L a = L r+ L m + L c
R a = R r+ R m + R c
L C L F il t e r
Vdc
V a fe
Lc and Cf is for low

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

direction is for motoring
The power factor is
controlled at the primary
side of the transformer.
Ignore Cf for
Power Flow
Calculation
Vector Diagram
V e c to r D ia g r a m
G e n e r a t io n
( I n v e r t e r B r a k in g )
Ia= Iq+Id
T h e r a d iu s o f V a fe ( m a x ) :
V d c /S Q R T (2 )* M p w m
R a * Ia
Id ref =0 (Pf=0)
Vafe Voltage Limit Factors
The mains voltage level
V a fe
in b r a k in g
DC voltage level
V0
jw L a * Ia
-10 to +5% of 630V
Vafe max <Vdc/sq(2)*Kpwm
Total Inductance
8 to 10% pu
Ia
- jw L a * Ia
PU base:
V a fe
in m o to r in g
630V and 1.2MW
Warning Message:
L o a d in g
( I n v e r t e r M o to r in g )
-R 1 * Ia
V a fe = V 0 - ( R a + jw L a ) * Ia
* W64 (Voltage Limit) Vafe magnitude is

at its limit.
AFE Control Block Diagram
AFE Module and

LCL Filter
Vector Control Block
The program is implemented in DSP (Digital Signal Processor).

DQ Control Block
Q Axis for Real Power
DC Voltage Regulation
PI Control
P gain: Par. 7-62 (Vary)
DC capacitance (Par. 7-60) influences

the P gain.
I time: Par. 7-63 (Default 5ms)
D Axis for Reactive Power
Zero reference
LCL Filter
LCL Filter Design
Function
Work for the power flow.
The total inductance is 8 to 10% pu.
Reduce the harmonics.
Lc and Cf is the low pass filter with 500 to 700Hz

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

Converter Side Vcap/Vconv, fres = 728.281Hz
10
Magnitude (dB)
0
-10
-20
-30
Phase (deg)
-40
0
-45
-90
-135
-180
10
Source
Impedance
10
Main Side
Frequency (Hz)
Filter
10
Converter
Side Filter
Ern
Rt
Lt
Rm
Lm
Rc
Lc
Esn
Rt
Lt
Rm
Lm
Rc
Lc
Etn
Rt
Lt
Rm
Lm
Rc
Lc
Ccf
Rcf
10
Ir
Design of the LCL filter is to

provided differential mode
filtering of the switching
frequency.
Desired resonance frequency is
between the current regulator
bandwidth and the switching
frequency of the AFE.
(I_BW<Fres<Fsw)
Damping resistors control the
amplitude of the filter
resonance. The system level
trade off is losses versus
damping.
Typical Drive Run Data
630VAC Mains Voltage
The plot on the left is the mains voltage before the

active front-end is turned on.
The plot on the right is the mains voltage with the
active front-end running with load.
1.2 MW AFE Current Steady-State

Transient imbalance is <8% peak
and <3% RMS (~30Amps)
1.2 MW AFE Current Steady-State
AFE Current - Motoring
Phase Currents ~900 Arms (~700kW Motoring)

DC Link Voltage Ripple ~3%
Mains Current - Motoring
Phase Currents ~900 Arms (~700kW Motoring)

Current THD <4%
DC Link Voltage Ripple ~3%
Mains Current / AFE Current - Motoring
Comparison of the active front-end current before and after the

LCL filter
AFE Transient from Generating to Motoring

Power flowing to the
grid (-430kW)
Power flowing from the

grid (+465kW)
00:13:11.20 42348 1
1.250 kAMP
Mains Input
Currents
R1
Transient time
~120msec
Voltage
regulation is
~4%
undershoot
(933 Vdc)
-1.250 kAMP
1.250 kAMP
S1
-1.250 kAMP
1.250 kAMP
T1
-1.250 kAMP
1.250 kAMP
Hoist#1 Motor
Currents
U1
-1.250 kAMP
1.250 kAMP
V1
-1.250 kAMP
1.250 kAMP
W1
-1.250 kAMP
DC
Link
Motoring
Generating
1.050 kVolt
VDC_ 2
900.0 Volt
13:10.811
100.0 ms/div
13:11.811
AFE Transient from Motoring to Generating

Power flowing off the
grid (+465kW)
Power flowing to the

grid (-430kW)
1.250 kAMP
Mai ns Input
Currents
R1
Transient time
~120msec
Voltage
regulation is
~4%
overshoot
(1008 Vdc)
-1.250 kAMP
1.250 kAMP
S1
-1.250 kAMP
1.250 kAMP
T1
-1.250 kAMP
1.250 kAMP
Hoist#1 Motor
Currents
U1
-1.250 kAMP
1.250 kAMP
V1
-1.250 kAMP
1.250 kAMP
W1
-1.250 kAMP
Motoring
DC
Link
1.050 kVolt
Generating
V DC_2
900.0 Volt
12:55.796
100.0 ms /div
12:56.796
Drive Designs
1. Drive Configuration
1.
2.
3.
4.
Standalone and Parallel Modules Cabinet

VSynch
MDCIC
Block Diagrams
1.
2.
3.
4.
5.
3 parallel-connected drive
3 independent drives
2 parallel-connected drive and 1 standalone drive
Inverter module
D-frame drive cabinet wiring
1.
Drive Configuration
(Standalone and Parallel Drive)
Standalone Drive
CC
Parallel Drives
MDCIC
CC
Mod1
LCP
Mod2
LCP
M1
S1
S2
Stand Alone Drive Block Diagram
Standalone T7 Drive (<560kW)

PC Functions
CC Functions
Local controls Fan control, Rec Control (not for AFE based drives)
Drive control Flux control/ AFE

control
Data acquisition Current feedback, IGBT NTC reading
Interface to PLC, Encoder, etc.
EEPROM (Basics)
Current protection Imax1 (Move to MDCIC for parallel drives)
Overall protection Imax2
M o d u le
IG B T 1
LC P
C o n tro l C a rd
(C C )
P o w e r C a rd
(P C )
G a te D r iv e
(G D )
IG B T 2
S c a lin g C a r d
IG B T 3
Parallel Drive Block Diagram -MDCIC
CAN bus communication
The module identifier is based on the 44-pin connector terminal location.
MDCIC (Multi Drive Control Interface Card) Functions
Sum up three current signals and its sum to CC

Imax1 detection and current balance detection
Distribute the gate signals into three modules.
Vsync detection
M o d u le L e ft
MDCIC
S c a lin g C a r d
LCP
C o n tr o l C a rd
(C C )
P o w e r C a rd
(P C )
3
44
1
2
Warning Messages
IG B T 1 - 3
M a s te r
44
44
G a te D r iv e
(G D )
M o d u le M id d le
P o w e r C a rd
(P C )
G a te D r iv e
(G D )
IG B T 1 - 3
S la v e 1
A70 (Illegal FC Config)
M o d u le R ig h t
Possible causes: Wrong CC (AFE vs INV), Wrong PC (AFE and INV

PC are different), Wrong EEPROM among the modules
A79 (Illegal Power Section Config)

Possible Causes: Mismatch between the setting and # of modules
connected such as improper MDCIC connector connection
P o w e r C a rd
(P C )
G a te D r iv e
(G D )
IG B T 1 - 3
S la v e 2
2. VSynch (Voltage Synchronization)
Vsync circuit is a part of MDCIC

board.
Function
Measure the mains voltage, in

front of the LCL filter.
Detect the zero crossing.
Send the zero crossing signal to
CC.
Control in CC
O p t o c o u p le r
Is o la tio n
V o lta g e D iv id e r
Z e ro C ro s s
D e te c to r
It is only used once.
Generate Vafe based on the

mains voltage and frequency
information (Par. 40-00 and 4001).
Fault investigation, if AFE fails at

the start up
L C L F il t e r
Common Alarms:
CC
DSP
Synchronize the Vafe according to

the zero crossing signal.
V s y n c C ir c u it
(A p a rt o f M D C IC )
Over Current (A13)

Output Frequency Limit (W62)
Output Voltage Limit (W??)
AFE
IN V
Questions to be investigated
1.
2.
3.
Are RST connected correctly?

Are the parameter setting (40-00
and 40-01) correct?
Are PI gains correct?
3. MDCIC Board
To CC
Scaling Card Terminals
Test Connector
Features:
PC terminals
Scaling terminals 1 to
4 corresponding to
PC terminals.
Vsync circuit
1 (M)
3 (S2)
Master provides CC
power, Vdc
measurement, and
EEPROM
2 (S1)
To PC
4 (S3)
#1 for Master
No skip
Can bus ID is
associated with the
PC terminal.
Note: Needs the correct

EEPROM in slaves.
RS485 Isolated 5V
voltage from 2nd PC
connector
Current scale change
Vsync Connector
4. Block Diagrams
Block Diagrams within Cabinet
3 Parallel-Connected Drive
3 Independent Drives
2 Parallel-Connected Drive and 1 Standalone
Drive
Inverter Module
D-frame Drive Cabinet Wiring

1. 3 Parallel-Connected Drive
LCP
CC
MDCIC
Vsync
Aux Relay
Soft
Charge
DC In
T5 Auto
Transformer
Door Fan
Fan Source
AC Out
2. 3 Independent Drives
3. 2 Parallel Drive and One Standalone Drive
4. Inverter/AFE Module
5. D-frame Drive Cabinet
Design Basics
AFE Basics Product

Design Details
1.
2.
3.
4.
5.
6.
7.
8.
9.
Start Sequence
Fuse Coordination
Inverter/AFE Module
Fan Circuit
Soft Charge Circuit
Component Layout within Cabinet
Emergency Run
IGBT Circuit Study
CE Certification
1. Start Sequence
Power Stage #1
Inverter #1
Hoist#1
Soft-Charge
Vrn
AC
Contactor
AC
Contactor
630VAC
Mains
Main Side
Filter
Converter
Side Filter
Lm
Rc
Lc
Ir
Rm
Lm
Rc
Lc
Is
Rm
Lm
Rc
Lc
It
T,
Vtn
Power Stage #2
Rm
Ccf
Vsn
Inverter #2
Hoist#2
Vrn
Vsn
T,
Vtn
Rcf
Power Stage #3
1. Input power is applied

2. Container Crane PLC closes soft charge AC contactor
3. AFE and motor drive controllers are powered up from
the DC link through SMPS (switching mode power
supply)
4. AFE ready signal is received by the PLC and the main
AC contactor is closed and soft charge AC contactor is
opened
Inverter #3
Trolley/
Boom
Vrn
Vsn
T,
Vtn
Inverter #4
Traction
T,
5. AFE receives the run command from the PLC and the
container crane system is ready for use
2. Fuse Coordination
Fuse Coordination Basics
Isolate the bad power module.

Make sure to have healthy power modules in circuit.
Strategy
All the fuses are selected for the largest power module. It is independent of the drive
power size.
Power module Failure Example
Must NOT open
Must open
Must NOT Open
3. Inverter/AFE Module
Front View
Side View
Inverter and AFE
modules use the
same hardware
except for the PC.
Power Card
Gate Drive Board
Scaling Card
Mounted on the
module for
standalone drives
and on MDCIC for
parallel drives
4. Fan Circuit
Single-phase (S and T phase) Source Voltage

The auto transformer is for T5 (380 to 500V).
The door fan and heat sink fans run together.
The choke is installed only in E-frame 500 and 560kW drives.
230V+
A lp h a
D oor Fan
230V
C h o k e o n ly
fo r la r g e fa n
T
380 - 500V
S in g le - p h a s e
A u to T ra n s fo rm e r
H e a t S in k F a n
Door Fan Strategy
Module Layout
Master is in the most left position.

Independent drive will be at the right of the Master and Slave
Fan Control Module Choice
Master for parallel drive

Parallel and Ind combination or All ind Left and Right Ends
No control from the middle in case #3 Assume that Ind1 and Ind2 are Hoist
Master and Slave combination.
2
1
3
5. Soft Charge Circuit/ Scheme
Each power module has the soft charge (SC) circuit except for the D-frame drives.
The SC resistors are in positive and negative paths.
# of SC circuit is equal to # of power modules.

No SC circuit is with D-frame drives.
R(SC neg) is added to eliminate the SC fuse blowing when the inverter motor is grounded.
Each cabinet has one set of SC fuses.

S C B o a r d a n d S C R e s is to r s
S C B o a rd
R (s c p o s )
Rsc(pos) and PTC limit the fault

current from the positive voltage.
PTC
( P o s it iv e T e m p
C o e f f i c i e n t R e s is t o r )
Fault Current from

Negative Fault Voltage
R (s c n e g )
IM Ground
Fault
L C L F ilt e r
Lm
Lc
IM
Rf Cf
Lm =29uH
Lc=100uH
C f= 2 4 0 u F
R f= 0 .0 9 O h m
A F E P o w e r M o d u le
I n v P o w e r M o d u le
Earth Fault (Alarm 14)
Detection Scheme
Calculate a sum of three currents.

If it exceeds the threshold, generate the fault
message and stop the operation.
Fault Cases
1. When the fault happens during the inverter
operation, it stops immediately.
2. When the fault happens after the inverter stops and
before the system starts, the SC charges the DC
bus. It activates the AFE. When the inverter is turned
on, the inverter should detect the fault immediately.
6. Component Layout within Cabinet

Fan Supply
Board (FSB)
NOTE:
Prevent the spike
voltage from
going through.
Soft Charge
Board (SCB)
and SC
Resistors
FSB Fuse
NOTE:
The fan voltage
choice per
module is
shifted to
reduce the fuse
stress.
SC Fuse
Magnified View of FSB and

SC Board
FSB
SC Board
SC Resistor
D-frame Drive Cabinet
CC
FSB
600mm Cabinet
900A DC Fuse
Revisions
Removed the door fan and

associated transformer.
DC Fuses
The D-frame drive internal

cooling is done with the top
fan.
Moved the FSB under the

control card (CC) position.
7. Emergency Run
Temporarily reduce the number of power modules and run the drive with a reduced
power.
W77 Reduced Power Mode
W78 Power Unit Setup
Correct running condition with a limited power (Rated power divided by a ratio of the module change)
Condition to disable the operation due to the mismatch between # of setting and # of actual modules
connected
Procedure
Physical Changes
3 to 2 Power Module Change
2 to 1 Power Module Change
Disconnect the power module physically.
Before start dismounting, make sure to have the DC capacitor discharged.

Change the 44-pin connector location in MDCIC.
Move Aux relay signal from the new Master power module.
Note: The door fan is run from the original Master power module. Since it is difficult to re-route the
wire from the new Master, the door fan is temporarily inoperative.
Do the processes above.
If RS485 interface is used, need to connect a special assembly to #2 terminal at MDCIC. The assembly generates
the isolated 5V for RS485 communication.
PLC command
Change the parameter setting from Setup #1 to Setup #2. (Par. 0-10)
Note: Review the PI gains.
8. IGBT Circuit Study
IGBT Design
IGBT circuit is designed to

maintain the over-voltage level
within its rating
IGBT temperature rise due to
the worst running condition is
within its temperature capability
IGBT current is limited to its
ability. (IMAX1 and IMAX2)
Snubber C ap
6* 1uF
in e a c h te r m in a ls
IG B T 1
AC1
Cap Bank 1
IG B T 2
B us1
AC2
Components
IGBT
DC Cap banks
Snubber Cap
Sandwiched Bus Assembly to
Cap Bank (Bus1)
Sandwiched Bus Assembly to
DC (Bus2)
IG B T 3
Cap Bank 2
T o ta l C a p a c ita n c e
1 1 .2 m F fo r
P 4 0 0 to P 5 6 0
AC3
B us2
DC
1. IT Mains Crane System
Drive Operation with One-point and Two-point Ground Fault

HF (High Frequency) Board
Noise path especially for IGBT switching noise containment
Iso-meter Function with the AFE Drive

AFE302P800T7
P D T e s t S e tu p
HF Board
AFE
L B -3 0 2 P 5 6 0 T 7
L C L F ilte r
Lm
Lc
AFE
IM
2 .5 M V A 6 3 0 V
Rf Cf
1500hp
690V
Lm =29uH
Lc=100uH
C f= 2 4 0 u F
R f= 0 .0 9 O h m
H F B o a rd
F a u lt
B e n d e r Is o m e te r
A 1 /+ A 1 /-
L1
L2
AK
KE
AK160
T1
T2
R1 R2 F1
F2
M + M - A
IR D H 2 7 5
11
12
14
21
22
24
AG H150W

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What are the main components of an AFE drive?

What are the main components of an AFE drive?

What are some benefits of using an AFE drive?

What are some benefits of using an AFE drive?

AFE Basics

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

The AFE and inverter have the same hardware

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

Low Harmonics and low THD (Total Harmonic

No brake resistor cooling space is needed.

Multi drive rigid operation

Each drives will be independent of each other

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

How the mains voltage is

8-10% Voltage Drop through

AFE Control Basics

Vdc goes down.

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

Simple Circuit Diagram

Lc and Cf is for low

The positive current

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

Vafe Voltage Limit Factors

The mains voltage level

-10 to +5% of 630V

Vafe max <Vdc/sq(2)*Kpwm

630V and 1.2MW

* W64 (Voltage Limit) Vafe magnitude is

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

AFE Control Block Diagram

AFE Module and

Vector Control Block

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

Q Axis for Real Power

P gain: Par. 7-62 (Vary)

DC capacitance (Par. 7-60) influences

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

D Axis for Reactive Power

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

| Confidential/Property of Danfoss Drives A/S | Saturday 21 May 2016 | 10

LCL Filter Design

The total inductance is 8 to 10% pu.

Reduce the harmonics.

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

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

LCL Filter - Resonance Frequency

Design of the LCL filter is to

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

Typical Drive Run Data

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

630VAC Mains Voltage

The plot on the left is the mains voltage before the

1.2 MW AFE Current Steady-State

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

1.2 MW AFE Current Steady-State

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

AFE Current - Motoring

Phase Currents ~900 Arms (~700kW Motoring)

Mains Current - Motoring