Danfoss MCI 25B Data sheet

Data sheet

CI-tronic™ Soft Start Motor Controller

Type MCI 25B with Brake

MCI 25B motor controller with brake is designed for soft starting and braking of 3 phase AC motors.

The digital controlled soft starter features accurate settings and several monitoring functions. Acceleration time and initial torque are along with the braking torque easily adjusted. During braking the MCI 25B will apply a DC current to all the windings of the motor, thus providing a powerful brake function. The automatic stop detection ensures a safe operation. For positioning applications the unique slow speed function can be applied.

The MCI 25B controller is typically applied on demanding braking applications such as saws, cranes, automatic doors, etc.

Features

y Adjustable acceleration time, 0 – 10 seconds

y Initial torque adjustable from 0 – 85%, with or

without kick start (break-away)

y Adjustable DC injection brake, 0 – 50 A DC

y Fast acting brake mode with automatic motor

ﬁeld reduction

y Automatic stop detection

y Universal control voltage 24 – 480 V AC/DC

y Slow speed function, 7.5% or 10% of nom.

speed

y SCR aux. contacts for external control of

by-pass, I-O and mechanical brake

y Automatic detection of missing phase(s)

y Automatic adaptation to 50/60 Hz

y Unlimited start and stop per hour

y IP 20 protection

y Compact DIN rail mountable design

y EN 60947-4-2

y CE, C-tick

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Data sheet | Soft Start Motor Controller, Type MCI 25B

Adjustments

Motor torque (voltage)

Ramp-up time 0 – 10 sec.

Danfoss

A37-217.20

Selection guide

Kick Start selectable

Slow speed

7.5% or 10%

Initial torque up to 85% of nom. torque

Braking torque 0 – 50 A

Operational

voltage

[V AC] [A] [kW/HP] [V AC/DC] [mm]

208 – 240 25 7.5/10 24 – 480 90 037N0061 380 – 480 25 1/15 25 – 480 90 037N0062

Motor

current

Motor power

Control voltage

Module

dimensions

Code no.

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Data sheet | Soft Start Motor Controller, Type MCI 25B

Technical data Control circuit speciﬁcations

Control voltage range 24 – 480 V AC/DC Pick-up voltage max. 20.4 V AC/DC Drop-out voltage min. 5 V AC/DC Max. control current for no operation 1 mA Control current / power max. 15 mA / 2 VA Response time max. 70 ms Ramp-up time Adjustable from 0 to 10 Sec. Brake current Adjustable from 0 to 50 A

Initial torque

SCR aux. contacts, voltage/current max. 24 – 480 V AC / 0.5 A (AC-14, AC-15) SCR aux. contacts, max. fuse 10 A gL/gG, I2t max. 72 A2s Design standard CE marked according to EN 60947-4-2 EMC immunity Meets requirements of EN 50082-1 and EN 50082-2

Output Speciﬁcations

Operational current max. (AC-3, AC-53a) 25 A Motor size at:

208 – 240 V AC 380 – 480 V AC

Leakage current max. 5 mA Minimum operational current 50 mA Overload relay trip class Class 10 Semiconductor protection fusing

Type 1 co-ordination Type 2 co-ordination I2t (t = 10 ms)

Rating index Slip ring motors: 25A: AC-52a: 4-13: 100-3000

Adjustable from 0 to 85 % of nominal torque with optional kick start

0.7 – 7.5 kW (1 – 10 HP) 1 – 11 kW (1.5 – 15 HP)

80 A gL/gG 6300 A2 S

Asynchronous motors: 25A: AC-53a: 8-3: 100-3000

Insulation

Rated insulation voltage, U Rated impulse withstand voltage, U Installation category III

imp

660 V AC 4 kV

Thermal Speciﬁcation

Power dissipation for continuous duty Pd max. 2 W/A Power dissipation for Intermittent duty Pd max. 2 W/A x Duty cycle Ambient temperature range -5 °C – 40 °C Cooling method Natural convection Mounting Vertical +/- 30 °C Max. ambient temperature with limited rating 60 °C, see derating for high temperatures in chart below Storage temp. range -20 °C – 80 °C Protection degree/pollution degree IP 20 / 3

Materials

Housing Self extinguishing PPO UL94V1 Heatsink Aluminum black anodized Base Electroplated steel

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Data sheet | Soft Start Motor Controller, Type MCI 25B

Functions

Control inputs

Operating mode selector, select slow speed and auxiliary contact function

Ramp up setting, accurately adjustable from 0 – 10 seconds

Initial torque setting, adjustable from 0 – 85%, with or without kick start

Brake torque setting, adjustable on a relative scale from 0 – 15

LED for status and error indication

Auxiliary contacts (SCR)

Functional diagram

Line voltage L1, L2, L3 Run command Slow speed command Brake command

Motor voltage T1, T2, T3 Brake on

Aux. contacts: 23-24 by-pass 13-14 I-O 13-14 ( M )

1. When line voltage is applied the brake will automatically stop a rotating motor.

2. The function of auxiliary contact 13-14 is selectable; “start - stop” or “mechanical brake”

Soft start function Ramp up

During ramp-up the controller will gradually increase the voltage to the motor until it reach full line voltage. The motor speed will depend on the actual load on the motor shaft. A motor with little or no load will reach full speed before the voltage has reached its maximum value.

The actual ramp time is digitally calculated and will not be inﬂuenced by other settings, net frequency or load variations.

Initial torque

The initial torque is used to set the initial starting voltage. This way it is possible to adapt the controller to an application requiring a higher starting torque. In some cases on application with very high break-away torque the initial torque can be combined with a kick start function. The kick start is a period of 200 ms where the motor receives full voltage.

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Data sheet | Soft Start Motor Controller, Type MCI 25B

Brake function Braking is achieved by injecting a DC current,

adjustable from 0 – 50 A, onto all the windings of the motor. The brake can be used on both star and delta connected motors, but is most eﬃcient if the motor is connected in star.

Adjustment

The actual braking torque is controlled indirectly by adjusting the braking voltage. The braking voltage can be set for 0 – 15. For small motors a relatively high braking voltage is necessary contrary to larger motors where a relatively low voltage is suﬃcient. For this reason the braking voltage must be adjusted to the actual application. Before starting up a new application set the Braking torque to 1. Increase incrementally until desired braking time is reached.

Automatic stop detection

When the brake function is applied the MCI-B will bring the motor to a stop before releasing the brake current.

Note: If a contactor is placed between motor and the MCI-B, do not open during braking as it can cause the contactor to fail.

If the motor does not stop within 30 seconds the DC brake will disengage and the controller will show a “brake failure” condition.

The automatic stop detection is accomplished by sensing the DC brake current on the motor, and as so the accuracy of the stop detection will depend on a correctly adjusted brake. The point of “no rotation” depends on the motor size and the brake voltage setting. If the motor voltage is set to low the brake will be switched oﬀ before the motor has come to a complete stop. However, if the brake voltage is set to high, out of detection range, it will not switch oﬀ the motor before the brake failure conditions occurs after 30 seconds.

Slow speed function The slow speed function is intended for short

time operation in applications where an exact positioning is needed, for example cranes. The function has two selectable slow speeds: 7.5% or 10% of nominal speed.

Auxiliary contacts The auxiliary contacts are made possible by

means of SCR technology and will only switch correctly on AC current.

Contact 13-14

The contact 13-14 is selectable for two diﬀerent functions; “I-O” or “Mechanical brake”. If the “I-O” is selected, the contact will be closed as long as a RUN command is given, see functional diagram

LED status indication

LED status indication:

The torque level will depend on the motor and selected slow speed, typically 25 – 40% of nominal torque. During slow speed the motor current will increase, typically 2 – 2.5 times the nominal current.

If “Mechanical brake” is selected, the contact will be closed as long as the motor is rotating. The “Mechanical brake” setting is intended for operating an external mechanical brake.

Contact 23-24

The contact 23-24 is intended for operating an external by-pass contactor. The contact will close when the controller is in steady state operation, see functional diagram.

IC.PD.C50.H3.02 | 5

Data sheet | Soft Start Motor Controller, Type MCI 25B

Wiring

Overload and short circuit protection

Run / brake command Slow speed command Forced brake command

MCI 25B

By-pass

I-O or mechanical brake

Common

Overload and short circuit protection is easily achieved by installing a circuit breaker on the line side of the motor controller. Select circuit breaker from the table according to motor full load current.

380 – 415 V AC

Type

CTI 25M

) Values based on let-through curves for appropriate circuit breaker

Motor full load current

[A] [kA]

4.0 – 6.3

6.3 – 10 10 – 16

14.5 – 20 18 – 25

Code number 037N0061 037N0062

Mains L1, L2, L3

Inputs (C, R, S, B)

Outputs (13/14, 23/24)

208 – 240 V AC 380 – 480 V AC

24 – 480 V AC/DC

24 – 480 V AC

max. 0.5 A

Be aware of the maxium prospective short circuit current breaking capacity. For further information please refer to data sheet for the circuit breaker.

Max. prospective short-circuit current Icc

100

1.8

1.5

24 – 480 V AC/DC

24 – 480 V AC

max. 0.5 A

Code no.Co-ordination 1)

047B3148 047B3149 047B3150 047B3151 047B3152

Dimensions mm (inches)

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Data sheet | Soft Start Motor Controller, Type MCI 25B

Operating at high temperatures

Operating on heavy loads

Overheat protection

Operation in temperatures from 40 °C up to 60 °C is possible if the power dissipation is limited

Ambient temperature Continuous operation

[°C] [A]

50 20 25 A with 80% duty cycle, max. on-time 15 min 60 15 25 A with 65% duty cycle, max. on-time 15 min

Load data is given for normal starts. If applied on heavy starts please derate according to table.

If required the controller can be protected against overheating by inserting a thermostat in the slot on the right-hand side of the controller.

Order: UP 62 thermostat 037N0050

either by reducing the current or by reducing the ON-time of the controller. Refer to table.

Duty-cycle rating

Overload relay trip class

10 (Light starts) 25

10 (Normal starts) 25

20 (Heavy starts) 20

30 (Very Heavy starts) 15

Max. current

[A]

For wiring connections see application examples.

Mounting instructions The controller is designed for vertical mounting.

If the controller is mounted horizontally the load current must be reduced by 50%.

The controller needs no side clearance.

Clearance between two vertical mounted controller must be minimum 80 mm (3.15”).

Clearance between controller and top and bottom walls must be minimum 30 mm (1.2”).

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37-218.20

Data sheet | Soft Start Motor Controller, Type MCI 25B

Application examples Overheat protection

Example 1

The thermostat can be connected in series with the control input of the Motor Controller. When the temperature of the heat sink exceeds 100 °C the Motor Controller will be switched OFF.

Note: when the temp. has dropped approx. 30 °C the Controller will automatically be switched ON again. This is not acceptable in some applications

Example 2

The thermostat is connected in series with the control circuit of the main contactor. When the temp. of the heat sink exceeds 100 °C the main contactor will be switched OFF. This circuit requires manual reset to restart the motor.

Standard start – brake wiring

If only the soft start and braking function is required it is easily achieved by wiring the control voltage to “R”. When control voltage is applied the controller will begin the soft start procedure. To brake the load the control voltage is disconnected.

Danfoss circuit breaker CTI 25M is in this example providing overload and short circuit protection.

MCI 25B

Danfoss CTI 25M

Danfoss

24 – 480 V AC

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A37-220.20

Application examples

(continued)

Direct wired start-stop with bypass

By wiring the auxiliary contact function 13-14 into the control circuit start and stop can be achieved by means of push buttons.

Note that the operating mode selector must be set for “I-0” control.

Auxiliary contact 23-24 is used to control and external by-pass contactor during steady state operation.

Danfoss circuit breaker CTI 25M is in this example providing overload and short circuit protection.

Wired for control of mechanical brake and bypass

The auxiliary contact function 13-14 is in this example used to control a mechanical brake. The brake is released when the controller is applying voltage to the motor.

MCI 25B

Danfoss CTI 25M

24 – 480 V AC

Danfoss

A37-219.20

Danfoss

Note that the operating mode selector must be set for “mechanical brake” control.

Auxiliary contact 23-24 is used to control an external by-pass contactor during steady state operation.

Danfoss circuit breaker CTI 25M is in this example providing overload and short circuit protection.

MCI 25B

24 – 480 V AC

Max. 0.5 A

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Danfoss MCI 25B Data sheet

Specifications and Main Features

Frequently Asked Questions

User Manual