Danfoss Electronics MCD 200 Design Guide

Contents
MCD 200 Design Guide
MCD 200 Series Overview
Description ............................................................................................................. 3
Ratings ................................................................................................................... 4
General Technical Data ........................................................................................... 5
Mechanical Installation ........................................................................................... 7
Cable Size .............................................................................................................. 9
Semiconductor Fuses ............................................................................................ 9
Frequently Asked Questions ................................................................................... 10
.......................................................................... 3
MCD 201 .............................................................................................................. 12
Electrical Schematic ............................................................................................... 12
Control Circuits ...................................................................................................... 13
Functionality ........................................................................................................... 13
Indication ............................................................................................................... 14
Fault Finding ........................................................................................................... 14
MCD 202 .............................................................................................................. 15
Electrical Schematic ............................................................................................... 15
Control Circuits ...................................................................................................... 15
Functionality ........................................................................................................... 16
Motor Thermistor Protection ................................................................................... 18
Indication ............................................................................................................... 18
Fault Finding ........................................................................................................... 18
Accessories ....................................................................................................... 19
Overview ................................................................................................................ 19
MCD 200 Remote Operator ................................................................................... 19
MCD 200 Modbus Module ..................................................................................... 19
MCD 200 Profibus Module ..................................................................................... 19
MCD 200 DeviceNet Module .................................................................................. 19
MCD 200 AS-i Module ........................................................................................... 19
MCD PC Software .................................................................................................. 19
Soft Start Ap plication Guide ..................................................................... 21
Reduced Voltage Starting ....................................................................................... 21
Types of Soft Start Control ............................................................................. ........ 22
Understanding Soft Starter Ratings ........................................................................ 22
Model Selection ..................................................................................................... 23
Typical Applications ................................................................................................ 23
Power Factor Correction ........................................................................................ 24
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1
Warnings
MCD 200 Design Guide
High Voltage Warning
The MCD 200 contains dangerous voltages when co nnected to line voltage. Only a
competent electrician should carry out the electrical installation. Improper instal lation of the motor or the MCD 200 may cause equipment failure, serious injury or death. Follow this manual, National Electrical Code (NEC®) and local safety codes.
Safety Regulations
1. The soft starter must be disconnected from the
mains if repair work is to be carried out.
It is the responsibilit y of the user or
the person installing the MCD 200 to
provide proper grounding and branch circuit protection according to the National Electrical Code (NEC®) and local safety codes.
Warning Against Unintended Start
1. The motor can be brought to a stop by means
of digital or bus commands while the soft starter is connected to the mains. If personal safety considerations make it necessary to ensure that no unintended start occurs, stop functions are not sufficient.
2. A motor that has been stopped may start if
faults occur in the electronics of the soft starter, or a temporary fault in the supply mains or the motor connection ceases.
correction, if used, must be connected on the mains side of the soft starter.
2. Do not apply incorrect voltages to the MCD 200 control inputs.
Electrostatic Precaution: Electrostatic discharge (E SD). Many electronic
components are sensitive to static electricity. Voltages so low that they cannot b e felt, seen o r heard, can reduce the life, affect performance, or completely destroy sensitive electronic co mponents. When performing service, proper ESD equipment should be used to prevent possible damage from occurring.
these
Symbols Used in this Manual
When reading this manual you will come across different symbols that require special attention. The symbols used are the following:
NB!:
Indicates something to be noted by the reader
Indicates a general warning
Indicates a high voltage warning
Avoiding Soft Starter D amage
Please read and follow all instructions in this manual. Additionally, take special note of the following:
1. Do not connect power factor correction capacitors to the soft starter output. Static power factor
2
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MCD 200 Series Overview
Description
The Danfoss MCD 200 Soft Starter series comprises two separate ranges:
MCD 201
MCD 202
MCD 201 and MCD 202 soft starters share a common power and mechanical design, but offer different levels of functionality. MCD 201 soft starters provide TVR (Timed Voltage Ramp) starting and stopping control and are designed for use with an external motor protection device. MCD 202 soft starters provide Current Limit starting control, TVR soft stop and include a range of motor protection functions.
NB!:
This manual makes reference to MCD 200, MCD 201 and MCD 202. The MCD
200 designation is used when referring to characteristics common to both the MCD 201 and MCD 202 ranges. In all other cases the text refers to the specific range MCD 201 or MCD 202.
MCD 200 Design Guide
Overview
MCD 200 Series
MCD 200 soft starters include an integral bypass function that bypasses the soft starter SCRs during run. This minimises heat dissipation during run and makes the MCD 200 suitable for installation within non-ventilated enclosures without th for an external bypass contactor.
Ordering Type Code
e need
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3
Ratings
MCD 200 Design Guide
MCD 200 Model
Continuous Ratings (Internally bypassed)
@ 40 °C Ambient Temperature, <1000 metres
Normal Heavy
007 18 A: AC53b 4-6:354 17 A: AC53b 4-20:340 015 34 A: AC53b 4-6:354 30 A: AC53b 4-20:340 018 42 A: AC53b 4-6:354 36 A: AC53b 4-20:340 022 48 A: AC53b 4-6:354 40 A: AC53b 4-20:340 030 60 A: AC53b 4-6:354 49 A: AC53b 4-20:340 037 75 A: AC53b 4-6:594 65 A: AC53b 4-20:580 045 85 A: AC53b 4-6:594 73 A: AC53b 4-20:580 055 100 A: AC53b 4-6:594 96 A: AC53b 4-20:580 075 140 A: AC53b 4-6:594 120 A: AC53b 4-20:580 090 170 A: AC53b 4-6:594 142 A: AC53b 4-20:580 110 200 A: AC53b 4-6:594 165 A: AC53b 4-20:580
MCD 200 Model
Continuous Ratings (Internally bypassed)
@ 50 °C Ambient Temperature, <1000 metres
Normal Heavy
007 17 A: AC53b 4-6:354 15 A: AC53b 4-20:340 015 32 A: AC53b 4-6:354 28 A: AC53b 4-20:340 018 40 A: AC53b 4-6:354 33 A: AC53b 4-20:340 022 44 A: AC53b 4-6:354 36 A: AC53b 4-20:340 030 55 A: AC53b 4-6:354 45 A: AC53b 4-20:340 037 68 A: AC53b 4-6:594 59 A: AC53b 4-20:580 045 78 A: AC53b 4-6:594 67 A: AC53b 4-20:580 055 100 A: AC53b 4-6:594 87 A: AC53b 4-20:580 075 133 A: AC53b 4-6:594 110 A:: AC53b 4-20:580 090 157 A: AC53b 4-6:594 130 A: AC53b 4-20:580 110 186 A: AC53b 4-6:594 152 A: AC53b 4-20:580
Contact Danfoss for other ratings.
Example
For 22 kW model: 48 A: AC53b: 4-6:354
48 A: Starter current rating.
AC53b: Load category for soft starters
with SCRs bypassed during run.
4-6: 400% start current for 6
seconds.
354: 354 seconds between the
end of one start to the beginning of the next start (i.e. 10 starts per ho ur).
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MCD 200 Design Guide
General Technical Data
Mains Supply (L1, L2, L3):
MCD 200-xxx-T4-xxx .............................................................................. 3 x 200 VAC ~ 440 VAC (+10% / - 15%)
MCD 200-xxx-T6-xxx .............................................................................. 3 x 200 VAC ~ 575 VAC (+10% / - 15%)
Supply frequency (at start) ................................................................................................................ 45 Hz - 66 Hz
Control Supply (A1, A2, A3):
MCD 200-xxx-xx-CV1 .......................................................................................................... 24 VAC/VDC (± 20%)
MCD 200- xxx-xx-CV3 .......................................... 110-240 VAC (+10% / - 15%) or 380-440 VAC (+10% / - 15%)
Control Inputs
Start Terminal N1 ............. ....................................................................................... Normally Open, 300 VAC max.
Stop Terminal N2 ............. ..................................................................................... Normally Closed, 300 VAC max.
Relay Outputs
Main Contactor (Terminals 13 & 14) ................................................................................................ Normally Open
Main Contactor (Terminals 13 & 14) .................................................... 6 A, 30 VDC resistive / 2 A, 400 VAC, AC11
Programmable Relay (Terminals 23 & 24) ...................................... .................................................. Normally Open
Programmable Relay (Terminals 23 & 24) ............................................ 6 A, 30 VDC resistive / 2 A, 400 VAC, AC 11
Environmental
Degree of protection MCD 200-007 to MCD 200-055 .................................................................................... IP20
Degree of protection MCD 200-075 to MCD 200-110 .................................................................................... IP00
Operating Temperatures ............................................................................................................... -10 °C / + 60 °C
Humidity ................................................................................................................... 5% to 95% Relative Humidity
Pollution Degree ........................................................................................................................ Pollution Degree 3
Vibration ................................................................................................................... IEC 60068 Test Fc Sinusoidal
Vibration ...................................................................................................... 4 Hz - 13.2 Hz: ± 1 mm displacement
Vibration ........................................................................................................................ 13.2 Hz - 100 Hz: ± 0.7 g
Overview
MCD 200 Series
EMC Emission
Equipment class (EMC) ................................................................. ............................................................. . Class A
Conducted radio frequency emission ................................................................ 0.15 MHz - 0.5 MHz: < 90 dB (µV)
Conducted radio frequency emission ............................................. ........................ 0.5 MHz - 5 MHz: < 76 dB (µV)
Conducted radio frequency emission ............................................. ....................... 5 MHz - 30 MHz: 80-60 dB (µV)
Radiated radio frequency emission ................................................................. 30 MHz - 230 MHz: < 30 dB (µV/m)
Radiated radio frequency emission ............................................................. 230 MH z - 1000 MHz: < 37 dB (µV/m)
This product has been designed for Class A equipment. Use of the product in domestic environments may cause radio interference, in which case the user may be required to employ additional mitigation methods.
EMC Immunity
Electrostatic discharge .......................................................................... 4 kV contact discharge, 8 kV air discharge
Radio frequency electromagnetic field ............................................................. 0.15 MHz - 1000 MHz: 140 dB (µV)
Rated impulse withstand voltage (Fast transients 5/50 ns) ............................................................ 2 kV line to earth
Rated insulation voltage (Surges 1.2/50 µs – 8/20 ms) ........................................ 2 kV line to earth, 1 kV line to line
Voltage dip and short time interruption ................................................................. 100 ms (at 40% nominal voltage)
Short Circuit
Rated short-circuit current MCD 200-007 to MCD 200-037 ............................................................................ 5 kA
Rated short-circuit current MCD 200-045 to MCD 200-110 .......................................................................... 10 kA
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5
MCD 200 Design Guide
Heat Dissipation
During Start ................................................................................................................................. 3 watts / ampere
During Run .............................................................................................................................................. < 4 watts
Standards Approvals
C ................................................................................................................................................. IEC 60947-4-2
UL / C-UL .................................................................................................................................................... UL508
CE .................................................................................................................................................. IEC 60947-4-2
CCC ................................................................................................................................................... GB 14048.6
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Mechanical Installation
1L13L25L3
1L13L25L3
50 (1.97)
1L13L25L3
MCD 200 Design Guide
1L13L25L3
1 L1 3 L2 5 L3
177HA201.11
2T14T26T3
2T14T26T3
2T14T26T3
2T14T26T3
100 (3.93)
1L13L25L3
2T14T26T3
50 (1.97)
1L13L25L3
MCD 200 FLC * 0.85
2T14T26T3
mm (inch)
MCD 200 Din Rail Foot Mounting
MCD 200-007 ~ MCD 200-030 30 mm Yes MCD 200-037 ~ MCD 200-110 Not available Yes
Dimensions and Weights
mm (inch)
MCD 201-007 ~ MCD 201-030 (2.2 kg / 4.8 lb)
MCD 202-007 ~ MCD 202-030 (2.4 kg / 5.3 lb)
98 (3.86) 165 (6.50)
82 (3.23)
2T14T26T3
Overview
MCD 200 Series
177HA242.11
23
23
(0.9)
(0.9)
MG.17.C2.02 - V LT is a registered Danfoss trademark
188 (7.40)
203 (7.99)
90.5 (3.56)
55 (2.17)
C
7
MCD 200 Design Guide
MCD 201-037 ~ MCD 201-055 (4.0 kg / 8.8 lb)
145 (5.71) 193 (7.60)
124 (4.88)
177HA243.11
MCD 202-037 ~ MCD 202-055 (4.3 kg / 9.5 lb)
196 (7.71)
215 (8.46)
110.5 (4.35)
37
37
(1.46)
(1.46)
MCD 201-075 ~ M CD 201-110 (6.1 kg / 13.5 lb)
202 (7.95) 214 (8.43)
160 (6.30)
177HA244.11
MCD 202-075 ~ MCD 202-110 (6.8 kg / 15.0 lb)
204 (8.03)
240 (9.45)
114.5 (4.5)
51
51
(2.0)
(2.0)
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Cable Size
MCD 200 Design Guide
MCD 200-007 ~ MCD 200-030
10 - 35 (8 - 2)
10 - 35 (8 - 2)
Torx (T20) 3 - 5 Nm.
2.2 - 3.7 ft-lb.
7 mm 3 - 5 Nm
2.2 - 3.7 ft-lb
14
(0.55)
mm (inch) mm (inch)
75ºC W ire. Use copper conductors only.
Semiconductor Fuses
Semiconductor fuses may be used with the MCD 200 soft starters. Use of semiconductor fuses will provide Type 2 coordination and reduce the potential of SCR damage due to transient overload currents and short circuits. MCD 200 soft starters have been tested t achieve Type 2 coordination with semiconductor fuses.
mm2 (AWG)
MCD 200-037 ~ MCD 200-055
25 - 50 (4 - 1/0)
25 - 50 (4 - 1/0)
Torx (T20) 4 - 6 Nm.
2.9 - 4.4 ft-lb.
7 mm 4 - 6 Nm
2.9 - 4.4 ft-lb
o
mm2 (AWG)
MCD 200-075 ~ MCD 200-110
N.A.
26
14
(0.55)
mm (inch) mm (inch)
(1.02)
N.A.
N.A.
N.A.
11
(0.43)
8.5
(0.33)
MCD 200-007 ~ MCD 200-110
0.14 - 1.5 (26 - 16)
0.14 - 1.5 (26 - 16)
N.A.
3.5 mm
0.5 Nm max.
4.4 lb-in max.
6
(0.24)
177HA245.11
Thefollowingtableprovidesalistofsuitable Ferraz and Bussman fuses. If selecting alternate brands ensure the selected fuse has a lower total
2
clearing I
t rating than the SCR, and can carry start
current for the full starting duration.
Overview
MCD 200 Series
MCD 200 SCR I2t(A2s) Ferraz Fuse
European/IEC Style (North
American Style)
MCD 200-007 1150
MCD 200-015 8000
MCD 200-018 10500
MCD 200-022 15000
MCD 200-030 18000
MCD 200-037 51200
MCD 200-045 80000
MCD 200-055 97000
MCD 200-075 168000
MCD 200-090 245000
MCD 200-110 320000
6.6URD30xxxA0063
(A070URD30xxx0063)
6.6URD30xxxA0125
(A070URD30xxx0125)
6.6URD30xxxA0160
(A070URD30xxx0160)
6.6URD30xxxA0160
(A070URD30xxx0160)
6.6URD30xxxA0160
(A070URD30xxx0160)
6.6URD30xxxA0250
(A070URD30xxx0250)
6.6URD30xxxA0315
(A070URD30xxx0315)
6.6URD30xxxA0315
(A070URD30xxx0315)
6.6URD31xxxA0450
(A070URD31xxx0450)
6.6URD31xxxA0450
(A070URD31xxx0450)
6.6URD31xxxA0450
(A070URD31xxx0450)
xxx = Blade Type.
Refer Ferraz for options.
Bussman Fuse
Square Body
(170M)
Bussman Fuse
British Style
(BS88)
170M-1314 63 FE
170M-1317 160 FEE
170M-1318 160 FEE
170M-1318 180 FM
170M-1319 180 FM
170M-1321 250 FM
170M-1321 250 FM
170M-1321 250 FM
170M-1322 500 FMM
170M-3022 500 FMM
170M-3022 500 FMM
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9
MCD 200 Design Guide
Frequently Asked Questions
What is the minimum allowable motor current
when using an MCD 201 open loop soft starter?
There is no minimum current when using an MCD 201 open loop soft starter
What is the minimum allowable motor
current when using an MCD 202 closed loop soft starter?
The minimum "Motor FLC" setting is 50% of the MCD 202 nameplate rating. All the motor protections are based on this setting. It is possible to operate an MCD 202 with a small kW motor, for testing purposes. In this case, the motor will effectively start DOL, and the MCD 202 will not protect the motor. The starter w ill not trip, because there is no undercurrent protection on MCD 202.
What type of motor protection does
theMCD202have?
The MCD 202 has built-in m otor overload protection of the electronic "thermal model" type. The motor cu rrent is continuously monitored and the expected temperature is calculated based on this monitored current. The rate of rise of the calculated motor temperature is determined by the M otor Trip Class setting. The lower this setting, the faster the rate of rise of calculated motor temperature. An Overcurrent trip (x 2 Ready L ED flashes) will occur when the calculated temperature reaches 105%. The setting of the Motor Trip Class pot is similar to a motor trip class setting on a standard thermal overload relay. An external motor protection device is not required when using an MCD 202 soft starter. MCD 202 is certified to conform to the IEC60947-4-2 standard for electronic soft starters. The reliability of the motor protection feature is part of this standard.
How do I select an MCD 200 soft starter
for duty cycles different from those listed in the standard ratings table?
The WinStart software package is available for selecting soft starters for different duty cycles.
Which MCD 200 models carry the UL mark?
All T6 models carry the UL mark.
What are the MCD 200 operational ratings
before maintenance may be required?
The operational ratings for MCD 200 are size-dependent, and are due to the capability of the internal bypass relays: Size 1 & 2 (7.5 ~ 55 kW): 1,000,000 operations Size 3 (75 ~ 110 kW): 100,000 operations.
When would I use a line contactor?
A line contactor may be compulsory for a specific installation. This requirement will be the same whether using a two-phase controlled soft
starter or a three-phase controlled soft starter (see Product Note for more detail).
How do I size the fuses of the motor branch circuit (Type 1) when using an MCD 200 soft starter?
For "Current Limit" settings 350% and start times15 seconds, the nominal rating of standard line
supply fuses (gG) should be 1.75 x Motor FLC. If motor rated fuses (gM) are being used, their nominal rating should be 1.5 x Motor FLC. For "Current Limit" settings > 350% and start times > 15 seconds, the nominal rating of standard line supply fuses (gG) should be 2 x Motor FLC. If motor rated fuses (gM) are being used, their nominal rating should be 1.75 x Motor FLC.
When would I use semiconductor fuses?
Either when specified for an installation, or when Type 2 coordination is required. The MCD 200 is internally bypassed, so the SCRs are in use only during starting and soft stopping.
What is the current consumption of the MCD 200 control supply?
The steady state consumption of the control supply is 100 mA maximum, for both CV1 and CV3 models. However, the short time inrush current at control supply "switch-on" can be as high as 10 A for CV3 models, and 2 A for CV1 models (due to the SMPS power supply).
How can the MCD 202 programmable output relay be used?
The programmable output relay provides an N/O contact, which can be used for a "Trip" or "Run" output. Trip o u t p u t : The relay operates when the MCD 202 trips on any fault. This can be used to operate a shunt-trip mechanism of an upstream circuit breaker to isolate the motor branch circuit. It couldalsobeusedtosignalMCD202"Trip" status to an automation system. Run output: The relay operates on completion of start ramp. This can be use d to operate a contactor for power factor correction capacitors. It could also be used to signal MCD 202 "Run" status to an automation system.
Is the MCD 202 suitable for flying start application?
Yes. There is a built-in 2 second delay between the end of one stop and the beginning of the next start. This delay allows the motor flux to decay, eliminating any chance of the MCD 202 tripping on Power Circuit fault (x 1 Ready LED flash) due to detection of motor back EMF when the start signal is applied. The major effect of a fl ying start is on
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MG.17.C2.02 - VLT is a registered Danfoss trademark
the actual time the MCD 202 "current limits". The ramp-up time will be reduced and is determined by the motor speed on reapplication of the start signal.
What is the remote start and stop input impedance? Are any special precautions necessary during installation?
The 01/02 input impedance is approximately 400
@ 300 VAC and 5.6 k @24VAC/VDC.All
k control wiring, for long runs, should be either twisted pair or shielded cable with the screen earthed at one end. Control wiring should be separated from power cables by a minimum distance of 300 mm. If long cable runs cannot be avoided, the best assurance against noise interference is to install an interposing relay in close proximity to the MCD 200 soft starter.
Why is it necessary to apply control voltage before (or with) mains voltage?
There is a possibility the soft starter could arrive at site with the internal bypass relays in "closed" state. On first application of control voltage, the bypass relays are commanded to open. If m ains voltage is applied without control voltage, this step is missed, and the motor may start DOL without warning (see Product Note for more d etail) .
What are the under- & over-frequency trip points for MCD 200 soft starters?
The trip points are 40 Hz and 72 Hz. If the frequency falls below 40 Hz or rises above 72 Hz, the soft starter will trip (x 6 Ready LED flashes). These trip points are not adjustable. A supply frequency trip will also occur if all three phases from the mains supply are lost, or fall below approximately 120 VAC while the soft starter is running. A supply frequency trip will occur if t he line contactor drops out during running.
Will the motor start DOL if the start ramp of MCD 201 open loop soft starter is set to "full voltage"?
No, the MCD 201 will still provide a l imited soft start. The voltage is ramped up from 0 to 100% in approximately 0.25 seconds.
MCD 200 Design Guide
Overview
MCD 200 Series
MG.17.C2.02 - V LT is a registered Danfoss trademark
11
MCD 201
MCD 201 Range
MCD 201 soft starters provide TVR (Timed Voltage Ramp) starting and stopping control and are designed for use with an external motor protection device.
Electrical Schematic
Example 1 – MCD 201 installed with motor protection circuit breaker.
L3L2L1
MCD 200 Design Guide
Example 2 – MCD 201 installed with m otor protection circuit b reaker and line contactor.
L3L2L1
I>I>I
Q1
K1M
>
I>I>I
Q1
Motor
1
6A@30VDCresistive/2A400VACAC11
2
Main Contactor
>
5/L33/L21/L1
6/T34/T22/T1
U
e
A3A2A1 N2N1
1,2
1413
177HA207.11
177HA241.10
Motor
5/L33/L21/L1
6/T34/T22/T1
K1M
A3A2A1 N2N1
1,2
1413
Control Voltage
177HA246.11
Example 3 – MCD 201 installed with c ircuit breaker, overload and line contactor.
L3L2L1
I>I>I
Q1
F1
>
12
K1M
Motor
5/L33/L21/L1
6/T34/T22/T1
K1M
A3A2A1 N2N1
1,2
Control Voltage
1413
177HA247.11
MG.17.C2.02 - VLT is a registered Danfoss trademark
MCD 200 Design Guide
Control Circuits
2WireControl
OR
24 VAC/VDC (CV1)
110-240 VAC (CV3)
380-440 VAC (CV3)
177HA211.10
START/
STOP
START/
STOP
*
*
* Also resets the MCD 201
3WireControl
OR
110-240 VAC (CV3)
24 VAC/VDC (CV1)
START
STOP
*
1 Initial Torque
Value:
A3
A1 (+)
A2
(-)
N1
N2
30% - 75% Initial Torque
50%
Function:
Determines the start torque generated by the motor when the start command is first applied.
Description of choice:
Set so that the motor begins to rotate as soon
A3
A1
A2
N1
N2
A3
A1 (+)
A2 (-)
N1
N2
as the start command is given.
U
100%
Initial Torque
(30 - 75%)
177HA249.10
2RampUp
Value:
2 - 20 seconds, Full Voltage
10 seconds
Function:
Determines the time taken for voltage to be ramped up to line voltage.
380-440 VAC (CV3)
177HA212.10
START
STOP
*
* Also resets the MCD 201
Functionality
User Adjustments
50%
30%
(% U)
10s
8s 12s
6s
4s
2s
Full
Voltage Start
(seconds)
70%
60%
10s
8s 12s
14s
6s
16s
4s
20s
2s
20s
No Soft Stop (seconds)
40%
A3
A1
A2
N1
N2
Initial Torque
U
Ramp Up
U
14s
16s
Ramp Down
U
Set to optimise motor acceleration and/or start current. Short ramp times result in quicker acceleration and higher start currents. Long ramp times result in slower acceleration and lower start current.
Ramp Up
(2 - 20 seconds, Full Voltage Start)
U
100%
Initial Torque
(30 - 75%)
177HA250.10
3RampDown
Value:
2 - 20 seconds, No Soft Stop
No Soft Stop
Function:
201
MCD
Sets the time of the soft stop voltage ramp. The soft stop function extends motor deceleration
Description of choice:
177HA248.10
time by ramping down voltage supplied to the motor when a stop is initiated.
MG.17.C2.02 - V LT is a registered Danfoss trademark
Description of choice:
Set the ramp time to optimise stopping characteristics for the load.
13
Indication
(2 - 20 seconds, No Soft Stop)
U
100%
1L13L25L3
MCD 200 Design Guide
Ramp Down
177HA251.10
177HA252.10
2T14T26T3
Ready
Run
LED OFF ON FLASH
Ready No control
power
Run Motor not
running
Ready Starter
tripped Motor running at full speed
Motor
starting or
stopping
Fault Finding
Ready LED Description
Power Circuit Fault: Check mains supply L1, L2 &
x1
L3, motor circuit T1, T2 & T3 and soft starter SCRs. Supply Frequency: Check supply frequency is in
x6
range Network Comms Failure (between accessory module
x8
and network): Check network connections and settings. Starter Comms Failure (between starter and accessory module):
x9
Remove and refit accessory module.
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MG.17.C2.02 - VLT is a registered Danfoss trademark
MCD 202
MCD 202 Range
MCD 202 soft starters provide Current Limit control, TVR soft stop and include a range of motor protection features.
Electrical Schematic
Example 1 – MCD 202 installed with system protection circuit breaker complete with shunt trip device.
MCD 200 Design Guide
Example 2 – MCD 202 installed with syste m protection circuit b reaker and line contactor.
L3L2L1
L3L2L1
>I>
I>I
Q1
5/L33/L21/L1
6/T34/T22/T1
A3A2A1 N2N1 0605
1,2
1413 2423
Motor
Shunt Trip
1
6A@30VDCresistive/2A400VACAC11
2
Main Contactor
177HA253.11
1,3
Control
Voltage
I>I
Q1
K1M
Control Circuits
2WireControl
OR
24 VAC/VDC (CV1)
110-240 VAC (CV3)
Motor
START/
STOP
>I>
*
5/L33/L21/L1
6/T34/T22/T1
A3A2A1 N2N1 0605
1,2 1,3
1413 2423
177HA254.11
K1M
Control Voltage
A3
A1 (+)
A2
(-)
N1
N2
U
e
177HA241.10
3
Auxiliary Relay Function = Trip (see parameter 8)
MG.17.C2.02 - V LT is a registered Danfoss trademark
A3
A1
A2
*
N1
N2
177HA211.10
380-440 VAC (CV3)
START/
STOP
* Also resets the MCD 202
15
202
MCD
MCD 200 Design Guide
3WireControl
A3
A1
OR
110-240 VAC (CV3)
START
24 VAC/VDC (CV1)
STOP
(+) A2
(-)
N1
*
N2
A3
A1
380-440 VAC (CV3)
177HA212.10
START
STOP
A2
N1
*
N2
* Also resets the MCD 202
Functionality
User Adjustments
%
F
L
0
C
0
2
5s
OFF
350%
OFF
15s
15
450%
20
2
2s
5
0
%
5s
F
L
C
400%300%
ANY
14
16
FWD
Trip
70% 80%
60% 90%
50%
100%
(% MCD202 FLC)(%FLC / Ramp Time)
10s
8s
12s
6s
4s
2s
No
Soft Stop
Phase
Rotation
ANY
FWD
Run
Aux Relay
14s
16s
20s
Excess
Start Time
81012
6
4
2
20
OFF
2s
15s
C
L
F
5s
%
0
2s
5
1
250%
(% Motor FLC )
Motor Trip
Class
81012
6
4
2
1 Motor FLC
Value:
50% - 100% MCD 202 FLC
Function:
Calibrates the MCD 202 for the Full Load Current of the motor.
Description of choice:
Current Ramp
I
Motor FLC
Current Limit
I
Soft Stop
U
14
16
177HA255.10
2 Current Limit
Value:
250% - 475% Motor FLC
350%
Function:
Sets the desired starting current limit.
Description of choice:
The current limit should be set so that the motor accelerates easily to full speed.
I
400%
Current Limit
(250 - 475%)
300%
200%
100%
177HA256.10
NB!:
Start current must be great enough to allow the motor to produce sufficient torque to
accelerate the connected load. The minimum current required to do this is dependent on motor design and load torque requirements.
3 Current Ramp
I
M
Value:
150% Motor FLC (2, 5 or 15 seconds)
Off
200% Motor FLC (2, 5 or 15 seconds) 250% Motor FLC (2, 5 or 15 seconds) Off
Function:
Sets the initial starting current and ramp time for the Current Ramp start mode.
Description of choice:
The Current Ramp start mode modifies the Current Limit start mode by adding an extended ramp.
400%
300%
200%
100%
(2, 5, 15 seconds, OFF)
I
Ramp Time
177HA257.10
100%
Initial Start Current
(150% FLC, 200% FLC, 250% FLC)
Typically the Current Ramp start mode would be used in two circumstances.
16
1. For applications where start conditions vary
between starts the Current Ramp mode provides an optimum soft start irrespective of motorloading e.g. a conveyor that may start loaded or unloaded. In this case make the following settings:
•SetParameter2Current Limit so that the motor
can accelerate to full speed when fully loaded.
•SetParameter3Current Ramp so that:
-the Initial Start Current allows the motor to
accelerate when unloaded
MG.17.C2.02 - VLT is a registered Danfoss trademark
MCD 200 Design Guide
- the ramp time provides the desired starting performance
2. On generator set supplies where a gradual increase in current is required to allow greater time for the generator set to respond to the increased loading. In this case make the following settings:
•SetParameter2Current Limit as desired.
•SetParameter3Current Ramp so that:
-theInitial Start Current is lower level than the Current Limit
- the ramp time achieves the desired gradual draw of start current
4 SoftStopRampTime
Value:
2 - 20 seconds, No Soft Stop
No Soft Stop
Function:
Setsthetimeofthesoftstopvoltageramp. The soft stop function extends motor deceleration time by ramping down voltage supplied to the motor when a stop is initiated.
Description of choice:
Set the ramp time to optimise stopping characteristics for the load.
Soft Stop
(2 - 20 seconds, No Soft Stop)
U
100%
Description of choice:
t(s)
1000
100
20
10
Cold Start Curves
177HA258.10
Class 20
Class 10
1
100 300 500 700 I (% FLC)
600
6 Excess Star t Time Protection
Value:
2 - 20 seconds, Off
10 seconds
Function:
Sets the maximum allowable start time.
Description of choice:
Set for a period slightly longer than the normal motor starting time. The MCD 202 will then trip if the start time exceeds normal.
Excess Start Time Protection
(2 - 20 seconds, Off- no excess start time protection)
I
400%
300%
200%
100%
177HA259.10
177HA268.10
5 Motor Trip Class
Value:
2-20,Off
Function:
Calibrates the MCD 202 motor thermal model according to the desired motor trip class.
10
This provides early indication that the application conditions ha ve changed or that the motor has stalled. It can also protect the soft starter from being operated outside its rated start capability.
NB!:
Ensure the Excess Start Time protection setting is within the MCD 202 rated capability.
7 Phase Rotation Protection
Value:
ANY, FWD
ANY
ANY = Forward & Reverse rotation permitted FWD = Forward Rotation Only
Function:
Sets the allowable phase rotation sequence of the incoming supply.
202
MCD
MG.17.C2.02 - V LT is a registered Danfoss trademark
17
MCD 200 Design Guide
Description of choice:
FWD ANY
L1 L2 L3
L1 L2 L3
MCD
MCD
The MCD 202 itself is phase rotation insensitive. This function allows motor rotation to be limited to one direction only. Set the protection according to application requirements.
8 Auxiliary Relay Function (Terminals 23, 24)
Value:
Trip, R u n
Function:
Sets the functionality of the Auxiliary Relay (Terminals 23,24).
Description of choice:
Set as required, using the combined Phase Rotation/Aux Relay adjustment.
U
e
Main Contactor
RUN
Motor Thermistor Protection
05
06
Or
05
06
177HA239.10
Tr ip
177HA240.11
177HA279.10
Fault Finding
Ready LED Description
Power Circuit F au lt:
x1
Check mains supply L1, L2 & L3, motor circuit T1, T2 & T3 and soft starter SCRs. Excess Start Time:
x2
Check load, increase start current or adjust Excess Start Time setting. Motor Overload: Allow motor to cool, reset soft
x3
starter and restart. (MCD 202 cannot be reset until motor has cooled adequately). Motor Thermistor:
x4
Check motor ventilation and thermistor connection 05 & 06. Allow motor to cool.
x5
x6
x7
Phase Imbalance: Check line current L 1, L2 & L3 . Supply Frequency: Check supply frequency is in range Phase Rotation: Check for correct phase rotation. Network Comms Failure (between
x8
accessory module and network): Check network connections and settings. Starter Comms Failure (between
x9
starter and accessory module): Remove and refit accessory module.
Motor thermistor cut out value = 2.8 k .
Indication
1L13L25L3
177HA260.10
2T14T26T3
Ready Run
LED OFF ON FLASH
Ready No control
Ready Starter
power
Run Motor not
running
Motor running at full speed
18
tripped Motor starting or stopping
MG.17.C2.02 - VLT is a registered Danfoss trademark
Accessories
Overview
The following optional accessory items are available for use with MCD 200 soft starters:
MCD 200 Design Guide
MCD 200 Remote Operator
Order Code: 175G9004
MCD 200 Remote Operator
(Order Code 175G9004)
MCD 200 Modbus Module
(Order Code 175G9000)
MCD 200 Profibus Module
(Order Code 175G9001)
MCD 200 DeviceNet Module
(Order Code 175G9002)
MCD 200 AS-i Module
(Order Code 175G9003)
MCD PC Software
Accessory items are integrated with the MCD 200 soft starters by means of a plug-in module as shown below.
The Danfoss Remote Operator can be use d with MCD 201, MCD 202 and MCD 3000 to provide the following functionality.
Feature MCD
201
Pushbutton C ontrol (Start, Stop, Reset) Starter Status LEDs (Starting, Running, Tripped)
MCD 202
Motor Current Display • Motor Temperature Display • Trip Code Display • 4-20 mA Output (Motor Current)
See the Remote Operator Operating Instructions for further details.
MCD 200 Modbus Module
Order Code: 175G9000
The Modbus Module supports M odbus RTU and AP ASCII. See the Modbus Module Operating Instructions for further details.
MCD 3000
177HA261.10
35 mm
(1.38 inches)
Control power and mains supply must be removed from the MCD
200 before atta chment or removal of accessory modules. Failure to do so may result in equipment damag e.
MCD 200 Profibus Module
Order Code: 175G9001
The Profibus Module c an be used with MCD 200 soft starters for control and monitoring via a Profibus network. See the Profibus Module Operating Instructions for further details.
MCD 200 DeviceNet Module
Order Code: 175G9002
The DeviceNet Module can be used with MCD 200 soft starters for control and monitoring via a DeviceNet ne twork. See the DeviceNet Module Operating Instructions for further details.
MCD 200 AS-i Module
Order Code: 175G9003
Under d evelopme nt.
MCDPCSoftware
The Danfoss MCD PC Software can be used with MCD 201, MCD 202 and MCD 3000 to provide the following functionality for networks of up to 99 soft starters.
Accessories
MG.17.C2.02 - V LT is a registered Danfoss trademark
19
MCD 200 Design Guide
Feature MCD
Operational Control (Start, Stop, Reset, Quick Stop)
MCD
201
202
MCD 3000
Status Monitoring (Ready, Starting, Running,
• Stopping, Tripped) Performance Monitoring (Motor Current, Motor
• Temperature) Upload Parameter Settings • Download Parameter Settings
Additionally, each MCD 200 soft starter connected to the network must be fitted with a Modbus Module (175G9000) or a Remote Operator (175G9004). See the PC Software Operating Instructions for further details.
20
MG.17.C2.02 - VLT is a registered Danfoss trademark
Soft Start Application Guide
MCD 200 Design Guide
Application Guide
This section provides data useful in the selection and application of soft starters.
Reduced Voltage Starting
When started under full voltage conditions AC induction motors initially draw locked rotor current (LRC) and produce locked rotor torque (LRT). As the motor accelerates the current falls and the torque increases to breakdown torque before falling to full speed levels. Both the magnitude a nd shape of the current and torque curves are dependent on motor design.
Full Voltage Stator Current
7 x FLC
6 x FLC
5 x FLC
4 x FLC
Full Voltage Start Torque
3 x FLC
2 x FLC
CURRENT (% Motor Full Load Current)
1 x FLC
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
ROTOR SPEED (% Full Speed)
Sample Load Torque Curve
2 x FLT
1 x FLT
177HA267.10
Motors with almost identical full speed characteristics often vary significantly in their starting capabilities. Locked rotor currents range from as low as 500%, to in excess of 900% of motor FLC. Locked rotor torques range from as low as 70%, to highs of around 230% motor full load torque (FLT).
The motors full voltage current and torque
characteristics set the limits for what can be achieved with a reduced voltage starter. For installations in which either minimising start current or maximising start torque is critical, it is important to ensure that a motor with low LRC and high LRT characteristics is used. When a reduced voltage starter is used, motor start torque is reduced according to the following formula.
T
ST
I
ST
art torque
=St
=Start current
LRC =Motor Lo c ked Rotor Current
LRT =Mot
or Locked Rotor Torque
The most common reduced voltage starters are:
Star/Delta starters
Auto-transformer starters
Primary resistance starters
Soft starters
Star/Delta starting is the c heapest form of reduced voltage starting, however performance is limited.
Guide
The two most significant limitations are:
1. There is no control over the level of current
Soft Start Application
and torque reduction; these are fixed at one
TORQUE (% Motor Full Load Torque)
third o f the full voltage levels.
2. There are normally large current and torque transients as the starter changes from star to delta. This causes mechanical and electrical stress often resulting in damage. The transients occur because as the m otor is spinning and then disconnected from the supply it acts as a generator with output voltage which may be at the same amplitude as the supply. This voltage is still present when the motor is reconnected in delta configuration, and can be exactly out of phase. The result is a current of up to twice locked rotor current and four times locked rotor torque.
Auto-transformer starting offers more control than the star/delta method, however voltage is still applied in steps.
Limitations of auto-transformer starting include:
1. Torque transients caused by switching between voltages.
2. Limited number of output voltage taps restricts the ability to closely select the ideal starting current.
3. High price for models suitable for frequent or extended starting conditions.
4. Cannot provide an effective reduced voltage start for loads with varying start requirements. For instance, a material conveyor may start loaded or unloaded. The auto-transformer starter can only be optimised for one condition.
Primary resistance starters also provide greater starting control than star/delta starters. However, they do have a number of characteristics that reduce their effectiveness.
Start current c an be reduced only to the point where the resulting start torque still exceeds the torque required by the load. Below this point motor acceleration will cease and the motor/load will not reach full speed.
MG.17.C2.02 - V LT is a registered Danfoss trademark
These include:
1. Difficult to optimise start performance when commissioning because the resistance value must
21
MCD 200 Design Guide
be calculated when the starter is manufactured and is not easily changed later.
2. Poor performance in frequent starting situations because the resistance value changes as heat is generated in the resistors during a start. A long cool down period is required between starts.
3. Poor performance for heavy duty or extended starts because heat build up in the resistors changes the resistance value.
4. Cannot provide an effective reduced voltage start for loads with varying start requirements.
Soft starters are the most advanced of the reduced voltage starters. They offer superior control over current and torque as well as incorporating advanced motor protection and interface features. The main starting advantages soft starters offer are:
1. Simple and flexible control over starting current and torque.
2. Smooth control of voltage and current free from steps or transitions.
3. Capable of frequent starting.
4. Capable of handling changing start conditions.
5. Soft stop control to extend motor deceleration times.
6. Braking control to reduce motor deceleration times.
very small motors and should only be applied to light applications with low to medium start frequency. Two-phase controllers control two phases while the third phase is uncontrolled. These controllers provide soft start and current reduction. Care should be taken to ensure that the control algorithms of two-phase controllers balance the output waveform in order to provide a symmetrical waveform. Basic two-phase controllers subject the motor to an asymmetrical output waveform which creates a DC field in the motor. This stationary DC field increases the required start current and increases motor heating. Such unbalanced controllers should not be applied to high ine rtia loads or in situations with high start frequencies. Three-phase controllers control all phases and are best suited for very large motors.
External or internal bypass c onnection: The SCRs in a soft starter can be bypassed once the motor is up to speed. This reduces heat generation and prevents damage to the SCR from overcurrent or overvoltage events that occur while the motor is running. Some soft starters include built-in bypass contactors while other provide terminals for connection of an external bypass contactor.
Types of Soft Start Control
The term soft startis applied to a range of
technologies. These technologies all relate to motor starting but there are significant differences in the methods used and the b enefits available. Some of the key differences are described below.
Control philosophy: Soft starters can generally be divided into two groups.
Timed Voltage Ramp (TVR) systems
Current controlled systems
TVR starters control voltage applied to the motor in a preset manner and receive no feedback on motor starting current. Control of start performance is provided to the users through settings such as Initial Voltage and Ramp up time. Soft Stop is also commonly available and provides the ability to extend motor stopping times. Current controlled soft starters monitor motor current and use this feedback to adjust voltage so that user specified starting current is m aintained. Soft Stop is also provided as are range of motor protection functions.
Power assemblies: Soft starters can provide control of one, two or all three phases. Single-phase controllers remove the torque shock associated with motor starting but provide no significant current reduction. They must be used with a line contactor and motor overload. They are suitable for
Understanding Soft Starter Ratings
The maximum rating of a soft starter is calculated so the junction temperature of the power m odule s (SCRs) does not exceed 125 °C. Five operating parameters effect the SCR junction temperature:
Motor Current, Start Current, Start Duration, Number of Starts Per Hour, Off Time. The full rating of a
particular soft start model must account for all these parameters. A current rating on its own is not sufficient to describe the capability of a soft starter.
IEC 60947-4-2 details the AC53 utilisation categories
for describing a soft startersratings.
TherearetwoAC53codes:
1. AC53a: for soft starters used without bypass contactors. For example, the following AC53a code describes a soft starter capable of supplying a 256 A run current and a start current of 4.5 x FLC for 30 seconds 10 times per hour where the motor runs for 70% of each operating cycle (operating cycle = 60 minutes / starts per hour).
256 A: AC-53a 4.5-30 : 70-10
Start Current
Start Time (seconds)
On-load Duty Cycle
Starter Current Rating
177HA280.10
Starts Per Hour
(multiple of FLC)
22
MG.17.C2.02 - VLT is a registered Danfoss trademark
MCD 200 Design Guide
Starter Current Rating: Maximum FLC rating
of the motor to be connected to the soft starter given the operating parameters specified by the remaining items in the AC53a code.
Start Current: The maximum start current
that will be drawn during start.
Start Time: The time taken for the
motor to accelerate.
On-load Duty Cycle: The percentage of each
operating cycle that the soft starter will run.
Starts Per Hour: The number of operating
cycles per hour.
2. AC53b: for soft starters used with bypass contactors. For example, the following AC53b code describes a soft starter which, when bypassed, is capable of supplying 145 A run current and a start current of 4.5 x FLC for 30 seconds with a minimum of 570 seconds between the end of one start and the commencement of the next.
145 A: AC-53b 4.5-30 : 570
Start Current
Start Time (seconds)
Starter Current Rating
177HA281.10
In summary, a soft starter has many current ratings. These current ratings are dependent on the start current and operational performance required by the application.
To compare the current rating of different soft starters it is important to ensure that operating parameters are identical.
Model Selection
NB!:
To fully understand the model selection procedures it is important to have a good knowledge of the fundamental principles of soft
starter ratings. See Understanding Soft Starter Ratings.
To sele ct the correct MCD 200 model:
1. Determine whether the application requires a normal duty or a heavy duty rating. The table below can be used as a guide.
2. See the tables in Ratings and select an
MCD 200 model with an FLC rating greater than that of the motor.
Off Time
(seconds)
(multiple of FLC)
Application Duty
General & Water
Agitator Normal
Centrifugal Pump Normal
Compressor (Screw, unloaded) Normal
Compressor (Reciprocating, unloaded) Normal
Conveyor Normal
Fan (damped) Normal
Fan (undamped) Heavy
Mixer Heavy
Positive Displacement Pump Normal
Submersible Pump Normal
Metals & Mining
Belt Conveyor Heavy
Dust Collector Normal
Grinder Normal
Hammer Mill Heavy
Rock Crusher Normal
Roller Conveyor Normal
Roller Mill Heavy
Tumb ler Normal
Wire Draw Machine Heavy
Food Processing
Bottle Washer Normal
Centrifuge Normal
Dryer Heavy
Mill Heavy
Palletiser Heavy
Separator Heavy
Slicer Normal
Pulp and Paper
Dryer Heavy
Re-pulper Heavy
Shredder Heavy
Petrochemical
Ball Mill Heavy
Centrifuge Normal
Extruder Heavy
Screw Conveyor Normal
Transport & Machine Tool
Ball Mill Heavy
Grinder Normal
Material Conveyor Normal
Palletiser Heavy
Press Normal
Roller Mill Heavy
Rotary Table Normal
Lumber & Wood products
Bandsaw Heavy
Chipper Heavy
Circular Saw Normal
Debarker Normal
Edger Normal
Hydraulic Power Pack Normal
Planer Normal
Sander Normal
NB!:
The a bove start current requirements are typical and appropriate in most circumstances.
However, start torque requirements and performance of motors and machines does vary. Please contact Danfoss if the application requires duties other than listed in this manual.
Guide
Soft Start Application
MG.17.C2.02 - V LT is a registered Danfoss trademark
23
MCD 200 Design Guide
Typical Applications
MCD 200 soft starters can offer benefits for almost all motor starting applications. Typical advantages are h ighlighted in the table below.
Application Benefits
Pumps • Minimised hydraulic shock in
pipelines during start and stop.
Reduced starting current.
Minimised m echanical stress
on motor shaft.
Phase rotation protection
prevents damage from reverse pump rotation.
Conveyor Belts • Con trolled soft start without
mechanical shocks, e.g. bottles on a belt do not fall over during starting, minimised belt stretch, reduced coun ter balance stress.
Controlled stop without
mechanical shocks. Soft stop.
Optimum soft start performance
evenwithvaryingstartingloads, e.g. coal conveyors started loaded or unloaded.
Extended mechanical lifetime.
Maintenance-free.
Centrifuges • Smooth application of torque
prevents mechanical stress.
Reduced starting times over
star/delta starting.
Ski Lifts • Jerk free acceleration increases
skier comfort and prevents swinging T-bars etc.
Reduced starting current allows
starting of large motors on a weak power supply.
Smooth and gradual acceleration
whether the ski lift is lightly or heavily loaded.
Phase rotation protection
prevents operation in reverse direction.
Application Benefits
Compressors • Reduce d mec hanica l shock
extends the life of the compressor, couplings and motor.
Limited start current enables
large compressors to be started when m ax imum power capacity is limited.
Phase rotation protection
prevents operation in reverse direction.
Fans • Extended coupling life through
reduced mechanical shock.
Reduced start current enables
large fans to be started when maximum power capacity is limited.
Phase rotation protection
prevents operation in reverse direction.
Mixers • Gentle rotation during start-up
reduces mechanical stress.
The starting current is reduced.
Power Factor Correction
If a soft starte r is us it must be connected to the supply side of the starter.
Connecting power factor correction capacitors to the output of the soft starter will result i
ed with static power factor correction
n damage to the soft starter.
24
MG.17.C2.02 - VLT is a registered Danfoss trademark
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