Danfoss Electronics VLT Soft Starter Sales Brochure

Danfoss VLT® Soft Starter

The single speed drive

3–1600 A

For any soft start
situation. VLT® Soft
Starters cover the full
range – from simple
start-stop operation to
high end performance.

Soft starts:
Protects processes, products and
equipment with smooth motor control

An AC motor switched directly
on to the mains power supply
will struggle to reach its nomi­nal speed as quickly as possi­ble.

This draws maximum current from the
power supply and accelerates the
application with its maximum torque.
Depending on the application, this can
cause different problems.

Applications like pumps, conveyers,
centrifuges and bandsaws must be
started slowly, and sometimes stopped
slowly, to prevent mechanical shocks
such as water hammer, and strains on
bands, couplings and shafts.

Principle of Phase
Angle Control

A soft starter is an electronic device
that regulates the voltage to the motor
and this provides a smooth transition
from standstill to full speed operation
of the application.

VLT® Soft Starters all use the principle
of phase angle control: Back-to-back
coupled thyristors ramp up the motor
voltage.

In some VLT® Soft Starters, current
transformers measure the motor cur­rent, providing feedback for starting
current control but also for numerous
motor and application protection func­tions.

VLT® Soft Starters cover
a comprehensive range

Soft starting and stopping can be
controlled in a number of ways
depending on the application. Some
applications require non-linear volt­age ramp-up and the voltage ramp is
therefore related to the actual current
drawn. Conversely, a band-saw usually
requires a quick stop function provided
by a DC brake.

Then again, a number of applica­tions require a kick-start torque for an
instantaneous period of time followed
by a soft ramp-up acceleration. VLT®
Soft Starters cover all of these applica­tions and much more.

2

VLT® Soft Starter MCD 500 VLT® Compact Starter MCD 200 VLT® Soft Starter MCD 100

n Fully featured Soft Starter for

motors up to 1100 HP

n Total motor starting solution
n Advanced protection features
n Adaptive Acceleration Control
n Inside Delta connection
n 4 line graphical display
n Multiple programming setup

menus

n Compact Soft Starter for

motors up to 150 HP

n Voltage ramps, current limit start

and intregrated motor protection

n Integral bypass design reduces

heat dissipation

n Wide power range with advanced

accessory modules

n Micro Soft Start controller for

motors up to 15 HP

n Extremely robust SCR design

with heavy ratings as standard

n Unlimited number of starts

per hour

n Contactor style design for

easy selection, installation and
commissioning

3

VLT® Soft Starter MCD 500

VLT® Soft Starter MCD 500 is a
total motor starting solution.
Current transformers measure
motor current and provide
feedback for controlled motor
ramp proles.

AAC, the Adaptive Acceleration
Control, automatically employs the
best starting and stopping prole for
the application. Adaptive Acceleration
Control means that for each start and
stop, the soft starter compares and
adapts the process to the chosen
prole best suited to the application.

The VLT® Soft Starter MCD 500 has a
four-line graphical display and a logic
keypad making programming easy.
Advanced setup is possible displaying
operational status.

Three menu systems: Quick Menu,
Application Setup and Main Menu
provide optimum programming
approach.

The perfect solution, also for
more severe applications:

n Pumps
n Conveyors
n Fans
n Mixers
n Compressors
n Centrifuges
n Mills
n Saws
n And many more

Power range

21 – 1600 A, 10-1100 HP
(1.2 MW inside Delta Connection)
Versions for 200 – 690 VAC

Features Benets

User friendly

AAC Adaptive Acceleration Control

Adjustable bus bars allow for both top and
bottom entry on 360-1600 amp models
(200-1100 HP)

DC injection braking distributed evenly
over three phases

Inside Delta (6-wire connection)

Log menus, 99 events and trip log provide
information on events, trips and performance

Auto Reset – Less down-time

Jog (slow-speed operation) – Application exibility

Second-order thermal model

Internal bypass contactors
(21 – 215 A, 10-150 HP)

Auto-start/stop clock – Application exibility

Compact size – amongst the smallest in their class

4-line graphical display

Multiple programming setup
(Standard Menu, Extended Menu, Quick Set)

8 language display options – Serving the whole world

– Automatically adapts to the chosen starting

and stopping prole

– Space saving, less cable cost

and easy retrotting

– Less installation cost and

less stress on the motor

– Smaller soft starter can be selected

for the application

– Eases analysis of the application

– Allows motors to be used to their

full potential without damage from
overloading

– Save space and wiring compared to

external bypass

– Very little heat dissipates when running.

Eliminates costly external fans, wiring
or bypass contactors

– Saves space in cabinets and other application

setups

– Optimum programming approach and setup

for viewing operational status

– Simplies the programming, allowing

maximum exibility

4

Dimensions

Current rating [A]

21, 37, 43 and 53 9.25

68 9.92

84, 89 and 105 10.8

131, 141, 195 and 215 32.8 17. 24 10.82 9.84 G2

245 52.6 18 .11 15. 35 10.98 G3

360, 380 and 428 77

595, 619, 790 and 927 100

1200, 1410 and 1600 264 33.70 23.03 14. 33 G5

Weight

[lbs]

Height

[inches]

11. 61

27.12 16.92 11. 82 G4

Width

[inches]

5.90

Depth

[inches]

7.20

8.38

MCD 500 operation options

Starting:

n AAC Adaptive Acceleration
n Control
n Current Ramp
n Constant Current
n Kickstart

Stopping:

n Coast to stop
n TVR soft Stop
n AAC Adaptive deceleration

Control

n Brake

Three Adaptive Acceleration Control (AAC) start
proles; early, constant and late acceleration

Frame size

G1

Constant current/ current ramp – here shown
with kickstart

Control Panel VLT® LCP 501

The screen view set-up is selected
from 8 views. Options include 7
standard and 1 user programmable
view.

Language selection:

English, Chinese, German, Spanish,
Portuguese, French, Italian, Russian.

The VLT® LCP 501 is connected to the
MCD 500 by using a 10 ft cable using

9 pin (D-sub) plug and 10 ft cable
With the Control Panel VLT® LCP 501
being a full function interface, every­thing you can do on the VLT® Soft
Starter MCD 500 is possible via the
LCP 501.

provided with the IP 65 (NEMA 12)

door-mount kit.

Once connected, the soft starter asks

whether you want to copy parameters

from LCP to starter or starter to LCP

(if dierent).

100% easy connection

n The Modbus, Probus and Device

net modules use another port on
the MCD 500 (at the side of the soft
starter)

n Separate LCP 501 output at the

bottom for 9 pin plug and 10 ft
cable

n One ordering number (LCP with

door-mount kit and cable)

n Plug & play connection

(also if soft starter is powered up)

n One cable for power and

communication

n Powered up by soft starter
n Copy of parameter set- up

5

VLT® Compact Soft Starter MCD 200

Danfoss VLT® Compact Soft
Starter series MCD 200
includes two families of soft
starters in the power range
from 10 – 150 HP.

The series oers easy DIN rail mount­ing for sizes up to 40 HP, 2-wire or
3-wire start/stop control and excellent
starting duty (4 x Ie for 6 seconds).

Heavy starting ratings at 4x Ie
for 20 seconds.

Compatible with grounded delta
power systems.

The perfect match for:

n Pumps
n Fans
n Compressors
n Mixers
n Conveyors
n And many more

Power range:

n 10 – 150 HP

MCD 201 MCD 202

MCD 202 provides enhanced
soft start functionality and various
motor protection features

U

Ramp up

Initial torque

Ramp
down

M

3~

I

Current

limit

Initial current

Ramp up

U

Ramp
down

M

3~

Features Benets

Small footprint and compact size – Saves panel space

– Minimizes installation cost and

Built-in bypass

Advanced accessories – Allows enhanced functionality

Advanced SCR control algorithms
balance output waveform

Reliable

Essential motor protection (MCD 202) – Reduces overall project investment

Max. ambient temperature 50˚C without derating – No external cooling or oversizing necessary

User friendly

Easy to install and use

Easy DIN rail mounting for sizes up to 40 HP – Saves time and space

eliminates power loss

– Reduces heat build up. Savings in

components, cooling, wiring and labor

– Allowing more starts per hour,

accepting higher load

Maximum up-time

Save commissioning

Remote operation

Remote operation of MCD 201
and MCD 202 is facilitated by the
dedicated remote operator kit.

The operator (IP 54/NEMA 12)
is mounted on the cabinet front
and allows remote control, status
indication and motor monitoring
of an individual VLT® Soft Starter
using RS485 serial communication.

6

Dimensions

Power range (575 V) 10 – 40 HP 50 – 75 HP 100 – 150 HP

Height [inches] 7.9 9 8.46 9.44

Width [inches] 3.85 5.70 7.9

Depth [inches] 6.49 7. 59 8.42

VLT® Soft Starter MCD 100

Danfoss VLT® Soft Start
Controller MCD 100 is a cost
eective and extremely com­pact soft starter for AC motors
up to 15 HP, due to a unique
semiconductor design.

MCD 100 is a true “t and forget”
product. Selection can be made on the
basis of the motor power – exactly as
with traditional contactors.

MCD 100 products provide timed
voltage ramp up and down.
Ramp time can be individually adjusted
with rotary switches from

0.4 to 10 seconds.

The start torque can be adjusted from
0 to 85% of the direct on-line torque.

All sizes are rated for line voltage
up to 600 V AC.

The perfect match for:

n Pumps
n Fans
n Compressors
n Mixers
n Conveyors
n and many more

“Kick start”
200 msec.
of max. torque

Features Benets

Small footprint and compact size – Saves panel space
Selection can be based on motor power – Easy selection

Universal control voltage

“Fit and forget” contactor design

Reliable Maximum up-time

Robust semiconductor design – Reliable operation

Almost unlimited number of starts
per hour without derating

Max. ambient temperature 50°C
without derating

User-friendly Save commissioning and operating cost

Easy to install and use – Saves times

Digitally controlled rotary switches

Easy DIN rail mounting for sizes up to 40 HP – Saves time and space

Motor torque

(Voltage)

100%

0%

Initial Torque up to
85% of nominal torque

Ramp-up time

0.5–10 sec.

Ramp-down time
0–10 sec.

Time

– Simplies selection
– Keeps stock at a minimum

– Simplies installation
– Reduces required panel space

– Prevents unauthorized changes

– No external cooling or oversizing necessary

– Secures precise settings and
simplies installation

Dimensions

Model

MCD 100

Power size

(HP)

2

10

15

Rated current

(Amps)

3 A

AC-53b: 4-10: 110

15 A

AC-53a: 8-3: 100-3000
AC-58a: 6-6: 100-3000

25 A

AC-53a: 8-3: 100-3000
AC-58a: 6-6: 100-3000

Dimensions

(inches) H x W x D

4.01 x 0.88 x 4.88

4.33 x 1.77 x 5.03

4.33 x 3.54 x 5.03

Approvals

UL, CSA, CE

7

Serial communication

MCD 201, MCD 202 and MCD 500
come with optional plug-in modules
for serial communication.

n DeviceNet

n Profibus

n Modbus RTU

n USB

MCD 100 MCD 201 MCD 202 MCD 500

Start/stop, reset

LED for start, run, trip

Trip codes

Current display

Motor temp. display

4 – 20 mA output

Programming keypad, graphical display

n n n n

n n n n

n n n n

n n

n n

n n

n

Ordering type codes

VLT® Compact Starter MCD 200 VLT® Soft Starter MCD 500

MCD 2 0 – – T – C V

Series

Soft start/stop 1

Soft start/stop
+ protection

Nominal Motor kW, 400 V

E.g. 55 kW 055

110 kW 110

Line Supply Voltage

200 – 440 V 4

200 – 575 V 6

Control Supply Voltage

24 V AC/DC 1

110 – 240 V AC and 380 – 440 V AC 3

2

MCD 5 – – T – G X – – C V

MCD5, 500 Series

FLC, [A]

0021
0037
0043
0053
0068
0084
0089
0105
0131
0141
0195
0215
0245
0360
0380
0428
0595
0619
0790
0927
1200
1410
1600

Bypass indication

B: With Internal
Bypass Contactor
C: Without Internal
Bypass Contactor
(Continuous)

Supply Voltage

T5, 200 – 525 VAC
T7, 380 – 690 VAC

Enclosure

G1, Frame size 1
G2, Frame size 2
G3, Frame size 3
G4, Frame size 4
G5, Frame size 5

IP Rating

00, IP 00
20, IP 20

Control Voltage

CV1, 24 VAC or 24 VDC
CV2, 110 or 220 VAC

8

Size indications

Size indication for
VLT® Compact Starter MCD 200

Model

MCD 201/
MCD 202

* Example: AC 53b: 42 A: 4-6: 354 starting current max. 4 times FLC (42 A)

in 6 seconds. 354 seconds minimum between starts.

Power size

(HP)

10 18 A: 4-6: 354

20 34 A: 4-6: 354

25 42 A: 4-6: 354

30 48 A: 4-6: 354

40 60 A: 4-6: 354

50 75 A: 4-6: 594

75 100 A: 4-6: 594

100 140 A: 4-6: 594

125 170 A: 4-6: 594

150 200 A: 4-6: 594

Rated current

AC-53b* (Amps)

Dimensions

(inches)

H x W x D

7.99 x 3.85 x 6.49

8.46 x 5.70 x 7.5960 85 A: 4-6: 594

9.44 x 7.95 x 8.42

Approvals

UL

C – UL

CE

CCC

C-tick

Lloyds

Size indication for
VLT® Soft Starter MCD 100

Model

MCD 100

Power size

(HP)

2

10

15

Rated current

(Amps)

3 A: 5-5:10

(AC 53b)

15 A: 8-3:
100-3000

(AC 53a)

25 A: 6-5:100-480

(AC 53a)

Dimensions

(inches)

H x W x D

4.01 x 0.88 x 4.88

4.33 x 1.77 x 5.03

4.33 x 3.54 x 5.03

Size indication for VLT® Soft Starter MCD 500

Motor size

(HP)

@

400 V

15
25 10 43 37 31 26
30 10 50 43 37 30
35 10 53 53 46 37

40
50 6 97 84 69 58
60 6 100 89 74 61
75 6 105 105 95 78

80

100 6 170 141 121 97
125 6 200 195 160 134
150 6 220 215 178 149

Motor size

(HP)

@

400 V

175
250
275 6 380 380 380 348 359 292 299
300 6 430 428 430 355 368 301 309
400 6 620 595 620 515 540 419 434
500 6 650 619 650 532 561 437 455
600 6 790 790 790 694 714 567 579
700 6 930 927 930 800 829 644 661
800
900 6 1410 1410 1410 1187 1319 1023 1114

1000 6 1600 1600 1600 1433 1600 1227 1353

Note: Optimise your selection with WinStart Soft Starter PC tool.

Frame size

code

G1

(no fan)

G1

G2

Frame size

code

G3x

G4x

G5x

Starts per

hour

10 23 21 17 15

6 76 68 55 47

6 145 131 106 90

Starts per

hour

6 255 245 255 195 201 171 176
6 360 360 360 303 310 259 263

6 1200 1200 1200 1135 1200 983 1071

Max. FLC

Max. FLC

Light 300%, 30s,

Internal bypass

Not

bypassed

External by-

pass

Rated FLC (104 F, 3,280 ft),

outside delta motor connection

Medium 400%, 20s,

Internal bypass

Not

bypassed

External

bypass

Heavy 450%, 30s,

Internal bypass

Not

bypassed

Approvals

UL, CSA, CE

External

bypass

9

Specifications

Type VLT® Soft Starter MCD 500 VLT® Soft Starter MCD 100

Concept

Start/stop

Protection

Outputs

Control

Other features

The total motor starter solution.
Provid es advanced control methods for starting and stop­ping and protection of motor and application

Enhanced soft start and soft stop
Motor and system protection
10 – 1100 HP @ 400 V (21-1600A)
200 – 690 V mains voltage
110 – 220 V AC or
24V AC/DC control supply
3-phase SCR control

Adaptive Acceleration Control (AAC)
Current limit start
Current ramp start
Dual parameter function
Kick-start
Jog

Adaptive Deceleration Control (AAC)
TVR soft stop (Timed Voltage Ramp)
Coast to stop
DC brake function – three phase
Soft brake function

Same as MCD 202 and:
Under current
Current imbalance
Starter overtemperature
Restart delay
Warning before trips
Adjustable phase imbalance sensitivity
– Programmable input trip
– Individual phase loss trips
– Individual shorted SCR trips
– Int. bypass relay overload
– Int. bypass relay fail
Fully adjustable protections
Network communication timeout
Heatsink overtemperature
Battery/clock failure
Supply frequency
External trip

Three programmable output relays:
Programmable analogue output
Motor thermistor

8 language graphical display and keypad
Quick menu and appplication menu
Buttons for start, stop, reset and remote control
Inputs for two- or three-wire control

Optional:
Modules for serial
communication
Control Panel VLT® LCP 501
PC software

Bypass up to 150 HP
Configurable bus bars from 360 A and up
Operation timers
Jog – slow speed operation
Auto reset of fault situations
Emergency run
99 event log
Trip log
User programmable metering and monitoring
Simulation before connecting line voltage

A true “fit and forget” soft starter for DIN rail mount, MCD
100 provides basic soft start and stop function

Soft start
Soft stop
1/3 – 15 HP @ 400 V
208 – 600 V mains voltage
24 – 480 V AC/DC
control voltage
2-phase SCR control

Timed voltage ramp-up
Adjustable start torque
Selectable kick-start function

Timed voltage ramp-down

Universal two-wire control
Programmable via 3 rotary switches

Extremely robust SCR design for
unlimited number of starts per
hour, LED indication, IP 20

10

Type

Concept

Start/stop

Protection

VLT® Compact Starter MCD 201 VLT® Compact Starter MCD 202

A physically compact starter providing basic soft start and
stop functionality

Soft start
Soft stop
10 – 150 HP @ 400 V
3 x 200 – 480 VAC (T6 model)
CV1 – 24 VAC / VDC
CV3 – 110-240 VAC & 380-440 VAC
2-phase SCR control

Timed voltage ramp-up
Adjustable initial torque

Timed voltage ramp-down Timed voltage ramp-down

Physically similar to MCD 201 but providing enhanced soft
start func tionality and various motor protection functions

Current limit start
Soft stop
Motor protection
10 – 150 HP @ 400 V
3 x 200 – 480 VAC (T6 model)
CV1 – 24 VAC / VDC
CV3 – 110-240 VAC & 380-440 VAC
2-phase SCR control

Current limit start
Initial current ramp-up

Motor overload
(adjustable trip class)
Excess start time
Reverse phase rotation
Motor thermistor input
Shorted SCR – no start
Supply fault – no start
Instantaneous overload

Outputs

Control

Other features

One output relay:
Line contactor control

Two- or three-wire control
Programmable via 3 rotary switches
Reset push button

Optional:
Modules for serial
communication
Remote operator kit
PC software

Integral SCR bypass for
minimum physical size and heat
dissipation during nominal operation
LED status indication
IP 20 (10 – 75 HP @ 400 V)
IP 00 (100 – 150 HP @ 400 V)
Protection kit available

Two output relays:
Line contactor control
Run contactor or trip function

Two- or three-wire control
Programmable via 8 rotary switches
Reset push button

Optional:
Modules for serial
communication
Remote operator kit
PC software

Integral SCR bypass for
minimum physical size and heat
dissipation during
nominal operation
LED status indication
IP 20 (10 – 75 HP @ 400 V)
IP 00 (100 – 150 HP @ 400 V)
Protection kit available

11

What VLT® is all about

Danfoss VLT Drives is the world leader among dedicated drives providers
– and still gaining market share.

Environmentally
responsible

VLT® products are manufactured with
respect for the safety and well-being of
people and the environment.

All activities are planned and performed
taking into account the individual em­ployee, the work environment and the
external environment. Production takes
place with a minimum of noise, smoke
or other pollution and environmentally
safe disposal of the products is pre­prepared.

UN Global Compact

Danfoss has signed the UN Global
Compact on social and environmental
responsibility and our companies act
responsibly towards local societies.

EU Directives

All factories are certied according to
ISO 14001 standard. All products full
the EU Directives for General Product
Safety and the Machinery directive.
Danfoss VLT Drives is, in all product
series, implementing the EU Directive
concerning Hazardous Substances in
Electrical and Electrical Equipment
(RoHS) and is designing all new product
series according to the EU Directive on
Waste Electrical and Electronic Equip­ment (WEEE).

Dedicated to drives

Dedication has been a key word since

1968, when Danfoss introduced the

world’s rst mass produced variable

speed drive for AC motors – and

named it VLT®.

Twenty ve hundred employees

develop, manufacture, sell and service

drives and soft starters in more than

one hundred countries, focused only

on drives and soft starters.

Intelligent and innovative

Developers at Danfoss VLT Drives have

fully adopted modular principles in

development as well as design, produc-

tion and conguration.

Tomorrow’s features are developed in

parallel using dedicated technology

platforms. This allows the development

of all elements to take place in parallel,

at the same time reducing time to

market and ensuring that customers

always enjoy the benets of the latest

features.

Rely on the experts

We take responsibility for every
element of our products. The fact that
we develop and produce our own
features, hardware, software, power
modules, printed circuit boards, and
accessories is your guarantee of reliable
products.

Local backup – globally

VLT® motor controllers are operating in
applications all over the world and
Danfoss VLT Drives’ experts located in
more than 100 countries are ready to
support our customers with applica­tion advice and service wherever they
may be.

Danfoss VLT Drives experts don’t stop
until the customer’s drive challenges
are solved.

Impact on energy savings

One year’s energy savings from our an­nual production of VLT® drives will save
the energy equivalent to the energy
production from a major power plant.
Better process control at the same time
improves product quality and reduces
waste and wear on equipment.