Design Guide MG17C302

Design Guide MG17C302
MCD 200 Design Guide
Contents
■ Warnings ...................................................................................................... 2
■ MCD 200 Series Overview
Description ....................................................................................................... 3
Ratings ............................................................................................................. 4
General Technical Data ...................................................................................... 5
Mechanical Installation ...................................................................................... 7
Dimensions and Weights .................................................................................... 7
Cable Size ......................................................................................................... 9
Semiconductor Fuses ........................................................................................ 9
Frequently Asked Questions ............................................................................ 10
■
MCD 201
Electrical Schematic ........................................................................................
Control Circuits ...............................................................................................
Functionality ....................................................................................................
Indication ........................................................................................................
Fault Finding ....................................................................................................
■
MCD 202
Electrical Schematic ........................................................................................
Control Circuits ...............................................................................................
Functionality ....................................................................................................
Motor Thermistor Protection ...........................................................................
Indication ........................................................................................................
Fault Finding ....................................................................................................
■
15
15
16
18
18
18
Accessories
Overview .........................................................................................................
MCD 200 Remote Operator .............................................................................
MCD 200 Modbus Module ...............................................................................
MCD 200 Profibus Module................................................................................
MCD 200 DeviceNet Module.............................................................................
MCD 200 AS-i Module .....................................................................................
MCD PC Software ...........................................................................................
■
12
13
13
14
14
19
19
19
19
19
19
20
Soft Start Application Guide
Reduced Voltage Starting ...............................................................................
Types of Soft Start Control ..............................................................................
Understanding Soft Starter Ratings .................................................................
Model Selection ..............................................................................................
Typical Applications ........................................................................................
Power Factor Correction .................................................................................
MG.17.C3.02 – VLT is a registered Danfoss trademark
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22
22
23
24
24
1
Contents
■
Warnings
MCD 200 Design Guide
■
Warnings
■ High Voltage Warning
The MCD 200 contains dangerous
voltages when connected to line voltage.
Only a competent electrician should carry
out the electrical installation. Improper installation of
the motor or the MCD 200 may cause equipment
failure, serious injury or death. Follow this manual,
®
National Electrical Codes (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 responsibility 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.
■ Avoiding Soft Starter Damage
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 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 (ESD). Many electronic
components are sensitive to static
electricity. Voltages so low that they cannot be felt,
seen or heard, can reduce the life, affect performance,
or completely destroy sensitive electronic
components. When performing service, proper ESD
equipment should be used to prevent possible
damage from occurring.
■ 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, these 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.
■ 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
2
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
MCD 200 Series Overview
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 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 the need for an
external bypass contactor.
■ Ordering Type Code
MCD 2
-
-
-
Series
201 = Soft Start Only
202 = Soft Start plus Protection
Nominal Motor kW @ 400 V
e.g. 55 kW = 055
22 kW = 022
Maximum Voltage Rating
T4 = 200 - 440 VAC
T6 = 200 - 575 VAC
Control Supply Voltage
CV1 = 24 VAC/VDC
CV3 = 110-240 VAC & 380-440 VAC
MG.17.C3.02 – VLT is a registered Danfoss trademark
3
MCD 200 Series Overview
MCD 200 Design Guide
■ Ratings
MCD 200
Model
007
015
018
022
030
037
045
055
075
090
110
MCD 200
Model
007
015
018
022
030
037
045
055
075
090
110
Continuous Ratings (Internally bypassed) @ 40
<1000 metres ✮
Normal
18 A: AC53b 4-6:354
34 A: AC53b 4-6:354
42 A: AC53b 4-6:354
48 A: AC53b 4-6:354
60 A: AC53b 4-6:354
75 A: AC53b 4-6:594
85 A: AC53b 4-6:594
100 A: AC53b 4-6:594
140 A: AC53b 4-6:594
170 A: AC53b 4-6:594
200 A: AC53b 4-6:594
o
Continuous Ratings (Internally bypassed) @ 50
<1000 metres ✮
Normal
17 A: AC53b 4-6:354
32 A: AC53b 4-6:354
40 A: AC53b 4-6:354
44 A: AC53b 4-6:354
55 A: AC53b 4-6:354
68 A: AC53b 4-6:594
78 A: AC53b 4-6:594
100 A: AC53b 4-6:594
133 A: AC53b 4-6:594
157 A: AC53b 4-6:594
186 A: AC53b 4-6:594
o
C Ambient Temperature,
Heavy
17 A: AC53b 4-20:340
30 A: AC53b 4-20:340
36 A: AC53b 4-20:340
40 A: AC53b 4-20:340
49 A: AC53b 4-20:340
65 A: AC53b 4-20:580
73 A: AC53b 4-20:580
96 A: AC53b 4-20:580
120 A: AC53b 4-20:580
142 A: AC53b 4-20:580
165 A: AC53b 4-20:580
C Ambient Temperature,
Heavy
15 A: AC53b 4-20:340
28 A: AC53b 4-20:340
33 A: AC53b 4-20:340
36 A: AC53b 4-20:340
45 A: AC53b 4-20:340
59 A: AC53b 4-20:580
67 A: AC53b 4-20:580
87 A: AC53b 4-20:580
110 A: AC53b 4-20:580
130 A: AC53b 4-20:580
152 A: AC53b 4-20:580
✮ Contact Danfoss for other ratings.
Example
For 22 kW model
48 A:
AC53b:
4-6:
354:
4
48 A: AC53b: 4-6:354
Starter current rating.
Load category for soft starters with SCRs bypassed during run.
400% start current for 6 seconds.
354 seconds between the end of one start to the beginning of the next start (i.e. 10 starts per
hour).
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
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
6 A, 30 VDC resistive / 2 A, 400 VAC, AC11
Programmable Relay (Terminals 23 & 24) ......................................................................................... Normally Open
6 A, 30 VDC resistive / 2 A, 400 VAC, AC11
Environmental
Degree of protection MCD 200-007 to MCD 200-055 .................................................................................... IP20
Degree of protection MCD 200-075 to MCD 200-110 .................................................................................... IP00
o
o
Operating Temperatures ............................................................................................................... - 10 C / + 60 C
Humidity ................................................................................................................... 5% to 95% Relative Humidity
Pollution Degree ......................................................................................................................... Pollution Degree 3
Vibration ................................................................................................................... IEC 60068 Test Fc Sinusoidal
4 Hz - 13.2 Hz: ± 1 mm displacement
13.2 Hz – 100 Hz: ± 0.7 g
EMC Emission
Equipment class (EMC) ............................................................................................................................... Class A
Conducted radio frequency emission ................................................................ 0.15 MHz - 0.5 MHz: < 90 dB (µV)
0.5 MHz - 5 MHz: < 76 dB (µV)
5 MHz - 30 MHz: 80-60 dB (µV)
Radiated radio frequency emission ................................................................. 30 MHz - 230 MHz: < 30 dB (µV/m)
230 MHz - 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
MG.17.C3.02 – VLT is a registered Danfoss trademark
5
MCD 200 Series Overview
■ General Technical Data
MCD 200 Series Overview
MCD 200 Design Guide
Heat Dissipation
During Start ................................................................................................................................. 3 watts / ampere
During Run ................................................................................................................................................ < 4 watts
Standards Approvals
C9 ................................................................................................................................................. IEC 60947-4-2
UL / C-UL .................................................................................................................................................... UL 508
CE .................................................................................................................................................. IEC 60947-4-2
CCC .................................................................................................................................................... GB 14048.6
6
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
1
L1
3
L2
5
L3
1
L1
3
L2
5
L3
1
L1
3
L2
5
L3
1
L1
3
L2
5
L3
2
T1
4
T2
6
T3
2
T1
4
T2
6
T3
2
T1
4
T2
6
T3
MCD 200 Series Overview
■ Mechanical Installation
50 (1.97)
1
2
T1
4
T2
6
L1
3
L2
5
L3
T3
100 (3.93)
1
L1
3
L2
5
L3
2
T1
4
T2
6
T3
50 (1.97)
MCD 200 FLC * 0.85
2
T1
4
T2
6
T3
mm (inch)
MCD 200
MCD 200-007 ~ MCD 200-030
MCD 200-037 ~ MCD 200-110
Din Rail
30 mm
Not available
Foot Mounting
Yes
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)
C
23 23
(0.9) (0.9)
MG.17.C3.02 – VLT is a registered Danfoss trademark
7
MCD 200 Series Overview
MCD 200 Design Guide
MCD 201-037 ~ MCD 201-055 (4.0 kg / 8.8 lb)
MCD 202-037 ~ MCD 202-055 (4.3 kg / 9.5 lb)
145 (5.71)
193 (7.60)
124 (4.88)
37
(1.46)
37
(1.46)
MCD 201-075 ~ MCD 201-110 (6.1 kg / 13.5 lb)
MCD 202-075 ~ MCD 202-110 (6.8 kg / 15.0 lb)
202 (7.95)
214 (8.43)
160 (6.30)
51
(2.0)
8
51
(2.0)
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
mm2 (AWG)
mm2 (AWG)
MCD 200-007 ~
MCD 200-030
MCD 200-037 ~
MCD 200-055
MCD 200-075 ~
MCD 200-110
10 - 35
(8 - 2)
25 - 50
(4 - 1/0)
N.A.
10 - 35
(8 - 2)
25 - 50
(4 - 1/0)
14
(0.55)
mm (inch)
MCD 200 Series Overview
■ Cable Size
14
(0.55)
11
(0.43)
8.5
26
(1.02) (0.33)
N.A.
mm (inch)
mm (inch)
MCD 200-007 ~
MCD 200-110
0.14 - 1.5
(26 - 16)
0.14 - 1.5
(26 - 16)
Torx (T20)
3 Nm
2.2 ft-lb
Torx (T20)
4 Nm
2.9 ft-lb
N.A.
N.A.
7 mm
3 Nm
2.2 ft-lb
7 mm
4 Nm
2.9 ft-lb
N.A.
3.5 mm
0.5 Nm max
4.4 lb-in max
6
(0.24)
mm (inch)
177HA245.12
75ºC Wire. 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 to achieve Type 2 coordination with
MCD 200
2
SCR I t
2
(A s)
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
semiconductor fuses. The following table provides a
list of suitable Ferraz and Bussman fuses. If selecting
alternate brands ensure the selected fuse has a
2
lower total clearing I t rating than the SCR, and can
carry start current for the full starting duration.
Ferraz Fuse
European/IEC Style
(North American Style)
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.
MG.17.C3.02 – VLT is a registered Danfoss trademark
Bussman Fuse
Bussman Fuse
Square Body
(170M)
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
9
MCD 200 Series Overview
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 will not trip, because there is no
undercurrent protection on MCD 202.
•
•
What are the MCD 200 operational ratings
before maintenance may be required?
The operational ratings for MCD 200 are sizedependent, 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
times < 15 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.
What type of motor protection does the MCD
202 have?
The MCD 202 has built-in motor overload
protection of the electronic "thermal model"
type. The motor current 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 Motor Trip
Class setting. The lower this setting, the faster
the rate of rise of calculated motor temperature.
An Overcurrent trip (x 2 Ready LED 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.
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.
•
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).
•
10
When would I use semiconductor fuses?
Either when specified for an installation, or when
Type 2 coordination is required.
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.
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
•
Run output:
The relay operates on completion of start ramp.
This can be used 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
flying start is on the actual time the MCD 202
“current limits”. The ramp-up time will be
reduced and is determined by the motor speed
on re-application of the start signal.
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 the 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 limited soft
start. The voltage is ramped up from 0 to 100%
in approximately 0.25 seconds.
What is the remote start and stop input
impedance? Are any special precautions
necessary during installation?
The N1/N2 input impedance is approximately
400 kΩ @ 300 VAC and 5.6 kΩ @ 24 VAC/VDC.
All 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 mains
voltage is applied without control voltage, this
step is missed, and the motor may start DOL
without warning (see Product Note for more
detail).
MG.17.C3.02 – VLT is a registered Danfoss trademark
11
MCD 200 Series Overview
Trip output:
The relay operates when the MCD 202 trips on
any fault. This can be used to operate a shunttrip mechanism of an upstream circuit breaker to
isolate the motor branch circuit. It could also be
used to signal MCD 202 “Trip” status to an
automation system.
MCD 201
MCD 200 Design Guide
■
MCD 201
Example 2 – MCD 201 installed with motor protection
circuit breaker and line contactor.
■ MCD 201 Range
L1
L2
L3
I>
I>
I>
1/L1
3/L2
5/L3
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.
L1
L2
Q1
K1M
L3
A1 A2 A3
N1 N2
1,2
I>
I>
I>
2/T1
4/T2
6/T3
13 14
177HA246.11
Q1
1/L1
3/L2
5/L3
A1 A2 A3
K1M
Motor
3Ø
N1 N2
Control
Voltage
1,2
2/T1
4/T2
6/T3
13 14
177HA207.11
Example 3 – MCD 201 installed with circuit breaker,
overload and line contactor.
Motor
3Ø
1
L1
6 A @ 30 VDC resistive / 2 A 400 VAC AC11
L2
L3
I>
I>
I>
1/L1
3/L2
5/L3
Q1
2
Main Contactor
F1
K1M
Ue
A1 A2 A3
N1 N2
177HA241.10
1,2
2/T1
4/T2
6/T3
13 14
177HA247.11
Motor
3Ø
K1M
Control
Voltage
12
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
1
2 Wire Control
Value:
30% - 75% Initial Torque
110-240 VAC (CV3)
OR
24 VAC/VDC (CV1)
A3
A1
(+)
A2
(-)
START/
STOP
✭ 75%
Function:
Determines the start torque generated by the motor
when the start command is first applied.
N1
*
Initial Torque
N2
380-440 VAC (CV3)
Description of choice:
Set so that the motor begins to rotate as soon as the
start command is given.
A3
A1
A2
START/
STOP
N1
*
N2
177HA209.12
* Also resets the MCD 201
2
3 Wire Control
Value:
2 - 20 seconds, Full Voltage
110-240 VAC (CV3)
OR
24 VAC/VDC (CV1)
A3
A1
(+)
A2
(-)
START
STOP
*
380-440 VAC (CV3)
✭ 10 seconds
Function:
Determines the time taken for voltage to be ramped up
to line voltage.
N1
N2
Description of choice:
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.
A3
A1
A2
START
STOP
Ramp Up
*
N1
N2
177HA210.11
* Also resets the MCD 201
■ Functionality
User Adjustments
Initial Torque
60%
10s
12s
14s
16s
20s
Full
Voltage Start
(seconds)
✭ No Soft Stop
Ramp Up
30% 70%
(% U)
8s
6s
4s
2s
Ramp Down
Value:
2 - 20 seconds, No Soft Stop
U
50%
40%
3
U
8s
6s
4s
2s
10s
12s
14s
16s
20s
Ramp Down
U
No
Soft Stop
(seconds)
Function:
Sets the time of the soft stop voltage ramp. The soft
stop function extends motor deceleration time by
ramping down voltage supplied to the motor when a
stop is initiated.
177HA248.11
MG.17.C3.02 – VLT is a registered Danfoss trademark
13
MCD 201
■ Control Circuits
MCD 201
MCD 200 Design Guide
Description of choice:
Set the ramp time to optimise stopping characteristics
for the load.
■ Indication
LED
Ready
Run
OFF
No control
power
Motor not
running
ON
Ready
Motor
running at
full speed
FLASH
Starter
tripped
Motor
starting or
stopping
■ Fault Finding
Ready LED
x1
x6
x8
x9
14
Description
Power Circuit Fault:
Check mains supply L1, L2 & L3,
motor circuit T1, T2 & T3 and soft
starter SCRs.
Supply Frequency:
Check supply frequency is in range
Network Comms Failure (between
accessory module and network):
Check network connections and
settings.
Starter Comms Failure (between starter
and accessory module): Remove and
refit accessory module.
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
Example 2 – MCD 202 installed with system protection
circuit breaker and line contactor.
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.
L1
L2
L3
I>
I>
L1
L2
L3
I>
I>
I>
1/L1
3/L2
5/L3
Q1
K1M
A1 A2 A3
N1 N2
1,2
I>
2/T1
Q1
4/T2
6/T3
05 06
1,3
13 14
23 24
177HA254.11
177HA253.11
1/L1
3/L2
5/L3
A1 A2 A3
N1 N2
05 06
1,2
1,3
13 14
23 24
K1M
Motor
3Ø
Control
Voltage
■ Control Circuits
2/T1
4/T2
6/T3
2 Wire Control
A3
110-240 VAC (CV3)
OR
24 VAC/VDC (CV1)
Motor
3Ø
Shunt Trip
START/
STOP
Control
Voltage
6 A @ 30 VDC resistive / 2 A 400 VAC AC11
2
Main Contactor
*
N1
N2
380-440 VAC (CV3)
1
A1
(+)
A2
(-)
A3
A1
A2
START/
STOP
Ue
*
N1
N2
177HA209.12
177HA241.10
3
* Also resets the MCD 202
Auxiliary Relay Function = Trip
(see parameter 8)
MG.17.C3.02 – VLT is a registered Danfoss trademark
15
MCD 202
■
3 Wire Control
2
110-240 VAC (CV3)
OR
24 VAC/VDC (CV1)
A3
N1
*
Current Limit
Value:
250% - 475% Motor FLC
A1
(+)
A2
(-)
START
STOP
✭ 350%
Function:
Sets the desired starting current limit.
N2
380-440 VAC (CV3)
Description of choice:
The current limit should be set so that the motor
accelerates easily to full speed.
A3
A1
A2
START
STOP
N1
*
N2
177HA210.11
* Also resets the MCD 202
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.
■ Functionality
User Adjustments
Current Ramp
I
70%
2s
5s
15
% FLC
50
250% FL
C
15s
200% FLC
2s 5s 15s
5s
2s
1
MCD 202
MCD 200 Design Guide
OFF
80%
60%
50%
Motor FLC
90%
3
I
100%
M
(%FLC / Ramp Time) (% MCD202 FLC)
Value:
150% Motor FLC (2, 5 or 15 seconds)
200% Motor FLC (2, 5 or 15 seconds)
250% Motor FLC (2, 5 or 15 seconds)
Off
Current Limit
350%
300%
4s
250%
(% Motor FLC )
Motor Trip
Class
6
8
4
2
OFF
I
12s
14s
16s
20s
No
Soft Stop
Soft Stop
2s
450%
10
10s
8s
400% 6s
Phase
Rotation
12 ANY
14
16
FWD
20
Trip
U
6
8
10
4
Run
Aux Relay
2
OFF
12
Function:
Sets the initial starting current and ramp time for the
Current Ramp start mode.
14
16
20
177HA255.11
1
✭ Off
Excess
Start Time
ANY
FWD
Current Ramp
Motor FLC
Value:
50% - 100% MCD 202 FLC
Description of choice:
The Current Ramp start mode modifies the Current
Limit start mode by adding an extended ramp.
✭ 100%
Function:
Calibrates the MCD 202 for the Full Load Current of
the motor.
Description of choice:
95%
=
95 A
100 A
177HA233.12
16
Typically the Current Ramp start mode would be used
in two circumstances.
1. For applications where start conditions vary
between starts the Current Ramp mode provides
an optimum soft start irrespective of motor
loading e.g. a conveyor that may start loaded or
unloaded.
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
4
Description of choice:
6
Excess Start Time Protection
Value:
2 - 20 seconds, Off
✭ 10 seconds
Function:
Sets the maximum allowable start time.
Soft Stop Ramp Time
Value:
2 - 20 seconds, No Soft Stop
MCD 202
2.
In this case make the following settings:
• Set Parameter 2 Current Limit so that the
motor can accelerate to full speed when fully
loaded.
• Set Parameter 3 Current Ramp so that:
- the initial start current allows the motor to
accelerate when unloaded
- the ramp time provides the desired starting
performance
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:
• Set Parameter 2 Current Limit as desired.
• Set Parameter 3 Current Ramp so that:
- the Initial Start Current is lower than the
Current Limit
- the ramp time achieves the desired gradual
draw of start current
✭ No Soft Stop
Function:
Sets the time of the soft stop voltage ramp. 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 for a period slightly longer than the normal motor
starting time. The MCD 202 will then trip if the start
time exceeds normal.
Description of choice:
Set the ramp time to optimise stopping characteristics
for the load.
This provides early indication that the application
conditions have 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.
5
Motor Trip Class
Value:
2 - 20, Off
Function:
Calibrates the MCD 202 motor thermal model
according to the desired motor trip class.
MG.17.C3.02 – VLT is a registered Danfoss trademark
✭ 10
7
Phase Rotation Protection
Value:
ANY, FWD
✭ ANY
ANY = Forward & Reverse rotation permitted
FWD = Forward Rotation Only
17
MCD 202
MCD 200 Design Guide
Function:
Sets the allowable phase rotation sequence of the
incoming supply.
LED
Ready
Run
Description of choice:
OFF
No control
power
Motor not
running
ON
Ready
Motor
running at
full speed
FLASH
Starter
tripped
Motor
starting or
stopping
■ Fault Finding
Ready LED
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
x1
x2
Auxiliary Relay Function (Terminals 23, 24)
x3
Value:
Trip, Run
✭ Trip
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.
x4
x5
x6
x7
Ue
x8
Main
Contactor
RUN
x9
Description
Power Circuit Fault:
Check mains supply L1, L2 & L3,
motor circuit T1, T2 & T3 and soft
starter SCRs.
Excess Start Time:
Check load, increase start current or
adjust Excess Start Time setting.
Motor Overload:
Allow motor to cool, reset soft starter
and restart. (MCD 202 cannot be reset
until motor has cooled adequately).
Motor Thermistor:
Check motor ventilation and thermistor
connection 05 & 06. Allow motor to
cool.
Phase Imbalance:
Check line current L1, L2 & L3.
Supply Frequency:
Check supply frequency is in range
Phase Rotation:
Check for correct phase rotation.
Network Comms Failure (between
accessory module and network):
Check network connections and
settings.
Starter Comms Failure (between starter
and accessory module): Remove and
refit accessory module.
■ Motor Thermistor Protection
Motor thermistor cut out value = 2.8 kΩ.
■ Indication
18
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
Accessories
■ MCD 200 Remote Operator
Order Code: 175G9004
■ Overview
The following optional accessory items are available
for use with MCD 200 soft starters:
• 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 used with
MCD 201, MCD 202 and MCD 3000 to provide the
following functionality:
Feature
MCD
201
MCD
202
MCD
3000
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Pushbutton Control
(Start, Stop, Reset)
Starter Status LEDs
(Starting, Running, Tripped)
Motor Current Display
Motor Temperature Display
Trip Code Display
4-20 mA Analogue Output
(Motor Current)
See the Remote Operator Operating Instructions for
further details.
■ MCD 200 Modbus Module
Order Code: 175G9000
The Modbus Module supports Modbus RTU and AP
ASCII. See the Modbus Module Operating
Instructions for further details.
177HA261.10
■ MCD 200 Profibus Module
Order Code: 175G9001
The Profibus Module can be used with MCD 200 soft
starters for control and monitoring via a Profibus
network. See the Profibus Module Operating
Instructions for further details.
35 mm
(1.38 inches)
Control power and mains supply must be
removed from the MCD 200 before
attachment or removal of accessory
modules. Failure to do so may result in
equipment damage.
■ 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 network. See the DeviceNet Module
Operating Instructions for further details.
■ MCD 200 AS-i Module
Order Code: 175G9003
Under development.
MG.17.C3.02 – VLT is a registered Danfoss trademark
19
Accessories
■
Accessories
MCD 200 Design Guide
■ MCD PC Software
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.
Feature
Operational Control
(Start, Stop, Reset, Quick
Stop)
Status Monitoring
(Ready, Starting, Running,
Stopping, Tripped)
Performance Monitoring
(Motor Current, Motor
Temperature)
Upload Parameter Settings
Download Parameter
Settings
MCD
201
MCD
202
MCD
3000
z
z
z
z
z
z
z
z
z
z
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.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
■
Soft Start Application Guide
■ 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 and shape of the
current and torque curves are dependent on motor
design.
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 motor's 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.
TST
TST
IST
LRC
LRT
= LRT x
I ST
2
( )
LRC
= Start torque
= Start current
= Motor Locked Rotor Current
= Motor Locked Rotor Torque
Start current can 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.C3.02 – VLT is a registered Danfoss trademark
Star/Delta starting is the cheapest form of reduced
voltage starting, however performance is limited. The
two most significant limitations are:
1. There is no control over the level of current and
torque reduction; these are fixed at one third of
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 motor 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. These include:
1. Difficult to optimise start performance when
commissioning because the resistance value must
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.
21
Soft Start Application Guide
■ Application Guide
This section provides data useful in the selection and
application of soft starters.
The most common reduced voltage starters are:
• Star/Delta starters
• Auto-transformer starters
• Primary resistance starters
• Soft starters
Soft Start Application Guide
MCD 200 Design Guide
3.
4.
Poor performance for heavy duty or extended
starts because heat build-up in the resistors
changes the resistance value.
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.
■ Types of Soft Start Control
The term 'soft start' is applied to a range of
technologies. These technologies all relate to motor
starting but there are significant differences in the
methods used and the benefits 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 maintained. 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 very small motors and should only be applied to
light applications with low to medium start frequency.
22
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
inertia 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 connection: 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.
■ Understanding Soft Starter Ratings
The maximum rating of a soft starter is calculated so
the junction temperature of the power modules (SCRs)
o
does not exceed 125 C. Five operating parameters
affect 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 starter's ratings. There are two
AC53 codes:
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).
MG.17.C3.02 – VLT is a registered Danfoss trademark
MCD 200 Design Guide
•
•
•
•
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.
Application
General & Water
Duty
Agitator
Centrifugal Pump
Compressor (Screw, unloaded)
Compressor (Reciprocating, unloaded)
Conveyor
Fan (damped)
Fan (undamped)
Mixer
Positive Displacement Pump
Submersible Pump
Normal
Normal
Normal
Normal
Normal
Normal
Heavy
Heavy
Normal
Normal
Soft Start Application 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.
Metals & Mining
Belt Conveyor
Dust Collector
Grinder
Hammer Mill
Rock Crusher
Roller Conveyor
Roller Mill
Tumbler
Wire Draw Machine
Heavy
Normal
Normal
Heavy
Normal
Normal
Heavy
Normal
Heavy
Food Processing
Bottle Washer
Centrifuge
Dryer
Mill
Palletiser
Separator
Slicer
Normal
Normal
Heavy
Heavy
Heavy
Heavy
Normal
Pulp and Paper
Dryer
Re-pulper
Shredder
Heavy
Heavy
Heavy
Petrochemical
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 select 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.
MG.17.C3.02 – VLT is a registered Danfoss trademark
Ball Mill
Centrifuge
Extruder
Screw Conveyor
Heavy
Normal
Heavy
Normal
Transport & Machine Tool
Ball Mill
Grinder
Material Conveyor
Palletiser
Press
Roller Mill
Rotary Table
Heavy
Normal
Normal
Heavy
Normal
Heavy
Normal
Lumber & Wood products
Bandsaw
Chipper
Circular Saw
Debarker
Edger
Hydraulic Power Pack
Planer
Sander
Heavy
Heavy
Normal
Normal
Normal
Normal
Normal
Normal
NB!:
The above start current requirements are
typical and appropriate in most circumstances.
However, start torque requirements and performance
of motors and machines do vary. Please contact
Danfoss if the application requires duties other than
listed in this manual.
23
Soft Start Application Guide
MCD 200 Design Guide
■ Typical Applications
MCD 200 soft starters can offer benefits for almost all
motor starting applications. Typical advantages are
highlighted in the table below.
Application Benefits
Pumps
• Minimised hydraulic shock in
pipelines during start and stop.
• Reduced starting current.
• Minimised mechanical stress on
motor shaft.
• Phase rotation protection prevents
damage from reverse pump
rotation.
Conveyor
Belts
•
•
•
Centrifuges
•
•
•
•
Ski Lifts
•
•
•
•
Compressors •
•
•
24
Application Benefits
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
Controlled soft start without
If a soft starter is used with static power factor
mechanical shocks, e.g. bottles on
correction it must be connected to the supply side of
a belt do not fall over during
the starter.
starting, minimised belt stretch,
Connecting power factor correction
reduced counter balance stress.
capacitors to the output of the soft starter
Controlled stop without mechanical
will result in damage to the soft starter.
shocks. Soft stop.
Optimum soft start performance
even with varying starting loads,
e.g. coal conveyors started loaded
or unloaded.
Extended mechanical lifetime.
Maintenance-free.
Smooth application of torque
prevents mechanical stress.
Reduced starting times over
star/delta starting.
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.
Reduced mechanical shock
extends the life of the compressor,
couplings and motor.
Limited start current enables large
compressors to be started when
maximum power capacity is
limited.
Phase rotation protection prevents
MG.17.C3.02 – VLT is a registered Danfoss trademark
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