www.danfoss.com/drives Design Guide MCD 200 MCD 201 MCD 202 175R0978 MG17C222 *MG17C222* Rev. 2004-09-08 MCD 200 Design Guide ■ Contents MCD 200 Series Overview .......................................................................... 3 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 13 13 15 15 16 16 MCD 202 17 17 17 18 20 20 21 Accessories 22 22 22 22 22 22 22 22 Soft Start Application Guide 24 24 25 25 26 27 28 .............................................................................................................. Electrical Schematic ............................................................................................... Control Circuits ...................................................................................................... Functionality ........................................................................................................... Indication ............................................................................................................... Fault Finding ........................................................................................................... .............................................................................................................. Electrical Schematic ............................................................................................... Control Circuits ...................................................................................................... Functionality ........................................................................................................... Motor Thermistor Protection ................................................................................... Indication ............................................................................................................... Fault Finding ........................................................................................................... ....................................................................................................... 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 .................................................................................................. ..................................................................... Reduced Voltage Starting ....................................................................................... Types of Soft Start Control ..................................................................................... Understanding Soft Starter Ratings ........................................................................ Model Selection ..................................................................................................... Typical Applications ................................................................................................ Power Factor Correction ........................................................................................ MG.17.C2.22 - VLT is a registered Danfoss trademark 1 MCD 200 Design Guide ■ Warnings ■ High voltage warning - MCD 200 DG 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 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 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. ■ 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. ■ 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. ■ 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: NOTE Indicates something to be noted by the reader Indicates a general warning Indicates a high voltage warning 2 MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide ■ MCD 200 Series Overview ■ Description The Danfoss MCD 200 Soft Starter series comprises two separate ranges: • • MCD 201 MCD 202 MCD 200 Series Overview 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. NOTE 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 minimizes 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 MG.17.C2.22 - VLT is a registered Danfoss trademark 3 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) @ 104 °F (40 °C) Ambient Temperature, <3281 ft (<1000 meters) Normal Heavy 18 A: AC53b 4-6:354 17 A: AC53b 4-20:340 34 A: AC53b 4-6:354 30 A: AC53b 4-20:340 42 A: AC53b 4-6:354 36 A: AC53b 4-20:340 48 A: AC53b 4-6:354 40 A: AC53b 4-20:340 60 A: AC53b 4-6:354 49 A: AC53b 4-20:340 75 A: AC53b 4-6:594 65 A: AC53b 4-20:580 85 A: AC53b 4-6:594 73 A: AC53b 4-20:580 100 A: AC53b 4-6:594 96 A: AC53b 4-20:580 140 A: AC53b 4-6:594 120 A: AC53b 4-20:580 170 A: AC53b 4-6:594 142 A: AC53b 4-20:580 200 A: AC53b 4-6:594 165 A: AC53b 4-20:580 Continuous Ratings (Internally bypassed) @ 122 °F (50 °C) Ambient Temperature, <3281 ft (<1000 meters) Normal Heavy 17 A: AC53b 4-6:354 15 A: AC53b 4-20:340 32 A: AC53b 4-6:354 28 A: AC53b 4-20:340 40 A: AC53b 4-6:354 33 A: AC53b 4-20:340 44 A: AC53b 4-6:354 36 A: AC53b 4-20:340 55 A: AC53b 4-6:354 45 A: AC53b 4-20:340 68 A: AC53b 4-6:594 59 A: AC53b 4-20:580 78 A: AC53b 4-6:594 67 A: AC53b 4-20:580 100 A: AC53b 4-6:594 87 A: AC53b 4-20:580 133 A: AC53b 4-6:594 110 A:: AC53b 4-20:580 157 A: AC53b 4-6:594 130 A: AC53b 4-20:580 186 A: AC53b 4-6:594 152 A: AC53b 4-20:580 Contact Danfoss for other ratings. Example For 29.5 HP (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 hour). 4 MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide ■ General Technical Data Line 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. 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, AC11 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 ....................................................................................... 14 °F / 140 °F (-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: ± 0.04 in (± 1 mm) displacement Vibration .................................................................................................... 13.2 Hz - 100 Hz: ± 0.0015 lb (± 0.7 g) 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 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 ground Rated insulation voltage (Surges 1.2/50 µs - 8/20 ms) ..................................... 2 kV line to ground, 1 kV line to line Voltage dip and short time interruption ................................................................. 100 ms (at 40% nominal voltage) MG.17.C2.22 - VLT is a registered Danfoss trademark 5 MCD 200 Series Overview Relay Outputs MCD 200 Design Guide 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 Heat Dissipation During Start ................................................................................................. 10 Btu/hr / ampere (3 watts / ampere) During Run .......................................................................................................................... < 13.7 Btu/hr (4 watts) Standards Approvals C ................................................................................................................................................. IEC 60947-4-2 UL / C-UL .................................................................................................................................................... UL508 CE .................................................................................................................................................. IEC 60947-4-2 CCC ................................................................................................................................................... GB 14048.6 6 MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide ■ Mechanical Installation 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 177HA201.11 1 50 (1.97) 1 2 T1 4 T2 6 L1 3 L2 5 L3 T3 100 (3.93) 3 L2 5 L3 T1 4 T2 6 T3 L3 2 2 1 L1 T1 4 3 L2 T2 6 5 50 (1.97) MCD 200 Series Overview L1 T3 1 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 1.18 in. (30 mm) Not available ■ Dimensions and Weights mm (inch) Foot Mounting Yes Yes 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) 55 (2.17) 177HA242.11 82 (3.23) 203 (7.99) 90.5 (3.56) 188 (7.40) C 23 23 (0.9) (0.9) MG.17.C2.22 - VLT is a registered Danfoss trademark 7 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) 215 (8.46) 110.5 (4.35) 196 (7.71) 177HA243.11 124 (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) 8 MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide 202 (7.95) 214 (8.43) MCD 200 Series Overview 240 (9.45) 114.5 (4.5) 204 (8.03) 177HA244.11 160 (6.30) 51 (2.0) 51 (2.0) ■ Cable Size 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) 14 (0.55) mm (inch) 25 - 50 (4 - 1/0) 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 - 5 Nm. 2.2 - 3.7 ft-lb. Torx (T20) 4 - 6 Nm. 2.9 - 4.4 ft-lb. N.A. N.A. 7 mm 3 - 5 Nm 2.2 - 3.7 ft-lb 7 mm 4 - 6 Nm 2.9 - 4.4 ft-lb N.A. 3.5 mm 0.5 Nm max. 4.4 lb-in max. 6 (0.24) mm (inch) 177HA245.11 167ºF (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 semiconductor fuses. MG.17.C2.22 - VLT is a registered Danfoss trademark The following table provides a list of suitable Ferraz and Bussman fuses. If selecting alternate brands, ensure that the selected fuse has a lower total clearing I2t rating than the SCR, and can carry start current for the full starting duration. 9 MCD 200 Design Guide MCD 200 SCR I2t (A2s) 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 Ferraz Fuse Bussman Fuse Bussman Fuse European/IEC Style (North Square Body British Style American Style) (170M) (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 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 to Ferraz for options. ■ 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 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 10 • • 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? MG.17.C2.22 - VLT is a registered Danfoss trademark • • • • • • 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 (10 ~ 74 HP / 7.5 ~ 55 kW): 1,000,000 operations Size 3 (100 ~ 148 HP / 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. 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 output: The relay operates when the MCD 202 trips on any fault. This can be used to operate a MG.17.C2.22 - VLT is a registered Danfoss trademark • • • • shunt-trip 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. 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 reapplication of the start signal. What is the remote start and stop input impedance? Are any special precautions necessary during installation? The N1/N2 input impedance is approximately 400 k @ 300 VAC and 5.6 k @ 24 VAC/VDC. All control wiring, for long runs, should be either twisted pair or shielded cable with the shield grounded at one end. Control wiring should be separated from power cables by a minimum distance of 11.8 in. (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) line voltage? There is a possibility that 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 line voltage is applied without control voltage, this step is missed, and the motor may start DOL without warning (see Product Note for more detail). 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, 11 MCD 200 Series Overview MCD 200 Design Guide MCD 200 Design Guide • 12 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 line 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. MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide ■ 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. Example 2 - MCD 201 installed with motor protection circuit breaker and line contactor. L1 L2 L3 I> I> I> 1/L1 3/L2 5/L3 ■ Electrical Schematic Example 1 - MCD 201 installed with motor protection circuit breaker. L1 L2 L3 Q1 K1M I> I> I> 1/L1 3/L2 5/L3 A1 A2 A3 N1 N2 Q1 A1 A2 A3 N1 N2 1,2 2/T1 1,2 4/T2 6/T3 13 14 177HA246.11 4/T2 6/T3 13 14 177HA207.11 Motor 3Ø Motor 3Ø K1M Control Voltage 1 6 A @ 30 VDC resistive / 2 A 400 VAC AC11 2 Main Contactor MCD 201 2/T1 Example 3 - MCD 201 installed with circuit breaker, overload and line contactor. Ue 177HA241.10 MG.17.C2.22 - VLT is a registered Danfoss trademark 13 MCD 200 Design Guide L1 L2 L3 I> I> I> 1/L1 3/L2 5/L3 Q1 F1 K1M A1 A2 A3 N1 N2 1,2 2/T1 4/T2 6/T3 13 14 177HA247.11 Motor 3Ø K1M Control Voltage 14 MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide ■ Control Circuits 2 Wire Control 1 Initial Torque Value: 30% - 75% Initial Torque 110-240 VAC (CV3) OR 24 VAC/VDC (CV1) A3 START/ STOP A1 (+) A2 (-) * ✭ 50% Function: Determines the start torque generated by the motor when the start command is first applied. N1 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 U 100% A2 START/ STOP * N1 Initial Torque N2 177HA211.10 (30 - 75%) 177HA249.10 * Also resets the MCD 201 3 Wire Control 2 Ramp Up 110-240 VAC (CV3) OR 24 VAC/VDC (CV1) A3 START STOP Value: 2 - 20 seconds, Full Voltage A1 (+) A2 (-) N1 * ✭ 10 seconds Function: Determines the time taken for voltage to be ramped up to line voltage. N2 Set to optimize 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. A1 A2 START STOP N1 * N2 177HA212.10 Ramp Up (2 - 20 seconds, Full Voltage Start) * Also resets the MCD 201 U 100% ■ Functionality User Adjustments Initial Torque (30 - 75%) Initial Torque 40% 60% Ramp Up 30% 70% (% U) 8s 6s 4s 2s 177HA250.10 U 50% 10s 12s 14s 16s 20s Full Voltage Start (seconds) U 8s 6s 4s 2s 10s 12s 14s 16s 20s 3 Ramp Down Value: 2 - 20 seconds, No Soft Stop ✭ No Soft Stop Ramp Down U No Soft Stop (seconds) Function: Sets the time of the soft stop voltage ramp. The soft stop function extends motor deceleration 177HA248.10 MG.17.C2.22 - VLT is a registered Danfoss trademark 15 MCD 201 380-440 VAC (CV3) Description of choice: A3 MCD 200 Design Guide time by ramping down voltage supplied to the motor when a stop is initiated. Description of choice: Set the ramp time to optimize stopping characteristics for the load. Ramp Down (2 - 20 seconds, No Soft Stop) U 100% 177HA251.10 ■ Indication L1 3 L2 5 L3 177HA252.10 1 Ready Run 2 LED Ready Run T1 4 T2 OFF No control power Motor not running 6 T3 ON Ready Motor running at full speed FLASH Starter tripped Motor starting or stopping ■ Fault Finding Ready LED x1 x6 x8 x9 16 Description Power Circuit Fault: Check line supply L1, L2 & L3, motor circuit T1, T2 & T3 and soft starter SCRs. Supply Frequency: Check if 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.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide ■ MCD 202 ■ MCD 202 Range MCD 202 soft starters provide current limit control and TVR soft stop, and include a range of motor protection features Example 2 – MCD 202 installed with system protection circuit breaker and line contactor. L1 ■ Electrical Schematic Example 1 – MCD 202 installed with system protection circuit breaker complete with shunt trip device. L1 L2 L3 L2 L3 I> I> I> 1/L1 3/L2 5/L3 Q1 K1M I> I> I> 1/L1 3/L2 5/L3 A1 A2 A3 N1 N2 05 06 Q1 177HA253.11 A1 A2 A3 N1 N2 1,2 05 06 2/T1 1,2 2/T1 4/T2 6/T3 4/T2 6/T3 13 14 23 24 177HA254.11 1,3 13 14 1,3 K1M Motor 3Ø 23 24 Control Voltage Motor 3Ø Control Voltage 1 2 6 A @ 30 VDC resistive / 2 A 400 VAC AC11 Main Contactor 110-240 VAC (CV3) OR 24 VAC/VDC (CV1) ■ Control Circuits 2 Wire Control Shunt Trip A3 START/ STOP * A1 (+) A2 (-) N1 N2 3 Auxiliary Relay Function = Trip (see parameter 8) A3 A1 A2 START/ STOP 177HA211.10 MCD 202 177HA241.10 380-440 VAC (CV3) Ue * N1 N2 * Also resets the MCD 202 MG.17.C2.22 - VLT is a registered Danfoss trademark 17 MCD 200 Design Guide 3 Wire Control Description of choice: 110-240 VAC (CV3) OR 24 VAC/VDC (CV1) A3 A1 (+) A2 (-) START = 95 A 100 A N1 * STOP 95% 380-440 VAC (CV3) N2 177HA233.12 2 Current Limit Value: 250% - 475% Motor FLC A3 A1 A2 START Function: Sets the desired starting current limit. N1 * STOP N2 177HA212.10 Description of choice: The current limit should be set so that the motor accelerates easily to full speed. * Also resets the MCD 202 ■ Functionality User Adjustments I 400% 300% Current Limit (250 - 475%) Current Ramp I 200% FLC 2s 5s 15s 2s 5s 15 70% FLC 50% 250% FL C 15s 5s 2s 1 OFF 60% 50% 177HA256.10 90% I 100% 4s 250% NOTE 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. M Motor Trip Class 6 8 4 2 OFF I 12s 14s 16s 20s No Soft Stop Soft Stop 2s 450% (% Motor FLC ) 10 10s 8s 400% 6s Phase Rotation 12 ANY 14 16 FWD 20 Trip 100% Motor FLC Current Limit 350% 200% 80% (%FLC / Ramp Time) (% MCD202 FLC) 300% ✭ 350% ANY FWD Run Aux Relay U Excess Start Time 6 8 10 4 2 OFF 12 14 16 20 3 Current Ramp 177HA255.10 1 Motor FLC Value: 50% - 100% MCD 202 FLC Function: Calibrates the MCD 202 for the Full Load Current of the motor. ✭ 100% 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 ✭ 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. 18 MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide Soft Stop Ramp Time I (2, 5, 15 seconds, OFF) (2 - 20 seconds, No Soft Stop) 400% U 300% Initial Start Current (150% FLC, 200% FLC, 250% FLC) 100% 200% 100% 177HA257.10 Typically, the Current Ramp start mode would be used in two circumstances. 4 Soft Stop Ramp Time Value: 2 - 20 seconds, No Soft Stop ✭ 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. Value: 2 - 20, Off ✭ 10 Function: Calibrates the MCD 202 motor thermal model according to the desired motor trip class. Description of choice: Cold Start Curves 177HA258.10 1000 100 20 Class 20 10 Class 10 1 100 300 500 600 700 I (% FLC) 6 Excess Start Time Protection Value: 2 - 20 seconds, Off ✭ 10 seconds Function: Sets the maximum allowable start time. Description of choice: MCD 202 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: • Set Parameter 2 Current Limit as desired. • Set Parameter 3 Current Ramp so that: - the Initial Start Current is at a lower level than the Current Limit - the ramp time achieves the desired gradual draw of start current 5 Motor Trip Class t(s) 1. For applications where start conditions vary between starts, the Current Ramp mode provides an optimum soft start regardless of motor loading, e.g. a conveyor that may start loaded or unloaded. 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 177HA268.10 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) Description of choice: Set the ramp time to optimize stopping characteristics for the load. I 400% 300% 200% 100% 177HA259.10 This provides early indication that the application conditions have changed or that the motor has MG.17.C2.22 - VLT is a registered Danfoss trademark 19 stalled. It can also protect the soft starter from being operated outside its rated start capability. 177HA240.11 MCD 200 Design Guide Ue NOTE Ensure the Excess Start Time protection setting is within the MCD 202 rated capability. Main Contactor RUN 7 Phase Rotation Protection Value: ANY, FWD ✭ ANY ■ Motor Thermistor Protection ANY = Forward & Reverse rotation permitted 05 Or FWD = Forward Rotation Only 06 Motor thermistor cut-out value = 2.8 k . ■ Indication Description of choice: L1 L2 L3 MCD 177HA239.10 MCD ANY 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. 3 L2 5 L3 8 Auxiliary Relay Function (Terminals 23, 24) Ready Run 2 LED Ready Run Value: Trip, Run L1 177HA260.10 1 FWD 06 177HA279.10 Function: Sets the allowable phase rotation sequence of the incoming supply. L1 L2 L3 05 T1 4 T2 OFF No control power Motor not running 6 T3 ON Ready Motor running at full speed FLASH Starter tripped Motor starting or stopping ✭ 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. 20 MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide ■ Fault Finding Ready LED x1 x2 x3 x4 x5 x6 x7 x8 Power Circuit Fault: Check line 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 if 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. MCD 202 x9 Description MG.17.C2.22 - VLT is a registered Danfoss trademark 21 MCD 200 Design Guide ■ Accessories ■ Overview The following optional accessory items are available for use with MCD 200 soft starters: • • • • • • ■ MCD 200 Remote Operator Order Code: 175G9004 The Danfoss Remote Operator can be used with MCD 201, MCD 202 and MCD 3000 to provide the following functionality. 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 Feature Accessory items are integrated with the MCD 200 soft starters by means of a plug-in module as shown below. Pushbutton Control (Start, Stop, Reset) Starter Status LEDs (Starting, Running, Tripped) Motor Current Display Motor Temperature Display Trip Code Display 4-20 mA Output (Motor Current) MCD 201 MCD 202 MCD 3000 • • • • • • • • • • • • • • • See the Remote Operator Operating Instructions for further details. ■ MCD 200 Modbus Module Order Code: 175G9000 177HA261.10 The Modbus Module supports Modbus RTU and AP ASCII. See the Modbus Module Operating Instructions for further details. ■ MCD 200 Profibus Module Order Code: 175G9001 35 mm (1.38 inches) Control power and line supply must be removed from the MCD 200 before attachment or removal of accessory modules. Failure to do so may result in equipment damage. 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. ■ 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. 22 MG.17.C2.22 - VLT is a registered Danfoss trademark 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 MCD MCD 201 202 3000 • • • • • • • • • • Accessories 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. MG.17.C2.22 - VLT is a registered Danfoss trademark 23 MCD 200 Design Guide ■ Soft Start Application 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 and shape of the current and torque curves are dependent on motor design. Full Voltage Stator Current 2 x FLT 6 x FLC 5 x FLC 4 x FLC Full Voltage Start Torque 1 x FLT 3 x FLC 2 x FLC 1 x FLC TORQUE (% Motor Full Load Torque) CURRENT (% Motor Full Load Current) 7 x FLC Sample Load Torque Curve 10% 20% 30% 40% 50% 60% 70% ROTOR SPEED (% Full Speed) 80% 90% 100% 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% of 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 minimizing start current or maximizing 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: 24 TST = Start torque IST = Start current LRC = Motor Locked Rotor Current LRT = 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. The most common reduced voltage starters are: • • • • Star/Delta starters Auto-transformer starters Primary resistance starters Soft starters 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 optimized for one condition. MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide These include: 1. Difficult to optimize 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. 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. ■ 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 MG.17.C2.22 - VLT is a registered Danfoss trademark 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 is a 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. 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 others 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) does not exceed 257 °F (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. 25 Soft Start Application Guide Primary resistance starters also provide greater starting control than star/delta starters. However, they do have a number of characteristics that reduce their effectiveness. MCD 200 Design Guide IEC 60947-4-2 details the AC53 utilization categories for describing a soft starter’s ratings. To compare the current rating of different soft starters, it is important to ensure that operating parameters are identical. 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). 256 A: AC-53a 4.5-30 : 70-10 tR en ing at r ou rH Pe Cycle ts ar uty St D ) s) ad cond f FLC -lo o se On e ( ltiple im u t T t (m ar en St rr Cu rt a St r ur rC te ar St 177HA280.10 • 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. ■ Model Selection NOTE 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. 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 c se e( ) ) im ds LC n fT co fF Of (se eo e ip l im ult t T t (m ar en St rr Cu rt a St r ur rC te ar St s) d on tR en ing at 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. 26 MG.17.C2.22 - VLT is a registered Danfoss trademark MCD 200 Design Guide General & Water Agitator Centrifugal Pump Compressor (Screw, unloaded) Compressor (Reciprocating, unloaded) Conveyor Fan (damped) Fan (undamped) Mixer Positive Displacement Pump Submersible Pump Metals & Mining Belt Conveyor Dust Collector Grinder Hammer Mill Rock Crusher Roller Conveyor Roller Mill Tumbler Wire Draw Machine Food Processing Bottle Washer Centrifuge Dryer Mill Palletizer Separator Slicer Pulp and Paper Dryer Re-pulper Shredder Petrochemical Ball Mill Centrifuge Extruder Screw Conveyor Transport & Machine Tool Ball Mill Grinder Material Conveyor Palletizer Press Roller Mill Rotary Table Lumber & Wood products Bandsaw Chipper Circular Saw Debarker Edger Hydraulic Power Pack Planer Sander Duty Normal Normal Normal Normal Normal Normal Heavy Heavy Normal Normal Heavy Normal Normal Heavy Normal Normal Heavy Normal Heavy Normal Normal Heavy Heavy Heavy Heavy Normal NOTE 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 those listed in this manual. ■ Typical Applications MCD 200 soft starters can offer benefits for almost all motor starting applications. Typical advantages are highlighted in the table below. Application Pumps Conveyor Belts Heavy Heavy Heavy Heavy Normal Heavy Normal Heavy Normal Normal Heavy Normal Heavy Normal Heavy Heavy Normal Normal Normal Normal Normal Normal MG.17.C2.22 - VLT is a registered Danfoss trademark Centrifuges Ski Lifts Benefits • Minimized hydraulic shock in pipelines during start and stop. • Reduced starting current. • Minimized mechanical stress on motor shaft. • Phase rotation protection prevents damage from reverse pump rotation. • Controlled soft start without mechanical shocks, e.g. bottles on a belt do not fall over during starting, minimized belt stretch, reduced counterbalance stress. • Controlled stop without mechanical 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. 27 Soft Start Application Guide Application MCD 200 Design Guide Application Compressors Fans Mixers Benefits • 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 operation in reverse direction. • 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. • Gentle rotation during startup reduces mechanical stress. • The starting current is reduced. ■ Power Factor Correction If a soft starter is used with static power factor correction, 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 in damage to the soft starter. 28 MG.17.C2.22 - VLT is a registered Danfoss trademark www.danfoss.com/drives Design Guide MCD 200 MCD 201 MCD 202 175R0978 MG17C222 *MG17C222* Rev. 2004-09-08
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