Danfoss VLT® MCD 3000 Operating Guide

www.danfoss.com/drives

175R0865 MG15A402 *MG15A402* Rev. 2003-10-09

Operating Instructions

MCD 3000 Soft Starter

Section 0.0

Section 1.0

Section 2.0

Section 3.0

Section 4.0

Section 5.0

Section 6.0

Section 7.0

Section 8.0

MCD3000 Series

■

Warnings

............................................................ 2

■

Quick Set-up

.................................................... 3

■

Description

....................................................... 4

■

Installation

3.1

Mechanical Installation ..................................... 6

3.2 Ventilation ........................................................ 6

3.3 General Layout ................................................ 6

3.4 Power Wiring - Standard Connection ............... 7

3.5 Power Wiring - Bypass Connection .................. 7

3.6 Power Wiring - D.C.Brake Connection .............. 8

3.7 Power Wiring – Inside Delta Connection ........... 8

3.8 Control Supply Voltage .................................... 8

3.9 Control Wiring ................................................. 9

3.10 Motor Thermistors ....................................... 10

3.11 Control Circuit Examples ............................. 10

3.12 Serial Communications ................................ 11

■

Programming

4.1

Programming Procedure ............................... 16

4.2 Programmable Functions ............................... 16

■

Operation

5.1

Local Control Panel ....................................... 27

5.2 Remote Control ............................................. 27

5.3 Serial Communications .................................. 28

5.4 Restart Delay ................................................. 28

5.5 Secondary Parameter Set .............................. 28

5.6 Motor Thermal Model .................................... 28

5.7 Pre-start Tests ............................................... 28

5.8 Operation After Power Loss ........................... 28

■

Specifications

6.1

General Technical Data .................................. 29

6.2 Current Ratings ............................................. 30

6.3 Power Termination Details ............................. 31

6.4 Semi-conductor Fuses .................................. 31

6.5 Dimensions/Weights ...................................... 32

■

Design Guide

7.1

Reduced Voltage Starting .............................. 33

7.2 Types Of Soft Start Control ............................ 34

7.3

MCD3000 Control Principles ......................... 34

7.4 Understanding Soft Starter Ratings ............... 34

7.5 Model Selection ............................................. 35

7.6 Typical Applications ....................................... 36

7.7 Power Factor Correction ............................... 38

7.8 Line Contactors ............................................. 38

7.9 Soft Braking .................................................. 38

■

Fault Procedure

8.1

Trip Codes .................................................... 39

8.2 Trip Log ......................................................... 40

8.3 General Faults ............................................... 41

8.4 Tests and Measurement Procedures ............. 42

MG.15.A4.02 - VLT is a registered Danfoss trademark 1

MCD3000 Series

The MCD3000 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 MCD3000 may cause equipment failure, serious injury or death. Follow this manual and

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.

2. The [STOP] on the control panel of the soft starter does not disconnect the equipment from the mains and thus is not to be used as a safety switch.

It is the responsibility of the user or the person installing the MCD3000 to provide proper grounding and branch circuit protection according to the National Electric Code

(NEC

®

) and local codes.

■

Warning against unintended start

1. The motor can be brought to a stop by means of digital commands, bus commands or a local stop, 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 if the soft starter’s Auto Reset function has been activated and 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:

■

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 voltage to the MCD3000 control inputs. The inputs are active 24 VDC and must be controlled with potential free circuits.

3. When installed in non-ventilated enclosures, soft starters should be used with a bypass contactor to prevent excessive enclosure temperatures.

4. When bypassing a soft starter take care to ensure phase connections are correct. i.e. B1-T1, L2-T2,

B3-T3.

5. When using the D.C.Brake function ensure the

D.C.Braking contactor is connected across output terminals T2-T3 only and that it operates only when the braking function is operating. Incorrect connection or operation will cause soft starter damage.

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.

Indicates something to be noted by the reader

Indicates a general warning

Indicates a high voltage warning

2 MG.15.A4.02 - VLT is a registered Danfoss trademark

■

Quick Set-up

For basic start/stop control only three steps are required to commission the MCD3000.

•

Install the MCD3000

•

Program the MCD3000

•

Start the motor.

The MCD3000 provides many other features that enable users to customise operation for their particular requirements. To learn more about these features please study this manual.

■

Install the MCD3000

Mounting, wiring and setting the soft starter into operation must be carried out properly by trained personnel.

1. Verify that the ratings of the MCD3000 are correct for the application.

2. Physically install the MCD3000. (Refer to the

Installation section of this manual)

3. Connect mains, motor, motor thermistor (if any) and control voltage circuits as shown below.

MCD3000 Series

1. Enter the programming mode by pressing the

[MENU/CANCEL] button on the Local Control

Panel. The display will show the number of the first programming parameter, Par.1 Motor FLC

2. Press the [CHANGE DATA/OK] button to display the programmed value. The setting may now be adjusted.

3. Using the [+/-] buttons adjust the setting to match the motor FLC.

4. When correct, store the Motor FLC setting by pressing the [CHANGE DATA/OK] button

(Pressing the [MENU/CANCEL] button returns you to the parameter number without saving the new value).

5. Return the MCD3000 to run mode by pressing the

[MENU/CANCEL] button.

The voltage of the soft starter is dangerous whenever the equipment is connected to the mains. Ensure the soft starter is correctly connected and that all safety measures have been taken before switching on the supply.

4. Turn on the supply.

■

Program the MCD3000

For simple applications the MCD3000 needs only to be programmed with the FLC (Full Load Current) of the connected motor.

To program the MCD3000 with the motor FLC do the following:

■

Start the motor

With the motor FLC programmed, the motor can now be started using the MCD3000 [START] button.

Other commonly used functions that may be useful in a Quick Set-up situation include:

•

Par. 5 Soft Stop (Refer to the Programming section of this manual for a description)

•

Par. 2 Current Limit (Refer to the Programming section of this manual for a description)

If required, set these parameters in the same manner as described for Par 1. Motor FLC


MCD3000 Series

MCD3015

MCD3018

MCD3022

MCD3030

MCD3037

MCD3045

MCD3055

MCD3075

MCD3090

MCD3110

MCD3132

MCD3185

MCD3220

MCD3300

MCD3315

MCD3400

MCD3500

MCD3600

MCD3700

MCD3800

■

Description

The Danfoss MCD3000 Soft Starter is an advanced electronic motor starting system. It performs four main functions;

The power circuit uses reverse parallel connected thyristors to provide full wave control on all three phases. The MCD3000 can be used with or, if local regulations permit, without a line contactor.

2. Stop control, including both soft stop (extended stop time) and braking (reduced stop time).

3. Electronic motor protection.

4. Monitoring & system interface.

Models MCD3007 - 3132 are IP21 (NEMA 1) rated and have a local control panel that includes start, stop

& reset push buttons. They are suitable for wall mounting, or installation in a switchboard.

Models MCD3185 - 3800 have an IP20 rating and must be installed in a switchboard or other enclosure.

The MCD3000 Soft Starters are complete and require no optional modules to add functionality.

Automatic detection and calibration for supply voltage and frequency eliminates the need for special models.

■

Ordering type code

MCD3000 Soft starters are available with two maximum voltage ratings.

•

200 VAC ~ 525 VAC

•

200 VAC ~ 690 VAC

.$% 3BUFE$VSSFOU "NQT

.PEFM

"$B

MCD3007 20

%JNFOTJPOTNN JODIFT

)FJHIU

530 (20.87)

8JEUI

132 (5.20)

%FQUI

1SPUFDUJPO

'PSNBU

270 (10.63) IP21 Book style (B21)

196

231

247

364

430

546

630

775

86

93

121

138

34

39

47

68

897

1153

1403

1564

530 (20.87) 132 (5.20)

530 (20.87) 132 (5.20)

530 (20.87) 132 (5.20)

530 (20.87) 132 (5.20)

270 (10.63) IP21 Book style (B21)

270 (10.63) IP21 Book style (B21)

270 (10.63) IP21 Book style (B21)

270 (10.63) IP21 Book style (B21)

530 (20.87) 132 (5.20)

530 (20.87) 132 (5.20)

270 (10.63) IP21 Book style (B21)

270 (10.63) IP21 Book style (B21)

530 (20.87) 132 (5.20) 270 (10.63) IP21 Book style (B21)

530 (20.87) 264 (10.40) 270 (10.63) IP21 Compact (C21)

530 (20.87) 264 (10.40) 270 (10.63) IP21 Compact (C21)

530 (20.87) 264 (10.40) 270 (10.63) IP21 Compact (C21)

530 (20.87) 396 (15.60) 270 (10.63) IP21 Compact (C21)

850 (33.46) 430 (16.93) 280 (11.02) IP20 Compact (C20)

850 (33.46) 430 (16.93) 280 (11.02) IP20 Compact (C20)

850 (33.46) 430 (16.93) 280 (11.02) IP20 Compact (C20)

850 (33.46) 430 (16.93) 280 (11.02) IP20 Compact (C20)

850 (33.46) 430 (16.93) 280 (11.02) IP20 Compact (C20)

850 (33.46) 430 (16.93) 280 (11.02) IP20 Compact (C20)

1000 (39.37) 560 (22.05) 315 (12.40) IP20 Compact (C20)

1000 (39.37) 560 (22.05) 315 (12.40) IP20 Compact (C20)

1000 (39.37) 560 (22.05) 315 (12.40) IP20 Compact (C20)


■

Functions

Function

Starting

•

Current Limit

•

Current Ramp

•

Torque Boost

•

Torque Control

Stopping

•

Soft Stop

•

Pump Control

•

D.C. Brake

Protection

•

Motor Overload

•

Phase Imbalance

•

Undercurrent

•

Instantaneous Overload

•

Phase Rotation

•

Restart Delay

•

Motor Thermistor

•

Power Circuit Tests

•

Shorted SCR

•

Starter Heatsink Overtemperature

•

Supply Frequency

•

RS485 Comms Error

Interface

•

Local Control Panel

•

Remote Inputs

•

Serial Communications (RS485)

•

Programmable Relay Outputs

Sundry

•

Password Protection

•

Dual Parameter Set

•

Trip Log

•

High & Low Current Flags

•

Automatic Reset

•

Current Display

•

Motor Temperature Display

•

Reset parameters to default settings

•

Program starter via serial link

Related

Parameters

2

3 & 4

16

16

5

17

18 & 19

6

7, 12 & 31

8, 13 & 32

9, 14 & 33

11

15

-

-

-

-

-

24

20

20

22, 23 & 24

36, 37 & 38

46, 47 & 48

25 - 33

45

34 & 35

-

-

39, 40, 41 &

42

49

-

MCD3000 Series

■

Electrical Schematic


MCD3000 Series

■

Mechanical installation

Models MCD3007~3132 have an IP21 rating and can be wall mounted or installed inside another enclosure.

These models can be mounted side by side with no clearance.

Models MCD3185~3800 have an IP20 rating and must be mounted in another enclosure. These models must have a clearance of 100mm on either side.

Motor

Amps

Heat

(watts)

Required Airflow m

3

/min

5 o C Rise 10 o C Rise

10 45 0.5 0.2

20 90 0.9 0.5

30 135 1.4 0.7

40 180 1.8 0.9

50 225 2.3 1.1

75 338 3.4 1.7

100 450 4.5 2.3

125 563 5.6 2.8

150 675 6.8 3.4

175 788 7.9 3.9

200 900 9.0 4.5

250 1125 11.3 5.6

300 1350 13.5 6.8

350 1575 15.8 7.9

400 1800 18.0 9.0

450 2025 20.3 10.1

500 2250 22.5 11.3

550 2475 24.8 12.4

600 2700 27.0 13.5

ATTENTION

If other heat sources are installed in an enclosure with the MCD3000, this heat must also be considered when calculating required airflow.

ATTENTION

If the MCD3000 is installed in an enclosure without ventilation a bypass contactor should be employed to prevent heat dissipation during run.

■

General layout

MCD3007 ~ MCD3055

ATTENTION

Do not mount in direct sunlight or near heat radiating elements.

■

Ventilation

MCD3000 cooling is by means of air circulation.

Consequently, the air needs to be able to move freely above and below the soft starter.

Soft starters dissipate approximately 4.5 watts per amp. When installing a soft starter in a switchboard or other enclosure, ensure there is sufficient airflow through the enclosure to limit heat rise in the enclosure.

The table below shows airflow requirements for selected motor currents.


MCD3075 ~ MCD3110

MCD3132

MCD3185 ~ MCD3800

MCD3000 Series

Use cables complying with local regulations.

■

Power wiring - Standard connection

Supply voltage must be connected to the starter input terminals L1, L2 & L3. The motor terminals must be connected to the soft starter output terminals T1, T2 &

T3.

■

Power wiring - Bypass connection

A bypass contactor may be used to bypass the starter during run. A separate set of power terminals is provided within the MCD3000 for connection of the bypass contactor. These bypass terminals enable the

MCD3000 to continue to provide all motor protection and current monitoring functions when the bypass contactor is closed.

Either Relay Output C or Relay Output A can be programmed to control operation of the bypass contactor.

Par. 36 Relay A - Function Assignment = 1 (Run)

Par. 38 Relay C - Function Assignment = 0 (Run)


MCD3000 Series

Failure to correctly connect the bypass contactor (B1-T1, L2,-T2, & B3-T3) will result in a loss of current based protection systems possibly leading to a motor failure.

Failure to correctly connect the bypass contactor (B1-T1, L2,-T2, & B3-T3) may result in a phase to phase short circuit causing severe equipment failure .

■

Power wiring - D.C.Brake connection

If the D.C.Braking function is to be used, a contactor must be wired to short output terminals T2 & T3 during the braking operation. This contactor must be controlled by the MCD3000 Relay Output C and Relay

Output C must be programmed for D.C.Brake operation.

•

Refer to Par. 18 and 19 for D.C.Brake parameter adjustments.

•

Refer Par. 38 Relay C - Function Assignment .

The MCD3000 power modules will be damaged if the D.C.Brake contactor is closed when the D.C.Brake function is not operating, or if the .D.C.Brake contactor is incorrectly connected between T1-T2 or T1-T3.

3 PHASE

SUPPLY

K1M

Legend

K1M Line Contactor

L1

L1B

L2

L2B

L3

L3B

T1

T2

T3

E

V1

W1

U1 U2

Motor

V2

W2

ATTENTION

For inside delta connection to be possible both ends of all three motor windings must be accessible.

When utilizing the inside delta connection method voltage remains connected to one end of the motor windings even when the soft starter is in the off or tripped state. A line contactor or shunt trip activated circuit breaker must be used to totally isolate the motor in the event of a fault condition.

When fitted with one of the kits from the following table, MCD3000 units are inside delta capable. The inside delta capability is additional to all normal functionality and is totally automatic. No user adjustment or settings are required.

MCD3000 Model Inside Delta Kit

MCD3185 175G3043

MCD3220 175G3044

MCD3300 175G3045

MCD3315 175G3046

MCD3400 175G3047

MCD3500 175G3048

MCD3600 175G3049

MCD3700 175G3050

MCD3800 175G3051

■

Control Supply Voltage

Voltage must be connected to the starter control voltage terminals. Control voltage can be either 230

VAC or 400 VAC (CV4)

■

Power wiring – Inside delta connection

Models MCD3185 ~ MCD3800 can be connected inside the delta circuit of the motor when fitted with an optional Inside Delta Kit.

Soft starters connected within the delta circuit of a motor control only phase current thereby enabling them to be used with larger motors than would be possible with normal line connection. See the

Specifications section of this manual for inside delta ratings.


MCD3000 Model Maximum VA

MCD3007~MCD3022 10VA





The following range of auto-transformers are available as optional accessories and can be fitted within the

MCD3000 where other control voltages must be used.

Input Voltage

110 VAC / 460 VAC

Part Number

MCD3007 ~ MCD3075 ~

MCD3055

175G5084

MCD3800

175G5144

110 VAC / 575 VAC

24 VAC / 110 VAC

175G5085

175G5087

175G5145

175G5146

Removing control voltage from the

MCD3000 resets the motor overload protection.

■

Control wiring

The MCD3000 can be controlled using the local push buttons, or via remote control inputs. Switch between the local and remote modes using the

[LOCAL/REMOTE] push button.

The MCD3000 has four remote control inputs.

Contacts used for controlling these inputs should be low voltage, low current rated (Gold flash or similar).

The Stop and Reset circuits must be closed for the MCD3000 to run in remote control mode.

Push button control example:

MCD3000 Series

Two wire control example:

ATTENTION

Simultaneously pressing the [STOP] and

[RESET] buttons causes the MCD3000 to immediately remove voltage from the motor resulting in a coast to stop. Any soft stop or D.C.Brake settings are ignored.

Do not apply voltage to the control inputs.

The inputs are active 24 VDC and must be controlled with potential free circuits.

The Par. Set input determines which of the two

MCD3000 motor parameter sets is operative. When a start is initiated the MCD3000 checks the state of the

Par. Set input. If there is an open circuit the primary parameters (Par. 1 - 9) are operative. If there is a closed circuit the secondary parameters (Par. 25 - 33) are operative.

The MCD3000 provides three relay outputs.

13

14

21

22

24

33

34

Output A

Output B

Output C

Line contactor

Run

High current flag

Low current flag

Trip

Output on

High current flag

Low current flag

Line contactor

Run

D.C.Brake contactor

All outputs are programmable. Refer Par. 36, 37 & 38

Relay Function Assignment .


MCD3000 Series

Example 2. MCD3000 installed with a line contactor and operated via a remote two wire start circuit with reset push button.

■

Motor thermistors

If the motor is fitted with thermistors these may be connected directly to the MCD3000. A trip will occur if the thermistor circuit resistance is above approximately 2.8k

Ω.

If thermistors are not connected to the MCD3000 there must be a link across the thermistor input terminals.

■

Control circuit examples

Example 1. A basic installation where motor operation is controlled using the MCD3000 Local Control Panel.

Notes:

1. The MCD3000 must be in remote mode to function with this circuit. Use the

[LOCAL/REMOTE] push button to switch between local and remote modes.

2. Relay Output A must be programmed for the Line

Contactor function. Refer Par. 36 Relay A -

Function Assignment .

Notes:

1. The MCD3000 must be in local mode to function with this circuit. Use the [LOCAL/REMOTE] push button to switch between local and remote modes.


Example 3. MCD3000 installed with a bypass contactor and controlled via a remote push button circuit.

MCD3000 Series

Example 4. MCD3000 controlled by remote 3 wire push button circuit.

Notes:



2. Relay Output C must be programmed for the Run function. Refer Par. 38 Relay C - Function

Assignment .

Notes:



■

Serial communications

The MCD3000 has a non-isolated RS485 serial communications link. The serial link can be used to;

•

Control MCD3000 operation

•

Query MCD3000 status and operating data

•

Read (download) MCD3000 parameter settings

•

Program (upload) MCD3000 parameters

MG.15.A4.02 - VLT is a registered Danfoss trademark

ATTENTION

Communications cabling should not be located within 300mm of power cabling.

Where this cannot be avoided consideration should be given to providing magnetic shielding to reduce induced common mode voltages.

Data transmitted to and from the MCD3000 must be in 8 bit ASCII, no parity, 1 stop bit.

11

MCD3000 Series

The MCD3000 can be programmed to trip if the

RS485 link fails. This is done by setting Par. 24 Serial

Communications - RS485 Time Out.

Baud rate is set by Par. 22 Serial Communication -

Baud Rate .

The starter address is assigned using Par. 23 Serial

Communications - Satellite Address .

ATTENTION

Slave address must be two digit, addresses less than 10 must have a leading zero (0).

ATTENTION

If no MCD3000 starter is configured to the specific slave address, no response will be received by the host.

ATTENTION

The MCD3000 may take up to 250ms to respond. The host software timeout should be set accordingly.

ATTENTION

The satellite address and baud rate may also be altered through the serial interface.

Behaviour of the serial interface will not be affected by such parameter changes until the current Serial

Programming mode session is terminated by the master. The serial master application must ensure that altering these parameters does not cause communication problems.

The details of the message fragments used in communicating with the MCD3000 are shown in the table below. The message fragments may be assembled into complete messages as described in the sections that follow.

Message

Fragment Type

Send Address

ASCII Character String or

(Hexidecimal Character

String)

EOT [nn] [lrc] ENQ or

(04h [nn] [lrc] 05h)

Send Command

Send Request

Read Parameters

Write Parameters

Receive Data

STX [ccc] [lrc] ETX or

(02h [ccc] [lrc] 03h)

Receive Status

STX [dddd] [lrc] ETX or

(02h [dddd] [lrc] 03h)

STX [ssss] [lrc] ETX or

(02h [ssss] [lrc] 03h)

Parameter Number DC1 [pppp] [lrc] ETX

(011h [pppp] [lrc] 03h)

Parameter Value DC2 [vvvv] [lrc] ETX

(012h [vvvv] [lrc] 03h)

Message

Fragment Type

ACK

ASCII Character String or

(Hexidecimal Character

String)

ACK or

(06h)

NAK NAK or

(15h)

ERR BEL

(07h) nn = two byte ASCII number representing the soft starter address where each decimal digit is represented by n. lrc = two byte longitudinal redundancy check in hexadecimal. ccc = three byte ASCII command number where each character is represented by a c. dddd = four byte ASCII number representing the current or temperature data where each decimal digit is represented by d. ssss= four byte ASCII number. The first two bytes are ASCII zero. The last two bytes represent the nibbles of a single byte of status data in hexadecimal. pppp = four byte ASCII number representing the parameter number where each decimal digit is represented by p. vvvv = four byte ASCII number representing the parameter value where each decimal digit is represented by v.

■

Serial communications - commands

Commands can be sent to the MCD3000 using the following format;

Send

Address

ACK

Send

Command

ACK

Possible error responses

NAK

Invalid LRC

= Master = Slave (MCD3000)

Command

Start

Stop

Reset

ASCII Comment

B10 Initiates a start.

B12 Initiates a stop

B14 Resets a trip state

Coast to stop B16 Initiates an immediate removal of voltage from the motor. Any soft stop or

D.C.Brake settings are ignored.

■

Serial communications – status retrieval

Starter status can be retrieved from the MCD3000 using the following format;


Send

Address

ACK

Send

Request


Receive

Data

NAK Invalid LRC

MCD3000 Series

Send

Address

ACK

Send

Request


Receive

Data

NAK Invalid LRC

= Master = Slave (MCD3000) = Master

Request ASCII Bit No.

Status C10

Receive Data

(ssss)

Requests the configuration status of the MCD3000.

(Positive logic 1 = true) rotation

Request ASCII Receive Data (dddd)

Current D10 Requests motor current. The data is 4 byte decimal ASCII.

Minimum value 0000, Maximum value 9999 Amps.

Status.2 Unallocated

D12 Requests the calculated value of the motor thermal model as a % of Motor Thermal Capacity.

The data is 4 byte decimal

ASCII. Minimum value 0000%.

Trip point 0105%.

Status.5 Unallocated

■

Serial communications – downloading parameter settings from the MCD3000

Status_1 C12 Requests the operational status of

Parameter settings may be downloaded from the

MCD3000 at any time using the following format; the MCD3000.

(Negative logic 0 = true) Repeat until master sends NAK

NOT Status._1.0 Power On

NOT Status._1.1 Output On

NOT Status._1.2 Run

NOT Status._1.3 Overload

NOT Status._1.4 Restart delay

NOT Status._1.5 Unallocated



Version C16 RS485 protocol version number.

Trip Code C18 Requests the trip status of the

MCD3000.

255= No Trip

0= Shorted SCR trip

1= Excess start time trip

Send

Address

ACK

Read

Par.


= Master

Read

Parameters

Download

Parameters

ACK

NAK

Par. No Par. Value NAK

Invalid

LRC

= Slave (MCD3000)

NAK

ERR

ASCII Comment

Invalid parameter number

P10 Readies MCD3000 to download parameter values.

■

Serial communications – uploading parameter settings to the MCD3000

Parameter adjustments may be uploaded to the

MCD3000 only when it is in the off state i.e. not starting, running, stopping or tripped. Use the following format to upload parameters;

4= Phase imbalance trip

5= Supply frequency trip

6= Phase rotation trip

7= Instantaneous overload trip

8= Power circuit fault

Enter serial programming mode

Send

Address

ACK

Write

Par.

ACK

Exit serial programming mode and store parameters to EEPROM

Repeat until master sends NAK

Par. No ACK Par. Value

Par.

Value

NAK

NAK

Invalid

LRC

= Slave (MCD3000)

NAK

Invalid

LRC

NAK

10= Starter overtemperature trip

■

Serial communications –data retrieval

Data can be retrieved from the MCD3000 using the following format;


ERR ERR

Unable to program

(motor running)

Invalid Par No.

ERR

Par. value out of range

= Master = Slave (MCD3000)


Write

Parameters

Upload

Parameters

ASCII Comment

P12 Readies the MCD3000 for uploading of parameter values

When the MCD3000 receives a Upload Parameters command it enters the Serial Programming mode.

When in the Serial Programming mode the MCD3000 local push buttons and remote inputs are inoperative, the serial start command is unavailable and MCD3000 numeric display flashes the letters ‘SP’.

When the Upload Parameters command is terminated by the master or with an error or with a timeout, the parameters are written to the EEPROM and the

MCD3000 exits the Serial Programming mode.

ATTENTION

The Serial Programming mode will timeout in

500ms if there has been no serial activity.

ATTENTION

The following parameters may not be adjusted, Par 43, 44, 45, 46 & 49. If values for these parameters are uploaded to the MCD3000 there will be no effect and no error generated.

■

Serial communications – calculating the check sum (LRC)

Each command string sent to and from the MCD3000 includes a check sum. The form used is the

Longitudinal Redundancy Check (LRC) in ASCII hex.

This is an 8-bit binary number represented and transmitted as two ASCII hexadecimal characters.

To calculate LRC:

1. Sum all ASCII bytes

3. 2’s complement

For example Command String (Start);

ASCII STX B 1 0 or 02h 42h 31h 30h

MCD3000 Series

ASCII Hex Binary

A5h 1010 0101 MOD 256 (2)

01h 0101 1011

ASCII 5

+ 1 =

0101 2’s COMPLEMENT (3)

B ASCII CONVERT (4) or 35h 42h LRC

The complete command string becomes or 02h 42h 31h 30h 35h 42h 03h

To verify a received message containing an LRC;

1. Convert last two bytes of message from ASCII to binary.

2. Left shift 2 nd

to last byte 4 bits.

3. Add to last byte to get binary LRC.

4. Remove last two bytes from message.

5. Add remaining bytes of message.

6. Add binary LRC.

7. Round to one byte.

8. The result should be zero.

Response or status bytes are sent from the MCD3000 as an ASCII string.

STX [d1]h [d2]h [d3]h [d4]h LRC1 LRC2 ETX d1 = 30h d2 = 30h d3 = 30h plus upper nibble of status byte right shifted by four binary places. d4 = 30h plus lower nibble of status byte.

For example status byte = 1Fh, response is


MCD3000 Series

■

Programming

Number Parameter Name

1 Motor FLC

2

Current Limit

3

Current Ramp - Initial Current

4

Current Ramp - Ramp Time

5 Soft Stop Ramp Time

6

Motor Thermal Capacity

7

Phase Imbalance Sensitivity

8

Undercurrent Trip Point

9 Instantaneous Overload Trip Point

10

Excess Start Time Protection

11

Phase Rotation Protection

12

Phase Imbalance Protection Delay

13 Undercurrent Protection Delay

14

Instantaneous Overload Protection Delay

15

Restart Delay

16

Torque Enhancement

17 Soft Stop Profile

18

D.C.Brake - Brake Time

19

D.C.Brake - Brake Torque

20

Local / Remote Mode

21 Current Gain

22

Serial Communication - Baud Rate

23

Serial Communication - Satellite Address

24

25

26

27

28

29

30

31

32

33

Serial Communication - RS485 Time Out

Motor FLC

1)

Current Limit 1)

Current Ramp - Initial Current 1)

Current Ramp - Ramp Time

1)

Soft Stop Ramp Time

1)

Motor Thermal Capacity 1)

Phase Imbalance Sensitivity 1)

Undercurrent Trip Point

1)

Instantaneous Overload Trip Point

1)

34 Low Current Flag Set Point

35 High Current Flag Set Point

36 Relay A - Function Assignment

37

Relay B - Function Assignment

38 Relay C - Function Assignment

39 Automatic Reset - Trip Types

40 Automatic Reset - Number Of Resets

41

Automatic Reset - Reset Delay Group 1&2

42 Automatic Reset - Reset Delay Group 3

45 Trip Log

46 Password

47

Change Password

48 Parameter Lock

49 Load Default Parameter Settings

50 Under Frequency Protection Delay

51

Phase Imbalance Protection Enable

✭

= factory setting


Number Parameter Name

52 Undercurrent Protection Enable

53 Expanded Supply Frequency Window

1)

Secondary Parameter Set adjustments

15

MCD3000 Series

■

Programming procedure

Parameter adjustments are made using the Local

Control Panel. Adjustments can only be made while the MCD3000 is stopped.

When the

MCD3000 is in programming mode the three LEDs to the right of the numeric display are illuminated.

To adjust parameters do the following:

■

Programmable functions

1 Motor

Value:

(Depends On Model) Amps

Function:

✭ Depends on Model

Calibrates the MCD3000 for the Full Load Current of the motor.

Description of choice:

Set according to motor nameplate Full Load Current.

2 Current

Value:

100% - 550% Motor FLC

Function:

✭ 350%

Sets the desired starting current limit.


The current limit should be set so that the motor accelerates easily to full speed.

✭

= factory setting

16

ATTENTION

Start current must be great enough to allow the motor to produce sufficient torque to accelerate the connected load. The minimum current required to do this is dependent on motor design and load torque requirements.

3 Current Ramp - Initial Current

Value:

10% - 550% Motor FLC ✭ 350%

Function:

Sets the initial starting current for the Current Ramp start mode. See also parameter 4.


MCD3000 Series


See parameter 4.

4 Current Ramp - Ramp Time

Value:

1 - 30 seconds ✭ 1 second

Function:

Sets the ramp time for the Current Ramp start mode.


The Current Ramp start mode modifies the Current

Limit start mode by adding an extended ramp.

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.

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 - Initial

Current so that the motor can accelerate when unloaded.

•

Set Parameter 4 Current Ramp - Ramp Time according to the desired start performance.

(Very short ramp time settings will result in higher than necessary start current for unloaded starts. Very long ramp time settings may cause starting delays for loaded starts).

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.

✭

= factory setting


•

Set Parameter 3 Current Ramp - Initial

Current to a lower level than the Current Limit .

•

Set Parameter 4 Current Ramp - Ramp Time to achieve the desired gradual draw of start current.

5 Soft Stop Ramp Time

Value:

0 - 100 seconds ✭ 0 seconds (Off)

Function:

Sets the time of the soft stop ramp. The soft stop function extends motor deceleration time by ramping down voltage supplied to the motor when a stop is initiated.


Set the ramp time to optimise stopping characteristics for the load.

The MCD3000 soft stop function has two modes, standard and enhanced pump control. The enhanced pump control mode can offer superior performance in some pumping applications. Refer Par. 17 Soft Stop

Profile .

ATTENTION

The MCD3000 soft stop function automatically determines the step-down voltage setting, no user adjustment is required.

ATTENTION

The Soft Stop and D.C.Brake functions cannot be used together. Setting a soft stop ramp time greater than 0 seconds causes Par. 18 D.C.Brake

- Brake Time to be set to 0 seconds and Par. 38 Relay

C - Function Assignment to be set to OFF.

6 Motor

Value:

5 - 120 seconds ✭ 10 seconds

Function:

Calibrates the MCD3000 motor thermal model for the connected motors thermal capacity. The Motor

Thermal Capacity is defined as the length of time the motor can sustain Direct-On-Line current.


The factory setting is adequate for most applications.

When setting the Motor Thermal Capacity two approaches can be taken.

17

MCD3000 Series

1. Set according to the Motor DOL time as shown on the motor data sheet. This makes the full thermal capacity of the connected motor available for use. The motor will be allowed to operate up to its maximum capability during start and when subjected to operational overloads.

This is ideal when starting high inertia loads or for applications such as Bandsaws that must ride through high operating overloads.

ATTENTION

The MCD3000 assumes Direct-On-Line current to be 600% of motor Full Load

Current. Actual motor DOL current can be accounted for by using the following formula to calculate the value of the Motor Thermal Capacity setting.

2. Set according to load requirements. While the

Motor Thermal Capacity can safely be set according to the motor’s published DOL time limit, some load types do not need this capacity for starting or riding through overloads while running.

In such circumstances setting the Motor Thermal

Capacity based on what the load requires will provide an earlier warning of abnormal operation.

To set the Motor Thermal Capacity according to load requirement, set MCD3000 display to read motor temperature, run the load, stop and restart the load while monitoring the calculated motor temperature. The Motor Thermal Capacity setting can be reduced until the temperature at the end of a restart is approximately 80%.

7 Phase Imbalance Sensitivity

Value:

1 - 10 ✭ 5 (Normal Sensitivity)

1 - 4 = Increased sensitivity

5 = Normal sensitivity

6 - 10 = Reduced sensitivity

Function:

Sets the sensitivity of the imbalance protection.


Adjust the trip point to accommodate the tolerated phase imbalance. The factory setting is normally acceptable but may have to be adjusted to accommodate individual site variations.

✭

= factory setting

18

Reaction time of the phase imbalance protection can also be adjusted. Refer Par. 12 Phase Imbalance

Protection Delay .

ATTENTION

The phase imbalance trip point is desensitised by 50% during starting and stopping.

8 Undercurrent Trip Point

Value:

15% - 100% Motor FLC

Function:

Sets the minimum allowable running current.


Where it is desired to stop motor operation on

✭ 20 % detection of an abnormally low current, set the

Undercurrent trip point above the motor magnetising current and below the normal running current.

To defeat the Undercurrent protection function, set the trip point below the motor’s magnetising current.

Typically < 25%.

Reaction time of the Undercurrent protection can also be adjusted. Refer Par. 13 Undercurrent Protection

Delay .

Undercurrent protection is disabled during starting and stopping.

9 Instantaneous Overload Trip Point

Value:

80% - 550% Motor FLC ✭ 400%

Function:

Sets the trip point for the Instantaneous Overload protection.


The instantaneous overload trip point should be set to trip the motor when it begins to stall.

Reaction time of the instantaneous overload protection can also be adjusted. Refer Par. 14 Instantaneous

Overload Protection Delay.

Instantaneous Overload protection is disabled during starting and stopping.

10 Excess Start Time Protection

Value:

0 - 255 seconds

✭

20 seconds


MCD3000 Series

Function:

Sets the maximum allowable start time.


Set for a period slightly longer than the normal motor starting time. The MCD3000 will then trip if the start

0 - 60 seconds

Function:

✭ 5 seconds

Delays tripping on detection of a motor current lower than the programmed Undercurrent Trip Point. (Par. 8

& Par. 32) time exceeds normal. 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.

A setting of 0 disables this protection.

ATTENTION

Ensure the Excess Start Time protection setting is within the MCD3000 rated capability.


Set to avoid unnecessary tripping due to temporary undercurrent situations.

Undercurrent protection is disabled during starting and stopping.

14 Instantaneous Overload Protection Delay

Value:


11 Phase Rotation Protection

Value:

0 - 2

0 = Off (Forward & Reverse rotation permitted)

✭

0 (Off)

1 = Forward Rotation Only

Function:

Delays tripping on detection of a motor current higher than the programmed Instantaneous Overload Trip

Point. (Par. 9 & Par. 33)

2 = Reverse Rotation Only

Function:

Sets the allowable phase rotation sequence of the incoming supply.


The MCD3000 is itself phase rotation insensitive. This


Set to avoid unnecessary tripping due to temporary high overload situations.

15 Restart

Value:

0 - 254 Units

1 Unit = 10 seconds

✭ 1 Unit (10 seconds) function allows motor rotation to be limited to one direction only. Set the protection according to application requirements.

12 Phase Imbalance Protection Delay

Value:


Function:

Sets the minimum time between the end of a stop and the beginning of the next start.


Set according to process requirements. A setting of zero achieves the minimum restart delay of 1 second).

Function:

Delays tripping on detection of a phase imbalance greater than allowed by the Phase Imbalance

During the Restart Delay period the LED to the right of the MCD3000 numeric display will flash, indicating the motor cannot be started.

Sensitivity setting. (Par. 7 & Par. 31)


Set to avoid unnecessary tripping due to temporary phase imbalances.

13 Undercurrent Protection Delay

Value:

✭

= factory setting


16 Torque

Value:

0 - 3

0 = Off

1 = Torque boost

✭ 0 (Off)

19

MCD3000 Series

2 = Torque control

3 = Torque boost & torque control

Function:

Activates the torque enhancement functions.


Torque boost provides extra torque at the beginning of a start. Torque boost can be used for loads that require high torque to breakaway but then accelerate freely with lower torque.

ATTENTION

Torque boost results in a fast application of torque. Ensure that the driven load and drive chain can handle DOL start torque characteristics.

Torque control provides a more linear application of torque during start.

17 Soft Stop Profile

Value:

0 - 3

0 = Standard mode

1 = Pump control (mode 1)



✭ 0 (Standard Mode)

Function:

Selects between soft stop profiles.


The standard mode is the default soft stop profile and is appropriate for most installations. In standard mode motor deceleration is monitored and soft stop operation is automatically adjusted to optimise performance.

In addition to the standard mode profile three specialised pump control modes are available. These modes provide alternate control algorithms which may deliver superior performance to the standard mode depending upon the individual motor and hydraulic characteristics of the application.

The D.C.Braking function decreases motor deceleration time by applying a D.C. current to the motor terminals when a stop command is given. This function requires that a contactor

(AC1 rated) be wired between output terminals

T2 & T3 as shown in the electrical schematic

✭

= factory setting

20

below and that the following MCD3000 parameters be adjusted.

•

Par 18. D.C.Brake - Brake Time

•

Par 19. D.C.Brake - Brake Torque

•

Par 38. Relay C - Function Assignment.

The MCD3000 power modules will be damaged if the D.C.Brake contactor is closed when the D.C.Brake function is not operating. Ensure the D.C.Brake contactor is controlled by Relay Output C and that

Par. 38 Relay C - Function Assignment is set for

D.C.Braking Contactor Control

The MCD3000 power modules will be damaged if the D.C.Brake contactor is incorrectly connected between T1-T2 or

T1-T3.

18 D.C.Brake - Brake Time

Value:

0 - 10 seconds ✭ 0 seconds (Off)

Function:

Sets the time of operation of the D.C. Braking function.


Set as required. A setting of 0 seconds turns the

D.C.Brake function Off.

ATTENTION

MCD3000 Relay Output C must be programmed for the D.C.Brake Contactor


MCD3000 Series

Control so that the shorting contactor functions correctly. Refer Par. 38 Relay C - Function Assignment for adjustment procedure.

ATTENTION

The D.C.Brake and Soft Stop functions cannot be used together. Setting a D.C.Brake - Brake

Time greater than 0 seconds causes Par. 5 Soft Stop

Ramp Time and Par.29. Soft Stop Ramp Time

(secondary parameter set) to be set to 0 seconds.

ATTENTION

During operation of the D.C.Brake function the

MCD3000 display shows the letters ’br’ as shown below.


Set according to desired operational requirements.

21 Current

Value:

85% - 115%

Function:

✭

100%

Adds a gain to the MCD3000 current monitoring circuits. These circuits are factory calibrated with an accuracy of ±5%. The gain can be used to match the

MCD3000 current read out with an external current monitoring system.

ATTENTION

This adjustment affects all current based functions. e.g. current read-out, motor

19 D.C.Brake - Brake Torque

Value:

30% - 100% Braking Torque ✭ 30%

Function:

Sets the D.C.Brake level as a % of maximum braking torque.


Set as required.

ATTENTION

For very high inertia loads more braking torque is available by use of the ’Soft Braking’ technique described in the Design Guide section of this manual. overload & all other current based protections and current outputs.


The gain should be adjusted according to the following formula.

20 Local / Remote Mode

Value:

0 - 3 ✭ 0 ([LOCAL/REMOTE] button enabled)

0 = [Local/Remote] push button on MCD3000 enabled all the time.

1 = [Local/Remote] push button on MCD3000 enabled only while motor stopped.

2 = Local control only. (MCD3000 push buttons enabled, remote inputs disabled)

3 = Remote control only. (MCD3000 push buttons disabled, remote inputs enabled)

Function:

Determines when MCD3000 push buttons and remote control inputs are operative. Also when, and if, the

22 Serial Communications - Baud Rate

Value:

1 - 5

1 = 1200 baud

2 = 2400 baud

3 = 4800 baud

4 = 9600 baud

5 = 19200 baud

✭ 4 (9600 baud)

Function:

Sets the baud rate for serial communications.


Set as appropriate.

[Local/Remote] push button can be used to switch between local and remote control.

✭

= factory setting


23 Serial Communications - Satellite Address

21

MCD3000 Series

Value:

1 - 99

Function:

Assigns the MCD3000 an address for serial communications.


Set a unique address number as appropriate.

✭ 20

100% - 550% Motor FLC ✭

See Par. 2 for Function & Description of choice.

350 %

27 Current Ramp - Initial Current

(Secondary Parameter Set)

Value:

10% - 550% Motor FLC

✭


350%

24 Serial Communications - RS485 Time Out

Value:

0 - 100 seconds

Function:

✭

0 seconds (Off)

Sets the maximum allowable period of RS485 inactivity.


Set this parameter if it is required that a trip should occur in the event of a failure of RS485 communications with the MCD3000.

A setting of 0 seconds allows the MCD3000 to continue operating without regular RS485 activity.

ATTENTION

In the event of a RS485 Time Out trip the

MCD3000 cannot be reset until the RS485 communication is resumed. If the RS485 communications cannot be immediately re-established and temporary manual control is required, Par 24

Serial Communications - RS485 Time Out must be set to 0 seconds.

The MCD3000 includes two motor operating parameter sets. Parameters 25 - 33 make up the secondary parameter set and replicate the primary parameter set, Parameters 1 - 9.

Refer to the Operation section of this manual for detail on enabling the secondary parameter set.

25 Motor


Value:

(Depends On Model)Amps ✭ Depends on Model


26 Current


Value:

✭

= factory setting

22

28 Current Ramp - Ramp Time


Value:

1 - 30 seconds


29 Soft Stop Ramp Time


Value:

0 - 100 seconds

✭ 1 second

✭ 0 seconds (Off)


30 Motor


Value:



31 Phase Imbalance Sensitivity


Value:

1 - 10 ✭ 5 (Normal Sensitivity)

1 - 4 = Increased sensitivity

5 = Normal sensitivity

6 - 10 = Reduced sensitivity


32 Undercurrent Trip Point


Value:

15% - 100% Motor FLC ✭ 20 %



MCD3000 Series

33 Instantaneous Overload Trip Point


Value:

80% - 550% Motor FLC ✭ 400%


34 Low Current Flag Set Point

Value:

1 - 100% Motor FLC

Function:

✭

50% Motor FLC

Sets the current at which the Low Current Flag operates. (Low current flags can occur only when the motor is running).

Relay Output B can be programmed to indicate the state of the Low Current Flag. The relay output will change state when motor current is below the set point.

See Par. 37 for Relay B - Function Assignment .


Set as appropriate.

35 High Current Flag Set Point

Value:

50 - 550% Motor FLC ✭ 105% Motor FLC

Function:

Sets the current at which the High Current Flag operates. (High current flags can occur only when the motor is running).

Relay Output B can be programmed to indicate the state of the High Current Flag. The relay output will change state when motor current is above the set point.

See Par. 37 for Relay B - Function Assignment .


Set as appropriate.

36 Relay A - Function Assignment

Value:

0 - 3

0 = Line Contactor

1 = Run

2 = High current flag (see Par. 35)

3 = Low current flag (see Par. 34)

✭ 0 (Line contactor)

✭

= factory setting


Function:

Sets the functionality of Relay Output A


Set as required.

37 Relay B - Function Assignment

Value:

0 - 4

0 = Trip

1 = Output on

2 = High current flag (see Par. 35)

3 = Low current flag (see Par. 34)

4 = Line contactor

Function:

Sets the functionality of Relay Output B


See Par. 36

✭

0 (Trip)

38 Relay C - Function Assignment

Value:

0 - 2

0 = Run

1 = D.C.Brake Contactor Control

✭ 0 (Run)

2 = Off (does not operate)

Function:

Sets the functionality of Relay Output C


Set to 1 (D.C.Brake Contactor Control) only when using the D.C.Brake function and make this adjustment only after first setting Par. 18 D.C.Brake -

Brake Time .

23

MCD3000 Series

ATTENTION

To reduce the chance of equipment damage through inappropriate adjustment of Relay C functionality the MCD3000 automatically sets this parameter to 2 (Off) in the following instances.

•

If a soft stop time is programmed while Par. 38.

Relay C - Function Assignment is set to 1

(D.C.Brake Contactor Control).

•

When Par. 18 D.C.Brake - Brake Time is changed to 0 seconds.

•

When Par. 18 D.C.Brake - Brake Time is changed from 0 seconds.

Function:

Sets the number of times faults will be reset before the trip condition is latched and a manual reset is required.


Set according to the maximum number of resets required.

The MCD3000 reset counter will increment by one when a trip occurs up to the programmed number of resets. A manual reset will then be required.

The reset counter decrements by one (to a minimum of zero) after each successful start/stop cycle.

The Automatic Reset function enables selected trip types to be automatically reset. Automatic

Reset operation is affected by three settings.

•

Trip Types

•

Number Of Resets

•

Reset Delay

If the start command is still present after a trip state is reset the motor will be restarted. Ensure that personal safety is not at risk from such operation and that all appropriate safety measures have been taken.

41 Automatic Reset - Reset Delay Group 1 & 2

Value:

5 - 999 seconds

Function:

Sets the delay before automatic reset of Group 1 and

Group 2 trips.


Set as required.

✭ 5 seconds

42 Automatic Reset - Reset Delay Group 3

39 Automatic Reset - Trip Types

Value:

0 - 3

0 = Off.

1 = Automatically reset Group 1 trips.

2 = Automatically reset Group 1 & 2 trips.

✭ 0 (Off)

Value:

5 - 60 minutes ✭ 5 minutes

Function:

Sets the delay before automatic reset of Group 3 trips.


Set as required.

3 = Automatically reset Group 1,2 & 3 trips.

Function:

Selects what fault types will be automatically reset.


Three groups of trips can be automatically reset.

43 Factory Diagnostic Display A

Value:

No adjustment

44 Factory Diagnostic Display B

Group Trip Type

1 Phase Imbalance, Phase Loss

2

3

Undercurrent, Instantaneous Overload

Overcurrent, Motor Thermistor

Value:

No adjustment

40 Automatic Reset - Number Of Resets

Value:

1 - 5 Resets

✭

= factory setting

24

✭ 1 Reset

45 Trip

Value:

Read Only

Function:

✭ No setting


MCD3000 Series

Displays the Trip Log. The trip log records the cause of the last 8 trip events.


Use the [+/-] buttons to scroll through the trip log.

Refer to the Fault Procedure section of this manual for a full explanation of the trip log, trip codes and related fault procedures.

46 Password

Value:

0 - 999 ✭ 0

Function:

Entry of the correct password number does two things.

1. If the parameter settings are currently in the Read

Only state (Refer Par. 48 Parameter Lock ) entering the correct password number temporarily enables the Read/Write state allowing parameter settings to be changed. On exit of the programming mode parameters return to the Read Only state.

2. Allows access to parameter numbers 47, 48 & 49.

These parameters allow the user to:

•

Change the password number

•

Change the parameter state between

Read/Write and Read Only thus providing control over unauthorised changes to program settings.

•

Load the default factory settings.


Enter the current password number. If the password number has been lost, contact your Danfoss representative.

47 Change

Value:

0 - 999

Function:

Sets the password number.


Set and record the password number as required.

✭ 0

48 Parameter

Value:

0 - 1 ✭ 0 (Read/Write)

✭

= factory setting


0 = Read/Write

1 = Read Only

Function:

Enables protection of program settings by restricting

Program Mode functionality to Read Only.


Set as required.

ATTENTION

When the parameter lock has been changed from Read/Write to Read Only the new setting only takes effect once the programming mode has been exited.

49 Load Default Parameter Values

Value:

0 - 100 ✭ 0

50 = Load default parameter values

Function:

Resets parameter values to factory default settings.


Set as required.

50 Under Frequency Protection Delay

Value:

0 – 60 seconds

Function:

✭ 0 seconds

Delays tripping on detection of a low supply frequency when the motor is running, <48Hz (50Hz supplies),

<58Hz (60Hz supplies).

ATTENTION

If the supply frequency drops below 45Hz

(50Hz supplies) or 55Hz (60Hz supplies) the

MCD3000 will trip instantly irrespective of the delay setting.


Set to allow continued operation during extreme but temporary under frequency conditions.

51 Phase Imbalance Protection Enable

Value:

0 – 1 ✭ 0 (On)

25

0 = On

1 = Off

Function:

Activates or defeats the phase imbalance protection.


Set as required.

52 Undercurrent Protection Enable

Value:

0 – 1

0 = On

1 = Off

✭

0 (On)

Function:

Activates or defeats the undercurrent protection.


Set as required.

53 Expanded Supply Frequency Window

Value:

0 – 1

0 = Normal (50Hz window: 48Hz- 52Hz, 60Hz window 58Hz – 62Hz)

1 = Expanded (50Hz window: 47Hz- 52Hz, 60Hz window 57Hz – 62Hz)

✭ 0

Function:

Expands the supply frequency window allowed by the

MCD3000 by reducing the lower limit by 1 Hz. This expansion accommodates power supplies which suffer long term low frequency situations.


Apply expansion if required.

MCD3000 Series

✭

= factory setting


MCD3000 Series

■

Operation

Once the MCD3000 has been installed, wired and programmed according to the instructions earlier in this manual, it can be operated.

■

Local control panel

.

The Local Control Panel can be used to operate the

MCD3000 when in local control mode.

During operation the display can show either motor current (Amps) or motor temperature (%) as calculated by the MCD3000 motor thermal model.

The information being displayed is indicated by the LEDs to the right of the display, and can be changed using the [+/-] buttons.

In the event of a trip the display shows the trip code. Refer to the Fault Procedure section of this manual.

ATTENTION

If motor current exceeds the maximum current able to be shown on the numeric display, the display will show dashes.

---

2. Starter Status LEDs

•

Start: Voltage is being applied to the motor

•

Run: Full voltage is being applied to the motor.

•

Trip: The starter has tripped.

•

Remote: The MCD3000 is in remote control mode. The local [START],[STOP],[RESET] push buttons are not operative.

Can be used to control operation when the

MCD3000 is in local mode. Switch between local and remote modes using the [LOCAL/REMOTE] push button.

ATTENTION

Par. 20 Local / Remote Mode can be set to prohibit either local or remote mode operation.

If the [LOCAL/REMOTE] button is used in an attempt to switch to a prohibited mode the numeric display will show ’OFF’.

Also, operation of the [LOCAL/REMOTE] push button can be restricted to when the motor is stopped. In this case pushing the [LOCAL/REMOTE] push button results in the numeric display showing ’OFF’.

ATTENTION

When control power is applied the MCD3000 may be in either local or remote mode according to the mode it was in when control power was removed. The factory setting is local control.

ATTENTION

Simultaneously pressing the [STOP] and

[RESET] buttons causes the MCD3000 to immediately remove voltage from the motor resulting in a coast to stop. Any soft stop or D.C.Brake settings are ignored.

Refer to the Programming Section of this manual.

5. Remote Control Input Status LEDs

Indicate the state of the circuits connected across the MCD3000 remote control inputs.

ATTENTION

When control power is applied to the

MCD3000, all LEDs and Numeric Display segments are illuminated for approximately 1 second to test their operation.

■

Remote control

Remote circuits connected to the MCD3000 control inputs can be used to operate the starter when in


MCD3000 Series remote control mode. Refer to the Installation section of this manual for detail on control wiring options.

■

Serial communication

The RS485 serial link can be used to control operation when the starter is either local or remote modes.

Programming of the MCD3000 via the serial link is also possible. Refer to the Installation section of this manual for detail on serial communications functions.

■

Restart delay

Par. 15 Restart Delay sets a minimum time between the end of a stop and the beginning of the next start.

During this period the LED to the right of the numeric display will flash, indicating the motor cannot be started.

■

Secondary parameter set

The MCD3000 has two motor parameter sets.

•

Primary Parameter Set : Par. 1 - 9

•

Secondary Parameter Set : Par. 25 - 33

When the MCD3000 is in the off state and is commanded to start, it checks the Par. Set control input. If open circuit the primary parameter set is used.

If closed circuit the secondary parameter set is used.

■

Pre-start tests

On receiving a start command, MCD3000 starters operate the Line Contactor relay output (if programmed) and then perform a series of tests before applying voltage to the motor terminals and operating the Output On relay output (if programmed).

■

Operation after power loss

When control and supply voltage is applied to the

MCD3000 it will enter either the local or remote mode according to the state it was in when voltage was removed.

If in remote mode, the condition of the remote control inputs is checked and if a start command is present the motor will be started.

If in local mode, the motor will not be restarted until the [START] push button is activated.

ATTENTION

If the start command is given while the

MCD3000 is in the process of stopping (Soft stop or D.C.Braking) the MCD3000 restarts without checking the Par. Set control input.

■

Motor thermal model

The MCD3000 motor overload protection is an advanced motor thermal model. Motor temperature is continuously calculated by the microprocessor that uses a sophisticated mathematical model to accurately reflect motor heat generation and dissipation during all stages of operation. e.g. Starting,

Running, Stopping & Stopped.

Because it operates continuously, the motor thermal model eliminates the need for protection systems such as; Excess Start Time, Limited Starts per hour etc

The state of the motor thermal model can be viewed on the numeric display while the MCD3000 is not in programming mode. Use the [+/-] keys to change the parameter shown on the numeric display.

Motor temperature is shown as a % of maximum temperature. An overload trip occurs at 105%.


MCD3000 Series

■

General Technical Data

Mains supply (L1, L2, L3):

Supply voltage MCD3000-T5 ..............................................................................................3 x 200 VAC ~ 525 VAC

..................................................................................................... 3 x 200 VAC ~ 440 VAC (Inside Delta Connection)

Supply voltage MCD3000-T7 ............................................................................................. 3 x 200 VAC ~ 690VAC

..................................................................................................... 3 x 200 VAC ~ 440 VAC (Inside Delta Connection)

Supply frequency (at start) ....................................................................................... 50HZ (

±

2Hz) / 60 Hz (

±

2Hz)

Supply frequency (during start) ........................................................ >45Hz (50Hz supply) or >55Hz (60 Hz supply)

Supply frequency (during run) .......................................................... >48Hz (50Hz supply) or >58Hz (60 Hz supply)

Electronics control voltage ......................................................... 230 VAC (+10%/-15%) or 400 VAC (+10%/-15%)

Control Inputs

Start (Terminals 15 & 16) .................................................................... Normally Open, Active 24 VDC, 8mA approx.

Stop (Terminals 17 & 18) ................................................................. Normally Closed, Active 24 VDC, 8mA approx.

Reset (Terminals 25 & 26) ............................................................... Normally Closed, Active 24 VDC, 8mA approx.

Parameter Set (Terminals 27 & 28) ..................................................... Normally Open, Active 24 VDC, 8mA approx.

Relay Outputs

Programmable Output A

1)

(Terminals 13 & 14) ...... Normally Open, 5 A @ 250 VAC/360 VA, 5 A @ 30 VDC resistive

Programmable Output B

2)

(Terminals 21, 22 & 24) .... Changeover, 5 A @ 250 VAC/360 VA, 5 A @ 30 VDC resistive

Output C

3)

(Terminals 33 & 34) .......................... Normally Open, , 5 A @ 250 VAC/360 VA, 5 A @ 30 VDC resistive

1)

Programmable functions: Line contactor, Run, High current flag, Low current flag

2)

Programmable functions: Tripped, Output on, High current flag, Low current flag, Line contactor

3)

Programmable functions: Run, D.C.Brake Contactor Control, Off

Environmental

Degree of protection MCD3007 to MCD3132 ................................................................................................. IP21

Degree of protection MCD3185 to MCD3800 ................................................................................................. IP20

Operating Temperatures ..................................................................................................................... -5 o

C / +60 o

C

Rated short-circuit current (with semi-conductor fuses) ................................................................................ 100kA

Rated insulation voltage (Surges) .......................................................................... 2 kV line to earth, 1kV line to line

Rated impulse withstand voltage (Fast transients) ............................................................................................. 2 kV

Pollution Degree ......................................................................................................................... Pollution Degree 3

Electro static discharge ......................................................................... 4 kV contact discharge, 8 kV air discharge

Equipment class (EMC) ............................................................................................................................... Class A

Radio-frequency electromagnetic field ...................................................................... 0.15 MHz - 80 MHz: 140dBµV

80 MHz - 1 GHz: 10 V/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.

Standards Approvals

C

9

......................................................................................................................................................... CISPR-11

UL

1

............................................................................................................................................................... UL508

C-UL

1

............................................................................................................................................. CSA 22.2 No. 14

CE .................................................................................................................................................. IEC 60947-4-2

1

Requires use of semi-conductor fuses. Excludes models MCD3600~MCD3800


MCD3000 Series

■

Current Ratings

Continuous Ratings (Not bypassed) at 40 o

C Ambient Temperature, < 1000 metres ✮

Model

MCD3007

MCD3015

MCD3018

MCD3022

MCD3030

MCD3037

3.0 x FLC

AC53a 3.0-30 : 50-10

20A

34A

39A

47A

68A

86A

4.0 x FLC

AC53a 4.0-20 : 50-10

16A

28A

33A

40A

54A

70A

MCD3045

MCD3055

MCD3075

MCD3090

93A

121A

138A

196A

76A

100A

110A

159A

MCD3110 231A 188A

MCD3132 247A

MCD3185 364A IDC 1

MCD3220 430A IDC 1

MCD3300 546A IDC

1

MCD3315 630A IDC

1

MCD3400 775A IDC 1

MCD3500 897A IDC 1

198A

IDC

IDC

1

1

(795A

MCD3600 1153A IDC

1

MCD3700 1403A IDC

1

IDC

1

(1437A

IDC

1

(1779A

MCD3800 1564A IDC 1

Bypassed Ratings at 40 o C Ambient Temperature, < 1000 metres ✮

4.5 x FLC

AC53a 4.5-30 : 50-10

14A

25A

29A

35A

48A

61A

65A

86A

97A

138A

163A

174A

IDC

1

)

IDC

1

)

IDC

1

)

IDC

1

)

Model

MCD3007

MCD3015

MCD3018

MCD3022

MCD3030

MCD3037

MCD3045

MCD3055

3.0 x FLC

AC53b 3.0-30 : 330

21A

35A

41A

50A

69A

88A

96A

125A

4.0 x FLC

AC53b 4.0-20 : 340

18A

32A

39A

49A

57A

73A

81A

107A

MCD3075

MCD3090

MCD3110

141A

202A

238A

115A

168A

199A

MCD3132 254A

MCD3185 364A IDC

1

MCD3220 430A IDC

1

MCD3300 546A IDC 1

MCD3315 630A IDC 1

MCD3400 775A IDC

1

MCD3500 897A IDC

1

MCD3600 1153A IDC 1

MCD3700 1403A IDC 1

MCD3800 1570A IDC

1

206A

IDC

1

(460A

IDC

1

(543A

IDC

1

(1053

IDC

1

(1249A

IDC

1

(2301A

1

. Inside delta connection

✮ For ambient temperature or altitude conditions beyond those listed contact Danfoss.

30

4.5 x FLC

AC53b 4.5-30 : 330

15A

27A

33A

40A

49A

63A

69A

91A

100A

144A

171A

179A

IDC

1

)

IDC

1

)

IDC

1

)

IDC

1

)

IDC

1

)


■

Power Termination Details

MCD3000 Series

■

Semiconductor Fuses

Semiconductor fuses listed below are manufactured by Bussman and should be ordered directly from Bussman or their local supplier. Instruction for selection of alternate semi-conductor fuses is available from Danfoss.

Model Bussmann Fuse 400V Bussmann Fuse 525V Bussmann Fuse 690V

MCD3007 170M1315 170M1314 170M1314

MCD3015 170M1318

MCD3018 170M1319

170M1317

170M1317

170M1317

I2t

1150

8000

170M1317 10500

MCD3022 170M1319

MCD3030 170M1319

MCD3037 170M1322

MCD3045 170M1322

MCD3055 170M1322

MCD3075 170M2621

MCD3090 170M3021

MCD3110 170M3023

MCD3132 170M3023

MCD3185 170M6011

MCD3220 170M6012

MCD3300 170M6014

MCD3315 170M5017

MCD3400 170M6019

MCD3500 170M6021

MCD3600 170M6021

MCD3700

MCD3800

170M6021

170M6021

170M1318

170M1319

170M1320

170M1321

170M1322

170M1322

170M3021

170M3023

170M3023

170M5012

170M4016

170M6014

170M6015

170M6018

170M6020

170M6020

170M6021

170M6021

170M1318 15000

170M2616 15000

170M1320 51200

170M1321 80000

170M1322 97000

170M1322 97000

170M3020 245000

170M3023 414000

170M3023 414000

170M4145 238000

170M6011 320000

170M4018 781000

170M6014 1200000

170M6017 2532000

170M6151 4500000

170M6151 4500000

2 x 170M5018

2 x 170M5018

6480000

13000000


32

MCD3000 Series

■

Dimensions / Weights

IP 21 Enclosure

MCD Model

A mm (inches)

MCD3007 530 (20.87)

MCD3015 530 (20.87)

MCD3018 530 (20.87)

MCD3022 530 (20.87)

MCD3030 530 (20.87)

MCD3037 530 (20.87)

MCD3045 530 (20.87)

MCD3055 530 (20.87)

MCD3075 530 (20.87)

MCD3090 530 (20.87)

MCD3110 530 (20.87)

MCD3132 530 (20.87)

IP 20 Enclosure

MCD Model

A mm (inches)

MCD3185 850 (33.46)

MCD3220 850 (33.46)

MCD3300 850 (33.46)

MCD3315 850 (33.46)

MCD3400 850 (33.46)

MCD3500 850 (33.46)

B mm (inches)

132 (5.20)

132 (5.20)

132 (5.20)

132 (5.20)

132 (5.20)

132 (5.20)

132 (5.20)

132 (5.20)

264 (10.40)

264 (10.40)

264 (10.40)

396 (15.60)

B mm (inches)

430 (16.93)

430 (16.93)

430 (16.93)

430 (16.93)

430 (16.93)

430 (16.93)

MCD3600 1000 (39.37) 560 (22.05)

MCD3700 1000 (39.37) 560 (22.05)

MCD3800 1000 (39.37) 560 (22.05)

MCD3007 ~ MCD3132

C mm (inches)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63)

270 (10.63) a mm (inches)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16)

512 (20.16) b mm (inches)

90 (3.54)

90 (3.54)

90 (3.54)

90 (3.54)

90 (3.54)

90 (3.54)

90 (3.54)

90 (3.54)

222 (8.74)

222 (8.74)

222 (8.74)

354 (13.94)

11

11

11

11

11.5

11.5

11.5

11.5

19.5

19.5

19.5

27

Weight

(kg)

C mm (inches)

280 (11.02)

280 (11.02)

280 (11.02)

280 (11.02)

280 (11.02)

280 (11.02)

315 (12.40)

315 (12.40)

315 (12.40) a mm (inches)

828 (32.59)

828 (32.59)

828 (32.59)

828 (32.59)

828 (32.59)

828 (32.59)

978 (38.49)

978 (38.49)

978 (38.49) b mm (inches)

370 (14.57)

370 (14.57)

370 (14.57)

370 (14.57)

370 (14.57)

370 (14.57)

500 (19.69)

500 (19.69)

500 (19.69)

49.5

49.5

49.5

49.5

49.5

49.5

Weight

(kg)

105

105

105

MCD3185 ~ MCD3800


MCD3000 Series

■

Design Guide

This section provides data useful in the selection and application of soft starters.

■

Reduced voltage starting

When started under full voltage conditions a.c.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 break down 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 to 500%, to in excess of 900% of motor FLC. Locked rotor torque 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.

T

ST

= LRT x

( I

ST

)

LRC

2

T

ST

I

ST

= Start torque

= 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 optimised for one condition.

Primary resistance starters also provide greater starting control than star/delta starters. However, they to 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.

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.

33

MCD3000 Series

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. Soft starters can be broken down into the following categories;

•

Torque controllers

•

Open loop voltage controllers

•

Closed loop voltage controllers

•

Closed loop current controllers

Torque controllers provide only a reduction in starting torque. Depending on their design they control one or two phases only. As a consequence there is no control of starting current as is provided by the more advanced soft start formats.

Single phase torque controllers must be used with a contactor and motor overload. They are suitable for light applications with low to medium start frequency.

Three phase control should be used for repetitive start or high inertia loads because single phase controllers cause increased motor heating during start. This occurs because almost full voltage current flows in the motor winding not controlled by the single phase controller. This current flows for a longer period than during a DOL start resulting in increased motor heating.

Two phase torque controllers must be used with a motor overload but can start and stop the motor without use of a contactor, however voltage is still present at the motor even when it is not running. If installed in this manner it is important to ensure adequate safety measures are taken and that such operation is permitted by local regulations.

Open loop voltage controllers control all three phases and provide both the electrical and mechanical benefits normally associated with soft start. These

34

systems control the voltage applied to the motor in a preset manner and receive no feedback on starting current. Control of start performance is provided to the users through settings such as, Initial Voltage, Rampup time and Dual Ramp-up time. Soft stop is also commonly available and provides the ability to extend motor stopping times.

Open loop voltage controllers must be used with a motor overload and, if required, a line contactor. As such they are a component part that must be integrated with other items to form a complete motor starter.

Closed loop voltage controllers are a variant of the open loop system. They receive feedback on motor start current and use this to stop the voltage ramp when a user set start current limit is reached. User settings and adjustments are the same as for the open loop voltage controllers with the addition of a current limit setting.

Motor current information is also often used to provide a number of current based protection functions. These functions include, motor overload, phase imbalance, electronic shearpin, undercurrent etc. These systems are complete motor starters providing both start/stop control and motor protection.

Closed loop current control is the most advanced form of soft start. Unlike voltage based systems closed loop current technology uses current as the primary reference. The advantages of this approach are precise control of starting current and ease of adjustment. Many of the user settings required by closed loop voltage systems can be made automatically by current based systems.

■

MCD3000 control principles

MCD3000 soft starters control all three phases supplied to the motor. They are closed loop current controllers employing constant current algorithms to provide the best in soft start control.

■

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 125 o C. Five operating parameters effect the SCR junction temperature; Motor Current ,

Start Current , Start Duration , Number of Starts Per

Hour , Off Time . The full rating of a particular soft start model must account for all these parameters. A current rating on its own is not sufficient to describe the capability of a soft starter.


MCD3000 Series

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)

•

Starter Current Rating : Maximum FLC rating of the motor to be connected to the soft starter given the operating parameters specified by the remaining items in the AC53a code.

•

Start Current : The maximum start current that will be drawn during start.

•

Start Time : The time taken for the motor to accelerate.

•

On-load Duty Cycle : The percentage of each operating cycle that the soft starter will run.

•

Starts Per Hour : The number of operating cycles per hour.

2. AC53b: for soft starters used with bypass contactors

For example, the following AC53b code describes a soft starter which, when bypassed, is capable of supplying 145 A run current and a start current of

4.5 x FLC for 30 seconds with a minimum of 570 seconds between the end of one start and the commencement of the next.

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

ATTENTION

To fully understand the model selection procedures it is important to have a good knowledge of the fundamental principles of soft starter ratings. Please read the previous section of this manual, Understanding soft starter ratings .

Model selection can be made in two ways. The most appropriate procedure is dependent on the individual circumstances of the application. Technical support is also available from your local supplier.

4UBOEBSENPEFMTFMFDUJPOQSPDFEVSF

This method is appropriate for typical industrial applications that operate within the standard

MCD3000 ratings of 10 starts per hour, 50% duty cycle, 40 o C, <1000 metres.

1. Use the table below to determine the typical start current required for the driven load.

2. Refer to the Current Ratings tables in the

Specifications section of this manual, and use the typical start current identified above to select a

MCD3000 model with a FLC rating greater or equal to the motor nameplate FLC.

Application Typical

Start Current

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

4.0 x FLC

3.5 x FLC

3.0 x FLC

4.0 x FLC

4.0 x FLC

3.5 x FLC

4.5 x FLC

4.5 x FLC

4.0 x FLC

3.0 x FLC

4.5 x FLC

3.5 x FLC

3.0 x FLC

4.5 x FLC

4.0 x FLC

3.5 x FLC

4.5 x FLC

4.0 x FLC

5.0 x FLC

3.0 x FLC

4.0 x FLC

4.5 x FLC

4.5 x FLC

35

MCD3000 Series

Application

Palletiser

Separator

Slicer

Pulp and Paper

Dryer

Re-pulper

Shredder

Petrochemical

Ball Mill

Centrifuge

Extruder

Screw Conveyor

Transport & Machine Tool

Ball Mill

Grinder

Material Conveyor

Palletiser

Press

Roller Mill

Rotary Table

Lumber & Wood products

Bandsaw

Chipper

Circular Saw

Debarker

Edger

Hydraulic Power Pack

Planer

Sander

Typical

Start Current

4.5 x FLC

4.5 x FLC

3.0 x FLC

4.5 x FLC

4.5 x FLC

4.5 x FLC

4.5 x FLC

4.0 x FLC

5.0 x FLC

4.0 x FLC

4.5 x FLC

3.5 x FLC

4.0 x FLC

4.5 x FLC

3.5 x FLC

4.5 x FLC

4.0 x FLC

4.5 x FLC

4.5 x FLC

3.5 x FLC

3.5 x FLC

3.5 x FLC

3.5 x FLC

3.5 x FLC

4.0 x FLC

ATTENTION

The above start current requirements are typical and appropriate in most circumstances.

However, start torque requirements and performance of motors and machines does vary. For greater accuracy use the advanced model selection procedure.

ATTENTION

For applications that operate outside the standard MCD3000 ratings of 10 starts per hour, 50% duty cycle, 40 o

C, <1000 metres consult your local supplier.

"EWBODFENPEFMTFMFDUJPOQSPDFEVSF

This method uses data on the motor and load to determine the required start current and assumes operation within the standard MCD3000 ratings of 10 starts per hour, 50% duty cycle, 40 o

C, <1000 metres.

Advanced model selection should be used where typical figures listed in the standard model selection procedure are not considered certain enough.

Advanced model selection is also recommended for high inertia applications and installations involving large motors where motor start performance can vary widely.

1. Calculate the required starting torque as a percentage of motor Full Load Torque (FLT).

Generally machine suppliers will be able to provide data regarding the start torque requirements of their machinery. Where this data is not provided as a percentage of motor FLT it will need to be converted.

A motor’s full load torque can be calculated as follows

2. Calculate the minimum start current required by the motor to produce the required torque as calculated above.

I

ST

= LRC x

T

ST

LRT

I

ST

= Minimum required start current

LRC = Motor Locked Rotor Current

LRT = Motor Locked Rotor Torque

T

ST

= Required start torque

3. Refer to the Current Ratings tables in the

Specifications section of this manual. Select a

Start Current column within the Current Ratings table that is greater than the required start current calculated above. Use this column to select a

MCD3000 model with a FLC rating greater or equal to the motor nameplate FLC.

■

Typical applications

MCD3000 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.

•

Undercurrent protection prevents damage from block pipe or low water situations.

•

Automatic reset functionality ensures continued operation of unmanned pump stations.


MCD3000 Series


•

Phase rotation protection prevents damage from reverse pump rotation.

•

Instantaneous overload protection prevents damage from debris

Conveyor

Belts sucked into the pump.

•

Controlled soft start without mechanical shocks, e.g. bottles on a belt do not fall over during starting, minimised belt stretch,

Centrifuges

Ski Lifts reduced counter balance 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.

•

Reduced stopping times.

(D.C.Brake and soft braking).

•

Jerk free acceleration increases skier comfort and prevents swinging T-bars etc.

•

Reduced starting current allows starting of large motors on a weak

Compressors 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.

•


•

Instantaneous overload protection prevents damage possible if liquid ammonia enters the compressor screw.



Fans •

Extended coupling life through reduced mechanical shock.

•

Reduced start current enables large fans to be started when maximum power capacity is limited.

•


Mixers •

Gentle rotation during start-up reduces mechanical stress.

•

The starting current is reduced.

Bandsaws •

Reduced saw band replacement times because the MCD3000 soft braking can stop the motor quickly.

•

Extended saw band life because torque shocks during start are eliminated.

•

Easier saw band alignment. Slow acceleration allows saw bands to be ’tracked’ without jogging.

•

Maximum overload capability available for ride through of operating overloads. The

Chippers

MCD3000 motor thermal model can account for the connected motors actual overload capability and will trip only if absolutely necessary.

•

Reduced starting current.

•

Instantaneous overload trip prevents mechanical damage from

Crushers jammed loads.

•

Reduced deceleration times through use of braking function.

•

Maximum overload capability available for ride through of operating overloads. The

MCD3000 motor thermal model can account for the connected motors actual overload capability and will trip only if absolutely necessary.

•

Maximum start capability available for starting if crusher stopped while not completely empty. The

MCD3000 motor thermal model can account for the connected motors actual overload capability and will allow the motor to provide start torque for the maximum possible time.

37

MCD3000 Series

■

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.

■

Line contactors

MCD3000 soft starters can operate with or without a line contactor. If installing the MCD3000 without a line contactor, ensure such connection complies with local regulations.

Use of a line contactor or similar physical disconnect provides better off state isolation than the soft starter thyristors. This improves operator safety.

Use of a line contactor also eliminates the potential for extreme supply voltage disturbances to damage the soft starter thyristors while they are in the off state.

Voltage disturbances resulting from supply resonance can typically be expected on high impedance supplies with power factor correction. Use of a line contactor is prudent in such conditions.

If using a line contactor and either the soft stop or

D.C.Brake functions the line contactor cannot be opened until the end of the stop. The MCD3000 should be used to directly control operation of the line contactor. Set programmable relay output A or B to the Line Contactor function.

As an alternative to a line contactor, either a circuit breaker with a no volt release coil operated by the

MCD3000 N.C. trip output or a motor operated circuit breaker can be considered.

■

Soft braking

In addition to the D.C.Brake function MCD3000 soft starters can be configured for ’Soft Braking’. Soft braking provides greater braking torque and lower motor heating. Soft braking should be considered for high inertia loads such as chippers, crushers, bandsaws etc.

To implement soft braking the MCD3000 is employed along with reversing contactors and a rotation sensor.

When a stop is called for, the phase rotation of the supply to the starter is reversed and the motor is ’soft started’ in reverse thus providing braking torque. The rotation sensor is used to end braking when the motor has stopped rotating.

The MCD3000 secondary parameter set (Par. 25-33) can be used to control braking torque independently of starting parameters. This is done by setting start performance using the primary parameter set (Par. 1-

9) and braking performance using the secondary parameter set (Par. 25-33). Closing the Par. Set control input when the stop is initiated then activates the secondary parameter set.

4PGU#SBLJOH4DIFNBUJD


MCD3000 Series

■

Fault Procedure

The MCD3000 Soft Starters include a range of protection functions. Faults identified by these systems are indicated with a trip code on the Local Control

Panel display. The following section of this manual explains the trip codes and action required.

Procedures for faults not identified with a trip code are detailed in the General Faults section.

The voltage of the soft starter is dangerous whenever the equipment is connected to the mains. Work on the equipment should be carried out by qualified personnel. Before performing any maintenance and repair work, switch off the electrical supply to the device and observe all safety regulations.

■

Trip Codes

When a protection function operates the MCD3000 enters a trip state and displays the following data.

•

The trip LED is illuminated

•

The [CODE] LED is illuminated indicating the display is showing trip code data

ATTENTION

You can view motor temperature as calculated by the MCD3000 motor thermal model by using the [+/-] push buttons to scroll the numeric display between current [AMPS], temperature [TEMP] and trip code [CODE].

The trip code data is made up of two parts.


The first digit indicates the trip number. (The

MCD3000 has a trip log that records the last eight trip events, trip number 1 is the most recent trip. Refer to the next section of the manual for description of the

Trip Log).

The second digit indicates the cause of the trip

Code Cause & Action

0

1

2

3

Shorted SCR trip.

The MCD3000 has detected a shorted

SCR.

•

Test the MCD3000 SCRs using the

Power Circuit Test described in the

Test and measurement procedures chapter later in this section of the manual.

•

A shorted SCR trip can only be reset by removing control voltage.

Excess start time trip.

The start time has exceed the maximum limit programmed in Par. 10 Excess

Start Time Protection.

•

Identify and remedy why the motor is taking longer than normal to accelerate.

•

Reset the MCD3000

•

Restart the motor.

Overcurrent trip.

The motor has experienced an overload condition that exceeded its thermal capability as programmed in Par. 6

Motor Thermal Capacity .

•

Identify and correct the cause of the overload.

•

Wait for the motor to cool sufficiently to allow a restart.

•

Reset the MCD3000.

•

Restart the motor.

In an emergency situation where it is critical to immediately restart the motor and overload protection of the motor is a secondary concern, the MCD3000 overload protection can be reset by temporarily removing control supply voltage.

Motor thermistor trip.

Thermistors in the motor have indicated an overtemperature state.

•

Identify and correct the cause of the motor overheating.

•

Wait for the motor to cool sufficiently to allow a restart.

•

Reset the MCD3000.

•

Restart the motor.

39

Code

40

4

5

6

7

8

MCD3000 Series

Cause & Action

If no motor thermistors are connected;

•

Ensure that there is a closed circuit across the MCD3000 motor thermistor input terminals.

Phase imbalance trip.

An imbalance in phase currents has exceeded the limits programmed in Par.

7 Phase Imbalance Sensitivity .

•

Check the supply voltage.

•

Verify the motor circuit.

•

Reset the MCD3000.

•

Restart the motor.

•

Check phase currents.

Supply frequency trip.

The supply frequency has varied outside the allowed limits. Refer to Specification section.

•

Identify and correct the cause of the frequency variations. (Note that the loss of the three phase supply is a

0Hz condition and may be the cause of a Supply frequency trip).

•

Reset the MCD3000.

•

Restart the motor.

Phase rotation trip.

Phase rotation protection has been set and a prohibited phase rotation has been detected. Refer Par. 11 Phase

Rotation Protection .

•

Correct the phase rotation.

•

Reset the MCD3000.

•

Restart the motor.

Instantaneous overload trip.

An instantaneous overload exceeding the limit programmed in Par. 9

Instantaneous Overload Trip Point has been detected.

•

Identify and correct the cause of the instantaneous overload.

•

Reset the MCD3000.

•

Restart the motor.

Power circuit fault.

•

Ensure voltage is present on the

MCD3000 input terminals (L1, L2 &

L3).

•

Ensure the motor is correctly connected to the MCD3000 output terminals (T1, T2 & T3).

•

Test the MCD3000 power modules

(SCRs) using the SCR Test described later in this section of the manual under the Test and

Measurement Procedures heading.

Code f

9 c e

P

■

Trip Log

Cause & Action

Undercurrent trip.

Motor run current has fallen below the limit programmed in Par. 8 Undercurrent

Trip Point.

•

Identify and correct the cause of the undercurrent situation.

•

Reset the MCD3000.

•

Restart the motor.

RS485 communications fault

The RS485 link with the MCD3000 has been inactive for a time greater than programmed in Par. 24 Serial

Communication - RS485 Time Out.

•

Identify and correct the cause of the

RS485 failure.

•

Reset the MCD3000.

EEPROM Read/Write failure.

The MCD3000 has been unable to

Read/Write to the internal EEPROM.

•

Contact your nearest Danfoss office.

FLC range error

The MCD3000 has detected that the motor is connected in the 3 Wire configuration and that Par 1. Motor FLC or Par. 25 Motor FLC has been set in excess of the MCD3000’s maximum capability for this connection format.

•

Reduce the motor FLC setting and then reset the MCD3000. Note that the MCD3000 cannot be reset until the FLC setting has been corrected.

.

Starter overtemperature.

An excessive heatsink temperature has been recorded.

•

Ensure all cooling fans are working.

•

Ensure cooling air is able to flow freely into and out of the starter.

•

Ensure the temperature of the cooling air entering the MCD3000 does not exceed the rated temperature.

•

Reset and restart the MCD3000 after allowing time for the heatsink to cool.

Motor connection error.

•

Ensure the motor is correctly connected to the MCD3000.


MCD3000 Series

When the MCD3000 enters a trip state, the cause of the trip is recorded in a trip log. The trip log records the cause of the last eight trip events. Each trip event is numbered. The most recent event is numbered 1, while the oldest is numbered 8.

ATTENTION

Control voltage must be present to enable the

MCD3000 to record the cause of a trip event.

Therefore, trips caused by, or involving a loss of control supply voltage may not be recorded.

To view the trip log;

•

Enter the programming mode and move to Par.

45, Trip Log .

•

Press the [CHANGE DATA/OK] button to view the most recent trip.

•

Use the [+/-] buttons to scroll through the trip log.

A ’marker’ can be placed in the trip log to enable easy identification of trips that have occurred after the marker has been placed.

To place a marker;

•

Enter the programming mode and move to Par.

45 Trip Log .

•

Press the [CHANGE DATA/OK] button to view the trip log.

•

While simultaneously holding down the [+], [-] buttons, press the [CHANGE DATA/OK] button.

The marker is added as the most recent trip and is displayed as the letter ’A’ as shown below. marker.

ATTENTION

Markers cannot be placed consecutively.

There must be at least one trip between each

■

General Faults

Symptom Cause & Action

Starter will not operate.

•

Incorrect or no control supply voltage. Ensure the correct voltage


Starter will not operate.

Starter will not enter program mode. is applied. (Terminals A1,A2 & A3).

•

MCD3000 is in programming mode.

Exit the programming mode.

•

Local push buttons not active. If attempting to use the start button on the Local Control Panel, ensure the

MCD3000 is in local control mode.

(Refer to Par. 20 Local/Remote

Mode for details).

•

Remote inputs not active. If attempting to use the MCD3000 remote inputs, ensure the MCD3000 is in remote control mode. (Refer to

Par. 20 Local/Remote Mode for details).

•

Remote start signal not valid. If attempting to use the remote start input on the MCD3000, ensure the remote contacts are correctly connected and operating properly.

Do this by observing the remote control input LEDs. The LEDs illuminate when there is a closed circuit. In addition to the start signal there must be a closed circuit across the stop and reset inputs for the starter to function.

•

Restart delay active. A start cannot be initiated within the programmed restart delay period. (Refer to Par.

15 Restart Delay for details).

•

Auto-Reset active. If there has been a trip and the Auto-Reset function has been turned ON, the MCD3000 will be in Auto-Reset mode. This includes a reset delay period, during which a start cannot be initiated without first resetting the starter.

(Refer to Par. 39,40, 41 & 42

Automatic-Reset for details).

•

Starter is running. Stop the starter and try again.

•

Incorrect or no control supply voltage. Ensure the correct supply voltage is applied. (Terminals A1,A2

& A3).

Symptom Cause & Action

Program settings

•

Read Only mode is active. Set Par. cannot be made.

48 Parameter Lock to Read/Write.

•

Incorrect programming procedure.

User programmed settings must be stored using the [CHANGE

41

DOL or uncontrolled start.

DATA/OK] button before moving to another parameter.

•

Power factor correction capacitors connected to starter output.

Remove any PFC from the starter output. Check for damage to the soft start power modules by performing the SCR Test as detailed in the next section of this manual.

•

Damaged soft starter power modules. Check the soft start power modules by performing the SCR

Test as detailed in the next section of this manual.

•

Damaged soft starter firing circuit.

Check the soft start firing circuit by performing the Firing Circuit Test as detailed in the next section of this

Motor will not

Erratic

Motor

Operation and tripping.

• manual.

Insufficient start current. Check the accelerate to full speed. load. Increase the start current supplied to the motor by adjusting

Par. 2 Current Limit .

•

Very small motor being controlled by a large starter. The current drawn by very small motors sometimes used to test soft starter installations can be too low to latch the soft starter

SCRs. Increase motor size.

MCD3000 display shows an ’h’

The [START] button on the MCD3000 local control panel is stuck. Release the button to restore normal operation. h

Soft stop function ceases before the set ramp time.

The MCD3000 soft stop function has significantly reduced the output voltage to the motor without detecting any reduction in motor speed. This indicates a no, or very light load condition that makes further control of the voltage ineffective, hence the soft stop function has been halted.

■

Test and measurement procedures

The following tests and measurements can be used to verify starter operation.

START PERFORMANCE TEST;

This procedure tests for correct operation of the

MCD3000 during start.

•

Calculate the expected start current by multiplying

Par. 1 Motor FLC by the Par. 2 Current Limit or, if

42

MCD3000 Series the secondary parameter set is being tested Par.

25 Motor FLC by the Par. 26 Current Limit .

•

Initiate a start and measure the actual start current.

•

If the measured start current is equal to the calculated current the starter is performing correctly.

RUN PERFORMANCE TEST;

This procedure tests for correct operation of the

MCD3000 during run.

•

Measure the voltage across each phase (L1-T1,

L2-T2, L3-T3) of the soft starter. A voltage drop of approximately 2 VAC or less indicates the starter is performing correctly.

POWER CIRCUIT TEST:

This procedure tests the MCD3000 power circuit including the SCR, firing loom and printed circuit board.

•

Disconnect the incoming supply (L1, L2, L3 and control voltage) from the starter.

•

Disconnect the motor cables (T1, T2,T3) from the starter.

•

Ensure the firing looms remain plugged in during the tests.

•

Using a 500 VDC insulation tester (low voltage ohm meters or multi-meters are not adequate), measure the resistance between the input and output on each phase (L1-T1, L2-T2, L3-T3). The resistance should be close to 33k

Ω

.

•

If the resistance measured across the SCR measures below about 10k

Ω

the SCR should be replaced.

•

If the resistance measured across the SCR is greater than 33k

Ω

there could be a control PCB or firing loom fault.

CONTROL INPUT TEST;

This procedure verifies the integrity of circuits connected to any of the remote control inputs. Start,

Stop, Reset and Par. Set.

•

Using a volt meter measure across each input. If

24VDC is measured when the circuit is closed, the switch/control is connected incorrectly or is faulty.


www.danfoss.com/drives

175R0865 MG15A402 *MG15A402* Rev. 2003-10-09

Operating Instructions

MCD 3000 Soft Starter

Danfoss VLT® MCD 3000 Operating Guide

www.danfoss.com/drives

Operating Instructions

MCD 3000 Soft Starter

Warnings

Quick Set-up

Description

Installation

Programming

Operation

Specifications

Design Guide

Fault Procedure

MG.15.A4.02 - VLT is a registered Danfoss trademark 1

Safety regulations

Warning against unintended start

Symbols used in this manual

Avoiding soft starter damage

2 MG.15.A4.02 - VLT is a registered Danfoss trademark

Quick Set-up

Install the MCD3000

Program the MCD3000

Start the motor

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Description

Ordering type code

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Functions

Electrical Schematic

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Mechanical installation

General layout

Ventilation

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Power wiring - Standard connection

Power wiring - Bypass connection

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Power wiring - D.C.Brake connection

Control Supply Voltage

Power wiring – Inside delta connection

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Control wiring

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Motor thermistors

Control circuit examples

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Serial communications

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Serial communications - commands

Serial communications – status retrieval

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Serial communications – downloading parameter settings from the MCD3000

Serial communications – uploading parameter settings to the MCD3000

Serial communications –data retrieval

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Serial communications – calculating the check sum (LRC)

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Programming

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Programming procedure

Programmable functions

16

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MG.15.A4.02 - VLT is a registered Danfoss trademark

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18

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MG.15.A4.02 - VLT is a registered Danfoss trademark

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20

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22

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