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MAKING MODERN LIVING POSSIBLE
Pocket Guide
VLT® Soft Starter – the single speed drive
Contents
Soft Starter Selection Guide
Warnings ............................................................................................................................................. 5
Common Applications ................................................................................................................... 6
MCD Soft Starter Features and Specifi cations ...................................................................... 8
Current Ratings ............................................................................................................................... 11
Soft Starter Sizing .......................................................................................................................... 14
FAQs
Adaptive Acceleration Control ................................................................................................... 15
AC53 Utilisation Codes ................................................................................................................ 16
Auto-Transformer Starters ......................................................................................................... 17
Braking ................................................................................................................................................. 18
Bypass Contactor ........................................................................................................................... 19
Cabling ............................................................................................................................................... 20
Extreme Conditions ...................................................................................................................... 22
Fault fi nding .......................................................................................................................................22
Flying Loads ..................................................................................................................................... 23
Harmonics ........................................................................................................................................ 23
IP Ratings .......................................................................................................................................... 24
NEMA Ratings .................................................................................................................................. 25
Inside delta Connection ...............................................................................................................26
Key Benefi ts ..................................................................................................................................... 27
Line Contactor ................................................................................................................................ 28
Minimum Start Current ............................................................................................................... 29
Multiple Motors .............................................................................................................................. 30
Power factor correction .............................................................................................................. 31
Motor Thermal Capacity ............................................................................................................. 31
Jog .........................................................................................................................................................32
Reversing .......................................................................................................................................... 32
Sealed Enclosures .......................................................................................................................... 33
Primary Resistance Starters ....................................................................................................... 33
Short Circuit Protection, Type 1 ................................................................................................ 34
Short Circuit Protection, Type 2 .................................................................................................35
Semiconductor Fuse Selection, Type 2 .................................................................................. 36
Slip-Ring Motors ............................................................................................................................ 39
Soft Braking ..................................................................................................................................... 40
VLT ® Soft Starter Pocket Guide 3
Star/Delta Starters ......................................................................................................................... 41
Thermal Model Protection ......................................................................................................... 43
Two Speed Motors ........................................................................................................................ 44
Types of Soft Starter ..................................................................................................................... 45
MCD Bus Options
MCD Bus Options – General Notes ..........................................................................................46
MCD 200 with MCD Remote Operator Option ....................................................................47
MCD 200 Modbus Option ........................................................................................................... 48
MCD 200 DeviceNet Option ....................................................................................................... 50
MCD 200 Profi bus Option ........................................................................................................... 51
MCD 200 USB Option .....................................................................................................................52
MCD 500 with MCD Remote Operator Option ....................................................................53
MCD 500 Modbus Option ............................................................................................................54
MCD 500 DeviceNet Option ........................................................................................................55
MCD 500 Profi bus Option ............................................................................................................56
MCD 500 USB Option .....................................................................................................................57
MCD 3000 with MCD Remote Operator Option ................................................................. 58
MCD 3000 Modbus Option ........................................................................................................ 59
MCD 3000 DeviceNet Option ................................................................................................... 60
MCD 3000 Profi bus Option ........................................................................................................ 61
Glossary
Glossary ..............................................................................................................................................62
Abbreviations ...................................................................................................................................67
Warnings
Soft starter selection requires information on the intended application, the features required, and the current rating of the associated motor.
For applications with extreme or unusual conditions, consult the relevant Design Guide and/or your supplier.
For example:
• High altitude installation (> 1000 m)
•
•
High ambient temperatures (> 40˚ C)
High and/or frequent operating overloads
•
•
High start frequency
Slip-ring motor operation
•
•
Part speed operation
Horizontal mounting of the starter
4 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 5
Common Applications
This table lists common applications for soft starters and it’s nominal duty ratings.
Application
Agitator
Auger
Blower (axial fan)
Bottle Washer
Centrifuge
Chipper
Compressor, centrifugal (rotary)
Compressor (reciprocating, unloaded)
Compressor (screw, unloaded)
Conveyor (loaded)
Conveyor (unloaded)
Crusher, cone
Crusher, jaw
Crusher, rotary (unloaded)
Debarker
Drilling machine
Dust Collector
Edger
Escalator
Fan, centrifugal (damped)
Fan, centrifugal (undamped)
Grinder
Hydraulic power pack
Mill, ball
Mill, hammer
Mill, roller
Milliscreen
Normal
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Heavy
•
•
•
•
•
•
•
•
•
Severe
•
•
•
6 VLT ® Soft Starter Pocket Guide
Application
Mixer (low viscosity)
Mixer (high viscosity)
Pelletiser
Planer
Press
Pump, bore
Pump, centrifugal
Pump, positive displacement
Pump, slurry
Pump, submersible
Pump, vacuum
Re-pulper
Rotary table
Sander
Saw, band
Saw, circular
Shredder
Separator, liquids
Separator, solids
Slabber
Slicer
Travelator
Tumbler/Dryer
Vibrating screen
Winch
Wire Draw machine (hydraulic)
VLT ® Soft Starter Pocket Guide
Normal
•
Heavy
•
•
•
•
•
•
•
•
•
•
Severe
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
7
MCD Soft Starter Features and Specifi cations
•
•
•
•
•
•
MCD 201
• Soft start/stop:
Timed voltage ramp
Motor protection: not included
System protection: not included
Metering: not included
Start/stop control: via inputs or via optional controller
Network communication: optional
Bypass: Internally bypassed
•
•
•
•
•
•
MCD 202
•
Soft start: Current limit
Soft stop: Timed voltage ramp
Motor protection:
•
Thermistor, Motor overload,
Phase imbalance
System protection: Phase rotation,
Excess start time, Bypass overload
& Instantaneous overload
Metering: optional extra
Start/stop control: via inputs or via optional controller
Network communication: optional
Bypass: Internally bypassed
•
•
•
MCD 201 and MCD 202
• Current: 7.5 kW ~ 110 kW @400 V
Mains voltage: 200 ~ 575 VAC
Supply frequency: 45 ~ 66 Hz
Enclosure: 7.5 ~ 55 kW IP 20,
75 ~ 110 kW IP00
8 VLT ® Soft Starter Pocket Guide
MCD 500
• Soft start: Current limit, Current
• ramp, Kickstart, AAC Adaptive
Acceleration Control
Soft stop: Timed voltage ramp, AAC
Adaptive Control, DC brake
•
•
Motor protection: Motor connection, Power loss, Phase loss, Mains frequency, Current imbalance,
Motor thermistor, Motor overload
System protection:
Phase sequence, Excess start time,
Undercurrent, Instantaneous
•
•
•
• overcurrent, Bypass relay overload,
Heatsink temperature
Metering: Current, Motor temperature, Motor kW, motor kVA,
Motor pf
Control option: Local control panel plus remote inputs/outputs
Network communication: options for DeviceNet, Modbus, Profibus and USB
Bypass:
7.5 ~ 110 kW internally bypassed;
132 ~ 800 kW dedicated terminals for external bypass connection
•
•
•
•
MCD 500
Current: 7.5 kW ~ 800 kW @400 V
Mains voltage: 200 ~ 690 VAC
Supply frequency: 50/60 Hz
Enclosure: 7.5 ~ 55 kW IP 20,
60 ~ 800 kW IP 00
VLT ® Soft Starter Pocket Guide 9
MCD 3000
• Soft start: Current limit,
•
Current ramp, Torque control,
Torque boost
Soft stop: Timed voltage ramp,
Pump control, DC brake, Soft brake
•
•
•
•
•
Motor protection: Thermistor,
Motor overload, Phase imbalance
System protection: Phase rotation,
Excess start time, Undercurrent,
Instantaneous overload
Metering: Current, motor temperature
Control option: Local pushbuttons plus remote inputs/outputs
Network communication:
•
AP ASCII plus options for
DeviceNet, Modbus and Profi bus
Bypass: Dedicated terminals for external connection
•
•
•
MCD3000
• Current: 7.5 kW ~ 800 kW @400 V
Mains voltage: 200 ~ 690 VAC
Supply frequency: 50/60 Hz
Enclosure: 7.5 ~ 132 kW IP 21,
185 ~ 800 kW IP 20
MCD 100
• Micro Soft Start Controller for motors up to 11 kW
• Extremely robust SCR design with heavy ratings as standard
• Unlimited number of starts per hour
• Contactor style design for easy selection, installation and commissioning
•
•
•
•
MCD 100
Current: 1.5 kW ~ 11 kW @400 V
Mains voltage: 208 ~ 600 VAC
Control voltage: 24 – 480 VAC/VDC
Enclosure: 1.5 ~ 11 kW IP 20
10 VLT ® Soft Starter Pocket Guide
Current Ratings
These duty ratings defi ne the load requirements, not the starter capabilities. Starter capability is specifi ed separately in User Manuals, Product Guides and WinStart. Use these charts to select a soft starter for a particular application.
MCD5-0021
MCD5-0037
MCD5-0043
MCD5-0053
MCD5-0068
MCD5-0084
MCD5-0089
MCD5-0105
MCD5-0131
MCD5-0141
MCD5-0195
MCD5-0215
MCD5-0245
MCD5-0360
MCD5-0380
MCD5-0428
MCD5-0595
MCD5-0619
MCD5-0790
MCD5-0927
MCD5-1200
MCD5-1410
MCD5-1600
Normal
21 (32)
37 (56)
43 (65)
53 (80)
68 (102)
84 (126)
89 (134)
105 (158)
131 (197)
141 (212)
195 (293)
215 (323)
255 (383)
360 (540)
380 (570)
430 (645)
620 (930)
650 (975)
790 (1185)
930 (1395)
1200 (1800)
1410 (2115)
1600 (2400)
Heavy
17 (26)
31 (47)
37 (56)
46 (69)
55 (83)
69 (104)
74 (112)
95 (143)
106 (159)
121 (181)
160 (241)
178 (268)
201 (302)
310 (465)
359 (539)
368 (552)
540 (810)
561 (842)
714 (1072)
829 (1244)
1200 (1800)
1319 (1979)
1600 (2400)
All ratings are for bypassed operation.
Brackets denote ratings for inside delta connection.
Severe
15 (22)
26 (39)
30 (45)
37 (55)
47 (71)
58 (87)
61 (92)
78(117)
90(136)
97 (146)
134 (201)
149 (223)
176 (264)
263 (395)
299 (449)
309 (463)
434 (651)
455 (683)
579 (869)
661 (992)
1071 (1607)
1114 (1671)
1353 (2030)
VLT ® Soft Starter Pocket Guide 11
MCD 201-007
MCD 201-015
MCD 201-018
MCD 201-022
MCD 201-030
MCD 201-037
MCD 201-045
MCD 201-055
MCD 201-075
MCD 201-090
MCD 201-110
MCD 202-007
MCD 202-015
MCD 202-018
MCD 202-022
MCD 202-030
MCD 202-037
MCD 202-045
MCD 202-055
MCD 202-075
MCD 202-090
MCD 202-110
Normal
85
100
140
170
200
18
34
42
48
60
74
85
100
140
170
200
18
34
42
48
60
74
Heavy
73
96
120
142
165
17
30
36
40
49
65
73
96
120
142
165
17
30
36
40
49
65
Severe
Consult Danfoss for suitability
Consult Danfoss for suitability
MCD3007
MCD3015
MCD3018
MCD3022
MCD3030
MCD3037
MCD3045
MCD3055
MCD3075
MCD3090
MCD3110
MCD3132
MCD3185
MCD3220
MCD3300
MCD3315
MCD3400
MCD3500
MCD3600
MCD3700
MCD3800
Normal
326 (489)
383 (575)
507 (761)
547 (820)
694 (1041)
822 (1233)
998 (1497)
1248 (1873)
1433 (2149)
83
111
117
172
202
208
17
30
36
45
57
76
Brackets denote ratings for inside delta connection.
Heavy
261 (392)
308 (462)
393 (590)
456 (684)
567 (850)
602 (904)
797 (1195)
990 (1485)
1128 (1293)
78
104
113
164
194
202
16
28
33
40
54
72
Severe
222 (333)
262 (394)
329 (493)
377 (566)
458 (687)
526 (789)
713 (1070)
865 (1297)
961 (1442)
68
90
99
143
169
178
14
24
29
35
47
62
12 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 13
Soft Starter Sizing
• The soft starter’s current rating at the required start duty must be at least equal to the motor’s nameplate rating. If the motor’s nameplate rating is not available, approximate information is available from the following table.
475
500
560
600
650
700
750
335
355
375
400
425
445
450
800
850
900
950
1000
185
200
220
250
257
280
295
300
315
90
110
132
140
147
150
160
22
25
30
37
45
55
75
Motor Power kW
7.5
HP
10
11
15
18.5
15
20
25
30
35
40
50
60
75
100
250
270
300
340
350
380
400
410
430
125
150
180
190
200
205
220
645
680
760
800
870
940
1000
1070
1140
1250
1275
1340
450
480
500
545
580
600
610
Note: Information is based on a 4-pole motor
826
900
948
980
990
1100
1150
1180
1250
472
483
520
595
626
700
800
220-230 V
27
39
52
64
75
85
103
126
150
182
240
295
356
425
450
2031
2187
2343
2499
2656
2812
2968
3124
1330
1400
1410
1490
1570
1750
1875
850
900
1000
1085
1176
1266
1357
620
636
670
710
760
790
800
1447
1537
1628
1718
1809
342
370
408
460
475
510
546
565
584
170
205
245
260
273
280
300
Current rating at diff erent voltages
380-400 V
15.5
440 V
13.7
500 V
12
22
30
37
20.1
26.5
32.8
18.4
23
28.5
44
52
60
72
85
105
138
39
45.3
51.5
64
76
90
125
33
39.4
45
55
65
80
105
146
178
215
227
236
246
256
295
321
353
401
412
450
473
481
505
263
281
310
360
365
400
416
420
445
129
156
187
200
207
210
220
730
780
860
937
1015
1093
1172
518
549
575
611
650
680
690
1250
1328
1406
1484
1562
645
680
760
825
894
962
1031
472
500
527
540
574
595
608
1100
1168
1237
1306
1375
280
305
320
325
337
355
370
395
410
152
159
170
200
215
235
274
660-690 V
8.9
14
17.3
21.3
25.4
30.3
34.6
42
49
61
82
98
118
140
145
677
729
781
833
885
937
989
1041
445
455
460
485
515
570
625
14 VLT ® Soft Starter Pocket Guide
ACC: What is Adaptive Acceleration Control?
AAC is the next evolution in soft starter technology.
Using AAC, the soft starter learns your motor’s performance during start and stop, then adjusts control to optimize performance.
The soft starter estimates the motor’s speed throughout each AAC start and stop, and adjusts power to the motor to provide the selected acceleration or deceleration profile.
AAC is largely unaffected by changes in load, and is particularly suitable for pumping situations.
AAC offers three starting and stopping profiles: early, constant and late acceleration/deceleration.
EARLY
CONSTANT
LATE
TIME
AAC is only available on MCD 500 soft starters.
LATE
CONSTANT
EARLY
VLT ® Soft Starter Pocket Guide 15
AC53 Utilisation Codes: What are AC53 Utilisation Codes?
AC53 utilisation codes describe the current rating for soft starters under specifi ed operating conditions.
The utilisation code determines the maximum motor size the soft starter can be used with, under the specifi ed conditions. The current rating may change under diff erent operating conditions.
AC53a: Non-bypassed soft starters
The rating depends on the number of starts per hour, the length and current level of the start, and the percentage of the operating cycle that the soft starter will be running (passing current).
Auto-Transformer Starters: How does soft start compare to auto-transformer starting?
Soft starters are much more fl exible than auto-transformer starters and provide a much smoother start, generally at a lower cost.
Auto-transformer starters cannot accommodate varying load conditions (e.g. loaded or unloaded starts) and the start torque cannot be freely adjusted to match motor and load characteristics. Damaging torque and current transients still occur at the steps between voltages, and auto-transformer starters are not capable of providing soft stop.
Auto-transformer starters are large and expensive, especially if high start frequency is required.
AC53b: Bypassed soft starters
The rating depends on the number of starts per hour, the length and current level of the start, and the amount of time the soft starter will be off (not passing current) between starts.
Danfoss soft starters provide a relay output, which can be used to control the main contactor. Ensure that the inrush VA rating of the contactor coil does not exceed the rating of the soft starter’s relay input.
16 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 17
Braking:
What are DC braking and soft braking?
DC braking and soft braking both reduce motor stopping time, unlike soft stopping which increases the stop time on frictional loads.
DC braking uses DC injection to reduce the motor’s stopping time.
The soft starter slows the motor to approximately 70% of its full running speed, then applies brake torque to stop the motor in the selected braking time.
MCD 3000 soft starters can provide DC braking via a dedicated braking contactor.
DC braking support is built into MCD 500 soft starters, and no additional equipment is required. MCD 500 DC braking controls all three phases, which reduces stress on the motor compared with two phase braking solutions.
Soft braking uses reversing contactors on the input side of the starter to start the motor in the reverse direction, which applies braking torque to the load.
Soft braking causes less motor heating and provides more braking torque for a given current than DC braking, and is better for extremely high inertia loads (e.g. band saw and circular saw applications).
Bypass Contactors:
When should a bypass contactor be used?
Bypass contactors bridge out the SCRs when the motor is running at full speed, eliminating heat dissipation during run. This allows the soft starter to be installed in enclosures without the need for forced-air cabinet ventilation.
If a soft starter is installed in a totally sealed enclosure (>IP 54) it must be bypassed.
Bypass contactors should be AC1 rated for the motor FLC (the bypass contactor does not carry start current).
Soft starters may be internally or externally bypassed:
18 VLT ® Soft Starter Pocket Guide
MCD 200 soft starters are internally bypassed, with built-in bypass relays.
MCD 500 soft starters are internally bypassed up to 110 kW.
Non-bypassed models include relay outputs to control an external bypass contactor. Dedicated bypass terminals mean motor protection still operates even when the starter is bypassed.
MCD 3000 soft starters provide relay outputs to control an external bypass contactor. Dedicated bypass terminals mean motor protection still operates even when the soft starter is bypassed.
VLT ® Soft Starter Pocket Guide 19
Cabling: How is cable selected for a soft starter installation?
Cable selection criteria depends on the circuit and the location of the soft starter within the circuit.
Cabling: What is the maximum allowable cable, distance between a soft starter and the motor?
The maximum distance between the soft starter and motor depends on the voltage drop and the cable capacitance.
Cable must be selected so that when the motor is running fully loaded, the voltage drop at the motor terminals does not exceed the limit specifi ed in local electrical regulations.
For distances greater than 500 metres, cable capacitance may be a factor. Contact Danfoss with details of the soft starter model, mains voltage and frequency.
1. Supply cable rating > nominal fuse/MCCB rating > motor FLC x 1.2
2. Inside delta motor circuit cable rating > motor FLC x 0.7
Installation factors (including grouping, ambient temperature, method of installation and single or parallel cabling) may aff ect the cable’s current rating. Always follow the manufacturer’s guidelines and derate appropriately.
20 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 21
Extreme Conditions: How can soft starters be selected for extreme conditions?
Soft starter ratings are based on specifi c operating conditions. These generally specify start time, start current, starts per hour, duty cycle and environmental factors such as ambient temperature and altitude.
If the soft starter will be used outside these conditions, the rating must be revised according to the manufacturer’s instructions.
Ratings for Danfoss soft starters are published in the soft starter’s Operating Instructions. Alternatively, WinStart can be used to model requirements outside the published ratings.
Fault fi nding: What are the key questions?
•
•
To assist your service engineer, they require the following information:
• Model and serial number of the soft starter
Motor kW and FLC
Main supply voltage and frequency
•
•
Control voltage
Application (e.g. pump, compressor)
•
•
Time installed before failure
Details of other soft starters on the supply bus. Are these failing?
•
•
If the soft starter trips, details of the code and mode of operation
The installation’s power and control schematic diagram
22 VLT ® Soft Starter Pocket Guide
Flying Loads: Are soft starters suitable for use with a fl ying load?
Soft starters can be used with fl ying loads (motors that are already rotating), without any special wiring or confi guration.
As a general rule, the faster the motor is rotating in the forward direction, the shorter the start time will be.
If the motor is rotating in the reverse direction, it will be slowed to a standstill before accelerating in the forward direction. In this case allow for the extended start time when rating the soft starter.
Harmonics: Are harmonics an issue for soft starter applications?
Harmonics are voltages and currents that create unwanted heating in motors, cables and other equipment. Harmonics may also disrupt operation of other electrical and electronic equipment.
Soft starters generate very low levels of harmonics, only during starting or soft stopping. According to IEC 60947-4-2 (8.3.2.1.1), “harmonic emissions are of short duration during starting, and there are no signifi cant emissions in the FULL-ON state”. No special considerations or fi ltering are required for soft start applications.
All MCD soft starters comply with the EMC directive on radiofrequency emissions and immunity.
VLT ® Soft Starter Pocket Guide 23
IP ratings
IEC 60529 specifi es protection ratings for enclosures.
The fi rst number describes the protection against solid objects, the second number describes the level of protection against entry of liquids. Example IP 20 is highlighted below.
IP Solids
0 No protection
1
Protected against solid objects greater than 50 mm (e.g. accidental touching by hand).
2
3
4
5
6
7
8
Protected against solid objects greater than 12 mm (e.g. fi ngers).
Protected against solid objects greater than 2.5 mm
(e.g. tools or wires)
Protected against solid objects greater than 1 mm
(e.g. tools and small wires).
Limited protection against dust
(some ingress but no harmful deposit).
Complete protection against dust.
Liquids
No protection.
Protected against vertically falling drops of water (e.g. condensation).
Protected against direct sprays of water up to 15° from vertical.
Protected against sprays of water up to 60° from vertical.
Limited protection against water sprayed from all directions (limited ingress permitted).
Limited protection against low pressure jets of water from all directions
(limited ingress permitted).
Protected against strong jets of water (limited ingress permitted).
Protected against the eff ects of immersion in water between 15 cm and 100 cm.
Protected against extended
immersion in water under pressure.
•
•
Examples
• MCD200-007 ~ MCD200-055 is IP 20
• MCD200-075 ~ MCD200-110 is IP 00
IP 20 with optional finger guard kit,
Order code 175G9007
MCD5-0021 ~ MCD5-0105 is IP 20
MCD5-0131 ~ MCD5-1600 is IP 00
IP 20 with optional finger guard kit.
•
•
Order codes are:
MCD5-0131~0215: 175G5662
MCD5-0245: 175G5663
MCD5-0360~0927: 175G5664
MCD5-1200~1600: 175G5665
MCD3007 ~ MCD3132 is IP 21
MCD3185 ~ MCD3800 is IP 20
24 VLT ® Soft Starter Pocket Guide
NEMA ratings
NEMA 250 is a product standard for enclosure design and performance.
NEMA Protection against solid objects
1 Indoor, protection from contact.
2
3
3R
4
4X
6
12
13
Indoor, limited protection from dirt and water.
Outdoor, some protection from rain, sleet, windblown dust and ice.
Outdoor, some protection from rain, sleet and ice.
Indoor or outdoor, some protection from windblown dust, rain, splashing water, hose-directed water and ice.
Indoor or outdoor, some protection from corrosion, windblown dust, rain, splashing water, hose-directed water and ice.
Indoor or outdoor, some protection from ice, hose-directed water, entry of water when submerged at limited depth.
Indoor, protection from dust, falling dirt and dripping non-corrosive liquids.
Indoor, protection from dust, spraying water, oil and non-corrosive liquids.
Approx. IP equivalent
IP 23
IP 30
IP 64
IP 32
IP 66
IP 66
IP 67
IP 55
IP 65
Warning:
Conversion from NEMA to IEC (IP) degrees of enclosure not to be used for converting from IEC to NEMA.
Please refer to NEMA publication 250, 2003.
VLT ® Soft Starter Pocket Guide 25
Inside delta Connection:
What is “inside delta” connection?
With inside delta (six wire connection), the soft starter SCRs are in series with each motor winding so that the soft starter carries only phase current, not line current. The soft starter can thus control a motor with greater full load current than normal.
Inside delta connection is only possible with motors that allow each end of all three motor windings to be connected separately, and not all soft starters can be connected using inside delta. A line contactor or shunt trip MCCB must always be used to disconnect the motor and soft starter from the supply in the event of a trip.
Inside delta connection simplifi es replacement of star/delta starters because the existing wiring can be used. In new installations, inside delta connection may reduce the size and cost of the soft starter, but there are additional costs for the line contactor/shunt trip MCCB and extra cabling.
MCD 200 soft starters cannot be installed using inside delta connection.
MCD 500 soft starters have built-in support for inside delta connection.
MCD 3000 soft starters can be installed using an inside delta connection (models MCD3185 ~ MCD3800 only; an additional installation kit is required).
26 VLT ® Soft Starter Pocket Guide
Key Benefi ts: What are the key benefi ts of soft start?
Soft start enhances motor start performance in many ways.
• The gradual application of voltage or current avoids the voltage and current transients associated with electro-mechanical reduced
• voltage starters.
Acceleration is also smoother, as soft start avoids the torque
•
transients associated with electro-mechanical reduced voltage starters.
Constant current control gives higher torque as motor speed increases, resulting in lower start currents and/or shorter start times
• Start performance can be adjusted to suit the motor and load,
including exact control over the current limit.
• Soft starting provides reliable performance even with frequent starts, or if load characteristics vary between starts (e.g. loaded or unloaded).
Soft starters also provide a range of features not available from other reduced voltage starters. This includes soft stop, which helps eliminate water hammer and DC braking.
Other features such as built-in protection for the motor and system, and metering and monitoring options, can reduce the overall installed cost of the equipment and reduce the long-term maintenance requirement.
VLT ® Soft Starter Pocket Guide 27
Line Contactors: When should a line contactor be used?
Soft starters can be installed with or without a line contactor.
A line contactor disconnects the SCRs from the supply when the motor is not in use. This isolates the soft starter, and protects the SCRs from damage due to severe overvoltage (e.g. lightning strikes) – SCRs are most susceptible to overvoltage damage when in the off state. The soft starter is also isolated from the supply in the event of a trip.
A line contactor may be required by local electrical regulations and should be AC3 rated for the motor FLC.
The line contactor can be controlled via the soft starter’s relay output. The inrush VA rating of the contactor coil must not exceed the rating of the soft starter’s relay output.
Minimum Start Current: What is the minimum start current required by a soft starter?
Soft starters can limit start current to any specifi ed level, but the practical minimum depends on the motor and load. Reducing the start current reduces the torque produced by the motor, so the load will stall if the start current is too low. In order to start successfully, the motor must produce more acceleration torque than the load requires throughout the start.
Successful start:
Unsuccessful start:
28 VLT ® Soft Starter Pocket Guide
Start current can be estimated based on previous experience, or the motor and load speed/torque curves can be analysed for a precise calculation.
VLT ® Soft Starter Pocket Guide 29
Multiple motors: Can one soft starter be used to control multiple motors?
A single soft starter can be used to control multiple motors, either in sequence or in parallel, provided the soft starter is correctly selected for the application.
Motors in sequence
For two or more motors in sequence, the soft starter must be capable of bearing the total start duty.
Installation requires additional wiring, plus separate overload protection and line and bypass contactors for each motor. The additional installation costs may be greater than the cost of individual soft starters.
Power factor correction: Can power factor correction be used with soft starters?
Power factor correction (PFC) capacitors can be used with soft starters, provided they are switched in using a dedicated contactor when the motor is running at full speed. PFC must always be installed on the input side of the soft starter; connecting PFC capacitors to the output of a soft starter causes resonance between the inductance of the motor and the power factor capacitance, resulting in severe overvoltage and equipment failure.
* This control method is complex and would require the use of a PLC or smart relay.
30 VLT ® Soft Starter Pocket Guide
The contactor should be AC6 rated for the motor full load current.
PFC capacitors can be sized using the following formula: kVA (Cap) = √
_
3 x V line
x 0.8 x motor no load current
1000
Motor thermal capacity: What is it?
Thermal capacity, also called “maximum locked rotor time” or
“maximum DOL start time”, describes the maximum time a motor can run at locked rotor current from cold. This information is usually available from the motor datasheet.
The MCD 202 and MCD 3000 overload protection can be set to match the motors thermal capability using the motors locked rotor time
(cold).
VLT ® Soft Starter Pocket Guide 31
Jog: What is the jog function?
MCD 500 includes a slow speed “jog” function which allows the operator to run the motor at reduced speed (approximately 11% of full speed) in either the forward or reverse direction. This is ideal for positioning of loads such as mixers or hopper bins ready for unloading.
Reversing: Can soft starters be used to reverse motor direction?
On their own, soft starters cannot run motors in reverse direction at full speed. However, an arrangement of forward and reverse contactors can be used to provide the same effect.
MCD 500 soft starters offer a part speed function that runs the motor at slow speed in either forward or reverse direction, without a reversing contactor. Reverse operation is limited to short periods at a fixed slow speed.
32 VLT ® Soft Starter Pocket Guide
Sealed enclosures: Can soft starters be installed in sealed enclosures?
Soft starters can be installed in sealed enclosures, provided the ambient temperature within the enclosure will not exceed the soft starter’s rated temperature.
All heat generated within the enclosure must be dissipated, either by ventilation or through the enclosure’s walls. This includes heat not only from the soft starter but also from other components such as fuses, cabling and switchgear. Heating from the soft starter can be minimised by installing the starter in a bypassed confi guration. To minimise external heating, protect the enclosure from direct sunlight.
WinStart includes a function to help design enclosure ventilation.
Primary Resistance Starters: How does soft start compare to primary resistance starting?
Soft starters are more fl exible and reliable than primary resistance starters.
Primary resistance starters cannot accommodate varying load conditions (e.g. loaded or unloaded starts) and the start torque cannot be fi ne-tuned to match motor and load characteristics. Performance may vary with multiple starts in close succession, because the start profi le changes as the resistance heats up. Damaging torque and current transients still occur at the steps between voltages, and primary resistance starters are not capable of providing soft stop.
Primary resistance starters are large and expensive, and liquid resistance starters require frequent maintenance.
VLT ® Soft Starter Pocket Guide 33
Short Circuit Protection: What is required for Type 1 short circuit protection of a soft starter?
Type 1 protection requires that in the event of a short circuit on the output of a soft starter the fault must be cleared without risk of injury to personnel. The soft starter may or may not be operational after the fault.
Type 1 protection is provided by HRC fuses or a MCCB within the motor branch circuit, which must be able to bear the required motor start current.
Short Circuit Protection: What is required for Type 2 short circuit protection of a soft starter?
Type 2 protection requires that in the event of a short circuit on the output of a soft starter the fault must be cleared without risk of injury to personnel or damage to the soft starter.
Type 2 protection is provided by semiconductor fuses, which must be able to carry motor start current and have a total clearing I2t less than the I 2 t of the soft starter SCRs.
Semiconductor fuses for Type 2 circuit protection are additional to HRC fuses or MCCBs that form part of the motor branch circuit protection.
Refer to the soft starter’s Design Guide for semiconductor fuse recommendations.
Typical selection criteria are as follows:
Starter type
Protection Type
MCD 200
MCD 500
MCD 3000
Fuse (non time delayed)
Fuse (time delayed)
MCCB*
Fuse (non time delayed)
Fuse (time delayed)
MCCB*
* Consult the manufacturer’s specifi cation.
Rating (% Motor FLC),
Start Current
< 350% FLC
15 seconds
175%
150%
> 350% FLC
15 seconds
200%
175%
150 – 200%
150%
125%
150 – 200%
Maximum fuse ratings for Type 1 motor protection are specifi ed in UL and IEC standards.
Fuse Rating (% Motor FLC)
Fuse (non-time delayed)
Fuse (time delayed)
300%
175%
34 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 35
Semiconductor Fuse Selection: Type 2
• Semiconductor fuses may be used with MCD soft starters. Use of semiconductor fuses will provide Type 2 coordination and reduce the potential of SCR damage due to transient overload currents and short circuits. MCD soft starters have been tested to achieve Type 2 coordination with semiconductor fuses. The following table provides a list of suitable Bussman fuses. If selecting alternate brands ensure the selected fuse has a lower total clearing I2t rating than the SCR, and can carry start current for the full start duration.
MCD 200
MCD200-007
MCD200-015
MCD200-018
MCD200-022
MCD200-030
MCD200-037
MCD200-045
MCD200-055
MCD200-075
MCD200-090
MCD200-110
200~575 V
Bussmann Fuse
Square Body (170M)
170M-1314
170M-1317
170M-1318
170M-1318
170M-1319
170M-1321
170M-1321
170M-1321
170M-1322
170M-3022
170M-3022
Bussmann Fuse
British Style (BS88)
63 FE
160 FEE
160 FEE
180 FM
180 FM
250 FM
250 FM
250 FM
500 FMM
500 FMM
500 FMM
SCR I
2 t
(A
2 s)
1150
8000
10500
15000
18000
51200
80000
97000
168000
245000
320000
MCD 500
MCD5-0021
MCD5-0037
MCD5-0043
MCD5-0053
MCD5-0068
MCD5-0084
MCD5-0089
MCD5-0105
MCD5-0131
MCD5-0141
MCD5-0195
MCD5-0215
MCD5-0245
MCD5-0360
MCD5-0380
MCD5-0428
MCD5-0595
MCD5-0619
MCD5-0790
MCD5-0927
MCD5-1200
MCD5-1410
MCD5-1600
• Semiconductor fuses listed below are manufactured by Bussman and should be ordered directly from Bussman or their local supplier.
Instruction for selection for alternative semi-conductor fuses is available from Danfoss.
400 V 690 V
Square Body British Style Square Body British Style
170M1314
170M1316
170M1318
170M1318
170M1319
170M1321
170M1321
170M1321
170M1321
170M2621
170M2621
170M2621
170M2621
170M6010
170M6011
170M6011
170M6015
170M6015
170M6017
170M6019
170M6021
170M6021
---
63FE
120FEE
120FEE
200FEE
200FEE
200FEE
280FM
280FM
280FM
450FMM
450FMM
450FMM
450FMM
---
2 x 400FMM
---
2 x 630FMM
2 x 630FMM
---
---
---
---
---
170M1314
170M1316
170M1318
170M1318
170M1318
170M1319
170M1321
170M1321
170M1321
170M2621
170M2621
170M2621
170M2621
170M6010
---
---
170M6014
170M6014
170M6016
170M6019
---
---
---
63FE
120FEE
120FEE
200FEE
200FEE
200FEE
280FM
280FM
280FM
450FMM
450FMM
450FMM
450FMM
---
2 x 400FMM
---
---
---
---
---
---
---
---
SCR I
2 t
(A
2 s)
1150
8000
10500
15000
15000
51200
80000
125000
125000
320000
320000
320000
320000
238000
320000
320000
1200000
1200000
2530000
4500000
4500000
6480000
12500000
36 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 37
MCD3000
MCD3007
MCD3015
MCD3018
MCD3022
MCD3030
MCD3037
MCD3045
MCD3055
MCD3075
MCD3090
MCD3110
MCD3132
MCD3185
MCD3220
MCD3300
MCD3315
MCD3400
MCD3500
MCD3600
MCD3700
MCD3800
• Semiconductor fuses listed below are manufactured by Bussmann and should be ordered directly from Bussmann or their local supplier.
Instruction for selection for alternate semi-conductor fuses is available from Danfoss.
Bussmann Fuse
400V
170M1315
170M1318
170M1319
170M1319
170M1319
170M1322
170M1322
170M1322
170M2621
170M3021
170M3023
170M3023
170M6011
170M6012
170M6014
170M5017
170M6019
170M6021
170M6021
170M6021
170M6021
Bussmann Fuse
690V
170M1314
170M1317
170M1317
170M1318
170M2616
170M1320
170M1321
170M1322
170M1322
170M3020
170M3023
170M3023
170M4145
170M6011
170M4018
170M6014
170M6017
170M6151
170M6151
2 x 170M5018
2 x 170M5018
97000
97000
245000
414000
414000
238000
320000
781000
1200000
SCR I 2 t
(A 2 s)
1150
8000
10500
15000
15000
51200
80000
2532000
4500000
4500000
6480000
13000000
Slip-Ring Motors: Are soft starters suitable for use with slip-ring motors?
Soft starters are suitable for use with slip-ring motors provided that the motor can still deliver the torque required to accelerate the load. Soft starters are not suitable if the load requires extremely high start torque, or if the slip-ring motor is intended to provide speed control. When considering a soft starter for slip-ring applications, a trial should be conducted to verify the performance.
To develop starting torque, some resistance must remain in the rotor circuit during motor starting. This resistance must be bridged out using a contactor (AC2 rated for rotor current) once the motor is running close to full speed.
Rotor resistance (R) can be sized using the following formula:
Where V
R
= open circuit rotor voltage
I
R
= full load rotor current
38 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 39
Soft Braking: What is soft braking?
Soft braking is a technique used by the soft starter to reduce motor stopping time, unlike soft stopping which increases the stop time on frictional loads. Soft braking requires the use of reversing contactors.
When the soft starter receives a stop command, it operates the reversing contactor connected on its input side to soft start the motor in the reverse direction. This applies braking torque to the load.
Motor speed detection is required to shut down the braking at motor standstill.
Star/Delta Starters: How does soft start compare with star/delta starting?
Soft starters are much more flexible than star/delta starters and provide a smooth start with no risk of transients.
Star/delta starters cannot accommodate varying load conditions (e.g. loaded or unloaded starts) and the start torque cannot be adjusted to match motor and load characteristics. In addition, the open transition between star and delta connection causes damaging torque and current transients. Star/delta starters are not capable of providing soft stop.
However, star/delta starters may be cheaper than a soft starter and they may limit the start current to a lower level than a soft starter when used on an extremely light load. However, severe current and torque transients may still occur.
Soft starters can also use ‘DC braking’ to reduce the stopping time, but soft braking causes less motor heating and provides more braking torque for a given current, and is better for extremely high inertia loads
(e.g. band saw and circular saw applications).
40 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 41
Star/Delta Starters: Can soft starters be used to replace star/delta starters?
If the soft starter supports inside delta connection, simply connect it in place of the star/delta starter.
If the soft starter does not support inside delta connection, connect the delta connection to the output side of the soft starter.
MCD 500 soft starters include built-in support for inside delta connection.
MCD 3000 soft starters support inside delta connection
(models MCD3185 ~ MCD3800 only; an additional installation kit is required).
Thermal Model Protection: How is a motor thermal model diff erent from other forms of overload protection?
The motor thermal model used in MCD soft starters offers precise motor protection normally only available from high-end motor protection relays. The thermal model constantly models motor temperature, based on information on the motor’s design characteristics and actual operation. The thermal model accounts for different heating and cooling rates when the motor is starting, running or stopped. Accurate modelling allows the motor to be used to its maximum potential without nuisance tripping.
The MCD 500 uses an advanced second order thermal model, which models iron and copper losses separately. This gives more precise modelling and provides greater protection for the motor.
Compared with a motor thermal model, thermal overload relays are less precise.
They do not account for iron loss or for different cooling rates at different stages of motor operation, and cannot be adjusted to match the characteristics of the individual motor because the mass of the bimetal strips is fixed. The bimetal strips are also affected by their own ambient temperature, which may be different from the motor’s ambient temperature.
Thermal modelling is also superior to inverse time-current and I2T electronic overloads, which do not account for iron loss or for different cooling rates at different stages of motor operation. They offer only limited adjustment and the trip curves do not closely match motor heating. Inverse time-current protection also does not allow for motor temperature before the overload.
42 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 43
Two-Speed Motors: Are soft starters suitable for use with two-speed motors?
Soft starters are suitable for use with Dahlander and dual winding motors, provided that separate motor protection is used for both low and high speed operation.
Dual-winding motors have one shaft with two separate pole confi gurations (e.g. 4 pole and 8 pole), providing two diff erent speeds.
The speed is selected using external contactors (AC3 rated).
Dahlander motors are often used for two-speed compressor or fan applications. The motor windings are externally confi gured using contactors for high speed (dual star) and low speed (delta) operation.
Types of Soft Starter: What are the diff erent types of soft starters?
There are three diff erent types of soft starter which off er diff erent features and control the motor in diff erent ways.
1. Torque controllers control only one phase during start. This reduces the torque shock at start but does not reduce start current. Torque controllers must be used in conjunction with a direct on-line starter.
2. Soft starters which control two phases can reduce start current as well as eliminating torque transients, and are suitable for normal and heavy duty loads, but not severe loads. The start current on the uncontrolled phase is slightly higher than the two controlled phases.
3. Soft starters which control all three phases provide the maximum level of soft start control and are the only soft start solution that is suitable for severe duty applications.
MCD 201 soft starters are designed for use with external motor protection devices and are ideal for two-speed motor applications. MCD 202 soft starters have motor protection built in and are less suitable for two-speed applications.
MCD 500 and MCD 3000 soft starters offer dual motor settings, which allows separate start profiles to be configured for each speed.
44 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 45
MCD Bus Options – General Notes
•
•
All bus options have the ability to:
Control the soft starter
Monitor the soft starter status
•
•
•
Monitor the soft starter trip state
Monitor the soft starter current (not available on MCD 201)
Monitor the soft starter thermal model overload temperature
(not available on MCD 201)
Parameters can also be uploaded to or downloaded from MCD 500 soft starters on Modbus, DeviceNet or Profibus networks.
In order for the MCD 500 to accept commands from the serial network, the soft starter must be in Auto On mode and links must be fitted to terminals 17 and 25 to 18. In Hand On mode, the starter will not accept commands from the serial network but the starter’s status can still be monitored.
The following information is a general guide to MCD 500, MCD 3000 and MCD 200 bus options. Refer to the relevant installation instructions and users manual for more detail.
MCD 200 with MCD Remote Operator Option
This requires an MCD Serial Interface Module which clips onto the side of the MCD 200. It is supplied with the MCD Remote Operator when ordering Cat. No: 175G9004.
MCD200
MCD
Serial
Interface
Module
-
69
61
GND
68
+
MCD Remote Operator
RS485
Starter
RS485
Network
-
B1 B6
-
GND
B2
+
B3
B7
GND
B8
+
Cat. No: 175G9004
Notes
• A single MCD Remote Operator and MCD Serial interface Module is required for each MCD 200.
•
•
No set-up or confi guration is required for operation.
If two Remote Operators are required, the RS485 Network side of the fi rst Remote Operator (terminals B6, B7, B8) must be connected to the
RS485 Starter side of the second Remote Operator (terminals B1, B2,
B3). The fi rst Remote Operator is ordered using Cat. No: 175G9004 and the second Remote Operator is ordered using Cat. No: 175G3061.
• The Serial Interface Module is powered by the MCD 200. The Remote
Operator requires an external 18-30 VAC/DC auxiliary supply.
• For more information on the MCD Remote Operator, refer to the User
Manual (MG.17.Ex.02)) located at www.danfoss.com/drives.
46 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 47
MCD 200 Modbus Option
There are two options to connect an MCD 200 to a Modbus network.
Option 1: Using an MCD Modbus Module (Cat. No: 175G9000)
MCD200
MCD
Modbus
Module
B6
-
B7
GND
B8
+
RS485 connection onto a
Modbus
RTU network
Cat. No: 175G9000
•
•
Notes
A single Modbus Module is required for each MCD 200.
Modbus Module settings are provided using two 8-way
•
DIP switches on the module.
Up to 31 Modbus Modules can be used as Modbus slave devices
•
• on a single Modbus RTU network.
The Modbus Module is powered-up by the MCD 200.
For more information about operating the MCD Modbus Module, refer to the Installation Instructions (MG.17.Fx.02), located at www.danfoss.com/drives.
MCD 200 Modbus Option
Option 2: Using the MCD Remote Operator as a Modbus RTU Gateway device (Cat. No: 175G9004)
MCD200
MCD
Serial
Interface
Module
-
69
61
GND
68
+
MCD Remote Operator
RS485
Starter
-
B1
RS485
Network
B6
-
GND
B2
+
B3
B7
GND
B8
+
Cat. No: 175G9004
RS485 connection onto a
Modbus
RTU network
Notes:
• A single Remote operator and Serial Interface Module
• is required for each MCD 200.
Parameters 1 to 5 of the Remote Operator are used to set it up
• as a Modbus slave device.
Up to 31 Remote Operators can be used as Modbus slave devices
• on a single Modbus network.
The Serial Interface Module is powered via the MCD200. The Remote
•
Operator requires an external 18-30 VAC/DC auxiliary supply.
For more information about operating the MCD Remote Operator as a Modbus RTU gateway, refer to the Installation Instructions
(MG.17.Fx.02), Appendix A, located at www.danfoss.com/drives.
48 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 49
MCD 200 DeviceNet Option
This requires an MCD DeviceNet Module which clips onto the side of the MCD 200 (Cat. No: 175G9002).
MCD200
MCD
DeviceNet
Module
(V+)
RD
WH
(CAN-H)
(SHIELD)
(CAN-L)
BU
BK
(V-)
Standard 5-wire connection onto a
DeviceNet network.
120 termination resistors are required at end of each end of the network cable.
Cat. No: 175G9002
•
•
Notes
A single DeviceNet Module is required for each MCD 200.
DeviceNet node address (MAC ID) and data rate are selected using
• three rotary switches on the DeviceNet Module.
Up to 63 DeviceNet Modules can be used as DeviceNet slaves
• on a single DeviceNet network.
The DeviceNet Module is powered via the network cable.
•
•
The MCD DeviceNet Module is ODVA tested and certifi ed.
For more information on the MCD DeviceNet Module, refer to the
Installation Instructions (MG.17.Hx.02), located at www.danfoss.com/drives.
MCD 200 Profi bus Option
This requires an MCD Profi bus Module which clips onto the side of the
MCD 200 (Cat. No: 175G9001).
MCD200
MCD
Profibus
Module
Standard
DB9 connection
Profibus DP network cable
Cat. No: 175G9001
Notes:
• A single Profi bus Module is required for each MCD 200.
• Profi bus node address is selected using two rotary switches.
Data rate is automatically detected.
• Up to 31 Profi bus Modules can be used as Profi bus slaves on a single Profi bus DP network.
•
•
•
The Profi bus Module requires and external 24 VDC auxiliary supply.
The MCD Profi bus Module is Profi bus tested and certifi ed.
For more information on the MCD Profi bus Module, refer to the
Installation Instructions (MG.17.Gx.02) at www.danfoss.com/drives.
50 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 51
MCD 200 USB Option
This is achieved using the MCD USB Module
(Cat. No: 175G9009).
MCD200
MCD
USB
Module
Cat. No: 175G9009
USB cable
PC
Notes
• A single USB Module is required for each MCD 200
• The USB Module acts as a physical interface when using PC based Master software such as WinMaster
•
V4.x or MCT10
Driver software must be installed before the USB
•
Module can be used (supplied with the module on
CD-ROM).
For more information on the MCD USB Module, refer to the Installation Instructions (MI.17.Cx.02) located at www.danfoss.com/drives
52 VLT ® Soft Starter Pocket Guide
MCD 500 with MCD Remote Operator Option
This requires a MCD Modbus Module which clips onto the side of the
MCD 500. The MCD Modbus Module is ordered using Cat. No: 175G9000 and the Remote Operator is ordered using Cat. No: 175G3061.
MCD500
(Auto On mode)
MCD
Modbus
Module
B6
-
B7
GND
B8
+
Cat. No: 175G9000
MCD Remote Operator
RS485
Starter
-
B1
RS485
Network
B6
-
GND
B2
+
B3
B7
GND
B8
+
Cat. No: 175G5061
•
•
Notes
• A single MCD Remote Operator and MCD Modbus Module is required for each MCD 500.
No set-up or configuration is required for the MCD Remote Operator.
The MCD Modbus Module DIP switches must be set for ASCII, Address
20, Baud Rate 9600, No Parity, No Timeout.
• If two Remote Operators are required, the RS485 Network side of the first Remote Operator (terminals B6, B7, B8) must be
• connected to the RS485 Starter side of the second Remote
Operator (terminals B1, B2, B3).
The Modbus Module is powered by the MCD 500. The Remote
Operator requires an external 18-30 VAC/DC auxiliary supply.
• For more information on the MCD Remote Operator, refer to the
User Manual (MG.17.Ex.02)) located at www.danfoss.com/drives.
VLT ® Soft Starter Pocket Guide 53
MCD 500 Modbus Option
This requires an MCD Modbus Module which clips onto the side of the
MCD 500 (Cat. No: 175G9000).
MCD500
(Auto On mode)
MCD
Modbus
Module
B6
-
B7
GND
B8
+
Cat. No: 175G9000
RS485 connection onto a
Modbus
RTU network
Notes:
• A single Modbus Module is required for each MCD 500.
• Modbus Module settings are provided using two 8-way DIP switches on the module.
• Up to 31 Modbus Modules can be used as Modbus slave devices on a single Modbus RTU network.
•
•
The Modbus Module is powered by the MCD 500.
For more information about operating the MCD Modbus Module, refer to the Installation Instructions (MG.17.Fx.02), located at www.danfoss.com/drives.
MCD 500 DeviceNet Option
This requires an MCD DeviceNet Module which clips onto the side of the MCD 500 (Cat. No: 175G9002).
MCD500
(Auto On mode)
MCD
DeviceNet
Module
(V+)
RD
WH
(CAN-H)
(SHIELD)
(CAN-L)
BU
BK
(V-)
Cat. No: 175G9002
Standard 5-wire connection onto a
DeviceNet network.
120 termination resistors are required at end of each end of the network cable.
Notes
• A single DeviceNet Module is required for each MCD 500.
• DeviceNet node address (MAC ID) and data rate are selected using three rotary switches on the DeviceNet Module.
• Up to 63 DeviceNet Modules can be used as DeviceNet slaves on a single DeviceNet network.
•
•
•
The DeviceNet Module is powered via the network cable.
The MCD DeviceNet Module is ODVA tested and certified.
For more information on the MCD DeviceNet Module, refer to the
Installation Instructions (MG.17.Hx.02), located at www.danfoss.com/drives.
54 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 55
MCD 500 Profi bus Option
This requires an MCD Profibus Module which clips onto the side of the
MCD 500 (Cat. No: 175G9001).
MCD500
MCD
Profibus
Module
Standard
DB9 connection
Profibus DP network cable
Cat. No: 175G9001
Notes:
• A single Profibus Module is required for each MCD 500.
• Profibus node address is selected using two rotary switches. Data rate is automatically detected.
• Up to 31 Profibus Modules can be used as Profibus slaves on a single
Profibus DP network.
•
•
•
The Profibus Module requires an external 24 VDC auxiliary supply.
The MCD Profibus Module is Profibus tested and certified.
For more information on the MCD Profibus Module, refer to the
Installation Instructions (MG.17.Gx.02) at www.danfoss.com/drives
MCD 500 USB Option
This is achieved using the MCD USB Module
(Cat. No: 175G9009).
MCD500
MCD
USB
Module
Cat. No: 175G9009
USB cable
PC
Notes
• A single USB Module is required for each MCD 500
• The USB Module acts as a physical interface when using PC based
Master software such as WinMaster V4.x or MCT10
• Driver software must be installed before the USB Module can be used
(supplied with the module on CD-ROM).
• For more information on the MCD USB Module, refer to the Installation Instructions (MI.17.Cx.02) located at www.danfoss.com/drives
56 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 57
MCD 3000 with MCD Remote Operator Option
This is achieved using the MCD Remote Operator
(Cat. No: 175G3061).
MCD3000
69
-
61
GND
68
+
MCD Remote Operator
RS485
Starter
RS485
Network
-
B1 B6
-
GND
B2
+
B3
B7
GND
B8
+
Cat. No: 175G3061
Notes
• A single Remote Operator is required for each MCD 3000
• If two Remote Operators are required, the RS485 Network side of the fi rst Remote Operator (terminals B6, B7, B8) must be connected to the
•
RS485 starter side of the second Remote operator
(terminals B1, B2, B3)
The Remote Operator requires an external 18-30 VAC/DC auxiliary supply.
• For more information on the MCD Remote Operator, refer to the Users
Manual (MG.17.Ex.02) located at www.danfoss.com/drives
MCD 3000 Modbus Option
This is achieved using the MCD Remote Operator
(Cat. No: 175G3061) as a Modbus RTU Gateway on the RS485 Network side.
MCD3000
69
-
61
GND
68
+
MCD Remote Operator
RS485
Starter
RS485
Network
-
B1 B6
-
GND
B2
+
B3
B7
GND
B8
+
Cat. No: 175G3061
RS485 connection onto a
Modbus
RTU network
Notes
• A single Remote Operator is required for each MCD 3000
• Parameters 1 to 5 of the Remote Operator are used to set it up as a Modbus slave device.
• Up to 31 Remote Operators can be used as Modbus slave devices on a single Modbus network.
• The Remote Operator requires an external 18-30 VAC/DC auxiliary supply.
• For more information on operating the MCD Remote Operator as a Modbus RTU gateway, refer to the MCD Modbus Module
Installation Instructions (MG.17-Fx.02), Appendix A, located at www.danfoss.com/drives.
58 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 59
MCD 3000 DeviceNet Option
This is achieved using an externally fi tted MCD3000 DeviceNet
Gateway (Cat. No: 175G9005)
RS485 DeviceNet Gateway
MCD3000
69
-
61
GND
68
+
-
6
GND
7
+
8
V+
5
4
CAN-H
3
SHIELD
2
CAN-L
V-
1
Standard 5-wire connection onto a
DeviceNet network.
120 termination resistors are required at each end of the network cable.
Cat. No: 175G9005
Notes
• A Single DeviceNet Gateway is required for each MCD 3000
• DeviceNet node address (MAC ID) and data rate are set using DIP switches 1 to 8 in the DeviceNet Gateway.
• Up to 63 DeviceNet Gateways can be used as DeviceNet slaves on a single DeviceNet network.
• The DeviceNet Gateway is powered via the network cable.
• For more information on the MCD3000 DeviceNet Gateway, refer to the User Manual (MG.15.Ex.02) at www.danfoss.com/drives.
60 VLT ® Soft Starter Pocket Guide
MCD 3000 Profi bus Option
This requires an externally fi tted MCD Profi bus Gateway
(Cat. No: 175G0092)
Address #1
ASCII
MCD Profibus
Gateway
PROFIBUS DP
MCD3000
External 24 VDC
supply required
Cat. No: 175G0092 Standard
3-wire Profibus network cable
MCD3000
Address #23
Notes
• Up to 23 MCD 3000 soft starters can be used as ASCII slave devices with a single MCD Profi bus Gateway.
• Each MCD 3000 must have a unique slave address starting from slave address 1 to the number of MCD3000 soft starters connected on the ASCII side of the MCD Profi bus Gateway.
• The MCD Profi bus gateway address (as seen by the Profi bus DP master) is set using DIP switches 1 to 8 on the MCD Profi bus Gateway.
• Both ASCII soft starter and Profi bus DP cable termination is provided
• using standard DB9 connectors on the MCD Profi bus Gateway.
If you require use of the MCD Remote Operator with your installation, refer to product note 01, MCD Profi bus Gateway and Remote
Operator compatibility.
• For more information on the MCD 3000 Profi bus Gateway, refer to the MCD Profi bus Gateway User Manual (V2.03) located at www.danfoss.com/drives.
VLT ® Soft Starter Pocket Guide 61
Glossary
AAC – Adaptive Acceleration Control. A new soft start control technique that allows the soft starter to estimate the motor’s speed and control it to match a selected acceleration or deceleration profile.
AC53 Utilisation Code – The specification of a soft starter’s current rating and intended operating conditions.
Auger – a device which uses a screw-like mechanism to move material or liquid, similar to the process that drives shavings up a drill bit and out of a hole during drilling.
Blower – see Fan.
Bow thruster – a steering mechanism in large ships which uses an impeller to force water through a tunnel in the bow below the waterline, causing the ship to turn.
Centrifuge – a machine which separates materials of different
densities (e.g. solids from liquids or liquids from liquid mixtures).
Chipper – a machine which cuts large pieces of wood into chips.
Compressor, centrifugal – a machine which accelerates gas through a housing then converts the velocity energy to pressure energy.
Normally used in heavy industrial applications.
Compressor, positive displacement – see Compressor, reciprocating.
Compressor, piston – see Compressor, reciprocating.
Compressor, reciprocating – a machine which compresses gas using pistons driven by a crankshaft. Small reciprocating compressors (up to 30 HP) are suitable for intermittent use and are commonly found in automotive applications. Larger units (up to 1000 HP) may be used for large industrial applications.
Compressor, screw – a machine which forces gas into a smaller space, using two meshed rotating positive-displacement screws.
Crusher – a machine which crushes material into smaller pieces.
Crusher, cone – a crusher consisting of two cones inside each other.
Material is fed into the top of the large, outer cone and is broken into progressively smaller pieces by the rotation of the inverted inner cone.
62 VLT ® Soft Starter Pocket Guide
Glossary
Crusher, jaw – a crusher with one fixed side and one moving “jaw”. The crusher is wider at the top than the bottom, and material is fed in at the top and moves down as it is broken into progressively smaller pieces.
Crusher, roller – a crusher with two horizontal rollers which rotate in opposite directions, crushing the material into smaller pieces.
Current limit – (1) a method of soft starting a motor by limiting the maximum amount of current the motor can draw during the start. (2)
The maximum amount of current the soft starter will allow a motor to draw during a current limit start.
Current ramp – a method of soft starting a motor by gradually increasing the amount of current from a specified point to the current limit.
Debarker – a machine that strips bark from logs.
Decanter – a type of centrifuge.
Edger – a machine that cuts large pieces of timber into usable sizes.
Escalator – a type of conveyor which is used to move people up or down, much like a moving staircase.
Fan, axial – a fan with blades that turn around a shaft, forcing air along the shaft and across the axis of the fan.
Fan, centrifugal – a fan which pulls air in near the shaft and forces it out through an opening in the outer edge of the fan casing. A centrifugal fan produces more pressure for a given air volume than an axial fan.
Fan, radial – see Fan, centrifugal.
Full load current – the amount of current a motor will draw when operating fully loaded and at full speed.
Full load torque – the amount of torque a motor will produce when operating fully loaded and at full speed.
Grinder – a machine which reduces the size of small particles through compression and attrition. For machines operating on larger items, see
Crusher.
VLT ® Soft Starter Pocket Guide 63
Glossary
Gyratory crusher – see Crusher, cone.
Hydraulic power pack – A hydraulic pump which is used to supply pressurised hydraulic fluid.
IP rating – a description of the soft starter’s level of physical protection, according to IEC 60529.
Kickstart – a method of soft starting a motor which uses a high level of current for a short period at the beginning of a current limit or current ramp start.
Locked rotor current – the amount of current a motor will draw in locked rotor situations, including full voltage starts. Locked rotor current is described as a percentage of full load current.
Locked rotor time – the maximum amount of time a motor can safely run at locked rotor current.
Locked rotor torque – the amount of torque a motor will produce at locked rotor current (such as a full voltage start). Locked rotor torque is described as a percentage of full load torque.
Mill, ball – a machine which grinds or mixes materials such as ores, chemicals, ceramics and paints. The machine consists of a horizontal cylinder which is rotated, causing the grinding medium, commonly stainless steel balls, to repeatedly crush the material inside into a powder.
Mill, hammer – a machine which crushes material into smaller pieces.
Hammers attached to rotating disks repeatedly strike the material until it is small enough to fall through openings at the bottom of the mill.
Mill, roller – a machine which crushes material into smaller pieces.
Material is passed between two horizontal rollers which rotate in opposite directions, crushing the material into smaller pieces.
Milliscreen – a machine which separates solids from slurry, using an inclined rotating drum with perforated sides.
Mixer – a machine which combines ingredients.
64 VLT ® Soft Starter Pocket Guide
Glossary
Nameplate rating – See Full load current.
NEMA – a description of the soft starter’s physical format, according to the National Electrical Manufacturers’ Association standard.
Pelletiser – a machine which turns powders into pellets.
Planer – a machine which draws boards over a cutting head to reduce them to a specified thickness.
Press – a machine which changes the shape and internal structure of metals (usually steel).
Pump – a machine which moves fluids.
Pump, bore – a submersible pump with a small diameter, suitable for operation down bores.
Pump, centrifugal – a pump with an impeller which causes fluid to rotate and move from the inlet to the outlet under its own momentum.
The fluid’s velocity increases as it progresses through the impeller passage. Diffuser, ring or volute cavities reduce the velocity of the fluid and convert the energy into pressure energy.
Pump, positive displacement – a pump which reduces the volume of the pump chamber to cause the fluid to move. Positive displacement pumps may be used for viscous fluids, and include rotary (lobe, screw or gear pump) and reciprocating (piston or diaphragm pump) types.
Pump, slurry – a centrifugal pump for pumping slurry.
Pump, submersible – a pump which is submerged in the fluid to be pumped. The sealed motor is close-coupled to the pump body.
Pump, vacuum – a pump which removes gas from a sealed chamber in order to create a partial vacuum. Multiple vacuum pumps may be used together for a single application.
Re-pulper – a machine which re-pulps raw product for further processing.
Rotary table – a large rotating table which is used to sort or move material.
VLT ® Soft Starter Pocket Guide 65
Glossary
Sander – a machine which smooths raw material by abrading the surface.
Saw – a machine which uses a serrated edge to cut materials.
Saw, band – a saw where the cutting edge is a long, thin strip of metal with teeth on one side, commonly used for ripping lumber.
Saw, circular – a saw where the cutting edge is a large rotating disk with teeth on the outer edge.
Screw feed – see Auger.
Separator – a type of centrifuge.
Shredder – a machine that tears objects such as paper, plastic or wood into smaller pieces.
Slabber – a machine consisting of several saws, which cuts edged logs into smaller pieces before further processing.
Slicer – a machine that slices materials, normally using more than one blade.
Travelator – a type of conveyor which is used to move people along a flat or inclined surface.
Tumbler – a machine which rotates to turn material over during drying or other processes.
Vibrating screen – a machine which separates particles of different sizes by vibrating horizontally. Smaller particles fall through gaps in the plane.
Winch – a machine which winds ropes or cables.
Wire draw machine – a machine which draws metal wire through progressively narrower dies to create finer wire.
Abbreviations
AC – Alternating Current
DC – Direct Current
DOL – Direct On Line
FLC – Full Load Current
FLT – Full Load Torque
HRC – High Rupturing Capacity
IP – International Protection kW – Kilowatt
LRC – Locked Rotor Current
MCCB – Moulded Case Circuit Breaker
PFC – Power Factor Correction
SCR – Silicon Controlled Rectifi er
TVR – Time Voltage Ramp
66 VLT ® Soft Starter Pocket Guide VLT ® Soft Starter Pocket Guide 67
DKDD.PB.07.B1.02 VLT® is a trademark of Danfoss A/S Produced by SMCC 2009.03
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