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*MG17C202*
175R0978 MG17C202 Rev. 2004-09-08
MCD 200 Design Guide
■ Contents
Accessories ....................................................................................................... 19
Overview ................................................................................................................ 19
MCD 200 Remote Operator ................................................................................... 19
MCD 200 Modbus Module ..................................................................................... 19
MCD 200 Profibus Module ..................................................................................... 19
MCD 200 DeviceNet Module .................................................................................. 19
MCD 200 AS-i Module ........................................................................................... 19
MCD PC Software .................................................................................................. 19
■ Warnings
NB!:
Indicates something to be noted by the reader
■ Description
The Danfoss MCD 200 Soft Starter series
comprises two separate ranges:
• MCD 201
• MCD 202
Overview
This manual makes reference to MCD
200, MCD 201 and MCD 202. The MCD
200 designation is used when referring to
characteristics common to both the MCD 201 and
MCD 202 ranges. In all other cases the text refers
to the specific range MCD 201 or MCD 202.
■ Ratings
Example
Control Inputs
Start Terminal N1 .................................................................................................... Normally Open, 300 VAC max.
Stop Terminal N2 .................................................................................................. Normally Closed, 300 VAC max.
Relay Outputs
Main Contactor (Terminals 13 & 14) ................................................................................................ Normally Open
Overview
Programmable Relay (Terminals 23 & 24) ........................................................................................ Normally Open
Programmable Relay (Terminals 23 & 24) ............................................ 6 A, 30 VDC resistive / 2 A, 400 VAC, AC11
Environmental
Degree of protection MCD 200-007 to MCD 200-055 .................................................................................... IP20
Degree of protection MCD 200-075 to MCD 200-110 .................................................................................... IP00
Operating Temperatures ............................................................................................................... -10 °C / + 60 °C
Humidity ................................................................................................................... 5% to 95% Relative Humidity
Pollution Degree ........................................................................................................................ Pollution Degree 3
Vibration ................................................................................................................... IEC 60068 Test Fc Sinusoidal
Vibration ...................................................................................................... 4 Hz - 13.2 Hz: ± 1 mm displacement
Vibration ........................................................................................................................ 13.2 Hz - 100 Hz: ± 0.7 g
EMC Emission
Equipment class (EMC) ............................................................................................................................... Class A
Conducted radio frequency emission ................................................................ 0.15 MHz - 0.5 MHz: < 90 dB (µV)
Conducted radio frequency emission ..................................................................... 0.5 MHz - 5 MHz: < 76 dB (µV)
Conducted radio frequency emission .................................................................... 5 MHz - 30 MHz: 80-60 dB (µV)
Radiated radio frequency emission ................................................................. 30 MHz - 230 MHz: < 30 dB (µV/m)
Radiated radio frequency emission ............................................................. 230 MHz - 1000 MHz: < 37 dB (µV/m)
This product has been designed for Class A equipment. Use of the product in domestic environments may
cause radio interference, in which case the user may be required to employ additional mitigation methods.
EMC Immunity
Electrostatic discharge .......................................................................... 4 kV contact discharge, 8 kV air discharge
Radio frequency electromagnetic field ............................................................. 0.15 MHz - 1000 MHz: 140 dB (µV)
Rated impulse withstand voltage (Fast transients 5/50 ns) ............................................................ 2 kV line to earth
Rated insulation voltage (Surges 1.2/50 µs – 8/20 ms) ........................................ 2 kV line to earth, 1 kV line to line
Voltage dip and short time interruption ................................................................. 100 ms (at 40% nominal voltage)
Short Circuit
Rated short-circuit current MCD 200-007 to MCD 200-037 ............................................................................ 5 kA
Rated short-circuit current MCD 200-045 to MCD 200-110 .......................................................................... 10 kA
Heat Dissipation
During Start ................................................................................................................................. 3 watts / ampere
During Run .............................................................................................................................................. < 4 watts
Standards Approvals
C ................................................................................................................................................. IEC 60947-4-2
UL / C-UL .................................................................................................................................................... UL508
CE .................................................................................................................................................. IEC 60947-4-2
CCC ................................................................................................................................................... GB 14048.6
■ Mechanical Installation
1 L1 3 L2 5 L3 1 L1 3 L2 5 L3 1 L1 3 L2 5 L3 1 L1 3 L2 5 L3
177HA201.11
50 (1.97)
1 L1 3 L2 5 L3
2 T1 4 T2 6 T3 2 T1 4 T2 6 T3 2 T1 4 T2 6 T3 2 T1 4 T2 6 T3
100 (3.93)
1 L1 3 L2 5 L3
2 T1 4 T2 6 T3
T3
L3
50 (1.97)
6
T2
L2
3
4
T1
L1
1
Overview
2 T1 4 T2 6 T3
mm (inch)
MCD 200 Din Rail Foot Mounting
MCD 200-007 ~ MCD 200-030 30 mm Yes
MCD 200-037 ~ MCD 200-110 Not available Yes
55 (2.17)
C
203 (7.99)
188 (7.40)
90.5 (3.56)
23 23
(0.9) (0.9)
177HA243.11
215 (8.46)
196 (7.71)
110.5 (4.35)
37 37
(1.46) (1.46)
204 (8.03)
240 (9.45)
114.5 (4.5)
51 51
(2.0) (2.0)
■ Cable Size
10 - 35 25 - 50 11 0.14 - 1.5
(8 - 2) (4 - 1/0) N.A. (0.43) (26 - 16)
26 8.5
(1.02) (0.33)
10 - 35 14 25 - 50 14 0.14 - 1.5 6
(8 - 2) (0.55) (4 - 1/0) (0.55) N.A. (26 - 16)
(0.24)
7 mm 7 mm 3.5 mm
3 - 5 Nm 4 - 6 Nm N.A. 0.5 Nm max.
2.2 - 3.7 ft-lb 2.9 - 4.4 ft-lb 4.4 lb-in max.
177HA245.11
Overview
The following table provides a list of suitable
Semiconductor fuses may be used with the MCD 200
Ferraz and Bussman fuses. If selecting alternate
soft starters. Use of semiconductor fuses will provide
brands ensure the selected fuse has a lower total
Type 2 coordination and reduce the potential of SCR
clearing I2t rating than the SCR, and can carry start
damage due to transient overload currents and short
current for the full starting duration.
circuits. MCD 200 soft starters have been tested to
achieve Type 2 coordination with semiconductor fuses.
MCD 200 SCR I2t (A2s) Ferraz Fuse Bussman Fuse Bussman Fuse
European/IEC Style (North Square Body British Style
American Style) (170M) (BS88)
6.6URD30xxxA0063
MCD 200-007 1150 170M-1314 63 FE
(A070URD30xxx0063)
6.6URD30xxxA0125
MCD 200-015 8000 170M-1317 160 FEE
(A070URD30xxx0125)
6.6URD30xxxA0160
MCD 200-018 10500 170M-1318 160 FEE
(A070URD30xxx0160)
6.6URD30xxxA0160
MCD 200-022 15000 170M-1318 180 FM
(A070URD30xxx0160)
6.6URD30xxxA0160
MCD 200-030 18000 170M-1319 180 FM
(A070URD30xxx0160)
6.6URD30xxxA0250
MCD 200-037 51200 170M-1321 250 FM
(A070URD30xxx0250)
6.6URD30xxxA0315
MCD 200-045 80000 170M-1321 250 FM
(A070URD30xxx0315)
6.6URD30xxxA0315
MCD 200-055 97000 170M-1321 250 FM
(A070URD30xxx0315)
6.6URD31xxxA0450
MCD 200-075 168000 170M-1322 500 FMM
(A070URD31xxx0450)
6.6URD31xxxA0450
MCD 200-090 245000 170M-3022 500 FMM
(A070URD31xxx0450)
6.6URD31xxxA0450
MCD 200-110 320000 170M-3022 500 FMM
(A070URD31xxx0450)
xxx = Blade Type.
Refer Ferraz for options.
Overview
There is a possibility the soft starter could arrive
at site with the internal bypass relays in "closed"
state. On first application of control voltage, the
bypass relays are commanded to open. If mains
voltage is applied without control voltage, this step
is missed, and the motor may start DOL without
warning (see Product Note for more detail).
• What are the under- & over-frequency trip
points for MCD 200 soft starters?
The trip points are 40 Hz and 72 Hz. If the
frequency falls below 40 Hz or rises above 72 Hz,
the soft starter will trip (x 6 Ready LED flashes).
These trip points are not adjustable.
A supply frequency trip will also occur if all
three phases from the mains supply are lost,
or fall below approximately 120 VAC while
the soft starter is running.
A supply frequency trip will occur if the line
contactor drops out during running.
• Will the motor start DOL if the start ramp
of MCD 201 open loop soft starter is
set to "full voltage"?
No, the MCD 201 will still provide a limited soft
start. The voltage is ramped up from 0 to 100%
in approximately 0.25 seconds.
■ MCD 201
■ Electrical Schematic
Example 1 – MCD 201 installed with motor
protection circuit breaker.
L1 L2 L3
I> I> I>
Q1
K1M
Motor Control
3Ø Voltage
Ue
F1
K1M
1,2
K1M
Motor
3Ø
Control
Voltage
A1
(+)
OR
A2
Function:
(-)
START/ * Determines the start torque generated by the motor
STOP N1
when the start command is first applied.
N2
Description of choice:
Set so that the motor begins to rotate as soon
as the start command is given.
380-440 VAC (CV3)
A3
A1 U
100%
A2
START/ *
STOP N1
N2
Initial Torque
177HA211.10 (30 - 75%)
177HA249.10
* Also resets the MCD 201
3 Wire Control
2 Ramp Up
A3
24 VAC/VDC (CV1)
110-240 VAC (CV3)
A1
Value:
(+)
✭ 10 seconds
OR
A2
2 - 20 seconds, Full Voltage
START
(-)
N1
STOP * Function:
N2
Determines the time taken for voltage to be
ramped up to line voltage.
Description of choice:
380-440 VAC (CV3)
A3
Set to optimise motor acceleration and/or start current.
A1
MCD
201
Short ramp times result in quicker acceleration and
START A2
higher start currents. Long ramp times result in
N1
STOP * slower acceleration and lower start current.
N2
177HA212.10
Ramp Up
(2 - 20 seconds, Full Voltage Start)
* Also resets the MCD 201 U
100%
■ Functionality
User Adjustments Initial Torque
(30 - 75%)
Initial Torque
177HA250.10
U
50%
40% 60%
Description of choice:
Set the ramp time to optimise stopping
characteristics for the load.
Ramp Down
(2 - 20 seconds, No Soft Stop)
U
100%
177HA251.10
■ Indication
1 L1 3 L2 5 L3
177HA252.10
Ready
Run
2 T1 4 T2 6 T3
■ Fault Finding
■ MCD 202
K1M
177HA253.11
1,2 1,3
1/L1 3/L2 5/L3 A1 A2 A3 N1 N2 05 06
K1M
Motor
2/T1 4/T2 6/T3 13 14 23 24 3Ø
Control
Voltage
Motor
3Ø ■ Control Circuits
Shunt Trip 2 Wire Control
A3
24 VAC/VDC (CV1)
110-240 VAC (CV3)
Control
Voltage A1
(+)
OR
A2
1 6 A @ 30 VDC resistive / 2 A 400 VAC AC11 (-)
START/ *
2 Main Contactor STOP N1
N2
Ue
MCD
202
177HA241.10
380-440 VAC (CV3)
A3
3 Auxiliary Relay Function = Trip (see parameter 8) A1
A2
START/ *
STOP N1
N2
177HA211.10
START A2 Function:
(-)
N1 Sets the desired starting current limit.
STOP *
N2 Description of choice:
The current limit should be set so that the motor
accelerates easily to full speed.
I
380-440 VAC (CV3)
A3 400%
300%
A1
Current Limit 200%
(250 - 475%)
START A2 100%
N1 177HA256.10
STOP *
N2 NB!:
177HA212.10
Start current must be great enough to allow
* Also resets the MCD 202 the motor to produce sufficient torque to
accelerate the connected load. The minimum
■ Functionality
current required to do this is dependent on motor
User Adjustments
design and load torque requirements.
Current Ramp
I
200% FLC
2s 5s 15s 70% 80%
15s 2s
3 Current Ramp
250% FL
FLC
5s 5s Motor FLC
60% 90% Value:
50%
2s 15 I
50%
C
1
OFF 100% M
(%FLC / Ramp Time) (% MCD202 FLC) 150% Motor FLC (2, 5 or 15 seconds) ✭ Off
Current Limit
350% 8s
10s
12s I
200% Motor FLC (2, 5 or 15 seconds)
300% 400% 6s 14s 250% Motor FLC (2, 5 or 15 seconds)
4s 16s
250% 450% 2s
No
20s Soft Stop Off
(% Motor FLC ) Soft Stop U
Motor Trip Phase Excess
Class Rotation Start Time Function:
10 10
8 12 ANY ANY 8 12
6 14 6 14 Sets the initial starting current and ramp time for
4 16 4 16
2
OFF
20
FWD
Trip Run
FWD
2
OFF
20 the Current Ramp start mode.
Aux Relay
177HA255.10 Description of choice:
The Current Ramp start mode modifies the Current
1 Motor FLC
Limit start mode by adding an extended ramp.
Value:
Ramp Time
50% - 100% MCD 202 FLC ✭ 100% (2, 5, 15 seconds, OFF)
I
400%
300%
Function: 200%
Initial Start Current
Calibrates the MCD 202 for the Full Load (150% FLC, 200% FLC, 250% FLC) 100%
t(s)
Cold Start Curves
1000
177HA258.10
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. 100
✭ 10
202
2 - 20, Off
is within the MCD 202 rated capability.
Function:
Calibrates the MCD 202 motor thermal model
according to the desired motor trip class. 7 Phase Rotation Protection
Value:
ANY, FWD ✭ ANY
ANY = Forward & Reverse rotation permitted
FWD = Forward Rotation Only
Function:
Sets the allowable phase rotation sequence
of the incoming supply.
177HA239.10
FWD ANY Ready LED Description
L1
L2 MCD
L3
x7
Check for correct phase rotation.
Ue
Network Comms Failure (between
accessory module and network):
x8
Check network connections and
Main settings.
Contactor
Starter Comms Failure (between
RUN starter and accessory module):
x9
Remove and refit accessory
module.
■ Motor Thermistor Protection
05 05
Or
06 06
177HA279.10
■ Indication
1 L1 3 L2 5 L3
177HA260.10
Ready
Run
2 T1 4 T2 6 T3
■ Accessories
■ Overview
The following optional accessory items are available ■ MCD 200 Remote Operator
for use with MCD 200 soft starters: Order Code: 175G9004
• MCD 200 Remote Operator The Danfoss Remote Operator can be used
(Order Code 175G9004) with MCD 201, MCD 202 and MCD 3000 to
• MCD 200 Modbus Module provide the following functionality.
(Order Code 175G9000)
Feature MCD MCD MCD
• MCD 200 Profibus Module
201 202 3000
(Order Code 175G9001)
Pushbutton Control
• MCD 200 DeviceNet Module • • •
(Start, Stop, Reset)
(Order Code 175G9002) Starter Status LEDs
• MCD 200 AS-i Module • • •
(Starting, Running, Tripped)
(Order Code 175G9003) Motor Current Display • •
• MCD PC Software Motor Temperature Display • •
Trip Code Display • • •
Accessory items are integrated with the MCD 200 soft
4-20 mA Output
starters by means of a plug-in module as shown below. • •
(Motor Current)
Under development.
■ MCD PC Software
The Danfoss MCD PC Software can be used with MCD
201, MCD 202 and MCD 3000 to provide the following
functionality for networks of up to 99 soft starters.
■ Application Guide
The most common reduced voltage starters are:
This section provides data useful in the selection
and application of soft starters. • Star/Delta starters
• Auto-transformer starters
■ Reduced Voltage Starting
• Primary resistance starters
When started under full voltage conditions AC induction
Guide
accelerates the current falls and the torque increases voltage starting, however performance is limited.
to breakdown torque before falling to full speed levels.
Both the magnitude and shape of the current and The two most significant limitations are:
torque curves are dependent on motor design.
1. There is no control over the level of current
7 x FLC Full Voltage Stator Current and torque reduction; these are fixed at one
third of the full voltage levels.
CURRENT (% Motor Full Load Current)
6 x FLC 2 x FLT
TORQUE (% Motor Full Load Torque)
be calculated when the starter is manufactured very small motors and should only be applied to light
and is not easily changed later. applications with low to medium start frequency.
2. Poor performance in frequent starting situations Two-phase controllers control two phases while the
because the resistance value changes as heat is third phase is uncontrolled. These controllers provide
generated in the resistors during a start. A long soft start and current reduction. Care should be taken
cool down period is required between starts. to ensure that the control algorithms of two-phase
3. Poor performance for heavy duty or extended controllers balance the output waveform in order to
starts because heat build up in the resistors provide a symmetrical waveform. Basic two-phase
changes the resistance value. controllers subject the motor to an asymmetrical
4. Cannot provide an effective reduced voltage start output waveform which creates a DC field in the
for loads with varying start requirements. motor. This stationary DC field increases the required
start current and increases motor heating. Such
Soft starters are the most advanced of the reduced unbalanced controllers should not be applied to
voltage starters. They offer superior control over high inertia loads or in situations with high start
current and torque as well as incorporating advanced frequencies. Three-phase controllers control all phases
motor protection and interface features. and are best suited for very large motors.
The main starting advantages soft starters offer are:
1. Simple and flexible control over starting External or internal bypass connection: The SCRs
current and torque. in a soft starter can be bypassed once the motor
2. Smooth control of voltage and current free is up to speed. This reduces heat generation and
from steps or transitions. prevents damage to the SCR from overcurrent or
3. Capable of frequent starting. overvoltage events that occur while the motor is
4. Capable of handling changing start conditions. running. Some soft starters include built-in bypass
5. Soft stop control to extend motor deceleration times. contactors while other provide terminals for connection
6. Braking control to reduce motor deceleration times. of an external bypass contactor.
St
On
St
St
ar
ar
ar
-lo (seco le of
rt
ts ty Cy
te
ad
Cu
rC
Pe
im
rr
Du s)
ur
rH
en
r
ou
nd
tR
r
cle
ult
at
ip
ing
Guide
• Starts Per Hour: The number of operating Metals & Mining
Belt Conveyor Heavy
cycles per hour.
Dust Collector Normal
Grinder Normal
2. AC53b: for soft starters used with bypass Hammer Mill Heavy
contactors. Rock Crusher Normal
For example, the following AC53b code describes Roller Conveyor Normal
Roller Mill Heavy
a soft starter which, when bypassed, is capable
Tumbler Normal
of supplying 145 A run current and a start current Wire Draw Machine Heavy
of 4.5 x FLC for 30 seconds with a minimum Food Processing
of 570 seconds between the end of one start Bottle Washer Normal
Centrifuge Normal
and the commencement of the next.
Dryer Heavy
145 A: AC-53b 4.5-30 : 570 Mill Heavy
Palletiser Heavy
St
St
Of
St
ar
ar
fT
rt
Separator Heavy
t T t (m
te
im
Cu
rC
im
e(
rr
ur
se
en
Slicer Normal
(se
co
enr
nd
co
nd
tR
s)
ult
)
ipl
177HA281.10
ing
eo
fF
Dryer Heavy
LC
)
Re-pulper Heavy
Shredder Heavy
In summary, a soft starter has many current
Petrochemical
ratings. These current ratings are dependent on Ball Mill Heavy
the start current and operational performance Centrifuge Normal
required by the application. Extruder Heavy
Screw Conveyor Normal
To compare the current rating of different soft Transport & Machine Tool
Ball Mill Heavy
starters it is important to ensure that operating
Grinder Normal
parameters are identical. Material Conveyor Normal
Palletiser Heavy
■ Model Selection Press Normal
Roller Mill Heavy
NB!: Rotary Table Normal
To fully understand the model selection Lumber & Wood products
Bandsaw Heavy
procedures it is important to have a good Chipper Heavy
knowledge of the fundamental principles of soft Circular Saw Normal
starter ratings. See Understanding Soft Starter Ratings. Debarker Normal
Edger Normal
To select the correct MCD 200 model: Hydraulic Power Pack Normal
Planer Normal
1. Determine whether the application requires a Sander Normal
normal duty or a heavy duty rating. The table
below can be used as a guide.
NB!:
2. See the tables in Ratings and select an
The above start current requirements are
MCD 200 model with an FLC rating greater
typical and appropriate in most circumstances.
than that of the motor.
However, start torque requirements and
performance of motors and machines does vary.
Please contact Danfoss if the application requires
duties other than listed in this manual.
*MG17C202*
175R0978 MG17C202 Rev. 2004-09-08