MCD3000 Series ■ Warnings ............................................................ 2 Section 4.0 ■ Programming 4.1 Programming Procedure ............................... 17 4.2 Programmable Functions ............................... 17 Section 5.0 ■ Operation 5.1 Local Control Panel ....................................... 5.2 Remote Control ............................................. 5.3 Serial Communications .................................. 5.4 Restart Delay ......................................
Warnings 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.
MCD3000 Series To program the MCD3000 with the motor FLC do the following: 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.
Description MCD3000 Series ■ Description The Danfoss MCD3000 Soft Starter is an advanced electronic motor starting system. It performs four main functions; 1. Start control. 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.
MCD3000 Series Function Starting • Current Limit • Current Ramp • Torque Boost • Torque Control Stopping • Soft Stop • Pump Control • D.C.
Installation 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. through the enclosure to limit heat rise in the enclosure. The table below shows airflow requirements for selected motor currents.
MCD3000 Series Installation MCD3007 ~ MCD3055 MCD3185 ~ MCD3800 MCD3075 ~ MCD3110 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. MCD3132 ■ Power wiring - Bypass connection A bypass contactor may be used to bypass the starter during run.
Installation MCD3000 Series 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) 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.
MCD3000 Series 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 MCD3185 MCD3220 MCD3300 MCD3315 MCD3400 MCD3500 MCD3600 MCD3700 MCD3800 Inside Delta Kit 175G3043 175G3044 175G3045 175G3046 175G3047 175G3048 175G3049 175G3050 175G3051 protection.
Installation MCD3000 Series 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. ■ Control circuit examples Example 1. A basic installation where motor operation is controlled using the MCD3000 Local Control Panel. The MCD3000 provides three relay outputs.
MCD3000 Series 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. MG.15.A4.22 - VLT is a registered Danfoss trademark Example 3. MCD3000 installed with a bypass contactor and controlled via a remote push button circuit. Installation Example 2.
Installation MCD3000 Series Example 4. MCD3000 controlled by remote 3 wire push button circuit. 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. 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.
MCD3000 Series ASCII Character String or (Hexidecimal Character String) Write Parameters Receive Data Receive Status Parameter Number Parameter Value ACK NAK ERR STX [dddd] [lrc] ETX or (02h [dddd] [lrc] 03h) STX [ssss] [lrc] ETX or (02h [ssss] [lrc] 03h) DC1 [pppp] [lrc] ETX (011h [pppp] [lrc] 03h) DC2 [vvvv] [lrc] ETX (012h [vvvv] [lrc] 03h) ACK or (06h) NAK or (15h) BEL (07h) Command Start Stop Reset Coast to stop two byte ASCII number representing the soft starter address where each decimal digit is
Installation MCD3000 Series Request ASCII Bit No. Receive Data (ssss) Requests the trip status of the MCD3000.
MCD3000 Series ■ 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 2. Mod 256 3. 2’s complement 4.
Programming MCD3000 Series ■ Programming Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 45 46 47 48 Parameter Name Motor FLC Current Limit Current Ramp - Initial Current Current Ramp - Ramp Time Soft Stop Ramp Time Motor Thermal Capacity Phase Imbalance Sensitivity Undercurrent Trip Point Instantaneous Overload Trip Point Excess Start Time Protection Phase Rotation Protection Phase Imbalance Protection Delay Undercurrent Protecti
MCD3000 Series ■ Programmable functions 1 Motor FLC Value: (Depends On Model) Amps ✭ Depends on Model Function: Calibrates the MCD3000 for the Full Load Current of the motor. Description of choice: Set according to motor nameplate Full Load Current. 2 Current Limit Value: 100% - 550% Motor FLC To adjust parameters do the following: ✭ 350% Function: Sets the desired starting current limit. Description of choice: The current limit should be set so that the motor accelerates easily to full speed.
Programming MCD3000 Series Sets the initial starting current for the Current Ramp start mode. See also parameter 4. 2. Description of choice: 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. Description of choice: 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.
MCD3000 Series Description of choice: The factory setting is adequate for most applications. When setting the Motor Thermal Capacity two approaches can be taken. 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.
Programming MCD3000 Series Description of choice: 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 Function: Sets the maximum allowable start time.
MCD3000 Series 15 Restart Delay Value: 0 - 254 Units ✭ 1 Unit (10 seconds) 1 Unit = 10 seconds Function: Sets the minimum time between the end of a stop and the beginning of the next start. Description of choice: Set according to process requirements. A setting of zero achieves the minimum restart delay of 1 second). During the Restart Delay period the LED to the right of the MCD3000 numeric display will flash, indicating the motor cannot be started.
MCD3000 Series Programming 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. Description of choice: 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. 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.
MCD3000 Series ATTENTION This adjustment affects all current based functions. e.g. current read-out, motor overload & all other current based protections and current outputs. Description of choice: The gain should be adjusted according to the following formula. 22 Serial Communications - RS485 Time Out Value: 0 - 100 seconds ✭ 0 seconds (Off) Function: Sets the maximum allowable period of RS485 inactivity.
Programming MCD3000 Series Value: 10% - 550% Motor FLC ✭ 350% See Par. 3 for Function & Description of choice. 28 ✭ 1 second See Par. 4 for Function & Description of choice. 29 Soft Stop Ramp Time (Secondary Parameter Set) Value: 0 - 100 seconds ✭ 0 seconds (Off) See Par. 5 for Function & Description of choice.
MCD3000 Series 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. Description of choice: Set as required. 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.
Programming MCD3000 Series Group 1 2 3 40 Trip Type Phase Imbalance, Phase Loss Undercurrent, Instantaneous Overload Overcurrent, Motor Thermistor 44 Value: No adjustment Automatic Reset - Number Of Resets Value: 1 - 5 Resets 45 ✭ 1 Reset Function: Sets the number of times faults will be reset before the trip condition is latched and a manual reset is required. Description of choice: Set according to the maximum number of resets required.
MCD3000 Series Change Password Value: 0 - 999 ✭0 ATTENTION If the supply frequency drops below 45Hz (50Hz supplies) or 55Hz (60Hz supplies) the MCD3000 will trip instantly irrespective of the delay setting. Function: Sets the password number. Description of choice: Set and record the password number as required. 48 Description of choice: Set to allow continued operation during extreme but temporary under frequency conditions.
Programming MCD3000 Series 53 Expanded Supply Frequency Window Value: 0–1 ✭0 0 = Normal (50Hz window: 48Hz- 52Hz, 60Hz window 58Hz – 62Hz) 1 = Expanded (50Hz window: 47Hz- 52Hz, 60Hz window 57Hz – 62Hz) 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. Description of choice: Apply expansion if required. ✭ = factory setting 28 MG.15.A4.
MCD3000 Series Operation ■ 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. 3. Operational buttons. 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.
Operation MCD3000 Series ■ Remote control Remote circuits connected to the MCD3000 control inputs can be used to operate the starter when in 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.
MCD3000 Series 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 ....................................
Specifications MCD3000 Series ■ Current Ratings Continuous Ratings (Not bypassed) at 40 C Ambient Temperature, < 1000 metres N o Model MCD3007 MCD3015 MCD3018 MCD3022 MCD3030 MCD3037 MCD3045 MCD3055 MCD3075 MCD3090 MCD3110 MCD3132 MCD3185 MCD3220 MCD3300 MCD3315 MCD3400 MCD3500 MCD3600 MCD3700 MCD3800 3.0 x FLC AC53a 3.
MCD3000 Series 1 Specifications . Inside delta connection N For ambient temperature or altitude conditions beyond those listed contact Danfoss. ■ Power Termination Details ■ 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.
Specifications MCD3000 Series ■ Dimensions / Weights IP 21 Enclosure MCD Model MCD3007 MCD3015 MCD3018 MCD3022 MCD3030 MCD3037 MCD3045 MCD3055 MCD3075 MCD3090 MCD3110 MCD3132 A mm (inches) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 530 (20.87) 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) C mm (inches) 270 (10.
MCD3000 Series ■ 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.
Design Guide MCD3000 Series 3. 4. generated in the resistors during a start. A long cool down period is required between starts. Poor performance for heavy duty or extended starts because heat build up in the resistors changes the resistance value. Cannot provide an effective reduced voltage start for loads with varying start requirements.
MCD3000 Series ■ Understanding soft starter ratings The maximum rating of a soft starter is calculated so the junction temperature of the power modules (SCRs) o does not exceed 125 C. Five operating parameters 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.
Design Guide MCD3000 Series 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 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 Metals & Mining Belt Conveyor Dust Collector Grinder Hammer Mill Rock Crusher Roller Conveyor Roller Mill Tumbler Wire Draw Machine 4.5 x FLC 3.
MCD3000 Series 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.
Design Guide MCD3000 Series Chippers • • • Crushers • • 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 jammed loads. Reduced deceleration times through use of braking function. Maximum overload capability available for ride through of operating overloads.
MCD3000 Series Design Guide 7SJX &VEOMRK 7GLIQEXMG MG.15.A4.
Fault Procedure 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.
MCD3000 Series 3 4 5 6 7 Cause & Action 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. If no motor thermistors are connected; • Ensure that there is a closed circuit across the MCD3000 motor thermistor input terminals. Phase imbalance trip.
Fault Procedure MCD3000 Series Code f P Cause & Action 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 • Starter will not enter program mode. Symptom Program settings cannot be made. • • 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.
Fault Procedure MCD3000 Series • • • • • • 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 33kΩ.
MCD3000 Series Fault Procedure MG.15.A4.
Fault Procedure MCD3000 Series 48 MG.15.A4.
