THE COMPLETE SOLUTION FOR STARTING AND STOPPING AC MOTORS. MCD 3000 Soft starter

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Shauna Phelps
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1 THE COMPLETE SOLUTION FOR STARTING AND STOPPING AC MOTORS MCD 3000 Soft starter

2 THE PERFECT SOFTENER OF ROUGH STARTS The MCD Soft starter ranging from 7.5 to 800 kw is the optimum solution to a range of problems bound up with direct on-line start of an AC motor, such as: High starting current, often causing an unacceptable load to the mains supply. Shock load on gear and other transmission elements, causing unnecessary wear on mechanical parts. Fast acceleration and deceleration, causing unstable process conditions e.g. in conveyors. start current level. This sometimes means the load cannot accelerate to full speed in star connection, thereby making the star/delta starter totally ineffective. does not impact on the way the motor stops, thus leaving the speed to ramp down without control. The auto transformer reduces start current but also allows some control over the level of start current. Auto transformer starters do not however eliminate the risk of a jump in torque when shifting voltage. 2 T N T N Flexibility to changes in the start conditions, increasing flexibility in the application. Soft stop control for extending the motor deceleration time. Braking control to reduce motor deceleration time. Torque Traditionally star/delta and auto transformer starters have been seen as solutions to these problems. However, both these options have drawbacks and do not solve the problems caused by wear of the transmission elements and unstable process conditions. The star/delta starter reduces start current but introduces a damaging torque transient when switching from star to delta connection. does not allow selection of the best Unlike traditional solutions the MCD 3000 Soft starter offers a wide range of benefits for motor and equipment operation as a whole, including: Flexible control of starting current and torque. Smooth control of current and voltage without any steps or transients. Frequent start/stop operation without mechanical damage Current 6 I N I N SOFT STARTER AUTO TRANSFORMER STAR/DELTA DOL Speed Speed

3 A Host of Applications The MCD 3000 Soft starter is extremely versatile, offering benefits to almost all motor starting applications. Here you will find some typical examples: Application Pumps Benefits Minimized hydraulic shocks in pipelines during start and stop. Minimized mechanical stress on motor shaft. Reduced starting current. Undercurrent protection preventing damage from blocked pipe or low water situations. Automatic reset functionality ensures continued operation of unmanned pump stations. Phase rotation protection prevents damage from reverse pump rotation. Instantaneous overload protection prevents damage from debris drawn into the pump. Conveyor Belts Controlled start without mechanical shocks, e.g. bottles on a belt do not fall over. Minimized belt stretch. Reduced counter balance stress. Controlled stop without mechanical shocks. Optimum soft start performance even with varying starting loads, e.g. coal conveyors starting loaded or unloaded. Extended mechanical lifetime. No maintenance. Centrifuges Smooth application of torque preventing mechanical stress. Reduced starting times over star/delta starting. Reduced stopping times thanks to DC brake and soft braking. Ski Lifts Jerk-free acceleration increases skiers comfort and prevents swinging T-bars. Reduced starting current allows starting of large motors on a low power supply. Smooth and gradual acceleration whether the lift is lightly or heavily loaded. Phase rotation protection prevents operation in reverse direction Compressors Reduced mechanical shocks extend the life of the compressor, couplings and motor. Limited start current enables large compressors to be started even when maximum power capacity is limited. Phase rotation protection prevents operation in reverse direction. Instantaneous overload protection prevents possible damage from liquid ammonia entering the compressor screw. Band saws Reduced time for saw band replacements since the soft braking function stops the motor quickly. Extended saw band life thanks to eliminated torque shocks during start. Easier saw band alignment. Slow acceleration allows saw bands to be 'tracked' without jogging. Maximum overload capability available for ride-through of operating overloads. The MCD 3000 Soft starter motor thermal model accounts for the actual overload capability of the connected motors and will trip only if absolutely necessary. Chippers Reduced starting current. Instantaneous overload trip prevents mechanical damage from jammed loads. Reduced deceleration times due to use of braking function. Crushers Maximum overload capability available for ride-through of operating overloads. The MCD 3000 Soft starter motor thermal model accounts for the connected motors actual over load capability and will trip only if absolutely necessary. Maximum start capability available for starting if crusher stops while not completely empty. The MCD 3000 Soft starter motor thermal model accounts for the actual overload capability of the connected motors and will allow the motor to provide start torque for the longest time possible.

4 Working principle Motor voltage is controlled by means of a phase cut principle. Two thyristors in each phase perform the power switching, enabling the starter to handle high starting torque and frequent starts/stops. Current transformers measure the motor current providing feedback for constant current control of motor starting, and also for numerous motor and application protection functions. Technical data MCD 3000 Soft starter Model Bookstyle Rated Current (Amps) AC53a 3-30:50-10 Dimensions (mm) H W D Protection Format MCD3007 -T5/-T IP 21 Book style (B21) MCD3015 -T5/-T IP 21 Book style (B21) Power Connection Cabling Mains, motor and bypass connectors: Bar type with thread for fastening bolts for cable shoes. Control cable connections: Terminal block for 0.14 m~1.5 m 2 /26~16 AWG. Control card supply connection: Terminal block for 2.5~4 mm 2 / 14~12 AWG The bottom plates are removable and include a drilling template for cable entries. Short circuit protection For proper protection semiconductor fuses must be used in front of the starter. Control inputs Start/stop. Can be configured for both two-wire and pulse (four-wire) start/stop commands. Reset. Parameter set. For selection between two motor parameter sets. Signal outputs Three relay outputs (programmable) for control of: Line, Bypass and DC brake contactors. Run, Trip, Output on, and High/low current flag. Bypass If the soft starter is mounted in a cabinet without ventilation, a bypass contactor should be applied to prevent heat dissipation during operation. The starter has built in bars for connection of a bypass contactor. This allows the MCD 3000 Soft starter to measure motor current and retain all motor protection functions even when the bypass contactor is closed. EMC Compliant with the requirements in the product standard IEC , AC semiconductor motor controllers and starters. MCD3018 -T5/-T IP 21 Book style (B21) MCD3022 -T5/-T IP 21 Book style (B21) MCD3030 -T5/-T IP 21 Book style (B21) MCD3037 -T5/-T IP 21 Book style (B21) MCD3045 -T5/-T IP 21 Book style (B21) MCD3055 -T5/-T IP 21 Book style (B21) Compact MCD3075 -T5/-T IP 21 Compact (C21) MCD3090 -T5/-T IP 21 Compact (C21) MCD3110 -T5/-T IP 21 Compact (C21) MCD3132 -T5/-T IP 21 Compact (C21) MCD3185 -T5/-T IP 20 Compact (C20) MCD3220 -T5/-T IP 20 Compact (C20) MCD3300 -T5/-T IP 20 Compact (C20) MCD3315 -T5/-T IP 20 Compact (C20) MCD3400 -T5/-T IP 20 Compact (C20) MCD3500 -T5/-T IP 20 Compact (C20) MCD3600 -T5/-T IP 20 Compact (C20) MCD3700 -T5/-T IP 20 Compact (C20) MCD3800 -T5/-T IP 20 Compact (C20) Power Supply voltage: VAC -T VAC -T7 Please specify voltage range at ordering. Supply frequency: 50/60 Hz Control voltage: 230 V (+10%/-15%) 400 V (+10%/-15%) Other control voltages can be accommodated by fitting an optional transformer within the starter. Ambient max temperature 40 C Approvals: UL(pending), CE, CSA, C Thermistor input Trip level at >2.8 kohm Busbar 4 16 mm Tap with 6 mm thread Busbar 5 16 mm Tap with 8 mm thread Busbar 6 22 mm Tap with 8 mm thread Busbar 6 24 mm Tap with 10 mm thread Busbar mm Hole for 10 mm bolt Busbar mm Hole for 12 mm bolt Model selection Model selection should not be based on motor size only. Consideration must also be given to required start current level. The AC53a 3-30:50-10 ratings above allow for 3 times Full Load Current (In), 30 s Start Time, 50% On Load Duty Cycle, 10 Starts Per Hour. If operating conditions differ from this, a different model may be required. Ordering should be done by means of type code strings: MCD 3xxx-T5 or T7-C20, C21 or B21-CV4 (control voltage) e.g. MCD3055-T5-B21-CV4 (55 kw at 400 V, V, Bookstyle, IP21, control voltage 230 V and 400 V).

PROTECTION AND EASY HANDLING The MCD 3000 Soft starter is second-to-none when it comes to compensating for the drawbacks of direct on-line starting and stopping of AC motors.

5 PROTECTION AND EASY HANDLING The MCD 3000 Soft starter is second-to-none when it comes to compensating for the drawbacks of direct on-line starting and stopping of AC motors. In addition it offers the most comprehensive protection of motor and application in the market, including: Motor Continuous monitoring of motor load for calculating motor temperature. The value is shown in the display as percentage of maximum temperature, and the function is active even when the power section is bypassed. Application Undercurrent protection. Particularly useful for ensuring that pumps do not run dry. Shear pin protection. Ensures detection of foreign bodies blocking operation. Phase sequence protection. Prevents machinery from running in reverse. Phase imbalance protection. Completing the picture Danfoss has added a range of user-friendly benefits to the MCD 3000 Soft starter. Among them are: Easy installation MCD 3000 Soft starter is truly wall mountable, offering ample space for glanding and terminating the cables. Side-by-side mounting without clearance (larger sizes only with 100 mm clearance). No optional equipment required to perform any tasks. Easy operation Only one parameter to adjust for basic operation. Only a few parameters to adjust for high level control and protection. No need for field calibration to ensure correct operation. The MCD 3000 Soft starter has a factory accuracy of ±5% for current measurement. Built-in local control panel with display. Quick set-up. Numeric display for programming or showing *current *motor temperature * fault code Starter status LED s *START. Voltage has been applied to the motor *RUN. Full voltage has been applied to the motor *TRIP. The starter has tripped *REMOTE. The motor is controlled via external control signals Programming buttons 3 Operational buttons for control of motor when in Local mode (can be selected by means of the LOCAL/REMOTE button) 4 Control input (digital) status LED s 5 5

MOTOR CONTROL AT A NEW LEVEL With the MCD 3000 Soft starters Danfoss is once again contributing to optimum motor control, offering perfect protection and operation for virtually all AC motors.

6 MOTOR CONTROL AT A NEW LEVEL With the MCD 3000 Soft starters Danfoss is once again contributing to optimum motor control, offering perfect protection and operation for virtually all AC motors. This step is a logical continuation of our untiring endeavours since we invented the first mass produced electronic frequency converter back in Ever since, frequent technological breakthroughs and constant extensions of the motor outputs covered have been our hallmark. Today we offer VLT drives for motor outputs from 0.37 kw to 500 kw, and supply voltages from 200 V to 240 V and 380 V to 500 V. This range makes it possible to find a Danfoss drive for practically all purposes. With Danfoss as partner you get the complete package. We develop, manufacture and market Bauer geared motors which provide the correct amount of torque to meet any customer requirement including operation under extreme conditions like high and low temperatures, dust, wetness and hazardous areas. We do, however, offer more than quality products. Our global team of experts is ready to assist with application, engineering, commissioning, training and service. And our organisation is at your disposal around the clock in 120 countries. Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved. DKDD.PB.05.A1.02 VLT is a trademark of Danfoss A/S Produced by Danfoss G1 advertising agency UF.V.VE.LS

VLT Soft Starter MCD 100, MCD 201, MCD 202, MCD 3000

VLT Soft Starter MCD 100, MCD 201, MCD 202, MCD 3000 Soft starts Protect Gear, Goods, Equipment and Environment An AC motor switched directly on to the mains power supply will struggle to reach its nominal