Danfoss MCD 200 Series, Service Manual

Page 1: ...75R0981 MG17D302 MG17D302 Service Manual MCD 200 MCD 201 MCD 202 Rev 2007 12 21 www danfoss com drives 175R0981 MG17D302 MG17D302 Service Manual MCD 200 MCD 201 MCD 202 Rev 2007 12 21 www danfoss com drives 175R0981 MG17D302 MG17D302 Service Manual MCD 200 ...

Page 2: ...ance Test 16 2 4 Power Circuit Test 18 2 5 Control Input Test 19 2 6 Power Voltage Supply Test 20 Section 3 0 Component Replacement Procedures 3 1 Disassembly Sequence 007 030 21 3 2 Exploded View MCD 201 007 030 22 3 3 Exploded View MCD 202 007 030 23 3 4 Disassembly Sequence 037 055 24 3 5 Exploded View MCD 201 037 055 25 3 6 Exploded View MCD 202 037 055 26 3 7 Disassembly Sequence 075 110 27 3...

Page 3: ...stalling the MCD 201 MCD 202 to provide proper grounding and branch circuit protection according to the National Electric Code NEC and local codes Symbols used in this manual The following symbols indicate items that require special attention Indicates a general warning Indicates a high voltage warning Avoiding soft starter damage Please read and follow all instructions in this manual Additionally...

Page 4: ...2 990 02378 00 175G9013 990 02379 00 1 1 1 1 1 1 1 1 1 1 1 Main Control PCB T6 Models Kit Part Number Item ID MCD 201 007 T6 xx MCD 201 015 T6 xx MCD 201 018 T6 xx MCD 201 022 T6 xx MCD 201 030 T6 xx MCD 201 037 T6 xx MCD 201 045 T6 xx MCD 201 055 T6 xx MCD 201 075 T6 xx MCD 201 090 T6 xx MCD 201 110 T6 xx MCD 202 007 T6 xx MCD 202 015 T6 xx MCD 202 018 T6 xx MCD 202 022 T6 xx MCD 202 030 T6 xx MC...

Page 5: ...2 055 MCD 202 075 MCD 202 090 MCD 202 110 number per unit 175G9018 990 02386 00 1 1 1 1 1 175G9057 990 02394 00 1 1 1 175G9050 990 02398 00 1 1 1 175G9021 990 02387 00 1 175G9022 990 02389 00 1 175G9023 990 02390 00 1 175G9024 990 02391 00 1 175G9025 990 02392 00 1 175G9058 990 02395 00 1 175G9059 990 02396 00 1 175G9060 990 02397 00 1 175G9051 990 02399 00 1 175G9052 990 02400 00 1 175G9053 990 0...

Page 6: ...2394 00 175G9058 990 02395 00 175G9059 990 02396 00 175G9060 990 02397 00 175G9050 990 02398 00 175G9051 990 02399 00 175G9052 990 02400 00 175G9053 990 02401 00 For interface PCB replacement of models 37 55 kw versions 1 9 and models 075 110 versions 1 7 use a relay conversion kit see page 12 ...

Page 7: ...D 202 030 MCD 202 037 MCD 202 045 MCD 202 055 MCD 202 075 MCD 202 090 MCD 202 110 number per unit 175G9032 2 2 175G9033 2 2 175G9034 2 2 175G9035 2 2 175G9036 2 2 175G9037 2 2 175G9038 2 2 175G9039 2 2 175G9040 2 2 175G9041 2 2 175G9042 2 2 MCD 200 Soft starters may be fitted with Semikron or Eupec SCRs The MCD 200 SCR spare part kits may include either Semikron or Eupec SCRs The Semikron and Eupe...

Page 8: ...MCD 200 Series MG 17 D3 02 VLT is a registered Danfoss trademark 7 Spare Parts 175G9037 175G9038 175G9039 175G9040 175G9041 175G9042 ...

Page 9: ...MCD 200 Series 8 MG 17 D3 02 VLT is a registered Danfoss trademark Spare Parts ...

Page 10: ...02 030 MCD 202 037 MCD 202 045 MCD 202 055 MCD 202 075 MCD 202 090 MCD 202 110 Bypass Contactors Kit Part Number Item ID number per unit 175G9043 990 02699 00 1 1 1 1 1 1 1 1 1 1 175G9056 350 04160 00 2 2 2 2 2 2 175G9049 350 02367 00 1 1 1 1 1 1 Applies to serial numbers from XXXX 01 XXX to XXXX 08 XXX Applies to serial numbers XXXX 09 XXX and above Version number is located in the serial number ...

Page 11: ...MCD 200 Series 10 MG 17 D3 02 VLT is a registered Danfoss trademark Spare Parts 175G9049 350 03901 00 ...

Page 12: ...nt transformers Current Transformers Kit Part Number 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 number per unit 175G9046 2 2 2 2 2 175G9047 2 2 2 175G9048 2 2 2 175G9046 175G9047 ...

Page 13: ... version 10 2 2 2 2 2 2 175G9049 version 8 1 1 1 1 1 1 Version number is located in the serial number found on the side of the soft starter e g XXXX 01 XXX is version 1 175G9043 175G9056 175G9049 Conversion Kit Kit Part Number MCD 201 037 MCD 201 045 MCD 201 055 MCD 201 075 MCD 201 090 MCD 201 110 MCD 202 037 MCD 202 045 MCD 202 055 MCD 202 075 MCD 202 090 MCD 202 110 number per kit 175G9147 versi...

Page 14: ...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 number per unit 175G9155 1 1 1 1 1 175G9156 1 1 1 175G9157 1 1 1 175G9161 1 1 1 1 1 175G9162 1 1 1 CV1 175G9163 1 1 1 175G9158 1 1 1 1 1 175G9159 1 1 1 175G9160 1 1 1 175G9164 1 1 1 1 1 175G9165 1 1 1 CV2 175G9166 1 1 1 175G9155 175G9161 175G9158 175G9164 175G9156 175G9162 175G9159 175G9...

Page 15: ...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 number per unit CV1 175G9167 1 1 1 1 1 1 1 1 1 1 1 CV3 175G9168 1 1 1 1 1 1 1 1 1 1 1 175G9167 175G9168 ...

Page 16: ... to line voltage before start dropping to 2 VAC at run and motor starting problems are still experienced The cause of the motor starting problem is not the MCD 201 Look for outside causes to the problem 2 If zero voltage is measured across the SCR before or at the commencement of a start The SCR may have failed Perform the Power Circuit Test described later in this section 3 If the voltage across ...

Page 17: ...ors This procedure tests the operation of the internal bypass contactors If the internal bypass contactor does not operate SCRs will eventually fail due to thermal stress This test is performed using an AC voltage meter Test While the MCD 200 is in the Off mode measure the voltage across each controlled phase L1 to T1 and L3 to T3 Line voltage should be measured Start the soft starter and listen f...

Page 18: ...are latching so voltage needs to be applied in both directions to fully check operational integrity Bypass Control Pins MCD 200 007 015 018 022 030 Bypass Control Pins MCD 200 037 045 055 Bypass Control Pins MCD 200 075 090 110 If the Bypass Contactor does not operate it must be replaced Verify Main Control PCB and Interface PCB operation using the following procedure Replace the Main Control PCB ...

Page 19: ...ent a repeat SCR failure Analysis of the MOVs situated on the MCD 200 Interface PCB and connected across each controlled phase L1 T1 and L3 T3 can provide a good indication of the mode of SCR failure MOV Location MCD 200 007 015 018 022 030 MOV Location MCD 200 047 045 055 MOV Location MCD 200 075 090 110 Overvoltage is the cause of SCR failure if the MOVs and or surrounding circuitry on the Inter...

Page 20: ... Interface PCB Control Input Test This procedure tests the condition of the soft starter control inputs This test is performed using a voltage meter Remove any external wiring from the soft starter control inputs N1 N2 Control voltage must still be connected to the soft starter A1 to A2 or A2 to A3 Measure the voltage from terminal A1 to each control input terminal A1 to N1 and A1 to N2 Action 1 I...

Page 21: ...age supply If the Ready LED Red is off verify that correct control voltage is connected to the correct control voltage input terminals On CV1 models A1 to A2 voltage must be 24 V AC or DC 20 20 On CV3 models A1 to A2 voltage must be 110 V AC to 240 V AC 10 15 or A2 to A3 voltage must be 380 V AC to 440 V AC 10 15 If the Ready LED Red remains off the Main PCB is damaged and must be replaced ...

Page 22: ... the MCD 200 unit on its side locate the blade of a small flat bladed screw driver in one of the four slots 2 each side on the side of the upper body moulding While ensuring the screw driver blade is pushed into the deepest part of the slot the edge nearest the heatsink of the MCD 200 tap the screw driver so that it is driven into the starter 5 10mm This will release the clip securing the upper bo...

Page 23: ...MCD 200 Series 22 MG 17 D3 02 VLT is a registered Danfoss trademark Component Replacement Exploded View MCD 201 007 MCD 201 030 ...

Page 24: ...MCD 200 Series MG 17 D3 02 VLT is a registered Danfoss trademark 23 Component Replacement Exploded View MCD 202 007 MCD 202 030 ...

Page 25: ... the MCD 200 unit on its side locate the blade of a small flat bladed screw driver in one of the four slots 2 each side on the side of the upper body moulding While ensuring the screw driver blade is pushed into the deepest part of the slot the edge nearest the heatsink of the MCD 200 tap the screw driver so that it is driven into the starter 5 10mm This will release the clip securing the upper bo...

Page 26: ...MCD 200 Series MG 17 D3 02 VLT is a registered Danfoss trademark 25 Component Replacement Exploded View MCD 201 037 MCD 201 055 ...

Page 27: ...MCD 200 Series 26 MG 17 D3 02 VLT is a registered Danfoss trademark Component Replacement Exploded View MCD 202 037 MCD 202 055 ...

Page 28: ...ng the following procedure With the MCD 200 unit on its side locate the blade of a small flat bladed screw driver in one of the four slots 2 each side on the side of the lid While ensuring the screw driver blade is pushed into the deepest part of the slot the edge nearest the front face of the MCD 200 tap the screw driver so that it is driven into the starter 5 10mm This will release the clip secu...

Page 29: ...MCD 200 Series 28 MG 17 D3 02 VLT is a registered Danfoss trademark Component Replacement Exploded View MCD 201 075 MCD 201 110 ...

Page 30: ...MCD 200 Series MG 17 D3 02 VLT is a registered Danfoss trademark 29 Component Replacement Exploded View MCD 202 075 MCD 202 110 ...

Page 31: ...stricted ventilation Inadequate ventilation Excessive ambient temperatures If the internal bypass relay does not operate SCRs will eventually fail due to thermal stress Protecting SCRs The SCRs used in modern soft starters are rugged and provide reliable operation in most industrial environments without the need for additional protection However the potential for SCR damage can be reduced by use o...

Page 32: ...ower supply circuitry This can have a damaging effect on the PCB mount relays if the contactor coil is switched directly Solution Before using an MCD 200 soft starter PCB mount output relay for direct switching of an electronic contactor coil consult the contactor manufacturer supplier to see if this is advisable Certain contactor manufacturers eg Klockner Moeller state that you cannot use PCB mou...

Page 33: ...us current of 100mA Incorrect configuration and wiring of the external contacts switches to the control input terminals N1 and N2 may cause damage If long cable runs are used wiring must be twisted pair or shielded cable and must be separated from AC power cables minimum distance 300mm Testing for Control Input failure Refer to the Control Input Tests detailed in Section 2 6 of this manual CAUTION...