Danfoss MCD3000 Series Manual
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Section 1.0
Section 2.0
Section 3.0
Section 4.0
MG.15.B2.02 - VLT is a registered Danfoss trademark
MCD3000 Series
Warnings
...................................................................... 3
1.1 Main Control Module .............................................. 4
1.2 Identity Module (Line Connection) ....................... 5
1.5 SCRs / Power Assemblies .................................... 9
1.6 Cooling Fans .......................................................... 12
1.7 Power Transformers ............................................. 13
Tests
2.1 Start Performance Test ........................................ 15
2.2 Run Performance Test ......................................... 15
2.3 Power Circuit Test ................................................ 15
2.4 Control Input Test ................................................. 16
2.5 Power Transformer Test ...................................... 16
3.1 Main Control Module
3007~3132 .............................................................. 17
3185~3800 .............................................................. 17
3007~3132 .............................................................. 18
3185~3800 .............................................................. 18
3007~3055 .............................................................. 19
3075~3132 .............................................................. 19
3185~3500 .............................................................. 20
3600~3800 .............................................................. 22
3.4 SCR / Power Assemblies
3007~3132 .............................................................. 23
3185~3800 .............................................................. 25
3030~3055 .............................................................. 27
3075~3110 .............................................................. 29
3132 .......................................................................... 31
3185~3800 .............................................................. 33
3.6 Power Transformers
3007~3055 .............................................................. 34
3075~3110 .............................................................. 35
3132~ ....................................................................... 36
3185~3800 .............................................................. 37
Schematics
4.1 3007~3022 T5 ....................................................... 39
4.2 3030~3055 T5 .........................................................40
4.3 3075~3110 T5 .........................................................41
4.4 3132 T5 ....................................................................42
4.5 3185~3500 T5 .........................................................43
4.6 3600~3800 T5 .........................................................44
4.7 3007~3022 T7 ........................................................ 45
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Table of Contents
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Summary of Contents for Danfoss MCD3000 Series

  • Page 1: Table Of Contents

    Section 4.0 Schematics 4.1 3007~3022 T5 ............39 4.2 3030~3055 T5 ............40 4.3 3075~3110 T5 ............41 4.4 3132 T5 ..............42 4.5 3185~3500 T5 ............43 4.6 3600~3800 T5 ............44 4.7 3007~3022 T7 ............45 MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 2 4.10 3132 T7 ..............48 4.11 3185~3500 T7 ............ 49 4.12 3600~3800 T7 ............. 50 Section 5.0 Appendix 5.1 Typical Causes of SCR Damage ......51 5.2 Output Relay Compatibility ........52 5.3 Remote Control Input Failure ........53 MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 3 When reading this manual you will come across different symbols that require special attention. The symbols used are the following: Indicates something to be noted by the reader Indicates a general warning Indicates a high voltage warning MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 4: Spare Parts

    Turn the Main Control Module over so you are looking at the printed circuit board. The number is etched on the board in the upper left region. (The characters either side are not relevant). Part Number PCB No. 175G5088 x1325x 175G5089 x1326x MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 5: Identity Module Line Connection

    175G5103 (0DCT220 / 990-00742-00) 175G5104 (0DCT300 / 990-00743-00) 175G5105 (0DCT315 / 990-00744-00) 175G5106 (0DCT400 / 990-00745-00) 175G5107 (0DCT500 / 990-00746-00) 175G5108 (0DCT600 / 990-00892-00) 175G5109 (0DCT700 / 990-00893-00) 175G5110 (0DCT800 / 990-00894-00) All Types MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 6: Identity Module Inside Delta Connection

    MCD3000 Series Identity Module Inside Delta Connection Part Number (number per unit) 175G3052 (990-02002-00) 175G3053 (990-02003-00) 175G3054 (990-02004-00) 175G3055 (990-02005-00) 175G3056 (990-02006-00) 175G3057 (990-02007-00) 175G3058 (990-02008-00) 175G3059 (990-02009-00) 175G3060 (990-02010-00) All Types MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 7: Snubber/Overvoltage Protection Module

    (0DSB4H / 2 2 2 2 2 2 990-00739-00) 990-00740-00) 175G5114 175G5118 (0DSB5 / (0DSB5H / 6 6 6 990-00895-00) 990-00896-00) 175G5115 (0DSB1H / 990-00451-00) 175G5112 (0DSB2 / 990-00695-00) 175G5116 (0DSB2H / 990-00696-00) MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 8 MCD3000 Series 175G5113 (0DSB4 / 990-00739-00) 175G5117 (0DSB4H / 990-00740-00) 175G5114 (0DSB5 / 990-00895-00) 175G5118 (0DSB5H / 990-00896-00) MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 9: Scrs / Power Assemblies

    175G5131 (8DAT315 / 994-00721-00) 175G5132 (8DAT400 / 994-00723-00) 175G5133 (8DAT500 / 994-00725-00) 175G5134 (8DAT600 / 994-00207-00) 175G5135 (8DAT700 / 994-00986-00) 175G5136 (8DAT800 / 994-00988-00) 175G5119 (SKKT27/16) 175G5120 (SKKT57/16) 175G5121 (SKKT72/16) 175G5122 (SKKT92/16) MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 10 MCD3000 Series 175G5123 (SKKT122/16) 175G5124 (SKKT132/16) 175G5125 (TT162N16) 175G5126 (TT250N16) 175G5127 (TT330N16) MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 11 175G5129 (8DAT220 / 994-00717-00) 175G5130 (8DAT300 / 994-00719-00) 175G5131 (8DAT315 / 994-00721-00) 175G5132 (8DAT400 / 994-00723-00) 175G5133 (8DAT500 / 994-00725-00) 175G5134 (8DAT600 / 994-00207-00) 175G5135 (8DAT700 / 994-00986-00) 175G5136 (8DAT800 / 994-00988-00) MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 12: Cooling Fans

    Cooling Fans Part Number (number per unit) 175G5137 (4214HR) 1 1 1 1 2 2 2 3 175G5138 (7214NR) 2 2 2 2 2 2 3 3 3 175G5137 (4214HR) 175G5138 (7214NR) MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 13: Power Transformers

    175G5152 1 1 1 (1PT23AT) (1PT23DT) 175G5142 175G5153 1 1 1 1 1 1 1 (1PT40AT) (1PT40DT) 175G5143 175G5154 1 1 1 (1PT55AT) (1PT55DT) 175G5139 (1PT10AV) 175G5150 (1PT10DV) 175G5140 (1PT17AT) 175G5151 (1PT17DT) MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 14 MCD3000 Series 175G5141 (1PT23AT) 175G5152 (1PT23DT) 175G5142 (1PT40AT) 175G5153 (1PT40DT) 175G5143 (1PT55AT) 175G5154 (1PT55DT) MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 15: Start Performance Test

    • A faulty firing circuit on the Main Control connections. Module. Exchange the Main Control Module to see if the fault is removed. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 16: Control Input Test

    This should be 9 to 14VAC. If no voltage is present the control transformer could be faulty or no control supply is present at terminals A1/A2 or MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 17: Component Replacement Procedures

    Lift the control module straight off. Lift the control module straight off. DO NOT Pivot. DO NOT Pivot. Step 3. Fit new Control Module in reverse order. Step 3. Fit new Control Module in reverse order. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 18 Step 4. Detach the Identity Module from the top gland plate (for models MCD3075~3132 the fan grill below the top gland plate must be removed to allow detachment). Fit the new Identity Module in reverse order. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 19: Snubber/Overvoltage Protection Module

    Step 4. Fit the new Snubber/Overvoltage Protection Module in reverse order. Step 4. Undo the fixing nuts (4) and remove the Snubber/Overvoltage Protection Module. Step 5. Fit the new Snubber/Overvoltage Protection Module in reverse order. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 20 Step 5. Cut the cable ties that secure the firing loom to the Snubber/Overvoltage Protection Module. Step 3. Undo fixing screws (4) securing the Main Control Module Mounting bracket. Step 6. Fold back the Main Control Module mounting bracket. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 21 Step 7. Unplug the SCR leads. Step 8. Undo fixing screws (2), undo the fixing nuts (6) and remove the Snubber/Overvoltage Protection Module. Step 9. Fit the new Snubber/Overvoltage Protection Module in reverse order. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 22 Control Module Mounting bracket and fold back the Main Control mounting bracket. Step 2. Undo fixing screws (4) and lift off Control Module. Step 5. Unplug the firing loom connection. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 23 (L1/B1, L2 or L3/B3) to the SCR being replaced. Model Torque MCD3007 ~ MCD3030 4 NM MCD3037 ~ MCD3075 7 NM MCD3090 ~ MCD3132 12NM Step 9. Fit the new Snubber/Overvoltage Protection Module in reverse order. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 24 Step 8. Apply a thin even film of heatsink paste to the bottom of the new SCR and replace the SCR in Model Torque MCD3007 ~ MCD3030 4 NM reverse order. MCD3037 ~ MCD3075 7 NM MCD3090 ~ MCD3132 12NM MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 25 Step 5. Cut the cable ties that secure the firing loom to the Snubber/Overvoltage Protection Module. Step 3. Undo fixing screws (4) securing the Main Control Module Mounting bracket. Step 6. Fold back the Main C ontrol Module mounting bracket. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 26 MCD3600~3800 this will also require removal of the polycarbonate fan insulation plate. The new Power Assembly must be fitted with the same mechanical orientation as the original Power Assembly. Step 13. Fit new Power Assembly in reverse order. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 27: Cooling Fans

    Step 4. Undo and remove the screws (2 per SCR) connecting the input and bypass bus bars (L1/B1, L2 & L3/B3) to each of the SCRs. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 28 Crimp terminals are supplied with the new fan for this purpose. Step 14 . Fit the new fan in reverse order. Step 10. Remove the screws (4) securing the fan bracket. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 29 Note 1. For MCD3090 & 3110 this will also require the detachment of input bus bar L2. Step 7. Remove the left hand side panel by removing the screws (4) securing the side panel to the base plate. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 30 Crimp terminals are supplied with the new fan for this purpose. Step 10. Remove the fan bracket from the starter. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 31 Step 4. Undo the scr ews securing the vertical support rail and slide the rail out of the way. Step 7. Undo the screws (2) securing the left side panel to the top and bottom cross supports. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 32 Step 13. Fit the fan bracket in reverse order. Step 10. Cut the crimp terminals (2) from the end of the fan wiring loom. New crimp terminals are supplied with the replacement fan for reassembly. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 33 Step 3. Undo the Cooling Fan mountin g assembly fixing screws (4) and remove the fan assembly. Step 5. Replace the damaged fan on the fan assembly and refit the Cooling Fan assembly in reverse order. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 34 Step 2. Remove the lower gland plate from the MCD3000. Step 5. Fit the new PT in reverse order. Step 3. Undo the screws (2) securing the power transformer and earth wire. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 35 Step 2. Remove the lower gland plate from the Step 5. Fit the new PT in reverse order. MCD3000. Step 3. Undo the screws (2) securing the power transformer and earth wire. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 36 PT. Crimp terminals are supplied with the new PT for this connection. Step 3. Undo the screws (2) securing the power transformer and earth wire. Step 6. Fit the new PT in reverse order. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 37 Step 2. Undo the screws (2) securing the power Step 5. Fit the new PT in reverse order. transformer and earth wire. Step 3. Unplug the white wires (2) running from the PT to the fan supply rectifier. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 38 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 39 MCD3000 Series Schematics MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 40 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 41 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 42 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 43 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 44 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 45 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 46 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 47 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 48 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 49 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 50 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 51 The reliability of the modern SCRs as used in the The SCRs used in modern soft starters are rugged MCD3000 Series soft starters is such that failures and provide reliable operation in most industrial attributable to faulty manufacture are almost nil. SCR...
  • Page 52 1. Use an MCD3000 soft starter output relay to control a slave relay. This slave relay can then be used to directly switch the electronic contactor coil circuit. MCD3000 OUTPUT RELAY SLAVE CONTACTOR RELAY COIL COIL MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 53 (eg, induced voltage from lightning strike) to the remote control input. ATTENTION Damage to the control inputs caused by application of external voltages is not covered by warranty. MG.15.B2.02 – VLT is a registered Danfoss trademark...
  • Page 54 MCD3000 Series MG.15.B2.02 – VLT is a registered Danfoss trademark...

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