Danfoss vlt soft starter mcd 500 User manual

Contents
1 Safety
5
Safety 5
Warnings 5
2 Introduction 7
Feature List 7
Type Code 8
3 Installation 9
Mechanical Installation 9
Dimensions and Weights 10
4 Electrical Installation 11
Control Wiring 11
Control Terminals 11
Remote Inputs 12
Serial Communication 12
Earth Terminal 12
Power Terminations 12
Motor Connection 14
In-Line Installation 15
In-line Installation, Internally Bypassed 15
In-line Installation, Non-bypassed 15
In-line Installation, Externally Bypassed 16
Inside Delta Installation 16
Inside Delta Installation, Internally Bypassed 17
Inside Delta Installation, Non-bypassed 17
Inside Delta Installation, Externally Bypassed 18
Current Ratings 18
In-line Connection (Bypassed) 19
AC-53 Rating for Bypassed Operation 19
In-line Connection (Non-bypassed/Continuous) 20
AC-53 Rating for Continuous Operation 20
Inside Delta Connection (Bypassed) 21
AC-53 Rating for Bypassed Operation 21
Inside Delta Connection (Non-bypassed/Continuous) 22
AC-53 Rating for Continuous Operation 22
Minimum and Maximum Current Settings 23
Bypass Contactor 23
Main Contactor 23
Circuit Breaker 23
MCD 500 Operating Instruction Contents
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Power Factor Correction 23
Fuses 24
Bussman Fuses - Square Body (170M) 25
Bussman Fuses - British Style (BS88) 26
Ferraz Fuses - HSJ 27
Ferraz Fuses - North American Style (PSC 690) 28
Ferraz Fuses - European Style (PSC 690) 29
Ferraz Fuses - AJT 30
Schematic Diagrams 31
Internally Bypassed Models 31
Non-bypassed Models 32
5 Application Examples 33
Motor Overload Protection 33
AAC Adaptive Acceleration Control 33
Starting Modes 33
Constant Current 33
Current Ramp 34
AAC Adaptive Acceleration Control 34
Kickstart 35
Stopping Modes 35
Coast to Stop 35
TVR Soft Stop 36
AAC Adaptive Acceleration Control 36
Brake 37
Jog Operation 37
Inside Delta Operation 38
Typical Start Currents 39
Installation with Main Contactor 41
Installation with Bypass Contactor 42
Emergency Run Operation 43
Auxiliary Trip Circuit 44
Soft Braking 45
Two Speed Motor 46
6 Operation 49
The LCP 49
Control Methods 49
Local Control Buttons 50
Displays 50
Temperature Monitoring Screen (S1) 51
Programmable Screen (S2) 51
Contents MCD 500 Operating Instruction
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Average Current (S3) 51
Current Monitoring Screen (S4) 51
Frequency Monitoring Screen (S5) 51
Motor Power Screen (S6) 52
Last Start Information (S7) 52
Date and Time (S8) 52
SCR Conduction Bargraph 52
Performance Graphs 53
7 Programming 55
Access Control 55
Quick Menu 56
Quick Setup 56
Application Setups 57
Loggings 58
Main Menu 58
Parameters 58
Parameter Shortcut 58
Parameter List 59
Primary Motor Settings 59
Brake 61
Protection 62
Current Imbalance 62
Undercurrent 62
Instantaneous Overcurrent 62
Frequency Trip 63
Inputs 64
Outputs 66
Relay A Delays 66
Relays B and C 66
Low Current Flag and High Current Flag 67
Motor Temperature Flag 67
Analog Output A 68
Start/Stop Times 68
Auto-Reset 69
Auto-Reset Delay 70
Secondary Motor Set 70
Display 72
User Programmable Screen 72
Performance Graphs 73
Restricted Parameters 74
MCD 500 Operating Instruction Contents
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Protection Action 76
Factory Parameters 76
8 Tools 77
Set Date and Time 77
Load/Save Settings 77
Reset Thermal Model 78
Protection Simulation 78
Output Signal Simulation 79
Digital I/O State 79
Temp Sensors State 79
Alarm Log 80
Trip Log 80
Event Log 80
Counters 80
9 Troubleshooting 83
Trip Messages 83
General Faults 86
10 Specifications 89
Accessories 90
Communication Modules 90
PC Software 90
Finger Guard Kit 91
11 Bus Bar Adjustment Procedure (MCD5-0360C -
MCD5-1600C)
93
Contents MCD 500 Operating Instruction
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1Safety
1.1 Safety
1.1.1 Warnings
When reading this manual you will come across different symbols that require special attention. The symbols used are the following:
NB!
Indicates something to be noted by the reader
Indicates a general warning
Indicates a high voltage warning
The examples and diagrams in this manual are included solely for illustrative purposes. The information contained in this manual is subject to change at
any time and without prior notice. In no event will responsibility or liability be accepted for direct, indirect or consequential damages resulting from the
use or application of this equipment.
WARNING - ELECTRICAL SHOCK HAZARD
MCD 500 soft starters contain dangerous voltages when connected to mains voltage. Only a competent electrician should carry out the
electrical installation. Improper installation of the motor or the soft starter may cause equipment failure, serious injury or death. Follow
this manual and local electrical safety codes.
Disconnect the soft starter from mains voltage before carrying out repair work.
It is the responsibility of the user or person installing the soft starter to provide proper grounding and branch circuit protection according
to local electrical safety codes.
Do not connect power factor correction capacitors to the output of MCD 500 soft starters. If static power factor correction is employed,
it must be connected to the supply side of the soft starter.
The motor can be stopped by means of digital or bus commands while the soft starter is connected to the mains, if the soft starter is in Auto On mode.
1. If personal safety considerations make it necessary to ensure that no unintended start occurs,
these stop functions are not sufficient.
2. A motor that has been stopped may start if faults occur in the electronics of the soft starter, or a temporary fault in the supply mains or the
motor connection ceases.
AUTO-START
Use the auto-start feature with caution. Read all the notes related to auto-start before operation.
MCD 500 Operating Instruction 1 Safety
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1

Equipment containing electrical components may not be disposed of together with domestic
waste.
It must be collected separately as electrical and electronic waste according to local and cur-
rently valid legislation.
1 Safety MCD 500 Operating Instruction
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2Introduction
The MCD 500 is an advanced digital soft start solution for motors from 7 kW to 800 kW. MCD 500 soft starters provide a complete range of motor and
system protection features and have been designed for reliable performance in the most demanding installation situations.
2.1.1 Feature List
Models for all connection requirements
• 21 A to 1600 A (in-line connection)
• In-line or inside delta connection
• Internally bypassed up to 215 A
• Mains voltage: 200 - 525 VAC or 380 - 690 VAC
• Control voltage: 24 VAC/VDC, 110 - 120 VAC or 220 - 240 VAC
User-friendly LCP
• Loggings
•Real-timegraphs
•SCRconductionbargraph
Tools
• Application setups
• Date and time stamped event log with 99 entries
•8mostrecenttrips
• Counters
•Protectionsimulation
• Output signal simulation
Inputs and Outputs
• Local or remote control input options
(3 x fixed 1 x programmable)
• Relay outputs (3 x programmable)
• Analog programmable output
• 24 VDC 200 mA supply output
Start and run modes
• AAC - Adaptive Acceleration Control
• Constant current
• Current ramp
•Kickstart
•Jog
• Emergency run operation
Stop modes
• AAC - Adaptive Acceleration Control
• Timed voltage ramp soft stop
•DCbrake
•Softbrake
•Emergencystop
Other features
• Auto start/stop timer
• Second order thermal model
• Battery backup of clock and thermal model
• Optional DeviceNet, Modbus or Profibus communication mod-
ules
Comprehensive protection
• Wiring/Connection/Supply
-Motor connection
-Phase sequence
-Power loss
-Individual phase loss
-Mains frequency
• Current
-Excess start time
-Current imbalance
-Undercurrent
-Instantaneous overcurrent
•Thermal
-Motor thermistor
-Motor overload
-Bypass relay overload
-Heatsink temperature
• Communication
-Network comms
-Starter comms
•External
-Input trip
•Starter
-Individual shorted SCR
-Battery/Clock
MCD 500 Operating Instruction 2 Introduction
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2.1.2 Type Code
MCD 5 -- - -
Current rating
0021 = 21 A, AC53b 3-30:330
0037 = 37 A, AC53b 3-30:330
0043 = 43 A, AC53b 3-30:330
0053 = 53 A, AC53b 3-30:330
0068 = 68 A, AC53b 3-30:570
0084 = 84 A, AC53b 3-30:570
0089 = 89 A, AC53b 3-30:570
0105 = 105 A, AC53b 3-30:570
0131 = 131 A, AC53b 3-30:570
0141 = 141 A, AC53b 3-30:570
0195 = 195 A, AC53b 3-30:570
0215 = 215 A, AC53b 3-30:570
0245 = 245 A, AC53a 3-30:50-6
0360 = 360 A, AC53a 3-30:50-6
0380 = 380 A, AC53a 3-30:50-6
0428 = 428 A, AC53a 3-30:50-6
0595 = 595 A, AC53a 3-30:50-6
0619 = 619 A, AC53a 3-30:50-6
0790 = 790 A, AC53a 3-30:50-6
0927 = 927 A,AC53a 3-30:50-6
1200 = 1200 A, AC53a 3-30:50-6
1410 = 1410 A, AC53a 3-30:50-6
1600 = 1600 A, AC53a 3-30:50-6
Mains voltage
T5 = 200 - 525 VAC
T7 = 380 - 690 VAC
IP rating
00 = IP00
20 = IP20
Control voltage
CV1 = 24 VAC/VDC
CV2 = 110-120 VAC or 220-240 VAC
B = Bypassed
C = Non-bypassed
Frame size
G1 = 0021 ~ 0105 A
G2 = 0131 ~ 0215 A
G3 = 0245 A
G4 = 0360 A ~ 0927 A
G5 = 1200 A ~ 1600 A
Not used
= Not selectable
177HA382.11
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3Installation
3.1 Mechanical Installation
1MCD5-0021B - MCD5-0245C: Allow 100 mm (3.94 inches) between soft starters.
MCD5-0360C - MCD5-1600C: Allow 200 mm (7.88 inches) between soft starters.
2MCD5-0021B - MCD5-0215B: Allow 50 mm (1.97 inches) between the soft starter and solid surfaces.
MCD5-0245C: Allow 100 mm (3.94 inches) between the soft starter and solid surfaces.
MCD5-0360C - MCD5-1600C: Allow 200 mm (7.88 inches) between the soft starter and solid surfaces.
3The soft starter may be mounted on its side. Derate the soft starter's rated current by 15%.
4Soft starters may be mounted side by side with clearance of 50 mm (1.97 inches) on both sides.
MCD 500 Operating Instruction 3 Installation
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3.2 Dimensions and Weights
177HA514.10
Model A mm
(inches)
B mm
(inches)
C mm
(inches)
D mm
(inches)
E mm
(inches)
Weight kg
(lbs)
MCD5-0021B
295
(11.6)
278
(10.9)
150
(5.9)
124
(4.9)
183
(7.2)
4.2
(9.3)
MCD5-0037B
MCD5-0043B
MCD5-0053B
MCD5-0068B 4.5
(9.9)
MCD5-0084B 213
(8.14)
4.9
(10.8)
MCD5-0089B
MCD5-0105B
MCD5-0131B
438
(17.2)
380
(15.0)
275
(10.8)
248
(9.8)
250
(9.8)
14.9
(32.8)
MCD5-0141B
MCD5-0195B
MCD5-0215B
MCD5-0245C 460
(18.1)
400
(15.0)
390
(15.4)
320
(12.6)
279
(11.0)
23.9
(52.7)
MCD5-0360C
689
(27.1)
520
(20.5)
430
(16.9)
320
(12.6)
302
(11.9)
35
(77.2)
MCD5-0380C
MCD5-0428C
MCD5-0595C
45
(99.2)
MCD5-0619C
MCD5-0790C
MCD5-0927C
MCD5-1200C 856
(33.7)
727
(28.6)
585
(23.0)
500
(19.7)
364
(14.3)
120
(264.6)
MCD5-1410C
MCD5-1600C
3 Installation MCD 500 Operating Instruction
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4 Electrical Installation
4.1.1 Control Wiring
The soft starter can be controlled in three ways:
• using the buttons on the LCP
• via remote inputs
• via a serial communication link
The MCD 500 will always respond to a local start or stop command (via the Hand On and Off buttons on the LCP). Pressing the Auto On button selects
remote control (the MCD 500 will accept commands from the remote inputs). In remote mode, the Auto On LED will be on. In local mode, the Hand On
LED will be on if the MCD 500 is starting or running and the Off LED will be on if the MCD 500 is stopped or stopping.
4.1.2 Control Terminals
Control terminations use 2.5 mm2plug-in terminal blocks. Different models require control voltage to different terminals:
CV1 (24 VAC/VDC) A5, A6
CV2 (110 - 120 VAC) A5, A6
CV2 (220 - 240 VAC) A4, A6
NB!
If you are not using a thermistor, do not short terminals 05, 06.
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4.1.3 Remote Inputs
The MCD 500 has three fixed inputs for remote control. These inputs should be controlled by contacts rated for low voltage, low current operation (gold
flash or similar).
177HA504.10
Start/stop
Reset
Start
Stop
Reset
Start
Stop
Reset
15
16
17
18
25
18
15
16
17
18
25
18
15
16
17
18
25
18
23
1
1Two-wirecontrol
2Three-wirecontrol
3 Four-wire control
The reset input can be normally open or normally closed. Use par. 3-8 to select the configuration.
Do not apply voltage to the control input terminals. These are active 24 VDC inputs and must be controlled with potential free contacts.
Cables to the control inputs must be segregated from mains voltage and motor cabling
4.1.4 Serial Communication
Serial communication is always enabled in local control mode, and can be enabled or disabled in remote control mode (see par. 3-2).
4.1.5 Earth Terminal
Earth terminals are located at the back of the soft starter.
• MCD5-0021B - MCD5-0105B have one terminal, on the input side.
• MCD5-0131B - MCD5-1600C have two terminals, one on the input side and one on the output side.
4.1.6 Power Terminations
Use only copper stranded or solid conductors, rated for 75°C.
NB!
Some units are aluminium bus bars. When connecting power terminations, we recommend cleaning the surface contact area thoroughly
(using an emery or stainless steel brush) and using an appropriate jointing compound to prevent corrosion.
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MCD5-0021B - MCD5-0105B MCD5-0131B MCD5-0141B - MCD5-0215B
MCD5-0245C MCD5-0360C - MCD50927C MCD5-1200C - MCD5-1600C
The bus bars on models MCD5-0360C - MCD5-1600C can be adjusted for top or bottom input and output as required. For step-by-step instructions on
adjusting the bus bars, refer to the supplied insert.
I/O
I
O
Input/Output
Input
Output
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4.1.7 Motor Connection
MCD 500 soft starters can be connected to the motor in-line or inside delta (also called three-wire and six-wire connection). The MCD 500 will automatically
detect the motor connection and perform the necessary calculations internally, so it is only necessary to program the motor full load current (par. 1-1).
NB!
For personnel safety, the power terminals on models up to MCD5-0105B are protected by snap-off tabs. When using large cables, it
may be necessary to break off these tabs.
Models which are internally bypassed do not require an external bypass contactor.
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4.2 In-Line Installation
4.2.1 In-line Installation, Internally Bypassed
177HA430.11
M
3
6/T3
2/T1
5/L3
3/L2
1/L1
13
14
4/T2
E
KM1
KM1 F1
KM1 Main contactor (optional)
F1 Fuses (optional)
4.2.2 In-line Installation, Non-bypassed
177HA429.11
6/T3
2/T1
5/L3
3/L2
1/L1
13
14
4/T2
E
KM1
KM1 F1
M
3
KM1 Main contactor (optional)
F1 Fuses (optional)
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4.2.3 In-line Installation, Externally Bypassed
Non-bypassed models have dedicated bypass terminals, which allow the soft starter to continue providing protection and monitoring functions even when
bypassed via external contactor. The bypass contactor must be connected to the bypass terminals and controlled by a programmable output configured
to Run (see par. 4.1 - 4.9).
177HA431.11
M
3
F1
6/T3
2/T1
5/L3
3/L2
1/L1
13
14
4/T2
E
KM1
KM1
L1B
L2B
L3B
KM2
34
33
KM2
KM1 Main contactor
KM2 Bypass contactor
F1 Fuses (optional)
NB!
The bypass terminals on MCD5-0245C are T1B, T2B, T3B. The bypass terminals on MCD5-0360C ~ MCD5-1600C are L1B, L2B, L3B.
The fuses can be installed on the input side if required.
4.3 Inside Delta Installation
NB!
When connecting the MCD 500 in inside delta configuration, always install a main contactor or shunt trip circuit breaker.
4 Electrical Installation MCD 500 Operating Instruction
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4.3.1 Inside Delta Installation, Internally Bypassed
KM1 Main contactor
F1 Fuses (optional)
4.3.2 Inside Delta Installation, Non-bypassed
177HA500.11
M
3
6/T3
2/T1
5/L3
3/L2
1/L1
13
14
4/T2
KM1
KM1 F1
U1(1) U2(4)
V1(2) V2(5)
W1(3) W2(6)
L2B
L1B
L3B
E
KM1 Main contactor
F1 Fuses (optional)
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4.3.3 Inside Delta Installation, Externally Bypassed
Non-bypassed models have dedicated bypass terminals, which allow the MCD 500 to continue providing protection and monitoring functions even when
bypassed via an external bypass contactor. The bypass relay must be connected to the bypass terminals and controlled by a programmable output
configured to Run (see par. 4-1 - 4-9).
177HA502.11
M
3
6/T3
2/T1
5/L3
3/L2
1/L1
13
14
4/T2
E
KM1
KM1 F1
U1(1) U2(4)
V1(2) V2(5)
W1(3) W2(6)
L2B
L1B
L3B
KM2
34
33
KM2
KM1 Main contactor
KM2 Bypass contactor
F1 Fuses (optional)
NB!
The bypass terminals on MCD5-0245C are T1B, T2B, T3B. The bypass terminals on MCD5-0360C - MCD5-1600C are L1B, L2B, L3B.
The fuses can be installed on the input side if required.
4.4 Current Ratings
Contact your local supplier for ratings under operating conditions not covered by these ratings charts.
All ratings are calculated at altitude of 1000 metres and ambient temperature of 40°C.
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4.4.1 In-line Connection (Bypassed)
NB!
Models MCD5-0021B - MCD5-0215B are internally bypassed. Models MCD5-0245C - MCD5-1600C require an external bypass contactor.
AC-53b
3-30:330
AC-53b
4-20:340
AC-53b
4.5-30:330
MCD5-0021B 21 A 17 A 15 A
MCD5-0037B 37 A 31 A 26 A
MCD5-0043B 43 A 37 A 30 A
MCD5-0053B 53 A 46 A 37 A
AC-53b
3-30:570
AC-53b
4-20:580
AC-53b
4.5-30:570
MCD5-0068B 68 A 55 A 47 A
MCD5-0084B 84 A 69 A 58 A
MCD5-0089B 89 A 74 A 61 A
MCD5-0105B 105 A 95 A 78 A
MCD5-0131B 131 A 106 A 90 A
MCD5-0141B 141 A 121 A 97 A
MCD5-0195B 195 A 160 A 134 A
MCD5-0215B 215 A 178 A 148 A
MCD5-0245C 255 A 201 A 176 A
MCD5-0360C 360 A 310 A 263 A
MCD5-0380C 380 A 359 A 299 A
MCD5-0428C 430 A 368 A 309 A
MCD5-0595C 620 A 540 A 434 A
MCD5-0619C 650 A 561 A 455 A
MCD5-0790C 790 A 714 A 579 A
MCD5-0927C 930 A 829 A 661 A
MCD5-1200C 1200 A 1200 A 1071 A
MCD5-1410C 1410 A 1319 A 1114 A
MCD5-1600C 1600 A 1600 A 1353 A
4.4.2 AC-53 Rating for Bypassed Operation
All ratings are calculated at altitude of 1000 metres and ambient temperature of 40°C.
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4.4.3 In-line Connection (Non-bypassed/Continuous)
AC-53a
3-30:50-6
AC-53a
4-20:50-6
AC-53a
4.5-30:50-6
MCD5-0245C 245 A 195 A 171 A
MCD5-0360C 360 A 303 A 259 A
MCD5-0380C 380 A 348 A 292 A
MCD5-0428C 428 A 355 A 300 A
MCD5-0595C 595 A 515 A 419 A
MCD5-0619C 619 A 532 A 437 A
MCD5-0790C 790 A 694 A 567 A
MCD5-0927C 927 A 800 A 644 A
MCD5-1200C 1200 A 1135 A 983 A
MCD5-1410C 1410 A 1187 A 1023 A
MCD5-1600C 1600 A 1433 A 1227 A
4.4.4 AC-53 Rating for Continuous Operation
Start Time (seconds)
Starts Per Hour
All ratings are calculated at altitude of 1000 metres and ambient temperature of 40°C.
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