Danfoss vlt soft starter mcd 500 Operating Manual

ENGINEERING TOMORROW

Operating Guide

VLT® Soft Starter MCD 500

vlt-drives.danfoss.com

Contents Operating Guide

Contents

1 Safety

1.1 Warnings

2 Introduction

3 Installation

3.1 Mechanical Installation

3.2 Dimensions and Weight

4 Electrical Installation

4.1 Control Wiring

4.1.1 Ways to Control the Soft Starter 13

4.1.2 Control Terminals 13

4.1.3 Remote Inputs 13

4.1.4 Serial Communication 14

4.1.5 Ground Terminal 14

4.1.6 Power Terminations 14

4.2 Power Input and Output Congurations

6

6

8

10

10

11

13

13

15

4.2.1 Internally Bypassed Models (MCD5-0021B to MCD5-0961B) 15

4.2.2 MCD5-0245C 16

4.2.3 MCD5-0360C to MCD5-1600C 16

4.3 Motor Connection

4.3.1 Testing the Installation 16

4.3.2 In-line Installation 17

4.3.2.1 Internally Bypassed 17

4.3.2.2 Non-bypassed 17

4.3.2.3 Externally Bypassed 17

4.3.3 Inside Delta Installation 18

4.3.3.1 Internally Bypassed 18

4.3.3.2 Non-bypassed 18

4.3.3.3 Externally Bypassed 19

4.4 Current Ratings

4.4.1 In-line Connection (Bypassed) 20

4.4.2 In-line Connection (Non-bypassed/Continuous) 21

4.4.3 Inside Delta Connection (Bypassed) 22

16

19

4.4.4 Inside Delta Connection (Non-bypassed/Continuous) 23

4.5 Minimum and Maximum Current Settings

4.6 Bypass Contactor

4.7 Main Contactor

4.8 Circuit Breaker

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 1

24

24

24

24

Contents

VLT® Soft Starter MCD 500

4.9 Power Factor Correction

4.10 Fuses

4.10.1 Power Supply Fuses 25

4.10.2 Bussmann Fuses 26

4.10.3 Ferraz Fuses 28

4.10.4 UL Fuse Selection and Short Circuit Ratings 30

4.11 Schematic Diagrams

5 Product Features

5.1 Motor Overload Protection

5.2 Adaptive Control

5.3 Starting Modes

5.3.1 Constant Current 36

5.3.2 Current Ramp 36

5.3.3 Adaptive Control 37

5.3.4 Kick Start 37

5.4 Stopping Modes

5.4.1 Coast to Stop 38

25

25

33

35

35

36

36

38

5.4.2 TVR Soft Stop 38

5.4.3 Adaptive Control 38

5.4.4 Pump Stopping 38

5.4.5 Brake 39

5.5 Jog Operation

5.6 Inside Delta Operation

5.7 Typical Start Currents

5.8 Installation with Main Contactor

5.9 Installation with Bypass Contactor

5.10 Emergency Run Operation

5.11 Auxiliary Trip Circuit

5.12 DC Brake with External Zero-speed Sensor

5.13 Soft Braking

5.14 Two-speed Motor

6 Operation

6.1 Control Methods

6.2 Operation and LCP

40

41

41

43

44

45

46

47

48

49

51

51

52

6.2.1 Operating Modes 52

6.3 Remote-mounted LCP

6.3.1 Synchronizing the LCP and the Soft Starter 53

6.4 Welcome Screen

6.5 Local Control Keys

2 Danfoss A/S © 05/2016 All rights reserved. MG17K602

53

53

53

Contents Operating Guide

6.6 Displays

6.6.1 Temperature Monitoring Screen (S1) 54

6.6.2 Programmable Screen (S2) 54

6.6.3 Average Current (S3) 54

6.6.4 Current Monitoring Screen (S4) 54

6.6.5 Frequency Monitoring Screen (S5) 54

6.6.6 Motor Power Screen (S6) 54

6.6.7 Last Start Information (S7) 54

6.6.8 Date and Time (S8) 54

6.6.9 SCR Conduction Bar Graph 55

6.6.10 Performance Graphs 55

7 Programming

7.1 Access Control

7.2 Quick Menu

7.2.1 Quick Set-up 56

7.2.2 Application Set-up Examples 57

7.2.3 Loggings 58

53

56

56

56

7.3 Main Menu

7.3.1 Parameters 58

7.3.2 Parameter Shortcut 58

7.3.3 Parameter List 59

8 Parameter Descriptions

8.1 Primary Motor Settings

8.1.1 Brake 61

8.2 Protection

8.2.1 Current Imbalance 62

8.2.2 Undercurrent 62

8.2.3 Instantaneous Overcurrent 62

8.2.4 Frequency Trip 62

8.3 Inputs

8.4 Outputs

8.4.1 Relay A Delays 64

8.4.2 Relays B and C 64

8.4.3 Low Current Flag and High Current Flag 65

58

60

60

61

63

64

8.4.4 Motor Temperature Flag 65

8.4.5 Analog Output A 65

8.5 Start/Stop Timers

8.6 Auto-Reset

8.6.1 Auto-Reset Delay 67

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66

Contents

VLT® Soft Starter MCD 500

8.7 Secondary Motor Set

8.8 Display

8.8.1 User-programmable Screen 68

8.8.2 Performance Graphs 69

8.9 Restricted Parameters

8.10 Protection Action

8.11 Factory Parameters

9 Tools

9.1 Set Date and Time

9.2 Load/Save Settings

9.3 Reset Thermal Model

9.4 Protection Simulation

9.5 Output Signal Simulation

9.6 Digital I/O State

9.7 Temp Sensors State

9.8 Alarm Log

9.8.1 Trip Log 74

67

68

69

71

71

72

72

72

72

73

73

73

73

74

9.8.2 Event Log 74

9.8.3 Counters 74

10 Troubleshooting

10.1 Trip Messages

10.2 General Faults

11 Specications

11.1 UL-compliant Installation

11.1.1 Models MCD5-0021B to MCD5-0105B 83

11.1.2 Models MCD5-0131B to MCD5-0215B 83

11.1.3 Models MCD5-0245B to MCD5-0396B 83

11.1.4 Models MCD5-0245C 83

11.1.5 Models MCD5-0360C to MCD5-1600C 84

11.1.6 Models MCD5-0469B to MCD5-0961B 84

11.1.7 Pressure Terminal/Connector Kits 84

11.2 Accessories

11.2.1 LCP Remote Mounting Kit 84

75

75

80

82

83

84

11.2.2 Communication Modules 84

11.2.3 PC Software 84

11.2.4 Finger Guard Kit 85

11.2.5 Surge Protection Kit (Lightning Protection) 85

12 Busbar Adjustment Procedure (MCD5-0360C to MCD5-1600C)

4 Danfoss A/S © 05/2016 All rights reserved. MG17K602

86

Contents Operating Guide

13 Appendix

13.1 Symbols, Abbreviations, and Conventions

Index

88

88

89

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 5

Safety

VLT® Soft Starter MCD 500

11

1 Safety

1.1 Warnings

The following symbols are used in this manual:

WARNING

Indicates a potentially hazardous situation that could
result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation that could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.

WARNING

PROPER GROUNDING

Disconnect the soft starter from mains voltage before
carrying out repair work.
It is the responsibility of the 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 the VLT® Soft Starter MCD 500. If static power
factor correction is employed, it must be connected to
the supply side of the soft starter.

WARNING

NOTICE

Indicates important information, including situations that
can result in damage to equipment or property.

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. Responsibility or liability is never
accepted for direct, indirect, or consequential damage
resulting from the use or application of this equipment.

NOTICE

Before changing any parameter settings, save the current
parameter to a le using MCD PC Software or the Save
User Set function.

WARNING

ELECTRICAL SHOCK HAZARD

VLT® Soft Starters MCD 500 contain dangerous voltages
when connected to mains voltage. Only a qualied
electrician should carry out the electrical installation.
Improper installation of the motor or the soft starter can
cause equipment failure, serious injury, or death. Follow
the guidelines in this manual and local electrical safety
codes.
Models MCD5-0360C ~ MCD5-1600C:
Treat the busbar and heat sink as live parts whenever
the unit has mains voltage connected (including when
the soft starter is tripped or waiting for a command).

IMMEDIATE START

In auto-on mode, the motor can be controlled remotely
(via remote inputs) while the soft starter is connected to
mains.
MCD5-0021B ~ MCD5-961B:
Transportation, mechanical shock, or rough handling
may cause the bypass contactor to latch into the On
state. To prevent the motor from starting immediately on
rst commissioning or operation after transportation,
always ensure that the control supply is applied before
the power. Applying control supply before power ensures
that the contactor state is initialized.

WARNING

SAFETY OF PERSONNEL

The soft starter is not a safety device and does not
provide electrical isolation or disconnection from the
supply.

If isolation is required, the soft starter must be

•

installed with a main contactor.

Do not rely on the start and stop functions for

•

safety of personnel. Faults occurring in the
mains supply, the motor connection, or the
electronics of the soft starter can cause
unintended motor starts or stops.

If faults occur in the electronics of the soft

•

starter, a stopped motor may start. A temporary
fault in the supply mains or loss of motor
connection can also cause a stopped motor to
start.

To provide safety of personnel and equipment, control
the isolation device through an external safety system.

6 Danfoss A/S © 05/2016 All rights reserved. MG17K602

Safety Operating Guide

NOTICE

Use the auto-start feature with caution. Read all the
notes related to auto-start before operation.

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 currently valid

legislation.

Table 1.1 Disposal Instructions

1 1

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 7

Introduction

2 Introduction

VLT® Soft Starter MCD 500

22

The VLT® Soft Starter MCD 500 is an advanced digital soft
start solution for 11–850 kW (15–1150 hp) motors. The soft
starters provide a complete range of motor and system
protection features and are designed for reliable
performance in the most demanding installation situations.

2.1.1 Feature List

Models for all connection requirements

21–1600 A (in-line connection).

•

In-line or inside delta connection.

•

Internally bypassed up to 961 A.

•

Mains voltage: 200–525 V AC or 380–690 V AC.

•

Control voltage: 24 V AC/V DC, 110–120 V AC, or

•

220–240 V AC.

User-friendly LCP

Loggings.

•

Real-time graphs.

•

SCR conduction bar graph.

•

Tools

Application set-ups.

•

Date and time stamped event log with 99 entries.

•

8 most recent trips.

•

Counters.

•

Protection simulation.

•

Output signal simulation.

•

Inputs and outputs

Local or remote control input options.

•

(3 x xed, 1 x programmable).

Relay outputs (3 x programmable).

•

Analog programmable output.

•

24 V DC 200 mA supply output.

•

Start and run modes

Adaptive control.

•

Constant current.

•

Current ramp.

•

Kick start.

•

Jog.

•

Emergency run operation.

•

Stop modes

Adaptive deceleration control.

•

Timed voltage ramp soft stop.

•

DC brake.

•

Soft brake.

•

Starter disable.

•

Other features

Auto start/stop timer.

•

Second-order thermal model.

•

Battery back-up of clock and thermal model.

•

Optional DeviceNet, Modbus, Ethernet, or

•

PROFIBUS communication modules.

Comprehensive protection

Wiring/connection/supply

•

- Motor connection.

- Phase sequence.

- Power loss.

- Individual phase loss.

- Mains frequency.

Current

•

- Excess start time.

- Current imbalance.

- Undercurrent.

- Instant overcurrent.

Thermal

•

- Motor thermistor.

- Motor overload.

- Bypass contactor overload.

- Heat sink temperature.

Communication

•

- Network comms.

- Starter comms.

External

•

- Input trip.

Starter

•

- Individually short-circuited SCR.

- Battery/clock.

8 Danfoss A/S © 05/2016 All rights reserved. MG17K602

MCD 5

- -

-

-

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, AC53b 3-30:570
0331 = 331 A, AC53b 3-30:570
0396 = 396 A, AC53b 3-30:570
0469 = 469 A, AC53b 3-30:570
0525 = 525 A, AC53b 3-30:570
0632 = 632 A, AC53b 3-30:570
0744 = 744 A, AC53b 3-30:570
0826 = 826 A, AC53b 3-30:570

0961 = 961 A, AC53b 3-30:570

00 = IP00
20 = IP20

G1 = 0021 ~ 0105 A
G2 = 0131 ~ 0215 A
G3 = 0245 ~ 0396 A
G4 = 0360 ~ 0961 A
G5 = 1200 ~ 1600 A

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

177HA382.11

Current rating

B = Bypassed

C = Non-bypassed

Mains voltage
T5 = 200 - 525 VAC
T7 = 380 - 690 VAC

Frame size

= Not selectable

Not used

IP rating

Control voltage

CV1 = 24 VAC/VDC

CV2 = 110-120 VAC or 220-240 VAC

Introduction Operating Guide

2.1.2 Type Code

2 2

Illustration 2.1 Type Code Ordering Form

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 9

Installation

VLT® Soft Starter MCD 500

3 Installation

3.1 Mechanical Installation

33

1 MCD5-0021B to MCD5-0215B: Allow 100 mm (3.94 in) between the soft starters.

MCD5-0245B to MCD5-0961B: Allow 200 mm (7.88 in) between the soft starters.

MCD5-0245C: Allow 100 mm (3.94 in) between the soft starters.

MCD5-0360C to MCD5-1600C: Allow 200 mm (7.88 in) between the soft starters.

2 MCD5-0021B to MCD5-0215B: Allow 50 mm (1.97 in) between the soft starter and solid surfaces.

MCD5-0245B to MCD5-0961B: Allow 200 mm (7.88 in) between soft starters.

MCD5-0245C: Allow 100 mm (3.94 in) between the soft starter and solid surfaces.

MCD5-0360C to MCD5-1600C: Allow 200 mm (7.88 in) between the soft starter and solid surfaces.

3 It is possible to mount the soft starter on its side. Derate the soft starter rated current by 15%.

4 If mounted without communication modules, soft starters may be mounted side by side with no clearance.

Illustration 3.1 Clearances and Derating Values at Installation

10 Danfoss A/S © 05/2016 All rights reserved. MG17K602

177HA514.10

Installation Operating Guide

3.2 Dimensions and Weight

3 3

Model A [mm] (in) B [mm] (in) C [mm] (in) D [mm] (in) E [mm] (in) Weight [kg] (lbs)

MCD5-0021B

MCD5-0037B

MCD5-0043B

MCD5-0053B

MCD5-0068B

MCD5-0084B

MCD5-0089B

MCD5-0105B

MCD5-0131B

MCD5-0141B

MCD5-0195B

MCD5-0215B

MCD5-0245B

MCD5-0331B

MCD5-0396B

MCD5-0469B

MCD5-0525B

MCD5-0632B

MCD5-0744B

MCD5-0826B

MCD5-0961B

MCD5-0245C 460 (18.1) 400 (15.0) 390 (15.4) 320 (12.6) 279 (11.0) 23.9 (52.7)

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

295 (11.6) 278 (10.9) 150 (5.9) 124 (4.9)

438 (17.2) 380 (15.0) 275 (10.8) 248 (9.8) 250 (9.8) 14.9 (32.8)

440 (17.3) 392 (15.4) 424 (16.7) 376 (14.8) 296 (11.7)

640 (25.2) 600 (23.6) 433 (17.0) 320 (12.6) 295 (11.6)

689 (27.1) 522 (20.5) 430 (16.9) 320 (12.6) 300 (11.8)

183 (7.2) 4.2 (9.3)

4.5 (9.9)

213 (8.14)

4.9 (10.8)

26 (57.2)

30.2 (66.6)

49.5 (109.1)

60.0 (132.3)

35 (77.2)

45 (99.2)

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 11

Installation

Model A [mm] (in) B [mm] (in) C [mm] (in) D [mm] (in) E [mm] (in) Weight [kg] (lbs)

MCD5-1200C

856 (33.7) 727 (28.6) 585 (23.0) 500 (19.7) 364 (14.3) 120 (264.6)MCD5-1410C

MCD5-1600C

VLT® Soft Starter MCD 500

33

Illustration 3.2 Dimensions and Weight

12 Danfoss A/S © 05/2016 All rights reserved. MG17K602

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

2

3

1

Electrical Installation Operating Guide

4 Electrical Installation

4.1 Control Wiring

4.1.1 Ways to Control the Soft Starter

Control the soft starter in 3 ways:

Pressing the keys on the LCP.

•

Via remote inputs.

•

Via a serial communication link.

•

The VLT® Soft Starter MCD 500 always responds to a local
start or stop command (via the [Hand On] and [O] keys
on the LCP). Pressing the [Auto On] key selects remote
control (the soft starter accepts commands from the
remote inputs). In remote mode, the Auto On LED is on. In
hand-on mode, the Hand On LED is on if the soft starter
starts or runs. The O LED is on if the soft starter is
stopped or stops.

4.1.2 Control Terminals

Control terminations use 2.5 mm2 (14 AWG) plug-in
terminal blocks. Dierent models require control voltage to
dierent terminals:

CV1 (24 V AC/V DC): A5, A6.

•

CV2 (110–120 V AC): A5, A6.

•

CV2 (220–240 V AC): A4, A6.

•

NOTICE

SELV oers protection by way of extra low voltage.
Protection against electric shock is ensured when the
electrical supply itself is of the SELV type and the instal­lation follows local/national regulations on SELV supplies.

4 4

NOTICE

Galvanic (ensured) isolation is obtained by fullling
requirements for higher isolation and by providing the
relevant creepages/clearance distances. These
requirements are described in the IEC 61140 standard.
The components that make up the electrical isolation
also comply with the requirements for higher isolation
and the relevant test as described in IEC 61140.

4.1.3 Remote Inputs

The soft starter has 3 xed inputs for remote control.
Control these inputs by contacts rated for low voltage, low
current operation (gold ash or similar).

1 2-wire control

2 3-wire control

3 4-wire control

Illustration 4.2 2-, 3-, and 4-wire Control

Illustration 4.1 Wiring to Control Terminals

NOTICE

Do not short terminals 05 and 06 without using a
thermistor.

The reset input can be normally open or normally closed.
To select the conguration, use parameter 3-8 Remote Reset
Logic.

WARNING

ELECTRICAL SHOCK HAZARD

All control terminals and relay terminals comply with SELV
(safety extra low voltage). This protection does not apply
to grounded delta leg above 400 V.

To maintain SELV, all connections made to the control
terminals must be PELV (for example thermistor must be
reinforced/double insulated from motor).

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 13

Do not apply voltage to the control input terminals.
These terminals are active 24 V DC inputs and must be
controlled with potential-free contacts.

Segregate cables to the control inputs from

•

mains voltage and motor cabling.

177HA646.10

177HA647.10

177HA648.10

177HA649.10

5 mm

15 mm

28 mm

11 mm

(M10)

177HA643.10

6 mm

15 mm

28 mm

11 mm

(M10)

177HA644.10

13 mm

12 mm

32 mm

11 mm

(M10)

177HA645.10

Electrical Installation

VLT® Soft Starter MCD 500

4.1.4 Serial Communication

Control via the serial communication network is always
enabled in hand-on mode and can be enabled or disabled
in remote control mode (see parameter 3-2 Comms in
Remote). Control via the serial communication network

4.1.6 Power Terminations

NOTICE

For personnel safety, snap-o tabs protect the power
terminals on models up to MCD5-0105B. When using
large cables, it may be necessary to break o these tabs.

requires an optional communication module.

44

4.1.5 Ground Terminal

Ground terminals are at the back of the soft starter.

NOTICE

Some units use aluminum busbars. When connecting
power terminations, clean the surface contact area
thoroughly (using an emery or stainless steel brush), and
use an appropriate jointing compound to prevent

MCD5-0021B to MCD5-0105B have 1 terminal on

•

corrosion.

the input side (top).

MCD5-0131B to MCD5-0961B and MCD5-0245C to

•

MCD5-1600C have 2 terminals; 1 on the input

Use only copper stranded or solid conductors, rated for
75 °C (167°F) or higher.

side (top), and 1 on the output side (bottom).

Cable size: 6–50 mm2 (AWG 10-1/0)

14 mm (0.55 in)

Torque: 4 Nm (35.4 in-lb)

MCD5-0021B to MCD5-0105B

38 Nm (336.3 in-lb)

Torx T20 x 150

Flat 7 mm x 150

MCD5-0131B MCD5-0141B to MCD5-0215B MCD5-0245B

38 Nm (336.3 in-lb) 38 Nm (336 in-lb)

MCD5-0331B to MCD5-0396B MCD5-0469B to MCD5-0961B MCD5-0245C

MCD5-0360C to MCD5-0927C MCD5-1200C to MCD5-1600C

Table 4.1 Measurements and Torques for Power Terminations

14 Danfoss A/S © 05/2016 All rights reserved. MG17K602

20.0

1/L1, 3/L2, 5/L3

2/T1, 4/T2, 6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1 3/L2 5/L3

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

177HA650.10

Electrical Installation Operating Guide

4.2 Power Input and Output Congurations

4.2.1 Internally Bypassed Models (MCD5-0021B to MCD5-0961B)

Models MCD5-0021B to MCD5-0215B have power inputs at the top of the unit and outputs at the bottom of the unit.

Internally bypassed models MCD5-0245B to MCD5-0396B have output busbars at the bottom of the unit and input busbars
at both the top and bottom. The AC supply can be connected top-in, bottom-out or bottom-in, bottom-out.

Internally bypassed models MCD5-0469B to MCD5-0961B have input and output busbars at the top and bottom of the unit.
The AC supply can be connected:

Top-in/bottom-out.

•

Top-in/top-out.

•

Bottom-in/bottom-out

•

Bottom-in/top-out.

•

4 4

Illustration 4.3 Internally Bypassed Models, MCD5-0021B to MCD5-0105B, MCD5-0131B to MCD5-0215B, MCD5-0245B to MCD5-0396B,

MCD5-0469B to MCD5-0961B

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 15

177HA651.10

1/L1 3/L2 5/L3

T1B T2B T3B

2/T1 4/T2 6/T3

(L1B L2B L3B)

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1 3/L2 5/L3

(L1B L2B L3B)

2/T1 4/T2 6/T3

(L1B L2B L3B)

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

1/L1 3/L2 5/L3

(L1B L2B L3B)

2/T1 4/T2 6/T3

177HA652.10

Electrical Installation

VLT® Soft Starter MCD 500

4.2.2 MCD5-0245C

MCD5-0245C has dedicated bypass terminals at the bottom
of the unit. The bypass terminals are:

T1B.

•

T2B.

•

T3B.

•

44

Illustration 4.5 Location of Bypass Terminals, MCD5-0360C to

MCD5-1600C

4.3 Motor Connection

VLT® Soft Starter MCD 500 soft starters can be connected
to the motor in-line or inside delta (also called 3-wire and

Illustration 4.4 Bypass Terminals on MCD5-0245C

4.2.3 MCD5-0360C to MCD5-1600C

MCD5-0360C to MCD5-1600C have dedicated bypass
terminals on the input busbars. The bypass terminals are:

L1B

•

L2B

•

L3B

•

The busbars on non-bypassed models MCD5-0360C to
MCD5-1600C can be adjusted for top or bottom input and
output as required. See chapter 12 Busbar Adjustment
Procedure (MCD5-0360C to MCD5-1600C) for step-by-step
instructions. The soft starters are manufactured top-in/
bottom-out.

6-wire connection). When connecting in inside delta, enter
the motor full load current (FLC) for parameter 1-1 Motor
Full Load Current. The MCD 500 automatically calculates
inside delta current based on this data. Parameter 15-7
Motor Connection is set to Auto Detect as default and can
be set to force the soft starter in inside delta or in-line.

4.3.1 Testing the Installation

The VLT® Soft Starter MCD 500 can be connected to a
small motor for testing. During this test, the control input
and relay output protection settings can be tested. This
test mode is not suitable for testing soft starting or soft
stopping performance.

The minimum FLC of the test motor is 2% of the minimum
FLC of the soft starter (see chapter 4.5 Minimum and
Maximum Current Settings).

NOTICE

For models MCD5-0360C to MCD5-1600C to be UL­compliant, mount them top-in, bottom-out, or top-out,
bottom-in. See chapter 11.1 UL-compliant Installation for
more information.

16 Danfoss A/S © 05/2016 All rights reserved. MG17K602

NOTICE

When testing the soft starter with a small motor, set
parameter 1-1 Motor FLC to the minimum allowable
value.
Models which are internally bypassed do not require an
external bypass contactor.

177HA430.12

M

3

6/T3

2/T1

5/L3

3/L2

1/L1

13

14

4/T2

E

K1

K1 F1

177HA429.12

6/T3

2/T1

5/L3

3/L2

1/L1

13

14

4/T2

E

K1

K1 F1

M
3

177HA617.11

M

3

F1

6/T3

2/T1

5/L3

3/L2

1/L1

13

14

4/T2

E

K1

K1

T1B

T2B

T3B

K2

34

33

K2

Electrical Installation Operating Guide

4.3.2 In-line Installation

4.3.2.1 Internally Bypassed

K1 Main contactor (optional)

F1 Semiconductor fuses (optional)

Illustration 4.6 In-line Installation, Internally Bypassed

4.3.2.3 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 an external contactor. Connect the bypass contactor to
the bypass terminals and control it by a programmable
output congured to Run (see parameters 4-1 to 4-9).

NOTICE

The bypass terminals on MCD5-0245C are:

T1B.

•

T2B.

•

T3B.

•

The bypass terminals on MCD5-0360C to MCD5-1600C
are:

L1B.

•

L2B.

•

L3B.

•

If necessary, the fuses can be installed on the input side.

4 4

4.3.2.2 Non-bypassed

K1 Main contactor

K2 Bypass contactor (external)

F1 Semiconductor fuses (optional)

K1 Main contactor (optional)

F1 Semiconductor fuses (optional)

Illustration 4.7 In-line Installation, Non-bypassed

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 17

Illustration 4.8 In-line Installation, Externally Bypassed,

MCD5-0245C

177HA431.12

M

3

F1

6/T3

2/T1

5/L3

3/L2

1/L1

13

14

4/T2

E

K1

K1

L1B

L2B

L3B

K2

34

33

K2

6/T

2/T

13

14

4/T

K1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

5/L3

3/L2

1/L1

E

K1 F1

M

3

177HA501.11

177HA500.12

M

3

6/T

2/T

5/L

3/L

1/L

1

1

4/T

K1

K1 F

U1(1 U2(4

V1(2

V2(5

W1( W2(

L2

L1

L3

E

Electrical Installation

VLT® Soft Starter MCD 500

4.3.3.1 Internally Bypassed

44

K1 Main contactor

K2 Bypass contactor (external)

F1 Semiconductor fuses (optional)

Illustration 4.9 In-line Installation, Externally Bypassed,

MCD5-0360C to MCD5-1600C

4.3.3 Inside Delta Installation

NOTICE

When connecting the VLT® Soft Starter MCD 500 in
inside delta conguration, always install a main
contactor or shunt trip circuit breaker.

NOTICE

When connecting in inside delta, enter the motor full
load current (FLC) for parameter 1-1 Motor FLC. The MCD
500 automatically calculates inside delta currents based
on this data. Parameter 15-7 Motor Connection is set to
Auto detect as default and can be set to force the soft
starter in inside delta or in-line.

K1 Main contactor

F1 Semiconductor fuses (optional)

Illustration 4.10 Inside Delta Installation, Internally Bypassed

4.3.3.2 Non-bypassed

K1 Main contactor

F1 Semiconductor fuses (optional)

Illustration 4.11 Inside Delta Installation, Non-bypassed

18 Danfoss A/S © 05/2016 All rights reserved. MG17K602

177HA618.11

M

3

6/T

2/T

5/L3

3/L2

1/L1

13

14

4/T

E

K1

K1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

T2B

T1B

T3B

K2

34

33

K2

F1

177HA502.12

M

3

6/T

2/T

5/L3

3/L2

1/L1

13

14

4/T

E

K1

K1 F1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

L2B

L1B

L3B

K2

34

33

K2

Electrical Installation Operating Guide

4.3.3.3 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 an external bypass contactor. Connect the bypass
contactor to the bypass terminals and control the
contactor by a programmable output congured to Run
(see parameters 4-1 to 4-9).

NOTICE

The bypass terminals on MCD5-0245C are:

T1B

•

T2B

•

T3B

•

The bypass terminals on MCD5-0360C to MCD5-1600C
are:

L1B

•

L2B

•

L3B

•

If necessary, the fuses can be installed on the input side.

4 4

K1 Main contactor

K2 Bypass contactor (external)

F1 Semiconductor fuses (optional)

Illustration 4.13 Inside Delta Installation, Externally Bypassed,

MCD5-0360C to MCD5-1600C

K1 Main contactor

K2 Bypass contactor (external)

F1 Semiconductor fuses (optional)

Illustration 4.12 Inside Delta Installation, Externally Bypassed,

MCD5-0245C

Current Ratings

4.4

Contact the local supplier for ratings under operating
conditions not covered by these ratings charts.

All ratings are calculated at an altitude of 1000 m (3281 ft)
and ambient temperature of 40 °C (104 °F).

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 19

Electrical Installation

VLT® Soft Starter MCD 500

4.4.1 In-line Connection (Bypassed)

NOTICE

Models MCD5-0021B to MCD5-0961B are internally bypassed. Models MCD5-0245C to MCD5-1600C require an external
bypass contactor.

Type code Ampere rating [A]

AC-53b

44

MCD5-0021B 21 17 15

MCD5-0037B 37 31 26

MCD5-0043B 43 37 30

MCD5-0053B 53 46 37

AC-53b

MCD5-0068B 68 55 47

MCD5-0084B 84 69 58

MCD5-0089B 89 74 61

MCD5-0105B 105 95 78

MCD5-0131B 131 106 90

MCD5-0141B 141 121 97

MCD5-0195B 195 160 134

MCD5-0215B 215 178 148

MCD5-0245B 245 194 169

MCD5-0245C 255 201 176

MCD5-0331B 331 266 229

MCD5-0360C 360 310 263

MCD5-0380C 380 359 299

MCD5-0396B 396 318 273

MCD5-0428C 430 368 309

MCD5-0469B 496 383 326

MCD5-0525B 525 425 364

MCD5-0595C 620 540 434

MCD5-0619C 650 561 455

MCD5-0632B 632 512 438

MCD5-0790C 790 714 579

MCD5-0744B 744 606 516

MCD5-0826B 826 684 571

MCD5-0927C 930 829 661

MCD5-0961B 961 796 664

MCD5-1200C 1200 1200 1071

MCD5-1410C 1410 1319 1114

MCD5-1600C 1600 1600 1353

3-30:330

3-30:570

AC-53b

4-20:340

AC-53b

4-20:580

AC-53b

4.5-30:330

AC-53b

4.5-30:570

Table 4.2 Internally Bypassed Models

20 Danfoss A/S © 05/2016 All rights reserved. MG17K602

Start Time (seconds)

Starts Per Hour

Electrical Installation Operating Guide

Illustration 4.14 AC-53 Rating for Bypassed Operation

All ratings are calculated at an altitude of 1000 m (3281 ft) and ambient temperature of 40 °C (104 °F).

4.4.2 In-line Connection (Non-bypassed/Continuous)

Type code Ampere ratings [A]

AC-53a

3-30:50-6

MCD5-0245C 245 195 171

MCD5-0360C 360 303 259

MCD5-0380C 380 348 292

MCD5-0428C 428 355 300

MCD5-0595C 595 515 419

MCD5-0619C 619 532 437

MCD5-0790C 790 694 567

MCD5-0927C 927 800 644

MCD5-1200C 1200 1135 983

MCD5-1410C 1410 1187 1023

MCD5-1600C 1600 1433 1227

Table 4.3 Non-bypassed Models

AC-53a

4-20:50-6

4 4

AC-53a

4.5-30:50-6

Illustration 4.15 AC-53 Rating for Continuous Operation

All ratings are calculated at an altitude of 1000 m (3281 ft) and ambient temperature of 40 °C (104 °F).

Contact a local supplier for ratings under operating conditions not covered by these ratings charts.

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 21

Electrical Installation

VLT® Soft Starter MCD 500

4.4.3 Inside Delta Connection (Bypassed)

NOTICE

Models MCD5-0021B to MCD5-0961B are internally bypassed. Models MCD5-0245C to MCD5-1600C require an external
bypass contactor.

Type code Ampere ratings A]

AC-53b

44

MCD5-0021B 32 26 22

MCD5-0037B 56 47 39

MCD5-0043B 65 56 45

MCD5-0053B 80 69 55

AC-53b

MCD5-0068B 102 83 71

MCD5-0084B 126 104 87

MCD5-0089B 134 112 92

MCD5-0105B 158 143 117

MCD5-0131B 197 159 136

MCD5-0141B 212 181 146

MCD5-0195B 293 241 201

MCD5-0215B 323 268 223

MCD5-0245B 368 291 254

MCD5-0245C 383 302 264

MCD5-0331B 497 400 343

MCD5-0360C 540 465 395

MCD5-0380C 570 539 449

MCD5-0396B 594 478 410

MCD5-0428C 645 552 463

MCD5-0469B 704 575 490

MCD5-0525B 787 637 546

MCD5-0595C 930 810 651

MCD5-0619C 975 842 683

MCD5-0632B 948 768 658

MCD5-0790C 1185 1072 869

MCD5-0744B 1116 910 774

MCD5-0826B 1239 1026 857

MCD5-0927C 1395 1244 992

MCD5-0961B 1441 1194 997

MCD5-1200C 1800 1800 1607

MCD5-1410C 2115 1979 1671

MCD5-1600C 2400 2400 2030

3-30:330

3-30:570

AC-53b

4.20-:340

AC-53b

4-20:580

AC-53b

4.5-30:330

AC-53b

4.5-30:570

Table 4.4 Bypassed Models

22 Danfoss A/S © 05/2016 All rights reserved. MG17K602

Start Time (seconds)

Starts Per Hour

Electrical Installation Operating Guide

Illustration 4.16 AC-53 Rating for Bypassed Operation

All ratings are calculated at an altitude of 1000 m (3281 ft) and ambient temperature of 40 °C (104 °F).

4.4.4 Inside Delta Connection (Non-bypassed/Continuous)

Type code Ampere ratings [A]

AC-53a

3-30:50-6

MCD5-0245C 368 293 257

MCD5-0360C 540 455 389

MCD5-0380C 570 522 438

MCD5-0428C 643 533 451

MCD5-0595C 893 773 629

MCD5-0619C 929 798 656

MCD5-0790C 1185 1042 851

MCD5-0927C 1391 1200 966

MCD5-1200C 1800 1702 1474

MCD5-1410C 2115 1780 1535

MCD5-1600C 2400 2149 1841

Table 4.5 Non-bypassed Models

AC-53a

4-20:50-6

4 4

AC-53a

4.5-30:50-6

Illustration 4.17 AC-53 Rating for Continuous Operation

All ratings are calculated at an altitude of 1000 m (3281 ft) and ambient temperature of 40 °C (104 °F).

Contact a local supplier for ratings under operating conditions not covered by these ratings charts.

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 23

Electrical Installation

VLT® Soft Starter MCD 500

4.5 Minimum and Maximum Current Settings

The minimum and maximum full load current settings depend on the model:

In-line connection Inside delta connection

Model Minimum [A] Maximum [A] Minimum [A] Maximum [A]

MCD5-0021B 5 23 7 34

MCD5-0037B 9 43 13 64

44

MCD5-0043B 10 50 15 75

MCD5-0053B 11 53 16 79

MCD5-0068B 15 76 23 114

MCD5-0084B 19 97 29 145

MCD5-0089B 20 100 30 150

MCD5-0105B 21 105 32 157

MCD5-0131B 29 145 44 217

MCD5-0141B 34 170 51 255

MCD5-0195B 40 200 60 300

MCD5-0215B 44 220 66 330

MCD5-0331B 70 350 70 525

MCD5-0396B 85 425 85 638

MCD5-0469B 100 500 100 750

MCD5-0525B 116 580 116 870

MCD5-0632B 140 700 140 1050

MCD5-0744B 164 820 164 1230

MCD5-0825B 184 920 184 1380

MCD5-0961B 200 1000 200 1500

MCD5-0245C 51 255 77 382

MCD5-0360C 72 360 108 540

MCD5-0380C 76 380 114 570

MCD5-0428C 86 430 129 645

MCD5-0595C 124 620 186 930

MCD5-0619C 130 650 195 975

MCD5-0790C 158 790 237 1185

MCD5-0927C 186 930 279 1395

MCD5-1200C 240 1200 360 1800

MCD5-1410C 282 1410 423 2115

MCD5-1600C 320 1600 480 2400

Table 4.6 Minimum and Maximum Full Load Current

Bypass Contactor

4.6

Some VLT® Soft Starter MCD 500 soft starters are internally
bypassed and do not require an external bypass contactor.

4.7 Main Contactor

Install a main contactor if the VLT® Soft Starter MCD 500 is
connected to the motor in inside delta format and is
optional for in-line connection. Select a contactor with an

Non-bypassed soft starters may be installed with an
external bypass contactor. Select a contactor with an AC1
rating greater than or equal to the full load current rating
of the connected motor.

AC3 rating greater than or equal to the full load current
rating of the connected motor.

4.8 Circuit Breaker

A shunt trip circuit breaker may be used instead of a main
contactor to isolate the motor circuit in the event of a soft
starter trip. The shunt trip mechanism must be powered
from the supply side of the circuit breaker or from a
separate control supply.

24 Danfoss A/S © 05/2016 All rights reserved. MG17K602

Electrical Installation Operating Guide

4.9 Power Factor Correction

CAUTION

EQUIPMENT DAMAGE

Connect power factor correction capacitors to the input
side of the soft starter. Connecting power factor
correction capacitors to the output side damages the
soft starter.

If power factor correction is used, use a dedicated
contactor to switch in the capacitors.

Standard HRC mains fuses: Minimum 150% motor

•

full load current.

Motor rated mains fuses: Minimum rating

•

100/150% motor full load current.

Motor control circuit breaker minimum long time

•

setting: 150% motor full load current

Motor control circuit breaker minimum short time

•

setting: 400% motor full load current for 30 s.

Fuse recommendations are calculated for 40 °C (104 °F), up
to 1000 m (3281 ft).

4 4

4.10 Fuses

4.10.1 Power Supply Fuses

Semiconductor fuses can be used for Type 2 coordination
(according to the IEC 60947-4-2 standard). They reduce the
risk of damage to SCRs from transient overload currents.

HRC fuses (such as Ferraz AJT fuses) can be used for Type
1 coordination according to the IEC 60947-4-2 standard.

NOTICE

Adaptive control regulates the speed prole of the motor
within the programmed time limit. This control may
result in a higher level of current than traditional control
methods.

For applications using adaptive control to soft stop the
motor with stop times greater than 30 s, select motor
branch protection as follows:

NOTICE

Fuse selection is based on a 400% FLC start for 20 s
with:

Standard published starts per hour.

•

Duty cycle.

•

40 °C (104 °F) ambient temperature.

•

Up to 1000 m (3281 ft) altitude.

•

For installations operating outside these conditions,
consult a local Danfoss supplier.
Table 4.7 to Table 4.12 contain recommendations only. To
conrm the selection for a particular application, always
consult a local supplier.

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 25

Electrical Installation

4.10.2 Bussmann Fuses

VLT® Soft Starter MCD 500

Model

MCD5-0021B 1150 170M1314 170M1314 170M1314

MCD5-0037B 8000 170M1316 170M1316 170M1316

MCD5-0043B 10500 170M1318 170M1318 170M1318

MCD5-0053B 15000 170M1318 170M1318 170M1318

44

MCD5-0068B 15000 170M1319 170M1319 170M1318

MCD5-0084B 512000 170M1321 170M1321 170M1319

MCD5-0089B 80000 170M1321 170M1321 170M1321

MCD5-0105B 125000 170M1321 170M1321 170M1321

MCD5-0131B 125000 170M1321 170M1321 170M1321

MCD5-0141B 320000 170M2621 170M2621 170M2621

MCD5-0195B 320000 170M2621 170M2621 170M2621

MCD5-0215B 320000 170M2621 170M2621 170M2621

MCD5-0245B 320000 170M2621 170M2621 170M2621

MCD5-0331B 202000 170M5011 170M5011 –

MCD5-0396B 320000 170M6011 – –

MCD5-0469B 320000

MCD5-0525B 781000 170M6013 170M6013 170M6013

MCD5-0632B 781000 170M5015 170M5015 –

MCD5-0744B 1200000 170M5017 170M6017 –

MCD5-0826B 2530000 170M6017 170M6017 –

MCD5-0961B 2530000 170M6018

MCD5-0245C 320000 170M2621 170M2621 170M2621

MCD5-0360C 320000 170M6010 170M6010 170M6010

MCD5-0380C 320000 170M6011 170M6011 –

MCD5-0428C 320000 170M6011 170M6011 –

MCD5-0595C 1200000 170M6015 170M6015 170M6014

MCD5-0619C 1200000 170M6015 170M6015 170M6014

MCD5-0790C 2530000 170M6017 170M6017 170M6016

MCD5-0927C 4500000 170M6019 170M6019 170M6019

MCD5-1200C 4500000 170M6021 – –

MCD5-1410C 6480000 – – –

MCD5-1600C 12500000

SCR I2t (A2s)

Supply voltage

(≤440 V AC)

170M6008

170M6019

1)

1)

Supply voltage

(≤575 V AC)

– –

170M6013

1)

– –

Supply voltage

(≤690 V AC)

–

Table 4.7 Square Body (170M)

1) Two fuses connected in parallel are required per phase.

26 Danfoss A/S © 05/2016 All rights reserved. MG17K602

Electrical Installation Operating Guide

Model

SCR I2t (A2s)

Supply voltage

(<440 V AC)

Supply voltage

(<575 V AC)

Supply voltage

(<690 V AC)

MCD5-0021B 1150 63FE 63FE 63FE

MCD5-0037B 8000 120FEE 120FEE 120FEE

MCD5-0043B 10500 120FEE 120FEE 120FEE

MCD5-0053B 15000 200FEE 200FEE 200FEE

MCD5-0068B 15000 200FEE 200FEE 200FEE

MCD5-0084B 512000 200FEE 200FEE 200FEE

MCD5-0089B 80000 280FM 280FM 280FM

MCD5-0105B 125000 280FM 280FM 280FM

MCD5-0131B 125000 280FM 280FM 280FM

MCD5-0141B 320000 450FMM 450FMM 450FMM

MCD5-0195B 320000 450FMM 450FMM 450FMM

MCD5-0215B 320000 450FMM 450FMM 450FMM

MCD5-0245B 320000 450FMM 450FMM 450FMM

MCD5-0331B 202000

MCD5-0396B 320000

MCD5-0469B 320000

MCD5-0525B 781000

MCD5-0632B 781000

315FM

400FMM

450FMM

500FMM

630FMM

1)

1)

1)

1)

1)

– –

– –

– –

1)

500FMM

– –

500FMM

MCD5-0744B 1200000 – – –

MCD5-0826B 2530000 – – –

MCD5-0961B 2530000 – – –

MCD5-0245C 320000 450FMM 450FMM 450FMM

MCD5-0360C 320000 – – –

MCD5-0380C 320000

400FMM

1)

400FMM

400FMM

MCD5-0428C 320000 – – –

MCD5-0595C 1200000

MCD5-0619C 1200000

630FMM

630FMM

1)

1)

630FMM

630FMM

1)

1)

–

–

MCD5-0790C 2530000 – – –

MCD5-0927C 4500000 – – –

MCD5-1200C 4500000 – – –

MCD5-1410C 6480000 – – –

MCD5-1600C 12500000 – – –

4 4

1)

1)

Table 4.8 British Style (BS88)

1) Two fuses connected in parallel are required per phase.

MG17K602 Danfoss A/S © 05/2016 All rights reserved. 27