Danfoss Electronics MCD 500 Operating Instructions

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Soft Starter MCD 500

vlt-drives.danfoss.com

Contents Operating Instructions

Contents

1 Safety

1.1 Warnings

2 Introduction

3 Installation

3.1 Mechanical Installation

3.2 Dimensions and Weights

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 15

4.2 Power Input and Output Congurations

4.2.1 Internally Bypassed Models (MCD5-0021B to MCD5-0961B) 16

4.2.2 MCD5-0245C 17

4.2.3 MCD5-0360C to MCD5-1600C 17

4.3 Motor Connection

4.3.1 Testing the Installation 17

4.3.2 In-line Installation 18

4.3.2.1 Internally Bypassed 18

4.3.2.2 Non-bypassed 18

4.3.2.3 Externally Bypassed 18

4.3.3 Inside Delta Installation 19

4.3.3.1 Internally Bypassed 19

4.3.3.2 Non-bypassed 19

4.3.3.3 Externally Bypassed 20

4.4 Current Ratings

4.4.1 In-line Connection (Bypassed) 21

4.4.2 In-line Connection (Non-bypassed/Continuous) 22

4.4.3 Inside Delta Connection (Bypassed) 23

4.4.4 Inside Delta Connection (Non-bypassed/Continuous) 24

4.5 Minimum and Maximum Current Settings

4.6 Bypass Contactor

4.7 Main Contactor

4.8 Circuit Breaker

Contents

VLT® Soft Starter MCD 500

4.9 Power Factor Correction

4.10 Fuses

4.10.1 Power Supply Fuses 26

4.10.2 Bussmann Fuses 27

4.10.3 Ferraz Fuses 29

4.10.4 UL Fuse Selection and Short Circuit Ratings 31

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 36

5.3.4 Kick Start 37

5.4 Stopping Modes

5.4.1 Coast to Stop 37

5.4.2 TVR Soft Stop 37

5.4.3 Adaptive Control 38

5.4.4 Pump Stopping 38

5.4.5 Brake 38

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

6.2.1 Operating Modes 51

6.3 Remote Mounted LCP

6.3.1 Synchronising the LCP and the Soft Starter 52

6.4 Welcome Screen

6.5 Local Control Keys

Contents Operating Instructions

6.6 Displays

6.6.1 Temperature Monitoring Screen (S1) 53

6.6.2 Programmable Screen (S2) 53

6.6.3 Average Current (S3) 53

6.6.4 Current Monitoring Screen (S4) 53

6.6.5 Frequency Monitoring Screen (S5) 53

6.6.6 Motor Power Screen (S6) 53

6.6.7 Last Start Information (S7) 53

6.6.8 Date and Time (S8) 53

6.6.9 SCR Conduction Bargraph 54

6.6.10 Performance Graphs 54

7 Programming

7.1 Access Control

7.2 Quick Menu

7.2.1 Quick Set-up 55

7.2.2 Application Set-up Examples 56

7.2.3 Loggings 57

7.3 Main Menu

7.3.1 Parameters 57

7.3.2 Parameter Shortcut 57

7.3.3 Parameter List 58

8 Parameter Descriptions

8.1 Primary Motor Settings

8.1.1 Brake 60

8.2 Protection

8.2.1 Current Imbalance 60

8.2.2 Undercurrent 61

8.2.3 Instantaneous Overcurrent 61

8.2.4 Frequency Trip 61

8.3 Inputs

8.4 Outputs

8.4.1 Relay A Delays 63

8.4.2 Relays B and C 63

8.4.3 Low Current Flag and High Current Flag 64

8.4.4 Motor Temperature Flag 64

8.4.5 Analog Output A 64

8.5 Start/Stop Timers

8.6 Auto-Reset

8.6.1 Auto-Reset Delay 65

Contents

VLT® Soft Starter MCD 500

8.7 Secondary Motor Set

8.8 Display

8.8.1 User Programmable Screen 67

8.8.2 Performance Graphs 68

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 72

9.8.2 Event Log 72

9.8.3 Counters 72

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 82

11.1.2 Models MCD5-0131B to MCD5-0215B 82

11.1.3 Models MCD5-0245B to MCD5-0396B 82

11.1.4 Models MCD5-0245C 82

11.1.5 Models MCD5-0360C to MCD5-1600C 82

11.1.6 Models MCD5-0469B to MCD5-0961B 82

11.1.7 Pressure Terminal/Connector Kits 82

11.2 Accessories

11.2.1 LCP Remote Mounting Kit 82

11.2.2 Communication Modules 82

11.2.3 PC Software 83

11.2.4 Finger Guard Kit 83

11.2.5 Surge Protection Kit (Lightning Protection) 83

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

Contents Operating Instructions

13 Appendix

13.1 Symbols, Abbreviations, and Conventions

Index

Safety

VLT® Soft Starter MCD 500

1 Safety

1.1 Warnings

When reading this manual, pay special attention to the following symbols:

NOTICE

Useful hints for the reader.

CAUTION

Indicates a general warning.

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. Responsibility or liability is under no circumstances accepted for direct, indirect, or consequential damages 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

WARNING - ELECTRICAL SHOCK HAZARD

VLT® Soft Starters MCD 500 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 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 bus bar and heat sink as live whenever the unit has mains voltage connected (including when the soft starter is tripped or waiting for a command).

WARNING

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 MCD 500 soft starters. If static power factor correction is employed, it must be connected to the supply side of the soft starter. MCD5-0021B ~ MCD5-961B: After transportation, mechanical shock, or rough handling there is a risk that the bypass contactor has latched 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 initialised.

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.

The start and stop functions of the soft starter

•

must not be relied upon for personnel safety. Faults occurring in the mains supply, the motor connection, or the electronics of the soft starter, can cause unintended motor starts or stops.

To provide machine or personnel safety, control the isolation device through an external safety system.

In Auto On mode, the motor can be controlled remotely (via remote inputs) while the soft starter is connected to mains.

CAUTION

These stop functions are not sucient to avoid unintended start. If faults occur in the electronics of the soft starter, a motor that has been stopped may start. A temporary fault in the supply mains or a cease in the motor connection can also cause a stopped motor to start.

Safety Operating Instructions

CAUTION

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

Introduction

2 Introduction

VLT® Soft Starter MCD 500

The VLT® Soft Starter MCD 500 is an advanced digital soft start solution for motors 11–850 kW. 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.

- Instantaneous 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.

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 Instructions

2.1.2 Type Code

2 2

Illustration 2.1 Type Code Ordering Form

Installation

VLT® Soft Starter MCD 500

3 Installation

3.1 Mechanical Installation

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

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

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

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

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

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

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

MCD5-0360C to MCD5-1600C: Allow 200 mm (7.88 inches) 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

177HA514.10

Installation Operating Instructions

3.2 Dimensions and Weights

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

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

295

(11.6)

438

(17.2)

440

(17.3)

640

(25.2)

460

(18.1)

689

(27.1)

278

(10.9)

380

(15.0)

392

(15.4)

600

(23.6)

400

(15.0)

522

(20.5)

150

(5.9)

275

(10.8)

424

(16.7)

433

(17.0)

390

(15.4)

430

(16.9)

124

(4.9)

248

(9.8)

376

(14.8)

320

(12.6)

320

(12.6)

320

(12.6)

183

(7.2)

213

(8.14)

250

(9.8)

296

(11.7)

295

(11.6)

279

(11.0)

300

(11.8)

4.2

(9.3)

4.5

(9.9)

4.9

(10.8)

14.9

(32.8)

26 (57.2)

30.2

(66.6)

49.5

(109.1)

60.0

(132.3)

23.9

(52.7)

(77.2)

(99.2)

Installation

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

MCD5-1200C

MCD5-1410C

MCD5-1600C

856

(33.7)

VLT® Soft Starter MCD 500

727

(28.6)

585

(23.0)

500

(19.7)

364

(14.3)

120

(264.6)

Illustration 3.2 Dimensions and Weights

177HA504.10

Start/stop

Reset

Start

Stop

Reset

Start

Stop

Reset

Electrical Installation Operating Instructions

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 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 local 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 plug-in terminal blocks. Dierent models require control voltage to dierent terminals:

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).

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

•

CV2 (110–120 V AC): A5, A6.

•

CV2 (220–240 V AC): A4, A6.

•

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

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

NOTICE

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

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).

CAUTION

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.

Electrical Installation

VLT® Soft Starter MCD 500

4.1.4 Serial Communication

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

4.1.5 Ground Terminal

Ground terminals are located at the back of the soft starter.

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

•

the input side (top).

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

•

MCD5-1600C have 2 terminals, 1 on the input side (top), and 1 on the output side (bottom).

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 Operating Instructions

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.

NOTICE

Some units use aluminium 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 corrosion.

Use only copper stranded or solid conductors, rated for 75 °C or higher.

4 4

Cable size: 6–50 mm2 (AWG 10-1/0)

14 mm (0.55 inch)

Torx T20 x 150

Torque: 4 Nm (2.9 ft-lb)

Flat 7 mm x 150

MCD5-0021B to MCD5-0105B

38 Nm (28 ft-lb)

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

38 Nm (28 ft-lb) 38 Nm (28 ft-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

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

2/T1 4/T2 6/T3

177HA650.10

Electrical Installation

VLT® Soft Starter MCD 500

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.

•

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

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 Operating Instructions

4.2.2 MCD5-0245C

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

T1B

•

T2B

•

T3B

•

Illustration 4.4 Bypass Terminals on MCD5-0245C

4.2.3 MCD5-0360C to MCD5-1600C

4 4

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

MCD5-1600C

4.3 Motor Connection

MCD 500 soft starters can be connected to the motor inline or inside delta (also called 3-wire and 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.

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

•

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.

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.

L1B

L2B

L3B

4.3.1 Testing the Installation

The 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

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

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

K1 F1

177HA429.12

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

K1 F1

177HA617.11

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

T1B

T2B

T3B

Electrical Installation

VLT® Soft Starter MCD 500

4.3.2 In-line Installation

4.3.2.1 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

K1 Main contactor (optional)

F1 Semiconductor fuses (optional)

•

L3B

•

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

Illustration 4.6 In-line Installation, Internally Bypassed

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

Illustration 4.8 In-line Installation, Externally Bypassed,

MCD5-0245C

177HA431.12

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

L1B

L2B

L3B

6/T

2/T

4/T

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

5/L3

3/L2

1/L1

K1 F1

177HA501.11

177HA500.12

6/T

2/T

5/L

3/L

1/L

4/T

K1 F

U1(1 U2(4

V1(2

V2(5

W1( W2(

Electrical Installation Operating Instructions

4.3.3.1 Internally Bypassed

4 4

K1 Main contactor

K2 Bypass contactor (external)

F1 Semiconductor fuses (optional)

Illustration 4.9 In-line Installation, Externally Bypassed,

MCD5-0360Cto MCD5-1600C

4.3.3 Inside Delta Installation

CAUTION

When connecting the MCD 500 in inside delta congu- ration, 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

177HA618.11

6/T

2/T

5/L3

3/L2

1/L1

4/T

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

T2B

T1B

T3B

177HA502.12

6/T

2/T

5/L3

3/L2

1/L1

4/T

K1 F1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

L2B

L1B

L3B

Electrical Installation

VLT® Soft Starter MCD 500

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.

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 and ambient temperature of 40 °C.

Electrical Installation Operating Instructions

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

AC-53b

3-30:330

[A]

MCD5-0021B 21 17 15

MCD5-0037B 37 31 26

MCD5-0043B 43 37 30

MCD5-0053B 53 46 37

AC-53b

3-30:570

[A]

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

AC-53b

4-20:340

[A]

AC-53b

4-20:580

[A]

AC-53b

4.5-30:330

[A]

AC-53b

4.5-30:570

[A]

4 4

Table 4.2 Internally Bypassed Models

Start Time (seconds)

Starts Per Hour

Electrical Installation

VLT® Soft Starter MCD 500

Illustration 4.14 AC-53 Rating for Bypassed Operation

All ratings are calculated at an altitude of 1000 m and ambient temperature of 40 °C.

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

Type code Ampere ratings

AC-53a

3-30:50-6

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

Table 4.3 Non-bypassed Models

AC-53a

4-20:50-6

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 and ambient temperature of 40 °C.

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

Electrical Installation Operating Instructions

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

AC-53b

3-30:330

[A]

MCD5-0021B 32 26 22

MCD5-0037B 56 47 39

MCD5-0043B 65 56 45

MCD5-0053B 80 69 55

AC-53b

3-30:570

[A]

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

AC-53b

4.20-:340

[A]

AC-53b

4-20:580

[A]

AC-53b

4.5-30:330

[A]

AC-53b

4.5-30:570

[A]

4 4

Table 4.4 Bypassed Models

Start Time (seconds)

Starts Per Hour

Electrical Installation

VLT® Soft Starter MCD 500

Illustration 4.16 AC-53 Rating for Bypassed Operation

All ratings are calculated at an altitude of 1000 m and ambient temperature of 40 °C.

4.4.4 Inside Delta Connection (Non-bypassed/Continuous)

Type code Ampere ratings

AC-53a

3-30:50-6

MCD5-0245C 368 A 293 A 257 A

MCD5-0360C 540 A 455 A 389 A

MCD5-0380C 570 A 522 A 438 A

MCD5-0428C 643 A 533 A 451 A

MCD5-0595C 893 A 773 A 629 A

MCD5-0619C 929 A 798 A 656 A

MCD5-0790C 1185 A 1042 A 851 A

MCD5-0927C 1391 A 1200 A 966 A

MCD5-1200C 1800 A 1702 A 1474 A

MCD5-1410C 2115 A 1780 A 1535 A

MCD5-1600C 2400 A 2149 A 1841 A

Table 4.5 Non-bypassed Models

AC-53a

4-20:50-6

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 and ambient temperature of 40 °C.

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

Electrical Installation Operating Instructions

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

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

4 4

Table 4.6 Minimum and Maximum Full Load Current

Electrical Installation

VLT® Soft Starter MCD 500

4.6 Bypass Contactor

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

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

CAUTION

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.

4.7 Main Contactor

A main contactor must be installed if the MCD 500 is connected to the motor in inside delta format and is optional for in-line connection. Select a contactor with an 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.

Power Factor Correction

4.9

Adaptive control controls 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:

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, up to 1000 m.

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.

Fuses

4.10

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.

NOTICE

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

Standard published starts per hour.

•

Duty cycle.

•

40 °C ambient temperature.

•

Up to 1000 m altitude.

•

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

Electrical Installation Operating Instructions

4.10.2 Bussmann Fuses

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

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

Supply voltage

(≤575 V AC)

– –

170M6013

– –

Supply voltage

(≤690 V AC)

–

4 4

Table 4.7 Square Body (170M)

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

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