VLT MCD 500 Operating Instructions Manual

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Page 1

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT® Soft Starter - MCD 500

Page 2

Contents MCD 500 Operating Instruction

Contents

1 Safety

1.1 Safety

2 Introduction

2.1.1 Feature List 7

2.1.2 Type Code 8

3 Installation

3.1 Mechanical Installation

3.2 Dimensions and Weights

4 Electrical Installation

4.1.1 Control Wiring 11

4.1.2 Control Terminals 11

4.1.3 Remote Inputs 11

4.1.4 Serial Communication 12

4.1.5 Earth Terminal 12

4.1.6 Power Terminations 12

5 5

9 9

4.2 Motor Connection

4.2.1 Testing the Installation 13

4.2.2 In-line Installation 14

4.2.2.1 In-line Installation, Internally Bypassed 14

4.2.2.2 In-line Installation, Non-bypassed 14

4.2.2.3 In-line Installation, Externally Bypassed 14

4.2.3 Inside Delta Installation 15

4.2.3.1 Inside Delta Installation, Internally Bypassed 15

4.2.3.2 Inside Delta Installation, Non-bypassed 15

4.2.3.3 Inside Delta Installation, Externally Bypassed 15

4.3 Current Ratings

4.3.1 In-line Connection (Bypassed) 17

4.3.2 AC-53 Rating for Bypassed Operation 17

4.3.3 In-line Connection (Non-bypassed/Continuous) 18

4.3.4 AC-53 Rating for Continuous Operation 18

4.3.5 Inside Delta Connection (Bypassed) 19

4.3.6 AC-53 Rating for Bypassed Operation 19

4.3.7 Inside Delta Connection (Non-bypassed/Continuous) 20

4.3.8 AC-53 Rating for Continuous Operation 20

4.4 Minimum and Maximum Current Settings

4.5 Bypass Contactor

4.6 Main Contactor

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21 21 21

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Contents MCD 500 Operating Instruction

4.7 Circuit Breaker

4.8 Power Factor Correction

4.9 Fuses

4.9.2 Bussman Fuses - Square Body (170M) 23

4.9.3 Bussman Fuses - British Style (BS88) 24

4.9.4 Ferraz Fuses - HSJ 25

4.9.5 Ferraz Fuses - North American Style (PSC 690) 26

4.9.6 UL Tested Fuses - Short Circuit Ratings 27

4.10 Schematic Diagrams

4.10.1 Internally Bypassed Models 28

4.10.2 Non-bypassed Models 29

5 Application Examples

5.1 Motor Overload Protection

5.2 AAC Adaptive Acceleration Control

5.3 Starting Modes

5.3.1 Constant Current 31

5.3.2 Current Ramp 31

21 22 22

30 30 30 31

5.3.3 AAC Adaptive Acceleration Control 31

5.3.4 Kickstart 32

5.4 Stopping Modes

5.4.1 Coast to Stop 32

5.4.2 TVR Soft Stop 32

5.4.3 AAC Adaptive Acceleration Control 33

5.4.4 Brake 33

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

34 35 35 38 39 40 41 42 42 44

6 Operation

6.1 Operation and LCP

6.1.1 Operating Modes 46

6.2 Remote Mounted LCP

6.2.1 Synchronising the LCP and the Starter 47

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46 46

Page 4

Contents MCD 500 Operating Instruction

6.3 Welcome Screen

6.4 Control Methods

6.5 Local Control Buttons

6.6 Displays

6.6.1 Temperature Monitoring Screen (S1) 48

6.6.2 Programmable Screen (S2) 48

6.6.3 Average Current (S3) 48

6.6.4 Current Monitoring Screen (S4) 49

6.6.5 Frequency Monitoring Screen (S5) 49

6.6.6 Motor Power Screen (S6) 49

6.6.7 Last Start Information (S7) 49

6.6.8 Date and Time (S8) 49

6.6.9 SCR Conduction Bargraph 49

6.6.10 Performance Graphs 49

7 Programming

7.1 Access Control

7.2 Quick Menu

47 47 48 48

50 50 51

7.2.1 Quick Setup 51

7.2.2 Application Setups 52

7.2.3 Loggings 53

7.3 Main Menu

7.3.1 Parameters 53

7.3.2 Parameter Shortcut 53

7.3.3 Parameter List 54

7.4 Primary Motor Settings

7.4.1 Brake 56

7.5 Protection

7.5.1 Current Imbalance 56

7.5.2 Undercurrent 57

7.5.3 Instantaneous Overcurrent 57

7.5.4 Frequency Trip 57

7.6 Inputs

7.7 Outputs

7.7.1 Relay A Delays 59

58 59

7.7.2 Relays B and C 59

7.7.3 Low Current Flag and High Current Flag 60

7.7.4 Motor Temperature Flag 60

7.7.5 Analog Output A 60

7.8 Start/Stop Timers

7.9 Auto-Reset

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60 61

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Contents MCD 500 Operating Instruction

7.9.1 Auto-Reset Delay 61

7.10 Secondary Motor Set

7.11 Display

7.11.1 User Programmable Screen 63

7.11.2 Performance Graphs 64

7.12 Restricted Parameters

7.13 Protection Action

7.14 Factory Parameters

8 Tools

8.1 Set Date and Time

8.2 Load/Save Settings

8.3 Reset Thermal Model

8.4 Protection Simulation

8.5 Output Signal Simulation

8.6 Digital I/O State

8.7 Temp Sensors State

8.8 Alarm Log

8.8.1 Trip Log 69

61 63

65 66 66

67 67 67 67 68 68 68 68 69

8.8.2 Event Log 69

8.8.3 Counters 69

9 Troubleshooting

9.1 Trip Messages

9.2 General Faults

10 Specifications

10.1 Accessories

10.1.1 LCP Remote Mounting Kit 76

10.1.2 Communication Modules 76

10.1.3 PC Software 77

10.1.4 Finger Guard Kit 77

10.1.5 Surge Protection Kit (Lightning Protection) 77

11 Bus Bar Adjustment Procedure (MCD5-0360C - MCD5-1600C)

70 70 73

75 76

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Page 6

Safety MCD 500 Operating Instruction

1 Safety

1.1 Safety

When reading this manual you will come across different symbols that require special attention. The symbols used are the following:

NOTE

Indicates something to be noted by 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. In no event will responsibility or liability be accepted for direct, indirect or consequential damages resulting from the use or application of this equipment.

NOTE

Before changing any parameter settings, ensure that the current parameter set is saved to an internal file. Refer to MCD 500 Operating Instructions, MG.17.KX.YY, for more information.

WARNING

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. Models MCD5-0360C - MCD5-1600C: The bus bar and heatsink are live while the unit is operating (starting, running or stopping). If the starter is installed without a main contactor, the bus bar and heatsink are live whenever mains voltage is connected (including when the starter is ready or tripped).

WARNING

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. MCD5-0021B - MCD5-0105B: After transportation, mechanical shock or rough handling there is possibility that the bypass contactor may have latched into the on state. To prevent the possibility of the motor starting immediately, on first commissioning or operation after transportation, always ensure that the control supply is applied before the power, so 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. A motor may start or stop unexpectedly if faults occur in the mains supply, the motor connection, or the electronics of the soft starter.

To provide machine or personnel safety, the isolation device must be controlled through an external safety system.

In Auto On mode, the motor can be stopped using digital or bus commands while the soft starter is connected to mains.

CAUTION

These stop functions are not sufficient to avoid unintended start. 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.

1 1

CAUTION

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

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Page 7

Safety MCD 500 Operating Instruction

Table 1.1

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 currently valid legislation.

6 MG17K402 - VLT® is a registered Danfoss trademark

Page 8

Introduction MCD 500 Operating Instruction

2 Introduction

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-time graphs

•

SCR conduction bar graph

•

Tools

Application setups

•

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 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

•

DC brake

•

Soft brake

•

Emergency stop

•

Other features

Auto start/stop timer

•

Second order thermal model

•

Battery backup of clock and thermal model

•

Optional DeviceNet, Modbus 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 relay overload

- Heatsink temperature

Communication

•

- Network comms

- Starter comms

External

•

- Input trip

Starter

•

- Individual shorted SCR

- Battery/Clock

2 2

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Page 9

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

Introduction MCD 500 Operating Instruction

2.1.2 Type Code

Illustration 2.1

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Installation MCD 500 Operating Instruction

3 Installation

3.1 Mechanical Installation

Illustration 3.1

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

3 The soft starter may be mounted on its side. Derate the soft starter's rated current by 15%. 4 Soft starters may be mounted side by side with clearance of 50 mm (1.97 inches) on both sides.

Table 3.1

MCD5-0021B - MCD5-0245C: Allow 100 mm (3.94 inches) between soft starters. MCD5-0360C - MCD5-1600C: Allow 200 mm (7.88 inches) between soft starters.

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.

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177HA514.10

Installation MCD 500 Operating Instruction

3.2 Dimensions and Weights

Illustration 3.2

Model A mm

MCD5-0021B MCD5-0037B MCD5-0043B MCD5-0053B MCD5-0068B

MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B MCD5-0195B MCD5-0215B MCD5-0245C 460

MCD5-0360C MCD5-0380C MCD5-0428C MCD5-0595C MCD5-0619C MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C

(11.6)

(inches)

295

438

(17.2)

(18.1)

689

(27.1)

856

(33.7)

B mm

(inches)

278 (10.9)

380

(15.0)

400

(15.0)

522 (20.5)

727

(28.6)

C mm

(inches)

150 (5.9)

275

(10.8)

390

(15.4)

430

(16.9)

585

(23.0)

D mm

(inches)

124 (4.9)

248

(9.8)

320

(12.6)

320

(12.6)

500

(19.7)

E mm

(inches)

183 (7.2)

213

(8.14)

250

(9.8)

279

(11.0)

300.2 (11.8)

364

(14.3)

Weight kg

(lbs)

4.2

(9.3)

4.5

(9.9)

4.9

(10.8)

14.9

(32.8)

23.9

(52.7)

(77.2)

(99.2)

120

(264.6)

Table 3.2

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Page 12

177HA504.10

Start/stop

Reset

Start

Stop

Reset

Start

Stop

Reset

Electrical Installation MCD 500 Operating Instruction

4 Electrical Installation

To maintain SELV, all connections made to the control

4.1 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.

terminals must be PELV (eg. thermistor must be reinforced/ double insulated from motor).

NOTE

SELV offers protection by way of extra low voltage. Protection against electric shock is ensured when the electrical supply is of the SELV type and the installation is made as described in local/national regulations on SELV supplies.

NOTE

Galvanic (ensured) isolation is obtained by fulfilling requirements for higher isolation and by providing the relevant creepages/clearance distances. These requirements are described in the IEC61140 standard. The components that make up the electrical isolation also comply with the requirements for higher isolation and the relevant test as described in IEC61140.

4 4

Control Terminals

4.1.2

Control terminations use 2.5 mm2 plug-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

Illustration 4.1

NOTE

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

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).

Illustration 4.2

1 Two-wire control 2 Three-wire control 3 Four-wire control

Table 4.1

The reset input can be normally open or normally closed. Use 3-8 Remote Reset Logic to select the configuration.

All control terminals and relay terminals comply with SELV (Protective Extra Low Voltage). This protection does not apply to grounded Delta leg above 400 V.

MG17K402 - VLT® is a registered Danfoss trademark 11

CAUTION

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

Page 13

Electrical Installation MCD 500 Operating Instruction

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 3-2 Comms in Remote).

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.

NOTE

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.

Table 4.2

Table 4.3

MCD5-0021B - MCD5-0105B MCD5-0131B MCD5-0141B - MCD5-0215B

MCD5-0245C

MCD5-0360C - MCD50927C MCD5-1200C - MCD5-1600C

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Page 14

177HA542.11

Electrical Installation MCD 500 Operating Instruction

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.

Illustration 4.3

4 4

I/O Input/Output I Input O Output

Table 4.4

4.2

Motor Connection

MCD 500 soft starters can be connected to the motor inline 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 (1-1 Motor FLC).

NOTE

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.

4.2.1 Testing the Installation

The minimum motor FLC for test purposes is 2% of the soft starter's minimum FLC (see 4.4 Minimum and Maximum Current Settings).

NOTE

When testing the soft starter with a small motor, set 1-1 Motor FLC to the minimum allowable value.

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

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Page 15

177HA430.11

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

KM1

KM1 F1

177HA429.11

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

KM1

177HA617.10

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

KM1

T1B

T2B

T3B

KM2

Electrical Installation MCD 500 Operating Instruction

4.2.2 In-line Installation

programmable output configured to Run (see parameters

4.1 thorugh 4.9).

4.2.2.1 In-line Installation, Internally Bypassed

NOTE

The bypass terminals on MCD5-0245C are T1B, T2B, T3B. The bypass terminals on MCD5-0360C ~ MCD5-1600C are L1B, L2B, L3B.

NOTE

The fuses can be installed on the input side if required.

Illustration 4.4

KM1 Main contactor (optional) F1 Fuses (optional)

Table 4.5

4.2.2.2

In-line Installation, Non-bypassed

KM1 Main contactor KM2 Bypass contactor (external) F1 Semiconductor fuses (optional)

Table 4.7

Illustration 4.5

KM1 Main contactor (optional) F1 Fuses (optional)

Illustration 4.6 MCD5-0245C

Table 4.6

4.2.2.3

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

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177HA431.11

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

KM1

L1B

L2B

L3B

KM2

177HA500.11

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

KM1

KM1 F1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

L2B

L1B

L3B

Electrical Installation MCD 500 Operating Instruction

4.2.3.1 Inside Delta Installation, Internally Bypassed

4 4

Illustration 4.7 MCD5-0360C ~ MCD5-1600C

KM1 Main contactor KM2 Bypass contactor (external) F1 Semiconductor fuses (optional)

Table 4.8

Inside Delta Installation

4.2.3

CAUTION

When connecting the MCD 500 in inside delta configuration, always install a main contactor or shunt trip circuit breaker.

NOTE

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

Illustration 4.8

KM1 Main contactor F1 Fuses (optional)

Table 4.9

4.2.3.2

Inside Delta Installation, Nonbypassed

Illustration 4.9

KM1 Main contactor F1 Fuses (optional)

Table 4.10

4.2.3.3

Inside Delta Installation, Externally Bypassed

Non-bypassed models have dedicated bypass terminals,

MG17K402 - VLT® is a registered Danfoss trademark 15

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 parameters 4-1 through 4-9).

Page 17

177HA618.10

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

KM1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

T2B

T1B

T3B

KM2

177HA502.11

6/T3

2/T1

5/L3

3/L2

1/L1

4/T2

KM1

KM1 F1

U1(1) U2(4)

V1(2)

V2(5)

W1(3) W2(6)

L2B

L1B

L3B

KM2

Electrical Installation MCD 500 Operating Instruction

NOTE

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

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.

Illustration 4.10 MCD5-0245C

KM1 Main contactor KM2 Bypass contactor (external) F1 Semicondutcor fuses (optional)

Table 4.11

Illustration 4.11 MCD5-0360C ~ MCD5-1600C

KM1 Main contactor KM2 Bypass contactor (external) F1 Semiconductor fuses (optional)

Table 4.12

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Electrical Installation MCD 500 Operating Instruction

4.3.1 In-line Connection (Bypassed)

NOTE

Models MCD5-0021B - MCD5-0215B are internally bypassed. Models MCD5-0245C - MCD5-1600C require an external bypass contactor.

AC-53b

3-30:330 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 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

AC-53b

4-20:340

AC-53b

4-20:580

AC-53b

4.5-30:330

AC-53b

4.5-30:570

4 4

Table 4.13

AC-53 Rating for Bypassed Operation

4.3.2

Illustration 4.12

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

MG17K402 - VLT® is a registered Danfoss trademark 17

Page 19

Start Time (seconds)

Starts Per Hour

Electrical Installation MCD 500 Operating Instruction

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

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

Table 4.14

4.3.4

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

AC-53 Rating for Continuous Operation

AC-53a

4-20:50-6

AC-53a

4.5-30:50-6

Illustration 4.13

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

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Page 20

Electrical Installation MCD 500 Operating Instruction

4.3.5 Inside Delta Connection (Bypassed)

NOTE

Models MCD5-0021B ~ MCD5-0215B are internally bypassed. Models MCD5-0245C ~ MCD5-1600C require an external bypass contactor.

AC-53b

3-30:330 MCD5-0021B 32 A 26 A 22 A MCD5-0037B 56 A 47 A 39 A MCD5-0043B 65 A 56 A 45 A MCD5-0053B 80 A 69 A 55 A

AC-53b

3-30:570 MCD5-0068B 102 A 83 A 71 A MCD5-0084B 126 A 104 A 87 A MCD5-0089B 134 A 112 A 92 A MCD5-0105B 158 A 143 A 117 A MCD5-0131B 197 A 159 A 136 A MCD5-0141B 212 A 181 A 146 A MCD5-0195B 293 A 241 A 201 A MCD5-0215B 323 A 268 A 223 A MCD5-0245C 383 A 302 A 264 A MCD5-0360C 540 A 465 A 395 A MCD5-0380C 570 A 539 A 449 A MCD5-0428C 645 A 552 A 463 A MCD5-0595C 930 A 810 A 651 A MCD5-0619C 975 A 842 A 683 A MCD5-0790C 1185 A 1072 A 869 A MCD5-0927C 1395 A 1244 A 992 A MCD5-1200C 1800 A 1800 A 1607 A MCD5-1410C 2115 A 1979 A 1671 A MCD5-1600C 2400 A 2400 A 2030 A

AC-53b

4.20-:340

AC-53b

4-20:580

AC-53b

4.5-30:330

AC-53b

4.5-30:570

4 4

Table 4.15

AC-53 Rating for Bypassed Operation

4.3.6

Illustration 4.14

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

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Page 21

Start Time (seconds)

Starts Per Hour

Electrical Installation MCD 500 Operating Instruction

4.3.7 Inside Delta Connection (Non-bypassed/Continuous)

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

Table 4.16

4.3.8

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

AC-53 Rating for Continuous Operation

AC-53a

4-20:50-6

AC-53a

4.5-30:50-6

Illustration 4.15

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

20 MG17K402 - VLT® is a registered Danfoss trademark

Page 22

Electrical Installation MCD 500 Operating Instruction

4.4 Minimum and Maximum Current Settings

The MCD 500's minimum and maximum full load current settings depend on the model:

In-line Connection Inside Delta Connection

Model Minimum Maximum Minimum Maximum MCD5-0021B 5 A 23 A 7 A 34 A MCD5-0037B 9 A 43 A 13 A 64 A MCD5-0043B 10 A 50 A 15 A 75 A MCD5-0053B 11 A 53 A 16 A 79 A MCD5-0068B 15 A 76 A 23 A 114 A MCD5-0084B 19 A 97 A 29 A 145 A MCD5-0089B 20 A 100 A 30 A 150 A MCD5-0105B 21 A 105 A 32 A 157 A MCD5-0131B 29 A 145 A 44 A 217 A MCD5-0141B 34 A 170 A 51 A 255 A MCD5-0195B 40 A 200 A 60 A 300 A MCD5-0215B 44 A 220 A 66 A 330 A MCD5-0245C 51 A 255 A 77 A 382 A MCD5-0360C 72 A 360 A 108 A 540 A MCD5-0380C 76 A 380 A 114 A 570 A MCD5-0428C 86 A 430 A 129 A 645 A MCD5-0595C 124 A 620 A 186 A 930 A MCD5-0619C 130 A 650 A 195 A 975 A MCD5-0790C 158 A 790 A 237 A 1185 A MCD5-0927C 186 A 930 A 279 A 1395 A MCD5-1200C 240 A 1200 A 360 A 1800 A MCD5-1410C 282 A 1410 A 423 A 2115 A MCD5-1600C 320 A 1600 A 480 A 2400 A

4 4

Table 4.17

4.5

Bypass Contactor

MCD 500 soft starters with model numbers MCD5-0021B - MCD5-0215B are internally bypassed and do not require an external bypass contactor.

MCD 500 soft starters with model numbers MCD5-0245C - MCD5-1600C are not internally bypassed and 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.

4.6 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 inline connection. Select a contactor with an AC3 rating greater than or equal to the full load current rating of the connected motor.

4.7 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.

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Electrical Installation MCD 500 Operating Instruction

4.8 Power Factor Correction

If power factor correction is used, a dedicated contactor should be used to switch in the capacitors. Power factor correction capacitors must be connected to the input side of the soft starter.

CAUTION

Power factor correction capacitors must be connected to the input side of the soft starter. Connecting power factor correction capacitors to the output side will damage the soft starter.

4.9 Fuses

4.9.1 Power Supply Fuses

Semiconductor fuses can be used for Type 2 coordination (according to IEC 60947-4-2 standard) and to 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 IEC 60947-4-2 standard.

NOTE

Adaptive Acceleration Control (AAC) controls the motor's speed profile, within the programmed time limit. This may result in a higher level of current than traditional control methods.

seconds, motor branch protection should be selected as follows:

Standard HRC line fuses: Minimum 150% motor

•

full load current Motor rated line 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 seconds

Fuses recommendations are calculated for 40° C, up to 1000 m.

NOTE

Fuse selection is based on a 400% FLC start for 20 seconds in conjunction with standard published starts per hour, duty cycle, 40° C ambient temperature and up to 1000 m altitude. For installations operating outside these conditions, consult your local supplier.

NOTE

These fuse tables contain recommendations only, always consult your local supplier to confirm the selection for your particular application.

For models marked - there is no suitable fuse.

For applications using Adaptive Acceleration Control to soft stop the motor with stop times greater than 30

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Page 24

Electrical Installation MCD 500 Operating Instruction

4.9.2 Bussman Fuses - Square Body (170M)

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 MCD5-0245C 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 170M6019* - -

SCR I2t (A2s)

Supply Voltage

(≤ 440 VAC)

Supply Voltage

(≤ 575 VAC)

Supply Voltage

(≤ 690 VAC)

4 4

Table 4.18

* Two parallel connected fuses required per phase.

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Page 25

Electrical Installation MCD 500 Operating Instruction

4.9.3 Bussman Fuses - British Style (BS88)

Model

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 MCD5-0245C 320000 450FMM 450FMM 450FMM MCD5-0360C 320000 - - MCD5-0380C 320000 400FMM* 400FMM 400FMM* MCD5-0428C 320000 - - MCD5-0595C 1200000 630FMM* 630FMM* MCD5-0619C 1200000 630FMM* 630FMM* MCD5-0790C 2530000 - - MCD5-0927C 4500000 - - MCD5-1200C 4500000 - - MCD5-1410C 6480000 - - MCD5-1600C 12500000 - - -

SCR I2t (A2s)

Supply Voltage

(< 440 VAC)

Supply Voltage

(< 575 VAC)

Supply Voltage

(< 690 VAC)

Table 4.19

* Two parallel connected fuses required per phase.

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Page 26

Electrical Installation MCD 500 Operating Instruction

4.9.4 Ferraz Fuses - HSJ

Model

MCD5-0021B 1150 HSJ40** HSJ40** MCD5-0037B 8000 HSJ80** HSJ80** MCD5-0043B 10500 HSJ90** HSJ90** MCD5-0053B 15000 HSJ110** HSJ110** MCD5-0068B 15000 HSJ125** HSJ125** MCD5-0084B 51200 HSJ175 HSJ175** MCD5-0089B 80000 HSJ175 HSJ175 MCD5-0105B 125000 HSJ225 HSJ225 MCD5-0131B 125000 HSJ250 HSJ250** MCD5-0141B 320000 HSJ300 HSJ300 MCD5-0195B 320000 HSJ350 HSJ350 MCD5-0215B 320000 HSJ400** HSJ400** MCD5-0245C 320000 HSJ450** HSJ450** MCD5-0360C 320000 MCD5-0380C 320000 MCD5-0428C 320000 MCD5-0595C 1200000 MCD5-0619C 1200000 MCD5-0790C 2530000 MCD5-0927C 4500000 MCD5-1200C 4500000 MCD5-1410C 6480000 MCD5-1600C 12500000

SCR I2t (A2s)

Supply Voltage

(< 440 VAC)

Not suitable

Supply Voltage

(< 575 VAC)

Not suitable

Supply Voltage

(< 690 VAC)

4 4

Not suitable

Table 4.20

** Two series connected fuses required per phase

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Page 27

Electrical Installation MCD 500 Operating Instruction

4.9.5 Ferraz Fuses - North American Style (PSC 690)

Model

MCD5-0021B 1150 A070URD30XXX0063 A070URD30XXX0063 MCD5-0037B 8000 A070URD30XXX0125 A070URD30XXX0125 A070URD30XXX0125 MCD5-0043B 10500 A070URD30XXX0125 A070URD30XXX0125 A070URD30XXX0125 MCD5-0053B 15000 A070URD30XXX0125 A070URD30XXX0125 A070URD30XXX0125

MCD5-0068B 15000 A070URD30XXX0160 A070URD30XXX0160 A070URD30XXX0160 MCD5-0084B 51200 A070URD30XXX0200 A070URD30XXX0200 A070URD30XXX0200 MCD5-0089B 80000 A070URD30XXX0200 A070URD30XXX0200 A070URD30XXX0200 MCD5-0105B 125000 A070URD30XXX0315 A070URD30XXX0315 A070URD30XXX0315 MCD5-0131B 125000 A070URD30XXX0315 A070URD30XXX0315 A070URD30XXX0315 MCD5-0141B 320000 A070URD30XXX0315 A070URD30XXX0315 A070URD30XXX0315 MCD5-0195B 320000 A070URD30XXX0450 A070URD30XXX0450 A070URD30XXX0450 MCD5-0215B 320000 A070URD30XXX0450 A070URD30XXX0450 A070URD30XXX0450 MCD5-0245C 320000 A070URD30XXX0450 A070URD30XXX0450 A070URD30XXX0450 MCD5-0360C 320000 A070URD33XXX0630 A070URD33XXX0630 A070URD33XXX0630 MCD5-0380C 320000 A070URD33XXX0700 A070URD33XXX0700 MCD5-0428C 320000 A070URD33XXX0700 A070URD33XXX0700 MCD5-0595C 1200000 A070URD33XXX1000 A070URD33XXX1000 A070URD33XXX1000 MCD5-0619C 1200000 A070URD33XXX1000 A070URD33XXX1000 A070URD33XXX1000 MCD5-0790C 2530000 A070URD33XXX1400 A070URD33XXX1400 A070URD33XXX1400 MCD5-0927C 4500000 A070URD33XXX1400 A070URD33XXX1400 A070URD33XXX1400 MCD5-1200C 4500000 A055URD33XXX2250 - MCD5-1410C 6480000 A055URD33XXX2250 - MCD5-1600C 12500000 - - -

SCR I2t (A2s)

Supply Voltage

< 440 VAC

Supply Voltage

< 575 VAC

Supply Voltage

< 690 VAC

Table 4.21

XXX = blade type. Refer to Ferraz catalog for details.

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Page 28

Electrical Installation MCD 500 Operating Instruction

4.9.6 UL Tested Fuses - Short Circuit Ratings

Model Nominal Rating (A) Short Circuit Rating 480V AC (kA) Short Circuit Rating 600V AC (kA) Fuse Ferraz MCD5-0021B 23 65 10 AJT50 A070URD30XXX0063 MCD5-0037B 43 65 10 AJT50 A070URD30XXX0125 MCD5-0043B 50 65 10 AJT50 A070URD30XXX0125 MCD5-0053B 53 65 10 AJT60 A070URD30XXX0125 MCD5-0068B 76 65 10 AJT80 A070URD30XXX0200 MCD5-0084B 97 65 10 AJT100 A070URD30XXX0200 MCD5-0089B 100 65 10 AJT100 A070URD30XXX0200 MCD5-0105B 105 65 10 AJT125 A070URD30XXX0315 MCD5-0131B 145 65 18 AJT150 A070URD30XXX0315 MCD5-0141B 170 65 18 AJT175 A070URD30XXX0315 MCD5-0195B 200 65 18 AJT200 A070URD30XXX0450 MCD5-0215B 220 65 18 AJT250 A070URD30XXX0450

MCD5-0245C 255 85 85 AJT300 A070URD30XXX0450 MCD5-0360C 360 85 85 AJT400 A070URD33XXX0630 MCD5-0380C 380 85 85 AJT450 A070URD33XXX0700

MCD5-0425B 430 85 85 AJT450 A070URD33XXX0700

MCD5-0595C 620 85 85 A4BQ800 A070URD33XXX1000 MCD5-0619C 650 85 85 A4BQ800 A070URD33XXX1000 MCD5-0790C 790 85 85 A4BQ1200 070URD33XXX1400 MCD5-0927C 930 85 85 A4BQ1200 A070URD33XXX1400 MCD5-1200C 1200 100 100 A4BQ1600 A065URD33XXX1800 MCD5-1410C 1410 100 100 A4BQ2000 A055URD33XXX2250 MCD5-1600C 1600 100 100 A4BQ2500 A055URD33XXX2250

4 4

Table 4.22

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Page 29

6/T3

2/T1

4/T2

5/L3

3/L2

1/L1

24 VDC

177HA425.10

Electrical Installation MCD 500 Operating Instruction

4.10 Schematic Diagrams

4.10.1 Internally Bypassed Models

Illustration 4.16

1 2 Outputs

Control supply (model dependent)

07, 08 Programmable analog output 16, 08 24 VDC output 3 Remote control inputs 11, 16 Programmable input 15, 16 Start 17, 18 Stop 25, 18 Reset 4 Motor thermistor input (PTC only) 5 Relay outputs 13, 14 Relay output A 21, 22, 24 Relay output B 33, 34 Relay output C

Table 4.23

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Page 30

177HA426.11

6/T3

2/T1

4/T2

5/L3

3/L2

1/L1

L3B

L2B

L1B

24 VDC

Electrical Installation MCD 500 Operating Instruction

4.10.2 Non-bypassed Models

4 4

Illustration 4.17

Control supply (model dependent) 2 Outputs 07, 08 Programmable analog output 16, 08 24 VDC output 3 Remote control inputs 11, 16 Programmable input 15, 16 Start 17, 18 Stop 25, 18 Reset 4 Motor thermistor input (PTC only) 5 Relay outputs 13, 14 Relay output A 21, 22, 24 Relay output B 33, 34 Relay output C

Table 4.24

NOTE

* MCD5-0245C current transformers are located on the output. Bypass terminals are labelled T1B, T2B and T3B.

MG17K402 - VLT® is a registered Danfoss trademark 29

Page 31

100 200 300

100

1000

10000

177HA596.10

Time in seconds to reach 100% of thermal model

Current (%motor full load current)

400 500

600 700

800 900 1000

Application Examples MCD 500 Operating Instruction

5 Application Examples

The memory function of the model means that

•

5.1 Motor Overload Protection

The thermal model used for motor overload in the MCD 500 has two components:

The overload protection function provided by this model is

Motor windings: These have a low thermal

•

capacity and affects the short term thermal

behaviour of the motor. This is where the heat is generated by the current.

Motor Body: This has a large thermal capacity and

•

affects the long term behaviour of the motor. The thermal model includes considerations for the following:

Motor current, iron losses, winding

•

resistance losses, motor body and winding thermal capacities, cooling during run and cooling at standstill.

The percentage of the rated capacity of

•

the motor. This sets the displayed value for the winding model and is affected by the motor FLC setting amongst others.

compliant with a NEMA 10 curve, but will provide superior protection at low levels of overload due to the separation of the winding thermal model.

the motor is fully protected in “warm start” situations. The model uses data from the real time clock to account for elapsed cooling time, even if control power has been removed.

NOTE

1-1 Motor FLC should be set to the motor's rated FLC. Do not add the overload rating as this is computed by the MCD500.

The thermal overload protection used in MCD500 has a number of advantages over the thermal relays.

The effect of fan cooling is accounted for when

•

the motor is running The actual full load current and locked rotor time

•

can be used to more accurately tune the model. The thermal characteristics of the windings are treated separately from the rest of the motor (ie. the model recognises that the windings have low thermal mass and high thermal resistance).

The winding portion of the thermal model

•

responds very rapidly compared with the body portion, meaning the motor can be run closer to its safe maximum operating temperature while still being protected from thermal damage.

The percentage of motor thermal capacity used

•

during each start is stored in memory. The starter can be configured to automatically determine whether or not the motor has sufficient thermal capacity remaining to successfully complete another start.

Illustration 5.1

MSTC1 = 5

MSTC1 = 10

MSTC1 = 20

MSTC is the Motor Start Time Constant and is defined as

the Locked Rotor Time (in 1-2 Locked Rotor Time) when the Locked Rotor Current is 600% of FLC.

5.2

AAC Adaptive Acceleration Control

AAC Adaptive Acceleration Control is a new form of motor control based on the motor's own performance characteristics. With AAC, the user selects the starting or stopping profile that best matches the load type and the starter automatically controls the motor to match the profile. The MCD 500 offers three profiles - early, constant and late acceleration and deceleration.

30 MG17K402 - VLT® is a registered Danfoss trademark

Page 32

700%

600%

500%

300%

100%

400%

200%

10% 20% 30% 40% 50%

Rotor speed (% full speed)

60% 70% 80% 90% 100%

177HA289.11

Current (% motor full load current)

700%

600%

500%

300%

100%

400%

200%

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

177HA290.10

CURRENT (% Motor Full Load Current)

ROTOR SPEED (% Full Speed)

Full Voltage Stator Current

Current Limit (e.g. Par. 2 = 400% x FLC)

Initial Current (e.g. Par. 3 = 250% x FLC)

Ramp Time

(eg Par. 4 = 10 secs)

Application Examples MCD 500 Operating Instruction

AAC uses two algorithms, one to measure the motor's characteristics and one to control the motor. The MCD 500 uses the first start to determine the motor's characteristics at zero speed and at maximum speed. During each subsequent start and stop, the starter dynamically adjusts its control to ensure the motor's actual performance matches the selected profile throughout the start. The starter increases power to the motor if the actual speed is too low for the profile, or decreases power if the speed is too high.

5.3 Starting Modes

5.3.1 Constant Current

Constant current is the traditional form of soft starting, which raises the current from zero to a specified level and keeps the current stable at that level until the motor has accelerated.

Constant current starting is ideal for applications where the start current must be kept below a particular level.

1-5 Initial Current to a level that will start the

Set motor with a light load, and 1-4 Current Limit to a level that will start the motor with a heavy load.

the load breaks away easily, but starting time

•

needs to be extended (for example a centrifugal pump where pipeline pressure needs to build up slowly).

the electricity supply is limited (for example a

•

generator set), and a slower application of load will allow greater time for the supply to respond.

5 5

Illustration 5.2

1: 1-5 Initial current 2: 1-4 Current limit 3: Full voltage current

Table 5.1

5.3.2

Current Ramp

Illustration 5.3

AAC Adaptive Acceleration Control

5.3.3

To use AAC Adaptive Acceleration Control to control starting performance:

Select Adaptive Control in 1-3 Start Mode.

Set 1-6 Start Ramp Time.

Select the desired profile in 1-13 Adaptive Start Profile.

Set 1-4 Current Limit sufficiently high to allow a successful start. The first AAC start will be a Constant Current start. This allows the MCD 500 to learn the characteristics of the connected motor. This motor data is used by the MCD 500 during subsequent AAC Adaptive Acceleration Control starts.

Current ramp soft starting raises the current from a specified starting level (1) to a maximum limit (3), over an extended period of time (2).

Current ramp starting can be useful for applications where:

•

the load can vary between starts (for example a conveyor which may start loaded or unloaded).

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Page 33

10%

20%

30%

40%

50%

Time

60%

70%

80%

90%

100%

177HA507.10

Speed

700%

600%

500%

300%

100%

400%

200%

10% 20% 30% 40% 50%

Rotor speed (% full speed)

60% 70% 80% 90% 100%

177HA508.10

Current (% motor full load current)

Application Examples MCD 500 Operating Instruction

Illustration 5.4

1. Early acceleration

2. Constant acceleration

3. Late acceleration

4. 1-16 Start Ramp Time

Table 5.2 1-13 Adaptive Start Profile

Illustration 5.5

1: 1-7 Kickstart Level 2: 1-8 Kickstart Time 3: 1-5 Initial Current 4: 1-6 Start Ramp Time 5: 1-4 Current Limit 6: Full voltage current

NOTE

AAC Adaptive Acceleration Control will control the load according to the programmed profile. Start current will vary according to the selected acceleration profile and the programmed start time. If replacing a motor connected to an MCD 500 programmed for AAC Adaptive Control starting or stopping, or if the starter has been tested on a different motor prior to actual installation, the starter will need to learn the characteristics of the new motor. The MCD 500 will automatically re-learn the motor's characteristics if 1-1 Motor Full Load Current or 1-12 Adaptive Control Gain is changed.

Table 5.3

5.4

Stopping Modes

5.4.1 Coast to Stop

Coast to stop lets the motor slow at its natural rate, with no control from the soft starter. The time required to stop will depend on the type of load.

TVR Soft Stop

5.4.2

Kickstart

5.3.4

Kickstart provides a short boost of extra torque at the

Timed voltage ramp reduces the voltage to the motor gradually over a defined time. The load may continue to run after the stop ramp is complete.

beginning of a start, and can be used in conjunction with current ramp or constant current starting.

Timed voltage ramp stopping can be useful for applications where the stop time needs to be extended, or

Kickstart can be useful to help start loads that require high

to avoid transients on generator set supplies.

breakaway torque but then accelerate easily (for example flywheel loads such as presses).

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Page 34

70%

60%

50%

30%

10%

40%

Time

Voltage (% full voltage)

20%

80%

90%

100%

177HA509.10

10%

20%

30%

40%

50%

Time

Speed

60%

70%

80%

90%

100%

177HA510.10

1 2

Application Examples MCD 500 Operating Instruction

NOTE

Adaptive control does not actively slow the motor down and will not stop the motor faster than a coast to stop. To shorten the stopping time of high inertia loads, use brake.

The first AAC Adaptive Deceleration Control stop will be a normal soft stop. This allows the MCD 500 to learn the characteristics of the connected motor. This motor data is used by the MCD 500 during subsequent Adaptive Control stops.

Illustration 5.6

1: 1-11 Stop Time

Table 5.4

AAC Adaptive Acceleration Control

5.4.3

To use AAC Adaptive Acceleration Control to control stopping performance:

Select Adaptive Control in 1-10 Stop Mode.

Set 1-11 Stop Time.

Select the required profile in 1-14 Adaptive Stop Profile.

NOTE

Adaptive Control will control the load according to the programmed profile. Stopping current will vary according to the selected deceleration profile and stop time. If replacing a motor connected to an MCD 500 programmed for AAC Adaptive Control starting or stopping, or if the starter has been tested on a different motor prior to actual installation, the starter will need to learn the characteristics of the new motor. The MCD 500 will automatically re-learn the motor's characteristics if 1-1 Motor Full Load Current or 1-12 Adaptive Control Gain is changed.

Brake

5.4.4

Brake reduces the time the motor requires to stop.

During braking an increased noise level from the motor may be audible. This is a normal part of motor braking.

CAUTION

If the brake torque is set too high, the motor will stop before the end of the brake time and the motor will suffer unnecessary heating which could result in damage. Careful configuration is required to ensure safe operation of the starter and motor.

5 5

Illustration 5.7

1. Early deceleration

2. Constant deceleration

3. Late deceleration

4. 1-10 Stop Time

Table 5.5 1-14 AAC Adaptive Stop Profile

CAUTION

A high brake torque setting can result in peak currents up to motor DOL being drawn while the motor is stopping. Ensure protection fuses installed in the motor branch circuit are selected appropriately.

NOTE

Brake operation causes the motor to heat faster than the rate calculated by the motor thermal model. If you are using brake, install a motor thermistor or allow sufficient restart delay (2-11 Restart Delay).

When brake is selected, the MCD 500 uses DC injection to slow the motor.

MG17K402 - VLT® is a registered Danfoss trademark 33

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100%

70%

30%

177HA511.10

Time

Speed

Application Examples MCD 500 Operating Instruction

MCD 500 braking

Does not require the use of a DC brake contactor

•

Controls all three phases so that the braking

•

currents and associated heating are evenly distributed through the motor

Braking has two stages

1. Pre-brake: provides an intermediate level of braking to slow motor speed to a point where full brake can be operated successfully (approxi-

To configure the MCD 500 for brake operation

mately 70% speed).

2. Full brake: brake provides maximum braking torque but is ineffective at speeds greater than approximately 70%.

Set 1-11 Stop Time for the desired stopping time duration (1). This is the total braking time and must be set sufficiently longer than the brake time (1-16 Brake Time) to allow the pre-braking stage to reduce motor speed to approximately 70%. If the stop time is too short, braking will not be successful and the motor will coast to stop.

Set 1-16 Brake Time to approximately one quarter of the programmed Stop Time. This sets the time for the Full Brake stage (2).

Adjust 1-15 Brake Torque so that the desired stopping performance is achieved. If set too low, the motor will not stop completely and will coast to stop by the end of the braking period.

NOTE

When using DC brake, the mains supply must be connected to the soft starter (input terminals L1, L2, L3) in positive phase sequence and 2-1 Phase Sequence must be set to Positive only.

NOTE

For loads which may vary between braking cycles, install a zero speed sensor to ensure that the soft starter ends DC braking when the motor stops. This avoids unnecessary heating of the motor.

For more information on using the MCD 500 with an external speed sensor, see 5.12 DC Brake with External Zero Speed Sensor.

5.5 Jog Operation

Jog runs the motor at reduced speed, to allow alignment of the load or to assist servicing. The motor can be jogged in either forward or reverse direction.

The maximum available torque for jog is approximately 50% - 75% of motor full load torque (FLT) depending on the motor. Available jog torque in reverse is approximately 50% - 75% of the jog torque in forward direction. To set the jog torque level, use 15-8 Jog Torque.

NOTE

Setting 15-8 Jog Torque above 50% may cause increased shaft vibration.

Illustration 5.8

1: 1-11 Stop Time 2: 1-16 Brake Time 3: Coast to stop time

Table 5.6

34 MG17K402 - VLT® is a registered Danfoss trademark

Page 36

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60%

50%

30%

10%

40%

20%

80%

90%

100%

177HA512.10

Application Examples MCD 500 Operating Instruction

CAUTION

Slow speed running is not intended for continuous operation due to reduced motor cooling. Jog changes the motor's heating profile and reduced the accuracy of the motor thermal model. Do not rely on motor overload protection to protection to protect the motor during jog operation.

5.6 Inside Delta Operation

AAC, Jog and Brake functions are not supported in inside delta (six-wire) operation. If these functions are programmed when the starter is connected inside delta the behaviour is as given below:

AAC Start The starter performs a Constant Current Start.

Illustration 5.9

1. Jog Forward

2. Jog Reverse

3. Normal Operation

AAC Stop The starter performs a TVR Soft Stop if Stop Time is

Jog The starter issues a warning with the error message

Brake The starter performs a Coast to Stop.

5 5

>0 secs. If Stop Time is set to 9 secs the starter performs a Coast to Stop.

Unsupported Option.

Table 5.7

To activate jog operation, use a programmable input (3-3 Input A Function).

To stop a jog operation, perform either of the following:

Remove the jog command

•

Press the OFF button on the LCP

•

Activate Emergency Stop using the LCP

•

programmable inputs

Jog will recommence at the end of a restart delay if the jog command is still present. All other commands except the above will be ignored during jog operation.

NOTE

Jog will operate in 2-wire mode regardless of the state of the remote Start, Stop and Reset inputs.

NOTE

Jog is only available for the primary motor (for more information on primary and secondary sets, see Secondary motor set. Soft start and soft stop are not available during jog operation.

MG17K402 - VLT® is a registered Danfoss trademark 35

Table 5.8

NOTE

When connected in inside delta, current imbalance is the only phase loss protection that is active during run. Do not disable current imbalance protection during inside delta operation.

NOTE

Inside delta operation is only possible with mains voltage ≤ 600 VAC.

5.7 Typical Start Currents

Use this information to determine the appropriate start current for your application.

NOTE

These start current requirements are appropriate and typical in most circumstances, However, the performance and start torque requirements of motors and machines do vary. For further assistance, contact your local supplier.

Page 37

Application Examples MCD 500 Operating Instruction

Application Typical Start Current General & Water Agitator 4.0 x FLC Centrifugal pump 3.5 x FLC Compressor (Screw, unloaded) 3.0 x FLC Compressor (Reciprocating, unloaded) 4.0 x FLC Conveyor 4.0 x FLC Fan (damped) 3.5 x FLC Fan (undamped) 4.5 x FLC Mixer 4.5 x FLC Positive displacement pump 4.0 x FLC

Submersible pump 3.0 x FLC Metals & Mining Belt conveyor 4.5 x FLC Dust collector 3.5 x FLC Grinder 3.0 x FLC Hammer mill 4.5 x FLC Rock crusher 4.0 x FLC Roller conveyor 3.5 x FLC Roller mill 4.5 x FLC Tumbler 4.0 x FLC Wire draw machine 5.0 x FLC Food Processing Bottle washer 3.0 x FLC Centrifuge 4.0 x FLC Dryer 4.5 x FLC Mill 4.5 x FLC Palletiser 4.5 x FLC Separator 4.5 x FLC Slicer 3.0 x FLC Pulp and Paper Dryer 4.5 x FLC Re-pulper 4.5 x FLC Shredder 4.5 x FLC Petrochemical Ball mill 4.5 x FLC Centrifuge 4.0 x FLC Extruder 5.0 x FLC Screw conveyor 4.0 x FLC Transport & Machine Tool Ball mill 4.5 x FLC Grinder 3.5 x FLC Material conveyor 4.0 x FLC Palletiser 4.5 x FLC Press 3.5 x FLC Roller mill 4.5 x FLC Rotary table 4.0 x FLC

Table 5.9

36 MG17K402 - VLT® is a registered Danfoss trademark

Page 38

Application Examples MCD 500 Operating Instruction

Application Typical Start Current Lumber & Wood products Bandsaw 4.5 x FLC Chipper 4.5 x FLC Circular saw 3.5 x FLC Debarker 3.5 x FLC Edger 3.5 x FLC Hydraulic power pack 3.5 x FLC Planer 3.5 x FLC Sander 4.0 x FLC

Table 5.10

5 5

MG17K402 - VLT® is a registered Danfoss trademark 37

Page 39

KM1

6/T3

2/T1

4/T2

5/L3

3/L2

1/L1

6 7

177HA522.10

24 VDC

Application Examples MCD 500 Operating Instruction

5.8 Installation with Main Contactor

The MCD 500 is installed with a main contactor (AC3 rated). Control voltage must be supplied from the input side of the contactor.

The main contactor is controlled by the MCD 500 Main Contactor output, which by default is assigned to Output Relay A (terminals 13, 14).

Illustration 5.10

1 2 24 VDC output F1 Semiconductor fuses (optional) 3 Remote control inputs S1 Start /stop 4 Motor thermistor input (PTC only) S2 Reset contact 5 Relay outputs 13, 14 Relay output A 6 3-phase supply 21, 22, 24 Relay output B 7 Motor terminals 33, 34 Relay output C

Table 5.11

Parameter settings:

4-1 Relay A Function

•

Control voltage (model dependent) KM1 Main contactor

Select Main Contactor - assigns the Main Contactor function to Relay Output A (default value).

•

38 MG17K402 - VLT® is a registered Danfoss trademark

Page 40

KM1

24 VDC

6/T3

2/T1

4/T2

5/L3

3/L2

1/L1

L3B

L1B

L2B

KM1

6 7

177HA523.10

Application Examples MCD 500 Operating Instruction

5.9 Installation with Bypass Contactor

The MCD 500 is installed with a bypass contactor (AC1 rated). The bypass contactor is controlled by the MCD 500 Run Output which by default is assigned to Output Relay B (terminals 21, 22, 24).

5 5

Illustration 5.11

1 2 24 VDC output F1 Semiconductor fuses (optional) 3 Remote control inputs S1 Start contact 4 Motor thermistor input (PTC only) S2 Stop contact 5 Relay outputs S3 Reset contact 6 3-phase supply 13, 14 Relay output A 7 Motor terminals 21, 22, 24 Relay output B 33, 34 Relay output C

Table 5.12

Parameter settings:

•

Control voltage (model dependent) KM1 Bypass contactor

4-4 Relay B Function

Select Run - assigns the run output function to Relay Output B (default value).

•

MG17K402 - VLT® is a registered Danfoss trademark 39

Page 41

KM1

24 VDC

6/T3

2/T1

4/T2

5/L3

3/L2

1/L1

6 7

177HA524.10

Application Examples MCD 500 Operating Instruction

5.10 Emergency Run Operation

In normal operation the MCD 500 is controlled via a remote two wire signal (terminals 17, 18).

Emergency Run is controlled by a two wire circuit connected to Input A (terminals 11, 16). Closing Input A causes the MCD 500 to run the motor and ignore all trip conditions.

Illustration 5.12

1 2 24 VDC output S2 Reset contact

Control voltage (model dependent) S1 Start/stop contact

3 Remote control inputs S3 Emergency Run contact 4 Motor thermistor input (PTC only) 13, 14 Relay output A 5 Relay outputs 21, 22, 24 Relay output B 6 3-phase supply 33, 34 Relay output C 7 Motor terminals

Table 5.13

Parameter settings:

•

3-3 Input A Function

•

15-3 Emergency Run

•

Select Emergency Run - assigns Input A to Emergency Run Function

Select Enable - Enables the Emergency Run mode

40 MG17K402 - VLT® is a registered Danfoss trademark

Page 42

KM1

24 VDC

6/T3

2/T1

4/T2

5/L3

3/L2

1/L1

6 7

177HA525.10

Application Examples MCD 500 Operating Instruction

5.11 Auxiliary Trip Circuit

In normal operation the MCD 500 is controlled via a remote two wire signal (terminals 17, 18).

Input A (terminals 11, 16) is connected to an external trip circuit (such as a low pressure alarm switch for a pumping system). When the external circuit activates, the soft starter trips, which stops the motor.

5 5

Illustration 5.13

Control voltage (model dependent) S1 Start/stop contact

1 2 24 VDC output S2 Reset contact 3 Remote control inputs S3 Auxiliary trip contact 4 Motor thermistor input (PTC only) 13, 14 Relay output A 5 Relay outputs 21, 22, 24 Relay output B 6 3-phase supply 33, 34 Relay output C 7 Motor terminals

Table 5.14

Parameter settings:

3-3 Input A Function

•

3-4 Input A Name

•

3-8 Remote Reset Logic

•

Select Input Trip (N/O) assigns the Input A to Auxiliary Trip (N/O) function

Select a name e.g. Low Pressure - assigns a name to Input A.

Select as required e.g. Normally Closed - the input behaves like a normally closed contact.

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Page 43

-F1

L3L2L1 N E

-KA1

L1 L2 L3

T1 T2 T3

A5A4 A6

15 16 17 18 25

11 16

-KA1

-KA2

-KA1

-KA2

T3T2T1

-KA2-KA1

-A2

177HA619.10

A B C D E

Application Examples MCD 500 Operating Instruction

5.12 DC Brake with External Zero Speed Sensor

1 Soft starter 4 Emergency stop mode (shown

on starter display)

2 Control voltage A Off (ready)

For loads which may vary between braking cycles, there

15,16Start B Start

are benefits in using an external zero-speed sensor to interface with the MCD 500 for brake shut-off. This control

17,18Stop C Run

method ensures that the MCD 500 braking will always shut off when the motor has reached a standstill, thus avoiding

25,18Reset D Stop

unnecessary motor heating.

2 Motor E Zero speed

The following schematic diagram shows how you can use a zero-speed sensor with the MCD 500 to turn the brake

function off at motor standstill. The zero-speed sensor (-

3 Three-phase supply 5 Start signal (2, 3, or 4-wire) 6 Zero speed detect 7 Zero speed sensor

A2) is often referred to as an under-speed detector. Its internal contact is open at zero-speed and closed at any

Table 5.15

speed above zero-speed. Once the motor has reached a standstill, the MCD 500 will go into Emergency Stop mode

For details on configuring DC Brake, see 5.4.4 Brake.

and remain in this state until the next start command is given (i.e. next application of –KA1).

NOTE

When using DC brake, the mains supply must be

The MCD 500 must be operated in remote mode and 3-3 Input A Function must be set to emergency stop.

connected to the soft starter (input terminals L1, L2, L3) in positive phase sequence and 2-1 Phase Sequence must be set to Positive only.

5.13 Soft Braking

For high inertia loads the MCD 500 can be configured for soft braking.

In this application the MCD 500 is employed with forward run and braking contactors. When MCD 500 receives a start signal (button S1), it closes the forward run contactor (KM1) and controls the motor according to the programmed primary motor settings.

When the MCD 500 receives a stop signal (button S2), it opens the forward run contactor (KM1) and closes the braking contactor (KM2) after a delay of approximately 2-3 seconds (KT1). KA3 is also closed to activate the secondary motor settings, which should be user programmed for the

Illustration 5.14

42 MG17K402 - VLT® is a registered Danfoss trademark

desired stopping performance characteristics.

When motor speed approaches zero, the external shaft rotation sensor (A2) stops the soft starter and opens the braking contactor (KM2).

Some shaft rotation sensors perform a self-test upon power-up and momentarily close the output relay. In these cases, also install a delay timer (KT3).

Page 44

177HA526.11

KT3

KM2

KA1 KA2 KA3 KA4KM1

54 55 585756

KM2 KM1

KA3

S2 KA4

KT1

KT1 KT2 KT3

KM1 KM2

KM1 KM2S1 KA1 KA1

KA1

KT2

4/T2

6/T3

1/L1

3/L2

5/L3

2/T1

A4 A5 A6

KA3

KA2 S3

Application Examples MCD 500 Operating Instruction

Illustration 5.15

5 5

1 Control voltage (model dependent) KA1 Run relay 2 Remote control inputs KA2 Start relay 3 Motor thermistor input (PTC only) KA3 Brake relay 4 Relay outputs KA4 Rotation sensing relay 5 3-phase supply KM1 Line contactor (Run) 6 Motor terminals KM2 Line contactor (Brake) A2 Shaft rotation sensor KT1 Run delay timer S1 Start contact KT2 Brake delay timer S2 Stop contact KT3 Shaft rotation sensor delay timer S3 Reset contact

Table 5.16

Parameter settings:

3-3 Input A Function

•

Select Motor Set Select - assigns Input A for Motor set selection

•

Set starting performance characteristics using the primary motor set (parameter group 1)

•

Set braking performance characteristics using the secondary motor settings (parameter group 7)

•

4-7 Relay C Function

•

Select Trip - assigns Trip function to Relay Output C

•

NOTE

If the MCD-500 trips on supply frequency (16-5 Frequency) when the braking contactor KM2 opens, modify the setting of Parameters 2-8 through 2-10.

MG17K402 - VLT® is a registered Danfoss trademark 43

Page 45

Application Examples MCD 500 Operating Instruction

5.14 Two Speed Motor

The MCD 500 can be configured for control of dual speed Dahlander type motors, using a high speed contactor (KM1), low speed contactor (KM2) and a star contactor (KM3).

NOTE

Pole Amplitude Modulated (PAM) motors alter the speed by effectively changing the stator frequency using external winding configuration. Soft starters are not suitable for use with this type of two-speed motor.

When the soft starter receives a high speed start signal, it closes the high speed contactor (KM1) and star contactor (KM3), then controls the motor according to the primary motor settings (parameters 1-1 through 1-16.)

When the soft starter receives a low speed start signal, it closes the low speed contactor (KM2). This closes Input A and the MCD 500 controls the motor according to the secondary motor settings (parameters 7-1 through 7-16).

NOTE

If the MCD 500 trips on supply frequency (16-5 Frequency) when the high-speed start signal (7) is removed, modify the setting of parameters 2-8 through 2-10.

44 MG17K402 - VLT® is a registered Danfoss trademark

Page 46

177HA527.10

2/T1

4/T2

6/T3

1/L1

3/L2

5/L3

KA1

KA2

KA1

KA2

KM3

KA1

KM2KA2

KM1

KM2

KM3

KM1

KM3

KM1

KM3

KM2

KM1

KA1

Application Examples MCD 500 Operating Instruction

5 5

Illustration 5.16

1 2 Remote control

Control voltage 6 Remote low-speed start input KM2 Line contactor (low speed)

7 Remote high-speed start input KM3 Star contactor (high speed)

inputs 3 Relay outputs KA1 Remote start relay (low speed) S1 Reset contact 4 3-phase supply KA2 Remote start relay (high speed) 21,

Relay output B

22, 24

5 Motor terminals KM1 Line contactor (high speed)

Table 5.17

NOTE

Contactors KM2 and KM3 must be mechanically interlocked.

Parameter settings:

3-3 Input A Function

•

Select Motor Set Select - assigns Input A for Motor set selection

•

Set high speed performance characteristics using parameters 1-1 - 2-9

•

Set low speed performance characteristics using parameters 7-1 - 7-16.

•

4-4 Relay B Function

Select Trip - assigns Trip function to Relay Output B

•

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177HA383.10

Operation MCD 500 Operating Instruction

6 Operation

6.1.2 The LCP

6.1 Operation and LCP

6.1.1 Operating Modes

In Hand On mode:

To soft start the motor, press [Hand On] on the

•

LCP To stop the motor, press [Off] on the LCP

•

To reset a trip on the starter, press [Reset] on the

•

LCP To emergency stop the motor, press the local

•

[Off] and [Reset] buttons at the same time. The soft starter will remove power from the motor and open the main contactor, and the motor will coast to stop. Emergency stop can also be controlled via a programmable input.

In Auto On mode:

Illustration 6.1

To soft start the motor, activate the Start remote

•

input To stop the motor, activate the Stop remote

•

input To reset a trip on the starter, activate the Reset

•

remote input

NOTE

Brake and Jog functions operate only with in-line connected motors (see Inside Delta Operation)

1 Four-line display for status and programming details. 2 Display control buttons: Status: Return to the status displays

Quick Menu: Open the Quick Menu Main Menu: Open the Main Menu

Alarm Log: Open the Alarm Log 3 Menu navigation buttons: [Back]: Exit the menu or parameter, or cancel a

parameter change

[OK]: Enter a menu or parameter, or save a parameter

change

[▲] [▼]: Scroll to the next or previous menu or

parameter, change the setting of the current

parameter or scroll through the status screens. 4 Soft starter local control buttons: [Hand On]: Start the motor and enter local control

mode.

[Off]: Stop the motor (only active in Hand On mode).

[Auto On]: Set the starter to Auto On mode.

[Reset]: Reset a trip (Hand On mode only). 5 Remote input status LEDs.

Table 6.1

6.2

46 MG17K402 - VLT® is a registered Danfoss trademark

Remote Mounted LCP

A remote mounted LCP can be installed with the MCD 500. The Control Panel LCP501 can be mounted up to 3 metres away from the starter, for control and monitoring.

Page 48

Operation MCD 500 Operating Instruction

The starter can be controlled and programmed from either the remote LCP or the LCP on the starter. Both displays show the same information.

6.2.1 Synchronising the LCP and the Starter

The DB9 cable can be connected/disconnected from the LCP while the starter is running.

The first time a LCP is plugged into a starter, the starter will copy its parameter settings to the LCP.

New display detected

Table 6.2

If the LCP has previously been used with a MCD 500, the operator can select whether to copy the parameters to the starter, or to copy the MCD 500's parameter settings into the LCP.

Select the required option using the [▲] and [▼] buttons. The selected option is surrounded by a dotted line. Press OK to proceed with the selection. Copy Parameters Display to Starter Starter to Display

Display to starter

Starter to display

Table 6.3

Copy parameters

NOTE

If the parameter software version in the LCP is different from the software version of the starter, only Starter to Display will be available.

Ready Welcome

1.05 / 2.0 / 1.13 MCD5-0053-T5-G1-CV2

Table 6.4

3rd display line: Software versions for Remote LCP, Control software, Model software 4th display line: Product model number

NOTE

The LCP version is only displayed if a Remote LCP 501 is connected when control power is applied. If no remote LCP is present, only the control software and model software versions will be displayed.

6.4 Control Methods

The MCD 500 can be controlled via the control buttons on the LCP (local control), via the remote inputs (remote control) or via the serial communication network.

Local control is only available in Hand On mode.

•

Remote control is only available in Auto On

•

mode. Control via the serial communication network is

•

always disabled in Hand On mode, and Start/Stop commands via the serial network may be enabled or disabled in Auto On mode by changing the setting of 3-2 Comms in Remote.

The MCD 500 can also be configured to auto-start or autostop. Auto-start/stop operation is only available in Auto On mode, and must be configured using parameters 5-1 - 5-4. In Hand On mode, the starter will ignore any auto-start/ stop setting.

To switch between Hand On and Auto On modes, use the local control buttons on the LCP.

NOTE

While the LCP is synchronising, only the [▲], [▼], [OK], and [Off] buttons are enabled.

6.3 Welcome Screen

When control power is applied, the starter will display the welcome screen

MG17K402 - VLT® is a registered Danfoss trademark 47

[Hand On]: Start the motor and enter Hand On mode. [Off]: Stop the motor and enter Hand On mode. [Auto On]: Set the starter to Auto On mode. [Reset]: Reset a trip (Hand On mode only).

The MCD 500 can also be set to allow local control only or remote control only, using 3-1 Local/Remote.

If 3-1 Local/Remote is set to Remote Control Only, the [Off] button is disabled and the motor must be stopped by remote control or via the serial communication network.

Page 49

Operation MCD 500 Operating Instruction

Hand On mode Auto On mode To soft start the motor press [Hand On] on the LCP activate the Start remote input To stop the motor press [Off] on the LCP activate the Stop remote input To reset a trip on the starter press [Reset] on the LCP activate the Reset remote input Auto start/stop operation Disabled Enabled

Table 6.5

To emergency stop the motor, press the local [Off] and [Reset] buttons at the same time. The soft starter will remove power from the motor and open the main contactor, and the motor will coast to stop. Emergency stop can also be controlled via a programmable input.

NOTE

Brake and Jog functions operate only with in-line connected motors (see 5.6 Inside Delta Operation)

6.5 Local Control Buttons

If 3-1 Local/Remote is set to LCL/RMT Anytime or LCL/RMT When OFF, the [Hand On] and [Auto On] buttons are always active. If the MCD 500 is in Auto On mode, pressing [Hand On] will enter Hand On mode and start the motor.

If 3-1 Local/Remote is set to Remote Control Only, the [Off] button is disabled and the motor must be stopped by remote control or via the serial communication network.

6.6 Displays

The LCP displays a wide range of performance information about the soft starter. Press [Status] to access the status

display screens, then use [▲] and [▼] to select the information to display. To return to the status screens from within a menu, press [Back] repeatedly or press [Status].

Temperature monitoring

•

Programmable screen (see parameters 8-2 - 8-5)

•

Current

•

Frequency

•

Motor power

•

Last start information

•

Date and time

•

SCR Conduction bar-graph

•

Performance graphs

•

NOTE

Screens shown here are with the default settings.

The temperature monitoring screen is the default status screen.

Ready S1 MS1 000.0A 000.0kW

Primary Motor Set

M1 000%

Table 6.6

6.6.2 Programmable Screen (S2)

The MCD 500's user-programmable screen can be configured to show the most important information for the particular application. Use parameters 8-2 to 8-5 to select which information to display.

Ready S2 MS1 000.0A 000.0kW

-.-- pf

00000 hrs

Table 6.7

Average Current (S3)

6.6.3

The average current screen shows the average current of all three phases.

Ready MS1 000.0A 000.0kW

0.0A

Table 6.8

6.6.1 Temperature Monitoring Screen (S1)

The temperature screen shows the temperature of the motor as a percentage of total thermal capacity, and also shows which motor data set is in use.

48 MG17K402 - VLT® is a registered Danfoss trademark

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177HA513.10

Operation MCD 500 Operating Instruction

6.6.4 Current Monitoring Screen (S4)

The current screen shows real-time line current on each phase.

Ready S4 MS1 000.0A 000.0kW

Phase currents

000.0A 000.0A 000.0A

Table 6.9

6.6.5 Frequency Monitoring Screen (S5)

The frequency screen shows the mains frequency as measured by the soft starter.

Ready S5 MS1 000.0A 000.0kW

00.0Hz

Table 6.10

Motor Power Screen (S6)

6.6.6

The motor power screen shows motor power (kW, HP and kVA) and power factor.

Ready MS1 000.0A 000.0kW

000.0kW 0000HP 0000kVA -. - - pf

Table 6.11

Last Start Information (S7)

6.6.7

The last start information screen shows details of the most recent successful start:

start duration (seconds)

•

maximum start current drawn (as a percentage of

•

motor full load current) calculated rise in motor temperature

•

Ready MS1 000.0A 000.0kW Last start 000 s 000 % FLC

ΔTemp 0%

6.6.8

Date and Time (S8)

The date/time screen shows the current system date and time (24 hour format). For details on setting the date and time, see 8.1 Set Date and Time.

Ready S8 MS1 000.0A 000.0kW

YYYY MMM DD HH:MM:SS

Table 6.13

SCR Conduction Bargraph

6.6.9

The SCR conduction bargraph shows the level of conduction on each phase.

Illustration 6.2

6.6.10 Performance Graphs

The MCD 500 can display real-time performance information for:

Current

•

Motor temperature

•

Motor kW

•

Motor kVA

•

Motor power factor

•

The newest information is displayed at the right hand edge of the screen. Older data is not stored. The graph can also be paused, to allow past performance to be analysed. To pause or unpause the graph, press and hold [OK] for more than 0.5 seconds.

NOTE

The MCD 500 will not collect data while the graph is paused. When graphing resumes, a small gap will be shown between the old data and the new data.

Table 6.12

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Programming MCD 500 Operating Instruction

7 Programming

It is possible to access the programming menus at any time, including while the soft starter is running. All changes take effect immediately.

7.1 Access Control

Critical parameters (parameter group 15 and higher) are protected by a four-digit security access code, preventing unauthorised users from viewing or modifying parameter settings.

When a user attempts to enter a restricted parameter group, the LCP prompts for an access code. The access code is requested once for the programming session, and

authorisation continues until the user closes the menu.

To enter the access code, press [Back] and [OK] to select a digit, and [▲] and [▼] to change the value. When all four

digits match the access code, press [OK]. The LCP will display an acknowledgement message before continuing.

To change the access code, use 15-1 Access Code.

Enter Access Code

####

Access Allowed

SUPERVISOR

Table 7.1

NOTE

The protection simulation and output simulation are also protected by the security access code. The counters and thermal model reset can be viewed without entering an access code, but an access code must be entered in order to reset. The default access code is 0000.

Lock the menus to prevent users from altering parameter settings. The adjustment lock can be set to allow Read & Write, Read Only or No Access in 15-2 Adjustment Lock.

If a user attempts to change a parameter value or access the Main Menu when the adjustment lock is active, an error message is displayed:

Access Denied Adj Lock is On

Table 7.2

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7.2 Quick Menu

7.2.1 Quick Setup

Quick setup provides access to commonly used parameters, allowing the user to configure the MCD 500 as required for the application. For details of individual parameters, see Parameter Descriptions.

1 Primary Mtr Set 1-1 Motor FLC 1-3 Start Mode 1-4 Current Limit 1-5 Initial Current 1-6 Start Ramp Time 1-9 Excess Start Time 1-10 Stop Mode 1-11 Stop Time 2 Protection 2-1 Phase Sequence 2-4 Undercurrent 2-5 Undercurrent Dly 2-6 Inst Overcurrent 2-7 Inst Overcurrent Dly 3 Inputs 3-3 Input A Function 3-4 Input A Name 3-5 Input A Trip 3-6 Input A Trip Dly 3-7 Input A Initial Dly 4 Outputs 4-1 Relay A Function 4-2 Relay A On Delay 4-3 Relay A Off Delay 4-4 Relay B Function 4-5 Relay B On Delay 4-6 Relay B Off Delay 4-7 Relay C Function 4-8 Relay C On Delay 4-9 Relay C Off Delay 4-10 Low Current Flag 4-11 High Current FLag 4-12 Motor Temp Flag 5 Start/Stop Timers 5-1 Auto-Start Type 5-2 Auto-Start Time 5-3 Auto-Stop Type 5-4 Auto-Stop Time 8 Display 8-1 Language 8-2 User Scrn Top L 8-3 User Scrn Top R 8-4 User Scrn Btm L 8-5 User Scrn Btm R

7 7

Table 7.3

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Programming MCD 500 Operating Instruction

7.2.2 Application Setups

The application setups menu makes it easy to configure the MCD 500 for common applications. The MCD 500 selects the parameters relevant to the application and suggests a typical setting, and you can adjust each parameter to suit your exact requirements.

On the display the highlighted values are suggested values and the values indicated by a ▶ are the loaded values.

Always set 1-1 Motor FLC to match the motor's nameplate full load current. The suggested value for motor FLC is the starter's minimum FLC.

Pump Centrifugal Suggested Value Compressor Recip Suggested Value Motor Full Load Current Motor Full Load Current Start Mode Adaptive Start Profile Start Ramp Time Stop Mode

Adaptive Stop Profile Stop Time Pump Submersible Conveyor Motor Full Load Current Motor Full Load Current Start Mode Adaptive Start Profile Start Ramp Time Stop Mode Adaptive Stop Profile Stop Time Fan Damped Crusher Rotary Motor Full Load Current Motor Full Load Current Start Mode Current Limit

Fan Undamped Crusher Jaw Motor Full Load Current Motor Full Load Current Start Mode Adaptive Start Profile Start Ramp Time Excess Start Time Locked Rotor Time Compressor Screw Motor Full Load Current Start Mode Start Ramp Time Current Limit

Adaptive Control Early Acceleration 10 seconds Adaptive Control Late Deceleration 15 seconds

Adaptive Control Early Acceleration 5 seconds Adaptive Control Late Deceleration 5 seconds

Constant Current 350%

Adaptive Control Constant Acceleration 20 seconds 30 seconds 20 seconds

Constant Current 5 seconds 400%

Start Mode Start Ramp Time Current Limit

Start Mode Start Ramp Time Current Limit Stop Mode Adaptive Stop Profile Stop Time

Start Mode Start Ramp Time Current Limit Excess Start Time Locked Rotor Time

Constant Current 10 seconds 450%

Constant Current 5 seconds 400% Adaptive Control Constant Deceleration 10 seconds

Constant Current 10 seconds 400% 30 seconds 20 seconds

Constant Current 10 seconds 450% 40 seconds 30 seconds

Table 7.4

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7.2.3 Loggings

The Loggings menu allows the user to view performance information in real-time graphs.

Current (%FLC)

•

Motor Temp (%)

•

Motor kW (%)

•

Motor kVA (%)

•

Motor pf

•

The newest information is displayed at the right hand edge of the screen. The graph can be paused to analyse data by pressing and holding the [OK] button. To re-start the graph, press and hold [OK].

7.3 Main Menu

The Main Menu button provides access to menus for setting up the MCD 500 for complex applications and for monitoring its performance.

Parameters

7.3.1

Parameters allows viewing and changing all programmable parameters that control how the MCD 500 operates.

To open Parameters, press [Main Menu] then select Parameters.

To navigate through Parameters:

to scroll through parameter groups, press [▲] or

•

[▼]. to view the parameters in a group, press [OK].

•

to return to the previous level, press [Back].

•

to close Parameters, press the [Back].

•

To change a parameter value:

scroll to the appropriate parameter and press

•

[OK] to enter edit mode.

to alter the parameter setting, use the [▲] and [▼]

•

buttons. to save changes, press [OK]. The setting shown

•

on the display will be saved and the LCP will return to the parameter list.

to cancel changes, press [Back]. The LCP will

•

return to the parameter list without saving changes.

Parameter Shortcut

7.3.2

The MCD 500 also includes a parameter shortcut, which allows you to directly access a parameter within the Parameters menu.

To access the parameter shortcut, press [Main

•

Menu] for three seconds

Use [▲] or [▼] to select the parameter group.

•

Press [OK] or [Back] to move the cursor.

•

Use [▲] or [▼] to select the parameter number.

•

Parameter shortcut

Please enter a

Parameter number

01-01

Table 7.5

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Programming MCD 500 Operating Instruction

7.3.3 Parameter List

1 Primary Mtr Set 4 Outputs 7-12 Adaptv Ctrl Gain-2 1-1 Motor FLC 4-1 Relay A Function 7-13 Adaptv Start Prof-2 1-2 Locked Rotor Time 4-2 Relay A On Delay 7-14 Adaptv Stop Prof-2 1-3 Start Mode 4-3 Relay A Off Delay 7-15 Brake Torque-2 1-4 Current Limit 4-4 Relay B Function 7-16 Brake Time-2 1-5 Initial Current 4-5 Relay B On Delay 8 Display 1-6 Start Ramp Time 4-6 Relay B Off Delay 8-1 Language 1-7 Kickstart Level 4-7 Relay C Function 8-2 User Scrn Top L 1-8 Kickstart Time 4-8 Relay C On Delay 8-3 User Scrn Top R 1-9 Excess Start Time 4-9 Relay C Off Delay 8-4 User Scrn Btm L 1-10 Stop Mode 4-10 Low Current Flag 8-5 User Scrn Btm R 1-11 Stop Time 4-11 High Current FLag 8-6 Graph Timebase 1-12 Adaptv Control Gain 4-12 Motor Temp Flag 8-7 Graph Max Adj 1-13 Adaptv Start Profile 4-13 Analog Output A 8-8 Graph Min Adj 1-14 Adaptv Stop Profile 4-14 Analog A Scale 8-9 Mains Ref Volt

1-15 Brake Torque 4-15 Analog A Max Adj 15 Restrict Paramtr 1-16 Brake Time 4-16 Analog A Min Adj 15-1 Access Code 2 Protection 5 Start/Stop Timers 15-2 Adjustment Lock 2-1 Phase Sequence 5-1 Auto-Start Type 15-3 Emergency Run 2-2 Current Imbalance 5-2 Auto-Start Time 15-4 Current Calibrat 2-3 Current Imbal Dly 5-3 Auto-Stop Type 15-5 Main Cont Time 2-4 Undercurrent 5-4 Auto-Stop Time 15-6 Bypass Cont Time 2-5 Undercurrent Dly 6 Auto-Reset 15-7 Motor Connection 2-6 Inst Overcurrent 6-1 Auto-Reset Action 15-8 Jog Torque 2-7 Inst Ocrnt Dly 6-2 Maximum Resets 16 Protection Action 2-8 Frequency Check 6-3 Reset Dly Grp A & B 16-1 Motor Overload 2-9 Freq Variation 6-4 Reset Delay Grp C 16-2 Current Imbalance 2-10 Frequency Delay 7 Secondary Mtr Set 16-3 Undercurrent 2-11 Restart Delay 7-1 Motor FLC-2 16-4 Inst Overcurrent 2-12 Motor Temp Check 7-2 Lock Rotor Time-2 16-5 Frequency 3 Inputs 7-3 Start Mode-2 16-6 Heatsink Overtemp 3-1 Local/Remote 7-4 Current Limit-2 16-7 Excess Start Time 3-2 Comms in Remote 7-5 Initial Crnt-2 16-8 Input A Trip 3-3 Input A Function 7-6 Start Ramp-2 16-9 Motor Thermistor 3-4 Input A Name 7-7 Kickstart Lvl-2 16-10 Starter Comms 3-5 Input A Trip 7-8 Kickstart Time-2 16-11 Network Comms 3-6 Input A Trip Dly 7-9 Excess Strt Time-2 16-12 Battery/Clock 3-7 Input A Initial Dly 7-10 Stop Mode-2 16-13 Low Control Volts 3-8 Remote Reset Logic 7-11 Stop Time-2

Table 7.6

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7.4 Primary Motor Settings

NOTE

Default settings are marked with *.

The parameters in Primary Motors Settings configure the soft starter to match the connected motor. These parameters describe the motor's operating characteristics and allow the soft starter to model the motor's temperature.

1-1 Motor FLC

Option: Function:

Model dependent

Matches the starter to the connected motor's full load current. Set to the full load current (FLC) rating shown on the motor nameplate.

1-2 Locked Rotor Time

Range: Function:

10 secs* [0:01 - 2:00

(min:sec)]

Sets the maximum length of the time the motor can run at locked rotor current from cold before reaching its maximum temperature. Set according to the motor datasheet. If this information is not available, we recommend the value should be less than 20 seconds.

1-3 Start Mode

Option: Function:

Selects the soft start mode. See 5.3 Starting Modes for more details.

Constant Current* Adaptive Control

1-4 Current Limit

Range: Function:

350%* [100% -

600% FLC]

Sets the current limit for constant current and current ramp soft starting, as a percentage of motor full load current. See 5.3 Starting Modes for more details.

1-5 Initial Current

Range: Function:

350%* [100% -

600% FLC]

Sets the initial start current level for current ramp starting, as a percentage of motor full load current. Set so that the motor begins to accelerate immediately after a start is initiated. If current ramp starting is not required, set the initial current equal to the current limit. See 5.3 Starting Modes for more details.

1-6 Start Ramp Time

Range: Function:

10 secs* [1 - 180

secs]

Sets the total start time for an AAC Adaptive Control start or the ramp time for current ramp starting (from the initial current to the current limit). See

5.3 Starting Modes for more details.

1-7 Kickstart Level

Range: Function:

500%* [100% -

700% FLC]

Sets the level of the kickstart current.

CAUTION

Kickstart subjects the mechanical equipment to increased torque levels. Ensure the motor, load and couplings can handle the additional torque before using this feature.

1-8 Kickstart Time

Range: Function:

0000 msecs*

[0 - 2000 msecs]

Sets the kickstart duration. A setting of 0 disables kickstart. See 5.3 Starting Modes for more details.

CAUTION

Kickstart subjects the mechanical equipment to increased torque levels. Ensure the motor, load and couplings can handle the additional torque before using this feature.

1-9 Excess Start Time

Range: Function:

Excess start time is the maximum time the MCD 500 will attempt to start the motor. If the motor does not reach full speed within the programmed limit, the starter will trip. Set for a period slightly longer than required for a normal healthy start. A setting of 0 disables

excess start time protection. 20 secs*

1-10 Stop Mode

Option: Function:

[0:00 - 4:00 (min:secs)]

Coast to Stop* TVR Soft Stop

Set as required.

Selects the stop mode. See 5.4 Stopping Modes for more details.

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Programming MCD 500 Operating Instruction

1-10 Stop Mode

7.4.1 Brake

Option: Function:

Adaptive Control Brake

1-11 Stop Time

Range: Function:

0 secs* [0:00 - 4:00

(min:secs)]

Sets the time for soft stopping the motor using timed voltage ramp or Adaptive Control (AAC). If a main contactor is installed, the contactor must remain closed until the end of the stop time. Use a programmable output configured to Run to control the main contactor. Sets the toal stopping time when using brake. See 5.4 Stopping Modes for more details.

Brake uses DC injection to actively slow the motor. See

5.4 Stopping Modes for more details.

1-15 Brake Torque

Range: Function:

20%* [20 - 100%] Sets the amount of brake torque the MCD

500 will use to slow the motor.

1-16 Brake Time

Range: Function:

1 sec* [1 - 30 secs] Sets the duration for DC injection during a

braking stop.

NOTE

This parameter is used in conjunction with 1-11 Stop Time. See for details.

1-12 Adaptive Control Gain

Range: Function:

75%* [1% -

200%]

Adjusts the performance of AAC adaptive acceleration control. This setting affects both starting and stopping control.

NOTE

We recommend leaving the gain setting at the default level unless AAC performance is not satisfactory. If the motor accelerates or decelerates quickly at the end of a start or stop, increase the gain setting by 5%~10%. If the motor speed fluctuates during starting or stopping, decrease the gain setting slightly.

7.5 Protection

2-1 Phase Sequence

Option: Function:

Selects which phase sequences the soft starter will allow at a start. During its pre-start checks, the starter examines the sequence of the phases at its input terminals and trips of the actual sequence does not match the selected

option. Any sequence* Positive only Negative only

1-13 Adaptive Start Profile

Option: Function:

Selects which profile the MCD 500 will use for an AAC adaptive acceleration control soft start. See 5.4 Stopping Modes for more details.

Early Acceleration Constant Acceleration* Late Acceleration

1-14 Adaptive Stop Profile

Option: Function:

Selects which profile the MCD 500 will use for an AAC adaptive acceleration control soft stop. See 5.4 Stopping Modes for more details.

Early Deceleration Constant Deceleration* Late Acceleration

7.5.1 Current Imbalance

The MCD 500 can be configured to trip if the currents on the three phases vary from each other by more than a specified amount. The imbalance is calculated as the difference between the highest and lowest currents on all three phases, as a percentage of the highest current.

Current imbalance detection is desensitised by 50% during starting and soft stopping.

2-2 Current Imbalance

Range: Function:

30%* [10% - 50%] Sets the trip point for current imbalance

protection.

2-3 Current Imbalance Delay

Range: Function:

3 secs* [0:00 - 4:00

(min:secs)]

Slows the MCD 500's response to current imbalance, avoiding trips due to momentary fluctuations.

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Programming MCD 500 Operating Instruction

7.5.2 Undercurrent

The MCD 500 can be configured to trip if the average current of all three phases drops below a specified level while the motor is running.

2-4 Undercurrent

Range: Function:

20%* [0% -

100%]

Sets the trip point for undercurrent protection, as a percentage of motor full load current. Set to a level between the motor's normal working range and the motor's magnetising (no load) current (typically 25% to 35% of full load current). A setting of 0% disables undercurrent protection.

2-5 Undercurrent Delay

Range: Function:

5 secs* [0:00 - 4:00

(min:secs)]

Slows the MCD 500's response to undercurrent, avoiding trips due to momentary fluctuations.

7.5.3 Instantaneous Overcurrent

The MCD 500 can be configured to trip if the average current of all three phases exceeds a specified level while the motor is running.

2-6 Instantaneous Overcurrent

Range: Function:

400%* [80% - 600%

FLC]

Sets the trip point for instantaneous overcurrent protection, as a percentage of motor full load current.

2-7 Instantaneous Overcurrent Delay

Range: Function:

0 secs* [0:00 - 1:00

(min:secs)]

Slows the MCD 500's response to overcurrent, avoiding trips due to momentary overcurrent events.

7.5.4 Frequency Trip

The MCD 500 monitors mains frequency throughout operation, and can be configured to trip is the frequency varies beyond a specified tolerance.

2-8 Frequency Check

Option: Function:

Do not Check Start Only Start/Run* Run Only

Determines when the starter will monitor for a frequency trip.

2-9 Frequency Variation

Option: Function:

Selects the soft starter's tolerance for frequency variation. Running a motor outside its specified frequency for long periods can cause damage and premature failure.

± 2 Hz ± 5 Hz* ± 10 Hz ± 15 Hz

2-10 Frequency Delay

Range: Function:

1 sec* [0:01 - 4:00

(min:sec)]

Slows the MCD 500's response to frequency disturbances, avoiding trips due to momentary fluctuations.

NOTE

If the mains frequency drops below 35 Hz or rises above 75 Hz, the starter will trip immediately.

2-11 Restart Delay

Range: Function:

10 secs*

[00:01 60:00 (min:secs)]

The MCD 500 can be configured to force a delay between the end of a stop and the beginning of the next start. During the restart delay, the display shows the time remaining before another start can be attempted.

NOTE

The restart delay is measured from the end of each stop. Changes to the restart delay setting take effect immediately.

2-12 Motor Temperature Check

Option: Function:

Selects whether the MCD 500 will verify the motor has sufficient thermal capacity for a successful start. The soft starter compares the motor's calculated temperature with the temperature rise from the last motor start and only operates if the motor is cool enough to start

successfully. Do not Check* Check

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Programming MCD 500 Operating Instruction

3-3 Input A Function

7.6 Inputs

3-1 Local/Remote

Option: Function:

Selects when the [Auto On] and [Hand On] buttons can be used to switch to Hand On or

Auto On modes. Lcl/Rmt anytime* Local Control Only Remote Control Only

3-2 Comms in Remote

Option: Function:

Disable Ctrl in RMT Enable Ctrl in RMT*

3-3 Input A Function

Option: Function:

Motor Set Select*

Input Trip (N/O)

Input Trip (N/C)

Local/Remote Select

The user can change between local and

remote control at any time.

All remote inputs are disabled.

Selects whether the starter can be used in

Hand On or Auto On modes.

Selects whether the starter will accept Start and Stop commands from the serial communication network when in Remote mode. The Force Comms Trip, Local/Remote Control and Test Start and Reset commands are always enabled.

Selects the function of Input A. The MCD 500 can be configured with two separate sets of motor data. The primary motor data is programmed using Parameters 1-1 to 1-16. The secondary motor data is programmed using Parameters 7-1 to 7-16. To use the secondary motor data, this parameter must be set to Motor Set Select and 11, 16 must be closed when a start command is given. The MCD 500 checks which motor data to use at a start, and will use that motor data for the entire start/stop cycle. Input A can be used to trip the soft starter. When this parameter is set to Input Trip (N/O), a closed circuit across 11, 16 trips the soft starter (Parameters 3-5, 3-6, 3-7). When this parameter is set to Input Trip (N/C), an open circuit across 11, 16 trips the soft starter (Parameters 3-5, 3-6, 3-7). Input A can be used to select between local and remote control, instead of using the buttons on theLCP. When the input is open, the starter is in local mode and can be controlled via the LCP. When the input is closed, the starter is in remote mode. The [Hand On] and [Auto On] buttons are disabled, and the soft starter will

Option: Function:

ignore any Local/Remote select command from the serial communications network. To use Input A to select between local and remote control, 3-1 Local/Remote must be set to LCL/RMT Anytime.

Emergency Run

Emergency Stop

Jog Forward Activates jog operation in a forward direction

Jog Reverse Activates jog operation in reverse direction (will

In emergency run the soft starter continues to run until stopped, ignoring all trips and warnings (see 15-3 Emergency Run for details). Closing the circuit across 11, 16 activates emergency run. Opening the circuit ends emergency run and the MCD 500 stops the motor. The MCD 500 can be commanded to emergency stop the motor, ignoring the soft stop mode set in 1-10 Stop Mode. When the circuit across 11, 16 is opened, the soft starter allows the motor to coast to stop.

(will operate only in Remote mode).

operate only in Remote mode).

3-4 Input A Name

Option: Function:

Selects a message for the LCP to display

when Input A is active. Input Trip* Low Pressure High Pressure Pump Fault Low Level High Level No Flow Emergency Stop Controller PLC Vibration Alarm

3-5 Input A Trip

Option: Function:

Selects when an input trip can occur.

Always Active*

Operating Only A trip can occur while the soft starter is

Run Only A trip can only occur while the soft starter is

A trip can occur at any time when the soft starter is receiving power.

running, stopping or starting.

running.

3-6 Input A Trip Delay

Range: Function:

0 secs* [0:00 - 4:00 (min:secs)] Sets delay between the input

activating and soft starter tripping.

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Programming MCD 500 Operating Instruction

3-7 Input A Initial Delay

Range: Function:

0 secs* [00:00 - 30:00

(min:secs)]

Sets a delay before an input trip can occur. The initial delay is counted from the time a start signal is received. The state of the input is ignored until the initial delay has elapsed.

3-8 Remote Reset Logic

Option: Function:

Selects whether the MCD 500's remote reset input (terminals 25, 18) is normally open or

normally closed. Normally Closed* Normally Open

7.7 Outputs

4-1 Relay A Function

Option: Function:

Selects the function of Relay A (normally

open). Off Relay A is not used Main Contactor*

Run The relay closes when the starter changes to

Trip The relay closes when the starter trips. Warning The relay closes when the starter issues a

Low Current Flag High Current Flag Motor Temp Flag

The relay closes when the MCD 500 receives

a start command, and remains closed as long

as the motor is receiving voltage.

run state.

warning.

The relay closes when the low current flag

activates (4-10 Low Current Flag).

The relay closes when the high current flag

activates (4-11 High Current Flag).

The relay closes when the motor temperature

flag activates (4-12 Motor Temperature Flag).

7.7.1 Relay A Delays

The MCD 500 can be configured to wait before opening or closing Relay A.

4-2 Relay A On Delay

Range: Function:

0 secs* [0:00 - 5:00 (min:secs)] Sets the delay for closing Relay

4-3 Relay A Off Delay

Range: Function:

0 secs* [0:00 - 5:00 (min:secs)] Sets the delay for re-opening

Relay A.

7.7.2 Relays B and C

Parameters 4-4 to 4-9 configure the operation of Relays B and C in the same way as parameters 4-1 to 4-3 configure Relay A.

4-4 Relay B Function

Option: Function:

Selects the function of Relay B (changeover). Off Relay B is not used Main Contactor The relay closes when the MCD 500 receives a

start command, and remains closed as long as

the motor is receiving voltage. Run*

Trip The relay closes when the starter trips. Warning The relay closes when the starter issues a

Low Current Flag High Current Flag Motor Temp Flag

4-5 Relay B On Delay

Range: Function:

0 secs* [0:00 - 5:00 (min:secs)] Sets the delay for closing Relay

4-6 Relay B Off Delay

Range: Function:

0 secs* [0:00 - 5:00 (min:secs)] Sets the delay for re-opening

4-7 Relay C Function

Option: Function:

Off Relay C is not used Main Contactor The relay closes when the MCD 500 receives a

Run The relay closes when the starter changes to

Trip* Warning The relay closes when the starter issues a

Low Current Flag High Current Flag Motor Temp Flag

The relay closes when the starter changes to

run state.

warning.

The relay closes when the low current flag

activates (4-10 Low Current Flag).

The relay closes when the high current flag

activates (4-11 High Current Flag).

The relay closes when the motor temperature

flag activates (4-12 Motor Temperature Flag).

Relay B.

Selects the function of Relay C (normally

open).

start command, and remains closed as long as

the motor is receiving voltage.

run state.

The relay closes when the starter trips.

warning.

The relay closes when the low current flag

activates (4-10 Low Current Flag).

The relay closes when the high current flag

activates (4-11 High Current Flag).

The relay closes when the motor temperature

flag activates (4-12 Motor Temperature Flag).

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Programming MCD 500 Operating Instruction

4-8 Relay C On Delay

Range: Function:

0 secs* [0:00 - 5:00 (min:secs)] Sets the delay for closing Relay

4-9 Relay C Off Delay

Range: Function:

0 secs* [0:00 - 5:00 (min:secs)] Sets the delay for re-opening

Relay C.

7.7.3 Low Current Flag and High Current Flag

The MCD 500 has low and high current flags to give early warning of abnormal operation. The current flags can be configured to indicate an abnormal current level during operation, between the normal operating level and the

undercurrent or instantaneous overcurrent trip levels. The flags can signal the situation to external equipment via one of the programmable outputs. The flags clear when the current returns within the normal operating range by 10% of the programmed motor full load current.

4-10 Low Current Flag

Range: Function:

50%* [1% - 100%

FLC]

Sets the level at which the low current flag operates, as a percentage of motor full load current.

4-11 High Current Flag

Range: Function:

100%* [50% - 600%

FLC]

Sets the level at which the high current flag operates, as a percentage of motor full load current.

4-13 Analog Output A

Option: Function:

Selects which information will be reported via

analog output A. Current (% FLC)* Motor Temp (%)

Motor kW (%)

Motor kVA (%)

Motor pf Motor power factor, measured by the soft starter.

Current as a percentage of motor full load

current.

Motor temperature as a percentage of the motor

service factor (calculated by the soft starter's

thermal model).

Motor kilowatts. 100% is motor FLC (1-1 Motor

FLC) multiplied by mains reference voltage (8-9

Mains Reference Voltage). Power factor is assumed

to be 1.0.

3 × V ×

Motor kilovolt amperes. 100% is motor FLC (1-1

Motor FLC) multiplied by mains reference voltage

(8-9 Mains Reference Voltage).

3 × V ×

1000

FLC

4-14 Analog A Scale

Option: Function:

Selects the range of the output. 0-20 mA 4-20 mA*

4-15 Analog A Maximum Adjustment

Range: Function:

100%* [0% - 600%] Calibrates the upper limit of the analog

output to match the signal measured on an external current measuring device.

4-16 Analog A Minimum Adjustment

Range: Function:

7.7.4 Motor Temperature Flag

The MCD 500 has a motor temperature flag to give early

0%* [0% - 600%] Calibrates the lower limit of the analog

output to match the signal measured on an external current measuring device.

warning of abnormal operation. The flag can indicate that the motor is operating above its normal operating temperature, but lower than the overload limit. The flag

7.8 Start/Stop Timers

can signal the situation to external equipment via one fo the programmable outputs.

4-12 Motor Temperature Flag

Range: Function:

80%* [0% - 160%] Sets the level at which the motor

temperature flag operates, as a percentage of the motor's thermal capacity.

7.7.5 Analog Output A

The MCD 500 has an analog output, which can be connected to associated equipment to monitor motor performance.

CAUTION

The auto-start timer overrides any other form of control. The motor may start without warning.

5-1 Auto-Start Type

Option: Function:

Selects whether the soft starter will auto-start after a specified delay, or at a time of day. The soft starter will not auto-start.

Off* Timer The soft starter will auto-start after a delay from the

next stop, as specified in 5-2 Auto-start Time.

Clock The soft starter will auto-start at the time programmed

in 5-2 Auto-start Time.

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Programming MCD 500 Operating Instruction

5-2 Auto-Start Time

Range: Function:

1 min* [00:01 - 24:00

(hrs:min)]

Sets the time for the soft starter to auto-start, in 24 hour clock format.

5-3 Auto-Stop Type

Option: Function:

Selects whether the soft starter will auto-stop after a specified delay, or at a time of day. The soft starter will not auto-stop.

Off* Time The soft starter will auto-stop after a delay from the

next start, as specified in 5-4 Auto-stop Time.

Clock The soft starter will auto-stop at the time programmed

in 5-4 Auto-stop Time.

5-4 Auto-Stop Time

Range: Function:

1 min* [00:01 -

24:00 (hrs:min)]

Sets the time for the soft starter to autostop, in 24 hour clock format.

CAUTION

This function should not be used in conjunction with remote two-wire control. The soft starter will still accept start and stop commands from the remote inputs or serial communication network. To disable local or remote control, use 3-1 Local/Remote. If auto-start is enabled and the user is in the menu system, auto-start will become active if the menu times out (if no LCP activity is detected for five minutes).

7.9 Auto-Reset

Other trips cannot be automatically reset.

This function is ideal for remote installations using 2-wire control in Auto On mode. If the 2-wire start signal is present after an auto-reset, the MCD 500 will restart.

6-1 Auto-Reset Action

Option: Function:

Selects which trips can be auto-reset. Do not Auto-Reset* Reset Group A Reset Group A & B Reset Group A, B & C

6-2 Maximum Resets

Range: Function:

1* [1 - 5] Sets how many times the soft starter will auto-reset,

if it continues to trip. The reset counter increases by one each time the soft starter auto-resets, and decreases by one after each successful start/stop cycle.

NOTE

The reset counter will return to 0 if the starter is manually reset.

7.9.1 Auto-Reset Delay

The MCD 500 can be configured to wait before autoresetting a trip. Separate delays can be set for trips in Groups A and B, or in Group C.

6-3 Reset Delay Groups A & B

Range: Function:

5 secs* [00:05 - 15:00

(min:secs)]

Sets the auto-reset delay for Group A and Group B trips.

7 7

The MCD 500 can be programmed to automatically reset certain trips, which can help minimise operating downtime. Trips are divided into three categories for autoreset, depending on the risk to the soft starter:

Group

Table 7.7

Current Imbalance Phase Loss

Power Loss Mains Frequency Undercurrent

Instantaneous Overcurrent Input A Trip Motor Overload

Motor Thermistor Starter Overtemperature

MG17K402 - VLT® is a registered Danfoss trademark 61

6-4 Reset Delay Group C

Range: Function:

5 min* [5 - 60 (minutes)] Sets the auto-reset delay for Group C

trips.

7.10 Secondary Motor Set

7-1 Motor FLC-2

Range: Function:

[Motor dependent]

Matches the starter to the second motor's full load current. Set to the full load current (FLC) rating shown on the motor nameplate.

Page 63

Programming MCD 500 Operating Instruction

7-2 Locked Rotor Time-2

Range: Function:

10 secs* [0:01 - 2:00

(min:secs)]

7-3 Start Mode-2

7-9 Excess Start Time-2

Range: Function:

excess start time protection. 20 secs*

[0:00 - 4:00 (min:secs)]

Set the excess time for the secondary

motor.

Option: Function:

Selects the start mode for the secondary

motor. Constant Current* Adaptive Control

7-4 Current Limit-2

Range: Function:

350%* [100% - 600%

FLC]

Sets the current limit for constant current and current ramp soft starting, as a percentage of motor full load current.

7-5 Initial Current-2

Range: Function:

350%* [100% -

600% FLC]

7-10 Stop Mode-2

Option: Function:

Selects the stop mode for the secondary

motor. Coast to Stop* TVR Soft Stop Adaptive Control Brake

7-11 Stop Time-2

Range: Function:

0 secs* [0:00 - 4:00

(min:secs)]

7-12 Adaptive Control Gain-2

7-6 Start Ramp Time-2

Range: Function:

10 secs* [1 - 180

secs]

Sets the total start time for an AAC Adaptive Control start or the ramp time for current ramp starting (from the initial current to the current limit).

7-7 Kickstart Level-2

Range: Function:

500%* [100% - 700% FLC] Sets the level of the kickstart

current.

7-8 Kickstart Time-2

Range: Function:

0000 msecs* [0 - 2000 msecs] Sets the kickstart duration. A

setting of 0 disables kickstart.

Range: Function:

75%* [1% -

200%]

Adjusts the performance of AAC adaptive

acceleration control.

NOTE

We recommend leaving the gain setting

at the default level unless AAC

performance is not satisfactory.

If the motor accelerates or decelerates

quickly at the end of a start or stop,

increase the gain by setting by 5% -

10%. If the motor speed fluctuates

during starting or stopping, decrease the

gain setting slightly.

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Programming MCD 500 Operating Instruction

7-13 Adaptive Start Profile-2

Option: Function:

Selects which profile the MCD 500 will use for an AAC adaptive acceleration

control soft start. Early Acceleration Constant Acceleration* Late Acceleration

7-14 Adaptive Stop Profile-2

Option: Function:

Selects which profile the MCD 500 will use for an AAC adaptive acceleration

control soft stop. Early Deceleration Constant Deceleration* Late Acceleration

7-15 Brake Torque-2

Range: Function:

20%* [20 - 100%] Sets the amount of brake torque the MCD

500 will use to slow the motor.

7-16 Brake Time-2

Range: Function:

1 sec* [1 - 30 secs] Sets the duration for DC injection during a

braking stop.

NOTE

This parameter is used in conjunction with 7-11 Stop Time-2.

7.11 Display

8-1 Language

Option: Function:

Selects which language the LCP will

use to display messages and feedback. English* Chinese (中丈) Spanish (Español) German (Deutsch) Portuguese (Português) French (Français) Italian (Italiano) Russian (Русский)

7.11.1 User Programmable Screen

Selects which four items will be displayed on the programmable monitoring screen.

8-2 User Screen - Top Left

Option: Function:

Selects the item displayed in the top left part of the screen.

Blank Displays no data in the selected area,

allowing long messages to be shown without overlapping.

Starter State The starter's operating state (starting,

running, stopping or tripped). Only available for “Top L” and “Btm L”.

Motor Current The average current measured on three

phases.

Motor pf*

Mains Frequency The average frequency measured on three

Motor kW The motor's running power in kilowatts. Motor HP The motor's running power in horsepower. Motor Temp The motor's temperature, calculated by the

kWh The number of kilowatt hours the motor has

Hours Run The number of hours the motor has run via

8-3 User Screen - Top Right

Option: Function:

Blank*

Starter State The starter's operating state (starting,

Motor Current The average current measured on three

Motor pf The motor's power factor, measured by the

Mains Frequency The average frequency measured on three

Motor kW The motor's running power in kilowatts. Motor HP The motor's running power in horsepower. Motor Temp The motor's temperature, calculated by the

kWh The number of kilowatt hours the motor has

Hours Run The number of hours the motor has run via

The motor's power factor, measured by the soft starter.

phases.

thermal model.

run via the soft starter.

the soft starter.

Selects the item displayed in the top right part of the screen. Displays no data in the selected area, allowing long messages to be shown without overlapping.

running, stopping or tripped). Only available for “Top L” and “Btm L”.

phases.

soft starter.

phases.

thermal model.

run via the soft starter.

the soft starter.

7 7

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Page 65

Programming MCD 500 Operating Instruction

8-4 User Screen - Bottom Left

7.11.2 Performance Graphs

Option: Function:

Selects the item displayed in the bottom left part of the screen.

Blank Displays no data in the selected area,

allowing long messages to be shown without overlapping.

Starter State The starter's operating state (starting,

running, stopping or tripped). Only available for “Top L” and “Btm L”.

Motor Current The average current measured on three

phases.

Motor pf The motor's power factor, measured by the

soft starter.

Mains Frequency The average frequency measured on three

phases.

Motor kW The motor's running power in kilowatts.

Motor HP The motor's running power in horsepower. Motor Temp The motor's temperature, calculated by the

thermal model.

kWh The number of kilowatt hours the motor has

run via the soft starter.

Hours Run*

The number of hours the motor has run via the soft starter.

8-5 User Screen - Bottom Right

Option: Function:

Selects the item displayed in the bottom right part of the screen.

Blank*

Starter State The starter's operating state (starting,

Motor Current The average current measured on three

Motor pf The motor's power factor, measured by the

Mains Frequency The average frequency measured on three

Motor kW The motor's running power in kilowatts. Motor HP The motor's running power in horsepower. Motor Temp The motor's temperature, calculated by the

kWh The number of kilowatt hours the motor has

Hours Run The number of hours the motor has run via

Displays no data in the selected area, allowing long messages to be shown without overlapping.

running, stopping or tripped). Only available for “Top L” and “Btm L”.

phases.

soft starter.

phases.

thermal model.

run via the soft starter.

the soft starter.

The loggings menu allows the user to view performance information in real-time graphs.

The newest information is displayed at the right hand edge of the screen. The graph can be paused to analyse data by pressing and holding the OK button. To re-start the graph, press and hold OK.

8-6 Graph Timebase

Option: Function:

Sets the graph time scale. The graph will progres-

sively replace the old data with new data. 10 secs* 30 secs 1 min 5 minutes 10 minutes 30 minutes 1 hour

8-7 Graph Maximum Adjustment

Range: Function:

400%* [0% - 600%] Adjusts the upper limit of the performance

graph

8-8 Graph Minimum Adjustment

Range: Function:

0%* [0% - 600%] Adjusts the lower limit of the performance

graph.

8-9 Mains Reference Voltage

Range: Function:

400 V* [100 - 690V]Sets the nominal voltage for the LCP's

monitoring functions. This is used to calculate motor kilowatts and kilovolt amperes (kVA), but does not affect the MCD 500's motor control protection. Enter the measured mains voltage.

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Page 66

Programming MCD 500 Operating Instruction

7.12 Restricted Parameters

15-1 Access Code

Range: Function:

0000* [0000 -

9999]

Sets the access code to enter the simulation tools and counter resets or the restricted section of the Programming Menu (parameter group 15 and higher). Use [Back] and [OK] to select which digit to

alter and use [▲] and [▼] to change the value.

NOTE

In the event of a lost access code, contact your supplier for master access code that allows you to re-program a new access code.

15-2 Adjustment Lock

Option: Function:

Selects whether the LCP will allow parameters to

be changed via the Programming Menu. Read & Write* Read Only Prevents users altering parameter values in the

No Access Prevents users adjusting parameters in the

Allows users to alter parameter values in the

Programming Menu

Programming Menu. Parameter values can still be

viewed.

Programming Menu unless an access code is

entered.

NOTE

Changes to the Adjustment Lock setting take

effect only after the Programming Menu has

been closed.

15-3 Emergency Run

Option: Function:

Selects whether the soft starter will permit emergency run operation. In emergency run, the soft starter will start (if not already running) and continue to operate until emergency run ends, ignoring stop commands and trips. Emergency run is controlled using a programmable input. When Emergency Run is activated in internally bypassed models which are not running, the starter will attempt a normal start while ignoring all trips. If a normal start is not possible, a DOL start via the internal bypass relays will be attempted. For non-bypassed models, an external emergency run bypass contactor may be used.

15-4 Current Calibration

Range: Function:

100%*

Motor Current Calibration calibrates the soft

[85%

starter's current monitoring circuits to match an

external current metering device.

115%]

Use the following formula to determine the necessary adjustment:

Calibration

e.g

. 102 % =

Current shown on MCD

( % ) =

Current measured by external device

500

display

NOTE

This adjustment affects all current-based functions.

15-5 Main Contactor Time

Range: Function:

400 msecs*

[100 2000 msecs]

Sets the delay period between the starter switching the main contactor output (terminals 13, 14) and beginning the pre-start checks (before start) or entering the not ready state (after a stop). Set according to the specifications of the main contactor used.

15-6 Bypass Contactor Time

Range: Function:

150 msecs* [100 - 2000

msecs]

Sets the starter to match the bypass contactor closing time. Set according to the specifications of the bypass contactor used. If the time is too short, the starter will trip.

15-7 Motor Connection

Option: Function:

Selects the soft starter will automatically detect

the format of the connection to the motor. Auto-Detect* In-line Inside Delta

15-8 Jog Torque

Range: Function:

50%* [20% - 100%] Sets the torque level for jog operation.

See the section Jog Operation for more details.

NOTE

Setting this parameter above 50% may cause increased shaft vibration.

7 7

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Page 67

Programming MCD 500 Operating Instruction

7.13 Protection Action

16-1 - 16-12 Protection Action

Option: Function:

Selects the soft starter's response to each protection.

16-1 Motor Overload

•

16-2 Current Imbalance

•

16-3 Undercurrent

•

16-4 Inst Overcurrent

•

16-5 Frequency

•

16-6 Heatsink Overtemp

•

16-7 Excess Start Time

•

16-8 Input A Trip

•

16-9 Motor Thermistor

•

Trip Starter* Warn and Log Log Only

16-10 Starter/Comms

•

16-11 Network/Comms

•

16-12 Battery/Clock

•

16-13 Low Control Volts

•

7.14 Factory Parameters

These parameters are restricted for Factory use and are not available to the user.

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Page 68

Tools MCD 500 Operating Instruction

8 Tools

To access Tools, open the Main Menu, scroll to Tools and press [OK].

8.1 Set Date and Time

To set the date and time:

1. Open the Tools Menu.

Scroll to Set Date & Time.

3. Press [OK] to enter edit mode.

4. Press [OK] to select which part of the date or time to edit.

Use [▲] and [▼] to change the value.

To save changes, press [OK] repeatedly. The MCD 500 will confirm the changes. To cancel changes, press [Back] repeatedly.

8.2 Load/Save Settings

The MCD 500 includes options to:

Load defaults: Load the MCD 500's parameters

•

with default values Load User Set 1: Reload previously saved

•

parameter settings from an internal file Save User Set 1: Save the current parameter

•

settings to an internal file

In addition to the factory default values file, the MCD 500 can store a user-defined parameter file. This file contains default values until a user file is saved.

To load or save parameter settings:

1. Open the Tools Menu.

Use [▼] to select the required function, then press [OK].

3. At the confirmation prompt, select YES to confirm or NO to cancel and then [OK] to load/save the selection or exit the screen.

Tools

Table 8.1

Load Defaults Load User Set 1 Save User Set 1

Load Defaults

Yes

Table 8.2

When the action has been completed, the screen will briefly display a confirmation message, then return to the status screens.

8.3 Reset Thermal Model

NOTE

This function is protected by the security access code.

The MCD 500's advanced thermal modelling software constantly monitors the motor's performance. This allows the MCD 500 to calculate the motor's temperature and ability to start successfully at any time.

The thermal model can be reset if required.

1. Open Tools.

2. Scroll to Reset Thermal Model and press [OK].

3. At the confirmation prompt, press [OK] to confirm then enter the access code, or press [Back] to cancel the action.

4. Select Reset or Do Not Reset, then press [OK]. When the thermal model has been reset, the MCD 500 will return to the previous screen.

Reset Thermal Model

M1 X%

OK to Reset

Table 8.3

Reset Thermal Model

Do Not Reset

Reset

Table 8.4

CAUTION

Adjusting the motor thermal model may compromise motor life and should only be done in the case of emergency.

8 8

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Page 69

Tools MCD 500 Operating Instruction

8.4 Protection Simulation

NOTE

This function is protected by the security access code.

Software simulation functions let you test the soft starter's operation and control circuits without connecting the soft starter to mains voltage.

The MCD 500 can simulate each different protection, in order to confirm that the soft starter is responding correctly and reporting the situation on the display and across the communication network.

To use the protection simulation:

1. Open the Main Menu.

2. Scroll to Protection Sim and press [OK].

Use [▲] and [▼] to select the protection you want to simulate.

4. Press [OK] to simulate the selected protection.

5. The protection message is displayed while [OK] is pressed. The soft starter's response depends on the Protection Action setting (parameter group

16).

6. Press [Back] to return to the simulation list.

Use [▲] or [▼] to select another simulation, or press [Back] to return to the Main Menu.

MS1 Tripped Selected Protection

Table 8.5

000.0A 0000.0kW

NOTE

If the protection trips the soft starter, reset before simulating another protection. If the protection action is set to Warn or Log, no reset is required. If the protection is set to Warn & Log, the warning message can be viewed only while [OK] is pressed. If the protection is set to Log only, nothing appears on the screen but an entry will appear in the log.

NOTE

To test operation of the flags (motor temperature and low/ high current), set an output relay to the appropriate function and monitor the relay's behaviour.

To use the output signal simulation:

1. Open the Main Menu.

2. Scroll to Output Signal Sim and press [OK], then enter the access code.

Use [▲] and [▼] to select a simulation, then press [OK].

Use [▲] and [▼] to turn the signal on and off. To confirm correct operation, monitor the state of the output.

5. Press [Back] to return to the simulation list.

Prog Relay A

Off

Table 8.6

8.6

Digital I/O State

This screen shows the current status of the Digital I/O in order.

The top line of the screen shows the start, stop, reset and programmable input.

The bottom line of the screen shows programmable outputs A, B and C.

The screen shot shows the stop input (17) as closed (1) and the start, reset and Input A inputs (15, 25, 11) as open (0). Relay A (13, 14) is closed and relays B and C (21, 22, 24 and 33, 34) are open.

Digital I/O State Inputs: 0100 Outputs: 100

Table 8.7

8.5 Output Signal Simulation

8.7

NOTE

This function is protected by the security access code.

The LCP allows the user to simulate output signalling in order to confirm that the output relays are operating correctly.

Temp Sensors State

This screen shows the state of the motor thermistor. The screen shot shows the thermistor state as O (open).

Temp Sensors State Thermistor: O S = shrt H=hot C=cld O=opn

Table 8.8

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Tools MCD 500 Operating Instruction

The resettable counters (hours run, starts and motor kWh)

8.8 Alarm Log

can only be reset if the correct access code is entered.

The [Alarm Log] button opens the Alarm Logs, which contains a Trip Log, Event Log, and Counters which store information on the MCD 500's operating history.

8.8.1 Trip Log

The Trip Log stores details of the eight most recent trips, including the date and time the trip happened. Trip 1 is the most recent and trip 8 is the oldest stored trip.

To open the Trip Log:

1. Open the Alarm Logs.

2. Scroll to Trip Log and press [OK].

Use [▲] and [▼] to select a trip to view, and press [OK] to display details.

To close the log and return to the main display, press [Back].

Event Log

8.8.2

The Event Log stores time-stamped details of the starter's 99 most recent events (actions, warnings and trips), including the date and time of the event. Event 1 is the most recent and event 99 is the oldest stored event.

To view the counters:

1. Open the Alarm Logs.

2. Scroll to Counters and press [OK].

Use [▲] and [▼] buttons to scroll through the counters. Press [OK] to view details.

4. To reset a counter, press [OK] then enter the access code. Select Reset, then press [OK] to confirm.

To close the counter and return to the Alarm Logs, press [Back].

8 8

To open the Event Log:

1. Open the Alarm Logs.

2. Scroll to Event Log and press [OK].

Use [▲] and [▼] to select an event to view, and press [OK] to display details.

To close the log and return to the main display, press [Back].

Counters

8.8.3

NOTE

This function is protected by the security access code.

The performance counters store statistics on the starter's operation:

Hours run (lifetime and since counter last reset)

•

Number of starts (lifetime and since counter last

•

reset) Motor kWh (lifetime and since counter last reset)

•

Number of times the thermal model has been

•

reset

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Page 71

Troubleshooting MCD 500 Operating Instruction

9 Troubleshooting

When a protection condition is detected, the MCD 500 will write this to the event log and may also trip or issue a

mechanisms are designed to protect the soft starter, or can

be caused by a fault within the soft starter. warning. The soft starter's response to some protections may depend on the Protection Action settings (parameter group 16).

9.1 Trip Messages

This table lists soft starter's protection mechanisms and the If the MCD 500 trips you will need to reset the soft starter

before restarting. If the MCD 500 has issued a warning, the soft starter will reset itself once the cause of the warning has been resolved.

probable cause of the trip. Some of these can be adjusted

using parameter group 2 Protection and parameter group

16 Protection Action, other settings are built-in system

protections and cannot be set or adjusted.

Some protections cause a fatal trip. This response is predefined and cannot be overridden. These protection

Display Possible cause/Suggested solution

Battery/Clock A verification error has occurred on the real time clock, or the backup battery voltage is low. If the

battery is low and the power is off, date/time settings will be lost. Reprogram the date and time. Related Parameter: 16-12 Battery Clock

Current Imbalance

Excess Start Time Excess start time trip can occur in the following conditions:

FLC Too High The MCD 500 can support higher motor FLC values when connected to the motor using inside

Frequency The mains frequency has gone beyond the specified range.

Current imbalance can be caused by problems with the motor, the environment or the installation, such as:

- An imbalance in the incoming mains voltage

- A problem with the motor windings

- A light load on the motor

Current imbalance can also be caused by incorrect cabling between the external bypass contactor and the soft starter or an internal problem with the soft starter, particularly an SCR that has failed open circuit. A failed SCR can only be definitely diagnosed by replacing the SCR and checking the starter's performance. Related Parameters: 2-3 - 2-3 and 16-2

1-1 Motor Full Load Current is not appropriate for the motor

•

1-4 Current Limit

•

1-6 Start Ramp Time has been set greater than the setting for 1-9 Excess Start Time Setting

•

1-6 Start Ramp Time is set too short for a high inertia load when using Adaptive Acceleration

•

Control

Related Parameters: 1-1, 1-6, 1-4, 1-9, 7-9, 7-1, 7-6, 7-4, and 16-7

delta configuration rather than in-line connection. If the soft starter is connected in-line but the programmed setting for 1-1 Motor Full Load Current is above the in-line maximum, the soft starter will trip at start. Related Parameters: 1-1 Motor FLC, 7-1 Motor FLC-2

Check for other equipment in the area that could be affecting the mains supply (particularly variable speed drives). If the MCD 500 is connected to a generator set supply, the generator may be too small or could have a speed regulation problem. Related Parameters: 2-8, 2-9, 2-10, and 16-5

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Troubleshooting MCD 500 Operating Instruction

Display Possible cause/Suggested solution

Heatsink Overtemp Check if cooling fans are operating. If mounted in an enclosure, check if ventilation is adequate.

Fans operate during Start, Run and for 10 minutes after the starter exits the Stop state.

NOTE

Models MCD5-0021B to MCD4-0053B and MCD5-0141B do not have a cooling fan. Models with fans will operate the cooling fans from a Start until 10 minutes after a Stop.

Related Parameters: 16-6 Heatsink Overtemp

Input A Trip Identify and resolve the condition which caused Input A to activate.

Related Parameters: 3-3, 3-4, 3-5, 3-6, 3-7, and 16-8

Inst Overcurrent The motor has experienced a sharp rise in motor current, probably caused by a locked rotor

condition (shearpin) while running. This may indicate a jammed load. Related Parameters: 2-6, 2-7, and 16-4

Internal Fault X The MCD 500 has tripped on an internal fault. Contact your local supplier with the fault code (X).

Related Parameters.: None L1 Phase Loss L2 Phase Loss L3 Phase Loss

L1-T1 Shorted L2-T2 Shorted L3-T3 Shorted Low Control Volts The MCD 500 has detected a drop in the control voltage.

Motor Overload/ Motor 2 Overlaod

Motor Connection The motor is not connected correctly to the soft starter for inline or inside delta use.

During prestart checks the starter has detected a phase loss as indicated.

In run state, the starter has detected that the current on the affected phase has dropped below

3.3% of the programmed motor FLC for more than 1 second, indicating that either the incoming

phase or connection to the motor has been lost.

Check the supply and the input and output connections at the starter and at the motor end.

Phase loss can also be caused by a failed SCR, particularly an SCR that has failed open circuit. A

failed SCR can only be definitely diagnosed by replacing the SCR and checking the starter's

performance.

Related Parameters: None

During prestart checks the starter has detected a shorted SCR or a short within the bypass

contactor as indicated.

Related Parameters: none

Check the external control supply (terminals A4, A5, A6) and reset the starter.

•

If the external control supply is stable:

the 24 V supply on the main control PCB may be faulty; or

•

the bypass driver PCB may be faulty (internally bypassed models only).

•

This protection is not active in Ready state.

Related Parameters: 16-13 Low Control Volts

The motor has reached its maximum thermal capacity. Overload can be caused by:

- The soft starter protection settings not matching the motor thermal capacity.

- Excessive starts per hour

- Excessive throughput

- Damage to the motor windings.

Resolve the cause of the overload and allow the motor to cool.

Related Parameters: 1-1, 1-2, 1-3, 1-4, 7-1, 7-2, 7-3, 7-4, and 16-1

- Check individual motor connections to the soft starter for power circuit continuity.

- Check connections at the motor terminal box.

Related Parameters: 15-7 Motor Connection

9 9

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Troubleshooting MCD 500 Operating Instruction

Display Possible cause/Suggested solution

Motor Thermistor The motor thermistor input has been enabled and:

The resistance at the thermistor input has exceeded 3.6 kΩ for more than one second.

- The motor winding has overheated. Identify the cause of the overheating and allow the motor to cool before restarting.

- The motor thermistor input has been open.

NOTE

If a valid motor thermistor is no longer used, a 1.2 kΩ resistor must be fitted across terminals 05, 06.

Related Parameters: 16-9 Motor Thermistor

Network Comms The network master has sent a trip command to the starter, or there may be a network communi-

cation problem. Check the network for causes of communication inactivity. Related Parameters: 16-11 Network/Comms

Parameter out of Range - A parameter value is outside the valid range.

The starter will load the default value for all affected parameters. Press [Main Menu] to go to the first invalid parameter and adjust the setting. Related Parameters: None

Phase Sequence The phase sequence on the soft starter's input terminals (L1, L2, L3) is not valid.

Check the phase sequence on L1, L2, L3 and ensure the setting in 2-1 Phase Sequence is suitable for the installation.

Power Loss The starter is not receiving mains supply on one or more phases when a Start Command is given.

Starter/Comms - There is a problem with the connection between the soft starter and the optional communi-

Thermistor Cct The thermistor input has been enabled and:

Time - Overcurrent The MCD 500 is internally bypassed and has drawn high current during running. (The 10 A

Undercurrent The motor has experienced a sharp drop in current, caused by loss of load. Causes can include

Unsupported Option The selected function is not available (e.g. jog is not supported in inside delta configuration).

Related Parameters: 2-1 Phase Sequence

Check that the main contactor closes when a start command is given, and remains closed until the end of a soft stop. If testing the soft starter with a small motor, it must draw at least 2% of its minimum FLC setting on each phase. Related Parameters: None

cations module. Remove and reinstall the module. If the problem persists, contact your local distributor.

- There is an internal communications error within the soft starter. Contact your local distributor.

Related Parameters: 16-10 Starter/Comms

The resistance at the input has fallen below 20 Ω (the cold resistance of most thermistors will be over this value) or

- A short circuit has occurred. Check and resolve this condition.

Check that a PT100 (RTD) is not connected to 05, 06. Related Parameters: None.

protection curve trip has been reached or the motor current has risen to 600% of the motor FLC setting.) Related Parameters: None

broken components (shafts, belts or couplings), or a pump running dry. Related Parameters: 2-4, 2-5, and 16-3

Related Parameters: None

Table 9.1

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Troubleshooting MCD 500 Operating Instruction

9.2 General Faults

This table describes situations where the soft starter does not operate as expected but does not trip or give a warning.

Symptom Probable Cause

Soft starter does not respond to commands. - If the soft starter does not respond to the [Reset] button on the LCP:

The soft starter may be in Auto On mode and will only accept commands from the remote control inputs. In Auto On mode, the Auto On LED on the LCP is illuminated. Press the [Hand On] or [Off] button to enable control via the LCP (this will also send a start or stop command to the MCD 500).

- If the soft starter does not respond to commands from the control inputs:

The soft starter may be in Hand On mode and will only accept commands from the LCP. When the soft starter is in Hand On control mode, the Off or Hand On LED on the LCP is active. To change to Auto On mode, press the [Auto On] button once. The control wiring may be incorrect. Check that the remote start, stop and reset inputs are configured correctly (see Control Wiring for details). The signals to the remote inputs may be incorrect. Test the signalling by activating each input signal in turn. The appropriate remote control input LED should activate on the LCP. The soft starter will only execute a start command from the remote inputs if the remote stop input is inactive and the remote reset input is activated (the Reset LED on the starter will be on).

- If the soft starter does not respond to a start command from either the local or remote controls:

The soft starter may be waiting for the restart delay to elapse. The length of the restart delay is controlled by Par. 2-11 Restart Delay. The motor may be too hot to permit a start. If Par. 2-12 Motor Temperature Check is set to Check, the soft starter will only permit a start when it calculates that the motor has sufficient thermal capacity to complete the start successfully. Wait for the motor to cool before attempting another start. The emergency stop function may be active. If Par. 3-3 is set to Emergency Stop and there is an open circuit on the corresponding input, the MCD 500 will not start. If the

emergency stop situation has been resolved, close the circuit on the input. The soft starter does not control the motor correctly during starting.

Motor does not reach full speed. - If the start current is too low, the motor will not produce enough torque to accelerate

- Start performance may be unstable when using a low Motor Full Load Current setting Par. 1-1). This can affect use on a small test motor with full load current between 5 A and 50 A.

- Power factor correction (PFC) capacitors must be installed on the supply side of the soft starter. To control a dedicated PFC capacitor contactor, connect the contactor to run relay terminals.

to full speed. The soft starter may trip on excess start time.

9 9

NOTE

Make sure the motor starting parameters are appropriate for the application and that you are using the intended motor starting profile. If Par. 3-3 is set to Motor Set Select, check that the corresponding input is in the expected state.

- The load may be jammed. Check the load for severe overloading or a locked rotor situation.

Erratic motor operation. - The SCRs in the MCD 500 require at least 5 A of current to latch. If you are testing the

soft starter on a motor with full load current less than 5 A, the SCRs may not latch correctly.

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Troubleshooting MCD 500 Operating Instruction

Symptom Probable Cause

Soft stop ends too quickly. - The soft stop settings may not be appropriate for the motor and load. Review the

settings of Pars. 1-10, 1-11, 7-10 and 7-11.

- If the motor is very lightly loaded, soft stop will have limited effect.

AAC adaptive acceleration control, DC brake and Jog functions not working

A reset does not occur after an Auto-Reset, when using a remote 2-wire control. Remote start/stop command is overriding Auto Start/Stop settings when using remote 2-wire control. After selecting AAC the motor used an ordinary start and/or the second start was different to the first. Non-resettable THERMISTOR CCT trip, when there is a link between Thermistor input 05, 06 or when the motor thermistor connected between 05, 06 is permanently removed.

Parameter settings cannot be stored. - Make sure you are saving the new value by pressing the [OK] button after adjusting a

- These features are only available with in-line installation. If the MCD 500 is installed inside delta, these features will not operate.

- The remote 2-wire start signal must be removed and reapplied for a re-start.

- Auto Start/Stop function should only be used in HAND ON mode or in tandem with HAND OFF mode, 3 and 4-wire control.

- The first AAC start is current limit so that the starter can learn from the motor characteristics. Subsequent starts use AAC.

- The thermistor input is enabled once a link is fitted and short circuit protection has activated.

Remove the link then load the default parameter set. This will disable the thermistor input and clear the trip. Place a 1k2 Ω resistor across the thermistor input. Turn thermistor protection to 'Log only' (Par. 16-9).

parameter setting. If you press [BACK], the change will not be saved.

- Check that the adjustment lock (Par. 15-2) is set to Read/Write. If the adjustment lock is on, settings can be viewed but not changed. You need to know the security access code to change the adjustment lock setting.

- The EEPROM may be faulty on the Main Control PCB. A faulty EEPROM will also trip the soft starter, and the LCP will display the message Par. Out of Range. Contact your local supplier for advice.

Table 9.2

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Specifications MCD 500 Operating Instruction

10 Specifications

Supply Mains voltage (L1, L2, L3) MCD5-xxxx-T5 200 VAC - 525 VAC (± 10%) MCD5-xxxx-T7 380 VAC - 690 VAC (± 10%) (in-line connection) MCD5-xxxx-T7 380 VAC - 600 VAC (± 10%) (inside delta connection) Control voltage (A4, A5, A6) CV1 (A5, A6) 24 VAC/VDC (± 20%) CV2 (A5, A6) 110~120 VAC (+ 10% / - 15%) CV2 (A4, A6) 220~240 VAC (+ 10% / - 15%) Current consumption (maximum) CV1 2.8 A CV2 (110 - 120 VAC) 1 A CV2 (220 - 240 VAC) 500 mA Mains frequency 50/60 Hz (± 10%) Rated insulation voltage to earth 600 VAC Rated impulse withstand voltage 4 kV Form designation Bypassed or continuous, semiconductor motor starter form 1

Short circuit capability Coordination with semiconductor fuses Type 2 Coordination with HRC fuses Type 1 MCD5-0021B to MCD5-0215B prospective current 65 kA MCD5-0245C to MCD5-0927B prospective current 85 kA MCD5-1200C to MCD5-1600C prospective current 100 kA

Electromagnetic capability (compliant with EU Directive 89/336/EEC) EMC Emissions IEC 60947-4-2 Class B and Lloyds Marine No 1 Specification EMC Immunity IEC 60947-4-2

Inputs Input Rating Active 24 VDC, 8 mA approx Start (15, 16) Normally open Stop (17, 18) Normally closed Reset (25, 18) Normally closed Programmable input (11, 16) Normally open Motor thermistor (05, 06) Trip >3.6 kΩ, reset <1.6kΩ

Outputs Relay Outputs 10A @ 250 VAC resistive, 5A @ 250 VAC AC15 pf 0.3 Programmable Outputs Relay A (13, 14) Normally open Relay B (21, 22, 24) Changeover Relay C (33, 34) Normally open Analog Output (07, 08) 0-20 mA or 4-20 mA (selectable) Maximum load 600 Ω (12 VDC @ 20 mA) Accuracy ± 5% 24 VDC Output (16, 08) Maximum load 200 mA Accuracy ± 10%

Environmental Protection MCD5-0021B - MCD5-0105B IP20 & NEMA, UL Indoor Type 1 MCD5-0131B - MCD5-1600C IP00, UL Indoor Open Type Operating temperature -10° C to 60° C, above 40° C with derating

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Specifications MCD 500 Operating Instruction

Storage temperature - 25° C to + 60° C Operating Altitude 0 - 1000 m, above 1000 m with derating Humidity 5% to 95% Relative Humidity Pollution degree Pollution Degree 3

Heat Dissipation During start 4.5 watts per ampere During run MCD5-0021B - MCD5-0053B = 39 watts approx MCD5-0068B - MCD5-0105B = 51 watts approx MCD5-0131B - MCD5-0215B = 120 watts approx MCD5-0245C - MCD5-0927C 4.5 watts per ampere approx MCD5-1200C - MCD5-1600C 4.5 watts per ampere approx

Certification C✓ IEC 60947-4-2 UL/ C-UL UL 508 CE IEC 60947-4-2 CCC GB 14048-6 Marine (MCD5-0021B - MCD5-0215B only) Lloyds Marine No 1 Specification RoHS Compliant with EU Directive 2002/95/EC

10.1 Accessories

10.1.1 LCP Remote Mounting Kit

The MCD 500 LCP can be mounted up to 3 metres away from the soft starter, allowing remote control and monitoring. The remote LCP also allows parameter settings to be copied between soft starters.

175G0096 Control Panel LCP501

•

10.1.2 Communication Modules

MCD 500 soft starters support network communication using the Profibus, DeviceNet and Modbus RTU protocols, via an easy-to-install communications module. The communications module plugs directly onto the side of the starter.

175G9000 Modbus Module

•

175G9001 Profibus Module

•

175G9002 DeviceNet Module

•

175G9009 MCD USB Module

•

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1/L1

2/T1

1/L1

2/T1

KM1

177RA001.10

Specifications MCD 500 Operating Instruction

10.1.3 PC Software

MCD PC Software can be used in conjunction with a communications module to provide the following functionality for networks of up to 99 soft starters.

Feature MCD-201 MCD-202 MCD500 Operational control (Start, Stop, Reset, Quick Stop) Starter status monitoring (Ready, Starting, Running, Stopping, Tripped) Performance monitoring (motor current, motor temperature) Upload parameter settings Download parameter settings

Table 10.1

The PC software available from Danfoss's website is:

WinMaster: VLT® Soft Starter software for control, configuration and management

•

: VLT® software for configuration and management.

•

● ● ●

● ●

●

10.1.4

Finger guards may be specified for personnel safety and can be used on MCD 500 soft starter models 0131B - 1600C. Finger guards fit over the soft starter terminals to prevent accidental contact with live terminals. Finger guards provide IP20 protection.

Finger Guard Kit

MCD5-0131B ~MCD5-0215B: 175G5662

•

MCD5-245C: 175G5663

•

MCD5-0360C ~MCD5-0927C: 175G5664

•

MCD5-1200C ~MCD5-1600C: 175G5665

•

10.1.5 Surge Protection Kit (Lightning Protection)

As standard, MCD 500 rated impulse withstand voltage is limited to 4 kV. The surge protection kits protect the system and make the soft starter immune to high voltage impulses.

6kV

175G0100 SPD Surge protection kit for G1

•

175G0101 SPD Surge protection kit, G2-G5

•

12kV

175G0102 SPD Surge protection kit for G1

•

175G0103 SPD Surge protection kit, G1-G5

•

Illustration 10.1

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Bus Bar Adjustment Procedur... MCD 500 Operating Instruction

11 Bus Bar Adjustment Procedure (MCD5-0360C - MCD5-1600C)

NOTE

Many electronic components are sensitive to static electricity. Voltages so low that they cannot be felt, seen or heard, can reduce the life, affect performance, or completely destroy sensitive electronic components. When performing service, proper ESD equipment should be used to prevent possible damage from occurring.

All units are manufactured with input and output bus bars at the bottom of the unit as standard. The input and/or output bus bars can be moved tot he top of the unit if required.

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Bus Bar Adjustment Procedur... MCD 500 Operating Instruction

1. Remove all wiring and links from the soft starter before dismantling the unit.

2. Remove the unit cover (4 screws).

3. Unscrew the main plastic and fold away from the starter (4 screws).

4. Unplug the keypad loom from CON 1 (see note).

5. label each SCR firing loom with the number of the corresponding terminal on the main control PCB, then unplug the looms.

6. Unplug the thermistor, fan and CT wires from the main control PCB.

NOTE

Remove the main plastic slowly to avoid damaging the keypad wiring loom which runs between the main plastic and the backplane PCB.

1. Unscrew and remove the magnetic bypass plates (models MCD5-0620C to MCD5-1600c ONLY).

2. Remove the CT assembly (three screws).

3. Identify which bus bars are to be moved. Remove the bolts holding these bus bars in place then slide the bus bars out through the bottom of the starter (four bolts per bus bar).

1. Slide the bus bars in through the top of the starter. For input bus bars, the short curved end should be outside the starter. For output bus bars, the unthreaded hole should be outside the starter.

2. Replace the dome washers with the flat face towards the bus bar, then tighten the bolts holding the bus bars in place to 20 Nm.

3. Place the CT assembly over the input bus bars and screw the assembly to the body of the starter (see note).

4. Run all wiring to the side of the starter and secure with cable ties.

Table 11.1

NOTE

If moving the input bars, the CTs must also be reconfigured.

1. Label the CTs L1, L2 and L3 (L1 is leftmost when working from the front of the starter). Remove the cable ties and unscrew the CTs from the bracket.

2. Move the CT bracket to the top of the starter. Position the CTs for the correct phases, then screw the CTs to the bracket. For models MCD5-0360C - MCD5-0930, the CTs must be placed on an angle (the left hand legs of each CT will be on the top row of holes and the right hand legs will be on the bottom tabs).

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www.danfoss.com/drives

175R0549 MG17K402 Rev. 2012–03–05

*MG17K402*