Danfoss vlt soft starter mcd 500, Operating Instruction

Page 1: ...nstallation 16 Inside Delta Installation Internally Bypassed 17 Inside Delta Installation Non bypassed 17 Inside Delta Installation Externally Bypassed 18 Current Ratings 18 In line Connection Bypasse...

Page 2: ...33 Current Ramp 34 AAC Adaptive Acceleration Control 34 Kickstart 35 Stopping Modes 35 Coast to Stop 35 TVR Soft Stop 36 AAC Adaptive Acceleration Control 36 Brake 37 Jog Operation 37 Inside Delta Ope...

Page 3: ...t 58 Parameter List 59 Primary Motor Settings 59 Brake 61 Protection 62 Current Imbalance 62 Undercurrent 62 Instantaneous Overcurrent 62 Frequency Trip 63 Inputs 64 Outputs 66 Relay A Delays 66 Relay...

Page 4: ...O State 79 Temp Sensors State 79 Alarm Log 80 Trip Log 80 Event Log 80 Counters 80 9 Troubleshooting 83 Trip Messages 83 General Faults 86 10 Specifications 89 Accessories 90 Communication Modules 90...

Page 5: ...local electrical safety codes Disconnect the soft starter from mains voltage before carrying out repair work It is the responsibility of the user or person installing the soft starter to provide prope...

Page 6: ...disposed of together with domestic waste It must be collected separately as electrical and electronic waste according to local and cur rently valid legislation 1 Safety MCD 500 Operating Instruction...

Page 7: ...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 Kick...

Page 8: ...3a 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 5...

Page 9: ...surfaces MCD5 0245C Allow 100 mm 3 94 inches between the soft starter and solid surfaces MCD5 0360C MCD5 1600C Allow 200 mm 7 88 inches between the soft starter and solid surfaces 3 The soft starter...

Page 10: ...5 0131B 438 17 2 380 15 0 275 10 8 248 9 8 250 9 8 14 9 32 8 MCD5 0141B MCD5 0195B MCD5 0215B MCD5 0245C 460 18 1 400 15 0 390 15 4 320 12 6 279 11 0 23 9 52 7 MCD5 0360C 689 27 1 520 20 5 430 16 9 32...

Page 11: ...e inputs In remote mode the Auto On LED will be on In local mode the Hand On LED will be on if the MCD 500 is starting or running and the Off LED will be on if the MCD 500 is stopped or stopping 4 1 2...

Page 12: ...rom mains voltage and motor cabling 4 1 4 Serial Communication Serial communication is always enabled in local control mode and can be enabled or disabled in remote control mode see par 3 2 4 1 5 Eart...

Page 13: ...n models MCD5 0360C MCD5 1600C can be adjusted for top or bottom input and output as required For step by step instructions on adjusting the bus bars refer to the supplied insert I O I O Input Output...

Page 14: ...internally so it is only necessary to program the motor full load current par 1 1 NB For personnel safety the power terminals on models up to MCD5 0105B are protected by snap off tabs When using large...

Page 15: ...2 E KM1 KM1 F1 KM1 Main contactor optional F1 Fuses optional 4 2 2 In line Installation Non bypassed 177HA429 11 6 T3 2 T1 5 L3 3 L2 1 L1 13 14 4 T2 E KM1 KM1 F1 M 3 KM1 Main contactor optional F1 Fus...

Page 16: ...1 M 3 F1 6 T3 2 T1 5 L3 3 L2 1 L1 13 14 4 T2 E KM1 KM1 L1B L2B L3B KM2 34 33 KM2 KM1 Main contactor KM2 Bypass contactor F1 Fuses optional NB The bypass terminals on MCD5 0245C are T1B T2B T3B The byp...

Page 17: ...Inside Delta Installation Non bypassed 177HA500 11 M 3 6 T3 2 T1 5 L3 3 L2 1 L1 13 14 4 T2 KM1 KM1 F1 U1 1 U2 4 V1 2 V2 5 W1 3 W2 6 L2B L1B L3B E KM1 Main contactor F1 Fuses optional MCD 500 Operatin...

Page 18: ...2 E KM1 KM1 F1 U1 1 U2 4 V1 2 V2 5 W1 3 W2 6 L2B L1B L3B KM2 34 33 KM2 KM1 Main contactor KM2 Bypass contactor F1 Fuses optional NB The bypass terminals on MCD5 0245C are T1B T2B T3B The bypass termin...

Page 19: ...1B 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 04...

Page 20: ...532 A 437 A MCD5 0790C 790 A 694 A 567 A MCD5 0927C 927 A 800 A 644 A MCD5 1200C 1200 A 1135 A 983 A MCD5 1410C 1410 A 1187 A 1023 A MCD5 1600C 1600 A 1433 A 1227 A 4 4 4 AC 53 Rating for Continuous O...

Page 21: ...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 MC...

Page 22: ...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 4 4 8 AC 53 Rating for Continu...

Page 23: ...d 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 Sele...

Page 24: ...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 f...

Page 25: ...21 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 238000...

Page 26: ...0FM 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...

Page 27: ...00 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 238000 Not s...

Page 28: ...0XXX0315 A070URD30XXX0315 A070URD30XXX0315 MCD5 0195B 320000 A070URD30XXX0450 A070URD30XXX0450 A070URD30XXX0450 MCD5 0215B 320000 A070URD30XXX0450 A070URD30XXX0450 A070URD30XXX0450 MCD5 0245C 320000 A...

Page 29: ...RD30D11A0315 6 9URD30D11A0315 MCD5 0195B 320000 6 9URD31D11A0450 6 9URD31D11A0450 6 9URD31D11A0450 MCD5 0215B 320000 6 9URD31D11A0450 6 9URD31D11A0450 6 9URD31D11A0450 MCD5 0245C 320000 6 9URD31D11A04...

Page 30: ...41B 320000 AJT175 AJT175 MCD5 0195B 320000 AJT200 AJT200 MCD5 0215B 320000 AJT250 AJT250 MCD5 0245C 320000 AJT300 AJT300 MCD5 0360C 238000 AJT400 AJT400 MCD5 0380C 320000 AJT450 AJT450 MCD5 0428C 3200...

Page 31: ...ply 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...

Page 32: ...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 3...

Page 33: ...tches 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 AAC uses two algorithm...

Page 34: ...upply to respond 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...

Page 35: ...75 adjust to 76 If 1 12 is not at default setting of 75 adjust to 75 5 3 4 Kickstart Kickstart provides a short boost of extra torque at the beginning of a start and can be used in conjunction with c...

Page 36: ...177HA510 10 1 2 4 3 AAC Adaptive stop profile Par 1 14 1 Early deceleration 2 Constant deceleration 3 Late deceleration 4 Stop time Par 1 10 NB AAC will control the load according to the programmed pr...

Page 37: ...eed to approximately 70 If the stop time is too short braking will not be successful and the motor will coast to stop 2 Set Brake Time Par 1 16 to approximately one quarter of the programmed Stop Time...

Page 38: ...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...

Page 39: ...start current requirements are appropriate and typical in most circumstances However the performance and start torque re quirements of motors and machines do vary For further assistance contact your l...

Page 40: ...le 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...

Page 41: ...S2 E 1 L1 5 6 7 4 2 A 3 1 177HA522 10 24 VDC 1 Control voltage model dependent KM1 Main contactor 2 24 VDC output F1 Semiconductor fuses optional 3 Remote control inputs S1 Start stop 4 Motor thermis...

Page 42: ...177HA523 10 1 Control voltage model dependent KM1 Bypass contactor 2 24 VDC output F1 Semiconductor fuses optional 3 Remote control inputs S1 Start contact 4 Motor thermistor input PTC only S2 Stop co...

Page 43: ...L1 5 6 7 4 2 A 3 1 177HA524 10 1 Control voltage model dependent S1 Start stop contact 2 24 VDC output S2 Reset contact 3 Remote control inputs S3 Emergency Run contact 4 Motor thermistor input PTC on...

Page 44: ...el dependent S1 Start stop contact 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 Re...

Page 45: ...KM1 KM2 S1 KA1 KA1 Y1 Y2 Y1 Y2 KA1 KT2 4 T2 6 T3 E 1 L13 L2 5 L3 2 T1 33 34 A4 A5 A6 05 06 KA3 KA2 S3 11 1 Control voltage model dependent KA3 Brake relay 2 Remote control inputs KA4 Rotation sensing...

Page 46: ...w 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 par 7 1 7 16 177HA527 10 2 T1 4 T2 6 T3 E T4...

Page 47: ...using par 1 1 2 9 Set low speed performance characteristics using par 7 1 7 16 Par 4 4 Relay B Function Select Trip assigns Trip function to Relay Output B NB If the MCD 500 trips on supply frequency...

Page 48: ...6 Operation MCD 500 Operating Instruction 48 MG 17 K2 02 VLT is a registered Danfoss trademark 6...

Page 49: ...ntrol 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...

Page 50: ...When OFF the Hand On and Auto On buttons are always active If the MCD 500 is in Auto On mode pressing the Hand On button will enter Hand On mode and start the motor If Par 3 1 is set to Remote Control...

Page 51: ...ation Use parameters 8 2 to 8 5 to select which information to display Ready S2 MS1 000 0A 000 0kW pf 00000 hrs 6 4 3 Average Current S3 The average current screen shows the average current of all thr...

Page 52: ...motor full load current calculated rise in motor temperature Ready S7 MS1 000 0A 000 0kW Last start 000 s 000 FLC Temp 0 6 4 8 Date and Time S8 The date time screen shows the current system date and t...

Page 53: ...Motor power factor 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 an...

Page 54: ...7 Programming MCD 500 Operating Instruction 54 MG 17 K2 02 VLT is a registered Danfoss trademark 7...

Page 55: ...select a digit and the and buttons to change the value When all four digits match your access code press OK The LCP will display an acknowledgement message before continuing To change the access code...

Page 56: ...current 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 R...

Page 57: ...me Adaptive Control Early Acceleration 5 seconds 350 Adaptive Control Late Deceleration 5 seconds Start Mode Adaptive Start Profile Start Ramp Time Current Limit Stop Mode Adaptive Stop Profile Stop T...

Page 58: ...roup press the OK button to return to the previous level press the BACK button to close Parameters press the BACK button To change a parameter value scroll to the appropriate parameter and press OK to...

Page 59: ...Type 15 4 Current Calibrat 2 4 Undercurrent 5 4 Auto Stop Time 15 5 Main Cont Time 2 5 Undercurrent Dly 6 Auto Reset 15 6 Bypass Cont Time 2 6 Inst Overcurrent 6 1 Auto Reset Action 15 7 Motor Connec...

Page 60: ...amp starting is not required set the initial current equal to the current limit See Starting Modes in chapter Application Examples for more details 1 6 Start Ramp Time Range Function 10 secs 1 180 sec...

Page 61: ...t 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 ga...

Page 62: ...ction 30 10 50 Sets the trip point for current imbalance protection 2 3 Current Imbal Dly Range Function 3 secs 0 00 4 00 min secs Slows the MCD 500 s response to current imbalance avoiding trips due...

Page 63: ...Function Do not Check Start Only Start Run Run Only Determines when the starter will monitor for a frequency trip 2 9 Freq Variation Option Function Selects the soft starter s tolerance for frequency...

Page 64: ...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 Disable Ctrl in RMT Enable Ctrl in RMT 3 3 Inpu...

Page 65: ...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 S...

Page 66: ...lay Range Function 0 secs 0 00 5 00 min secs Sets the delay for re opening Relay A 7 8 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...

Page 67: ...rning 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 overcurr...

Page 68: ...mA 4 15 Analog A Max Adj 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 Min Adj Range Func...

Page 69: ...e Loss Power Loss Mains Frequency B Undercurrent Instantaneous Overcurrent Input A Trip C Motor Overload Motor Thermistor Starter Overtemperature Other trips cannot be automatically reset This functio...

Page 70: ...2 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 cu...

Page 71: ...e toal stopping time when using brake 7 12 Adaptv Ctrl Gain 2 Range Function 75 1 200 Adjusts the performance of AAC adaptive acceleration control We recommend leaving the gain setting at the default...

Page 72: ...urrent 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 r...

Page 73: ...starter 8 5 User Scrn Btm R Option Function Selects the item displayed in the bottom right part of the screen Blank Displays no data in the selected area allowing long messages to be shown without ov...

Page 74: ...nt 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...

Page 75: ...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 th...

Page 76: ...nt 16 5 Frequency 16 6 Heatsink Overtemp 16 7 Excess Start Time 16 8 Input A Trip 16 9 Motor Thermistor 16 10 Starter Comms 16 11 Network Comms 16 12 Battery Clock Trip Starter Warn and Log Log Only 7...

Page 77: ...rameter 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 param...

Page 78: ...lation NB 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 mai...

Page 79: ...m and press OK then enter the access code 3 Use the and buttons to select a simulation then press OK 4 Use the and buttons to turn the signal on and off To con firm correct operation monitor the state...

Page 80: ...trips including the date and time of the event Event 1 is the most recent and event 99 is the oldest stored event To open the Event Log 1 Open the Alarm Logs 2 Scroll to Event Log and press OK 3 Use...

Page 81: ...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 pr...

Page 82: ...9 Troubleshooting MCD 500 Operating Instruction 82 MG 17 K2 02 VLT is a registered Danfoss trademark 9...

Page 83: ...ce 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 sof...

Page 84: ...tected a shorted SCR or a short within the bypass contactor as indicated Related Pars none Low Control Volts The internal 24 VDC rail has dropped below 19V This may have been caused by a fluctuation o...

Page 85: ...ontact your local distributor There is an internal communications error within the soft starter Contact your local distributor Related Pars 16 10 Thermistor Cct The thermistor input has been enabled a...

Page 86: ...lete 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...

Page 87: ...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 tr...

Page 88: ...10 Specifications MCD 500 Operating Instruction 88 MG 17 K2 02 VLT is a registered Danfoss trademark 10...

Page 89: ...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...

Page 90: ...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 1...

Page 91: ...it over the soft starter terminals to prevent accidental contact with live terminals Finger guards provide IP20 protection MCD5 0068B MCD5 0105B 175G5662 MCD5 0131B MCD5 0215B 175G5663 MCD5 0245B MCD5...

Page 92: ...11 Bus Bar Adjustment Procedure MCD5 0360C MCD5 1600C MCD 500 Operating Instruction 92 MG 17 K2 02 VLT is a registered Danfoss trademark 11...

Page 93: ...ve 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 o...

Page 94: ...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 ba...

Page 95: ...cket 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 C...