VLT MCD 500 Operating Instructions Manual

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT

®

Soft Starter - MCD 500

Contents MCD 500 Operating Instruction

Contents

1 Safety

1.1 Safety

2 Introduction

2.1.1 Feature List

2.1.2 Type Code

3 Installation

3.1 Mechanical Installation

3.2 Dimensions and Weights

4 Electrical Installation

4.1.1 Control Wiring

4.1.2 Control Terminals

4.1.3 Remote Inputs

4.1.4 Serial Communication

4.1.5 Earth Terminal

4.1.6 Power Terminations

4.2 Motor Connection

4.2.1 Testing the Installation

4.2.2 In-line Installation

4.2.2.1 In-line Installation, Internally Bypassed

4.2.2.2 In-line Installation, Non-bypassed

4.2.2.3 In-line Installation, Externally Bypassed

4.2.3 Inside Delta Installation

4.2.3.1 Inside Delta Installation, Internally Bypassed

4.2.3.2 Inside Delta Installation, Non-bypassed

4.2.3.3 Inside Delta Installation, Externally Bypassed

4.3 Current Ratings

4.3.1 In-line Connection (Bypassed)

4.3.2 AC-53 Rating for Bypassed Operation

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

4.3.4 AC-53 Rating for Continuous Operation

4.3.5 Inside Delta Connection (Bypassed)


4.3.7 Inside Delta Connection (Non-bypassed/Continuous)


4.4 Minimum and Maximum Current Settings

4.5 Bypass Contactor

4.6 Main Contactor

MG17K402 - VLT ® is a registered Danfoss trademark

19

19

20

20

17

17

18

18

21

21

21

15

15

15

16

13

14

14

14

14

15

12

12

12

13

11

11

11

11

9

9

10

7

7

8

5

5

1

2


4.7 Circuit Breaker

4.8 Power Factor Correction

4.9 Fuses

4.9.2 Bussman Fuses - Square Body (170M)

4.9.3 Bussman Fuses - British Style (BS88)

4.9.4 Ferraz Fuses - HSJ

4.9.5 Ferraz Fuses - North American Style (PSC 690)

4.9.6 UL Tested Fuses - Short Circuit Ratings

4.10 Schematic Diagrams

4.10.1 Internally Bypassed Models

4.10.2 Non-bypassed Models

5 Application Examples

5.1 Motor Overload Protection

5.2 AAC Adaptive Acceleration Control

5.3 Starting Modes

5.3.1 Constant Current

5.3.2 Current Ramp

5.3.3 AAC Adaptive Acceleration Control

5.3.4 Kickstart

5.4 Stopping Modes

5.4.1 Coast to Stop

5.4.2 TVR Soft Stop


5.4.4 Brake

5.5 Jog Operation

5.6 Inside Delta Operation

5.7 Typical Start Currents

5.8 Installation with Main Contactor

5.9 Installation with Bypass Contactor

5.10 Emergency Run Operation

5.11 Auxiliary Trip Circuit

5.12 DC Brake with External Zero Speed Sensor

5.13 Soft Braking

5.14 Two Speed Motor

6 Operation

6.1 Operation and LCP

6.1.1 Operating Modes

6.2 Remote Mounted LCP

6.2.1 Synchronising the LCP and the Starter


35

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39

40

33

33

34

35

41

42

42

44

31

31

31

32

32

32

32

30

30

30

31

46

46

46

46

47

24

25

26

27

21

22

22

23

28

28

29


6.3 Welcome Screen

6.4 Control Methods

6.5 Local Control Buttons

6.6 Displays

6.6.1 Temperature Monitoring Screen (S1)

6.6.2 Programmable Screen (S2)

6.6.3 Average Current (S3)

6.6.4 Current Monitoring Screen (S4)

6.6.5 Frequency Monitoring Screen (S5)

6.6.6 Motor Power Screen (S6)

6.6.7 Last Start Information (S7)

6.6.8 Date and Time (S8)

6.6.9 SCR Conduction Bargraph

6.6.10 Performance Graphs

7 Programming

7.1 Access Control

7.2 Quick Menu

7.2.1 Quick Setup

7.2.2 Application Setups

7.2.3 Loggings

7.3 Main Menu

7.3.1 Parameters

7.3.2 Parameter Shortcut

7.3.3 Parameter List

7.4 Primary Motor Settings

7.4.1 Brake

7.5 Protection

7.5.1 Current Imbalance

7.5.2 Undercurrent

7.5.3 Instantaneous Overcurrent

7.5.4 Frequency Trip

7.6 Inputs

7.7 Outputs

7.7.1 Relay A Delays

7.7.2 Relays B and C

7.7.3 Low Current Flag and High Current Flag

7.7.4 Motor Temperature Flag

7.7.5 Analog Output A

7.8 Start/Stop Timers

7.9 Auto-Reset


56

56

57

57

53

54

55

56

52

53

53

53

50

50

51

51

59

60

60

60

57

58

59

59

60

61

49

49

49

49

49

49

48

48

48

49

47

47

48

48

3

4


7.9.1 Auto-Reset Delay

7.10 Secondary Motor Set

7.11 Display

7.11.1 User Programmable Screen


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

8.8.2 Event Log

8.8.3 Counters

9 Troubleshooting

9.1 Trip Messages

9.2 General Faults

10 Specifications

10.1 Accessories

10.1.1 LCP Remote Mounting Kit

10.1.2 Communication Modules

10.1.3 PC Software

10.1.4 Finger Guard Kit

10.1.5 Surge Protection Kit (Lightning Protection)

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

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69

69

69

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64

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78


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.

CAUTION

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

1 1

MG17K402 - VLT ® is a registered Danfoss trademark 5

1 1

Safety MCD 500 Operating Instruction

Equipment containing electrical components may not be disposed of together with domestic waste.

It must be collected separately as electrical and electronic waste according to local and currently valid legislation.

Table 1.1

6 MG17K402 - VLT ® is a registered Danfoss trademark

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

-

-

-

• Current

-

-

Power loss

Individual phase loss

Mains frequency

Excess start time

Current imbalance

-

-

• Thermal

-

Undercurrent

Instantaneous overcurrent

Motor thermistor

-

Motor overload

Bypass relay overload

Heatsink temperature

• Communication

Network comms

Starter comms -

• External

-

•

Starter

-

Input trip

Individual shorted SCR

Battery/Clock


2 2

2 2

Introduction

2.1.2 Type Code

MCD 500 Operating Instruction

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

B = Bypassed

C = Non-bypassed

Mains voltage

T5 = 200 - 525 VAC

T7 = 380 - 690 VAC

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

IP rating

00 = IP00

20 = IP20

Control voltage

CV1 = 24 VAC/VDC

CV2 = 110-120 VAC or 220-240 VAC

= Not selectable

-

Illustration 2.1


Installation

3 Installation

3.1 Mechanical Installation


3 3

Illustration 3.1

1

2

3

4

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.

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

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

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

The soft starter may be mounted on its side. Derate the soft starter's rated current by 15%.

Soft starters may be mounted side by side with clearance of 50 mm (1.97 inches) on both sides.


3 3

Installation

3.2 Dimensions and Weights


10

Illustration 3.2

Model

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

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

Table 3.2

A mm

(inches)

295

(11.6)

438

(17.2)

460

(18.1)

689

(27.1)

856

(33.7)

B mm

(inches)

278

(10.9)

727

(28.6)

380

(15.0)

400

(15.0)

522

(20.5)

275

(10.8)

390

(15.4)

430

(16.9)

585

(23.0)

C mm

(inches)

150

(5.9)

248

(9.8)

320

(12.6)

320

(12.6)

500

(19.7)

D mm

(inches)

124

(4.9)

250

(9.8)

279

(11.0)

300.2

(11.8)

E mm

(inches)

183

(7.2)

213

(8.14)

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)

35

(77.2)

45

(99.2)

120

(264.6)


Electrical Installation MCD 500 Operating Instruction

4 Electrical Installation

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.

4.1.2 Control Terminals

Control terminations use 2.5 mm 2 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

To maintain SELV, all connections made to the control 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.

4.1.3 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).

1

Start/stop

Reset

Illustration 4.2

18

25

18

15

16

17

Start

Stop

Reset

2

18

25

18

15

16

17

Start

Stop

Reset

3

18

25

18

15

16

17

4 4

Illustration 4.1

NOTE

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

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.

1

2

3

Table 4.1

Two-wire control

Three-wire control

Four-wire control

The reset input can be normally open or normally closed.

Use 3-8 Remote Reset Logic to select the configuration.

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



4 4

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

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

Table 4.3

MCD5-0245C MCD5-0360C - MCD50927C MCD5-1200C - MCD5-1600C



The bus bars on models MCD5-0360C - MCD5-1600C can be adjusted for top or bottom input and output as required. For step-by-step instructions on adjusting the bus bars, refer to the supplied insert.

4 4

Illustration 4.3

I

I/O

O

Table 4.4

Input/Output

Input

Output

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 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.

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.


4 4

Electrical Installation

KM1 F1

1/L1

3/L2

5/L3

E

2/T1

4/T2

6/T3


4.2.2 In-line Installation

4.2.2.1 In-line Installation, Internally

Bypassed

3

M programmable output configured to Run (see parameters

4.1 thorugh 4.9).

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.

KM2

Illustration 4.4

13

14

KM1

KM1

F1

Table 4.5

Main contactor (optional)

Fuses (optional)

4.2.2.2 In-line Installation, Non-bypassed

KM1 F1

1/L1

3/L2

5/L3

E

2/T1

4/T2

6/T3

3

M

13

14

KM1

Illustration 4.5

KM1

F1

1/L1

3/L2

5/L3

E

Illustration 4.6 MCD5-0245C

KM1

KM2

F1

Table 4.7

Main contactor

Bypass contactor (external)

Semiconductor fuses (optional)

2/T1

T1B

4/T2

T2B

6/T3

T3B

33

34

13

14

KM1

KM2

3

M

KM1

F1

Table 4.6

Main contactor (optional)

Fuses (optional)

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



KM2

4.2.3.1 Inside Delta Installation, Internally

Bypassed

KM1 F1

1/L1

L1B

3/L2

L2B

5/L3

L3B

E

2/T1

4/T2

6/T3

13

14

KM1

33

34

KM2

Illustration 4.7 MCD5-0360C ~ MCD5-1600C

3

M

Illustration 4.8

KM1

KM2

F1

Table 4.8

Main contactor



4.2.3 Inside Delta Installation

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.

KM1

F1

Table 4.9

Main contactor

Fuses (optional)

4.2.3.2 Inside Delta Installation, Nonbypassed

KM1

Illustration 4.9

F1

1/L1

L1B

3/L2

L2B

5/L3

L3B

E

2/T1

4/T2

U1(1) U2(4)

V1(2)

W1(3)

3

M

V2(5)

W2(6)

6/T3

13

14

KM1

KM1

F1

Table 4.10

Main contactor

Fuses (optional)

4.2.3.3 Inside Delta Installation, Externally

Bypassed

Non-bypassed models have dedicated bypass terminals, which allow the MCD 500 to continue providing protection and monitoring functions even when bypassed via an external bypass contactor. The bypass relay must be connected to the bypass terminals and controlled by a programmable output configured to Run (see parameters

4-1 through 4-9).

4 4


4 4


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.

KM2

KM1 F1

1/L1

3/L2

5/L3

E

33

34

13

14

2/T1

T1B

4/T2

T2B

6/T3

T3B

KM1

KM2

V1(2)

W1(3)

U1(1) U2(4)

3

M

V2(5)

W2(6)

Illustration 4.10 MCD5-0245C

KM1

KM2

F1

Table 4.11

Main contactor


Semicondutcor fuses (optional)

KM2

KM1 F1

1/L1

L1B

3/L2

L2B

5/L3

L3B

E

2/T1

4/T2

6/T3

13

14

KM1

33

34

KM2

Illustration 4.11 MCD5-0360C ~ MCD5-1600C

U1(1) U2(4)

V1(2)

W1(3)

3

M

V2(5)

W2(6)

KM1

KM2

F1

Table 4.12

Main contactor





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.

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

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

68 A

84 A

89 A

105 A

131 A

141 A

195 A

215 A

255 A

360 A

AC-53b

3-30:330

21 A

37 A

43 A

53 A

AC-53b

3-30:570

380 A

430 A

620 A

650 A

790 A

930 A

1200 A

1410 A

1600 A

Table 4.13


55 A

69 A

74 A

95 A

106 A

121 A

160 A

178 A

201 A

310 A

AC-53b

4-20:340

17 A

31 A

37 A

46 A

AC-53b

4-20:580

359 A

368 A

540 A

561 A

714 A

829 A

1200 A

1319 A

1600 A

47 A

58 A

61 A

78 A

90 A

97 A

134 A

148 A

176 A

263 A

AC-53b

4.5-30:330

15 A

26 A

30 A

37 A

AC-53b

4.5-30:570

299 A

309 A

434 A

455 A

579 A

661 A

1071 A

1114 A

1353 A

4 4

Illustration 4.12




4 4

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

Table 4.14

MCD5-0245C

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

AC-53a

3-30:50-6

245 A

360 A

380 A

428 A

595 A

619 A

790 A

927 A

1200 A

1410 A

1600 A


AC-53a

4-20:50-6

195 A

303 A

348 A

355 A

515 A

532 A

694 A

800 A

1135 A

1187 A

1433 A

Star t T ime (sec

Star ts P er H our ond s)

Illustration 4.13


AC-53a

4.5-30:50-6

171 A

259 A

292 A

300 A

419 A

437 A

567 A

644 A

983 A

1023 A

1227 A



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.

MCD5-0021B

MCD5-0037B

MCD5-0043B

MCD5-0053B

Table 4.15

MCD5-0068B

MCD5-0084B

MCD5-0089B

MCD5-0105B

MCD5-0131B

MCD5-0141B

MCD5-0195B

MCD5-0215B

MCD5-0245C

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C


AC-53b

3-30:330

32 A

56 A

65 A

80 A

293 A

323 A

383 A

540 A

570 A

645 A

930 A

975 A

1185 A

AC-53b

3-30:570

102 A

126 A

134 A

158 A

197 A

212 A

1395 A

1800 A

2115 A

2400 A

AC-53b

4.20-:340

26 A

47 A

56 A

69 A

241 A

268 A

302 A

465 A

539 A

552 A

810 A

842 A

1072 A

AC-53b

4-20:580

83 A

104 A

112 A

143 A

159 A

181 A

1244 A

1800 A

1979 A

2400 A

AC-53b

4.5-30:330

22 A

39 A

45 A

55 A

201 A

223 A

264 A

395 A

449 A

463 A

651 A

683 A

869 A

AC-53b

4.5-30:570

71 A

87 A

92 A

117 A

136 A

146 A

992 A

1607 A

1671 A

2030 A

4 4

Illustration 4.14




4 4

4.3.7 Inside Delta Connection (Non-bypassed/Continuous)

Table 4.16

MCD5-0245C

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

AC-53a

3-30:50-6

368 A

540 A

570 A

643 A

893 A

929 A

1185 A

1391 A

1800 A

2115 A

2400 A

AC-53a

4-20:50-6

293 A

455 A

522 A

533 A

773 A

798 A

1042 A

1200 A

1702 A

1780 A

2149 A


Star t T ime (sec

Star ts P er H our ond s)

Illustration 4.15


AC-53a

4.5-30:50-6

257 A

389 A

438 A

451 A

629 A

656 A

851 A

966 A

1474 A

1535 A

1841 A



Table 4.17

Model

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

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

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

Minimum Maximum

29 A

34 A

40 A

44 A

51 A

72 A

76 A

86 A

5 A

9 A

10 A

11 A

15 A

19 A

20 A

21 A

124 A

130 A

158 A

186 A

240 A

282 A

320 A

620 A

650 A

790 A

930 A

1200 A

1410 A

1600 A

145 A

170 A

200 A

220 A

255 A

360 A

380 A

430 A

23 A

43 A

50 A

53 A

76 A

97 A

100 A

105 A

Inside Delta Connection

Minimum Maximum

44 A

51 A

60 A

66 A

77 A

108 A

114 A

129 A

7 A

13 A

15 A

16 A

23 A

29 A

30 A

32 A

186 A

195 A

237 A

279 A

360 A

423 A

480 A

930 A

975 A

1185 A

1395 A

1800 A

2115 A

2400 A

217 A

255 A

300 A

330 A

382 A

540 A

570 A

645 A

34 A

64 A

75 A

79 A

114 A

145 A

150 A

157 A

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.

4 4



4 4

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.

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



4.9.2 Bussman Fuses - Square Body (170M)

Model SCR I 2 t (A 2 s)

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

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

1150

8000

10500

15000

15000

512000

80000

125000

125000

320000

320000

320000

320000

320000

320000

320000

1200000

1200000

2530000

4500000

4500000

6480000

12500000

Table 4.18

* Two parallel connected fuses required per phase.

Supply Voltage

( ≤ 440 VAC)

170M1314

170M1316

170M1318

170M1318

170M1319

170M1321

170M1321

170M1321

170M1321

170M2621

170M2621

170M2621

170M2621

170M6010

170M6011

170M6011

170M6015

170M6015

170M6017

170M6019

170M6021

-

170M6019*

Supply Voltage

( ≤ 575 VAC)

170M1314

170M1316

170M1318

170M1318

170M1319

170M1321

170M1321

170M1321

170M1321

170M2621

170M2621

170M2621

170M2621

170M6010

170M6011

170M6011

170M6015

170M6015

170M6017

170M6019

-

-

-

Supply Voltage

( ≤ 690 VAC)

170M1314

170M1316

170M1318

170M1318

170M1318

170M1319

170M1321

170M1321

170M1321

170M2621

170M2621

170M2621

170M2621

170M6010

-

-

170M6014

170M6014

170M6016

170M6019

-

-

-

4 4



4 4

4.9.3 Bussman Fuses - British Style (BS88)


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

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

1150

8000

10500

15000

15000

512000

80000

320000

1200000

1200000

2530000

4500000

4500000

6480000

12500000

125000

125000

320000

320000

320000

320000

320000

320000

Table 4.19

* Two parallel connected fuses required per phase.

Supply Voltage

(< 440 VAC)

63FE

120FEE

120FEE

200FEE

200FEE

200FEE

280FM

280FM

280FM

450FMM

450FMM

450FMM

450FMM

-

400FMM*

-

630FMM*

630FMM*

-

-

-

-

-

Supply Voltage

(< 575 VAC)

63FE

120FEE

120FEE

200FEE

200FEE

200FEE

280FM

280FM

280FM

450FMM

450FMM

450FMM

450FMM

-

400FMM

-

630FMM*

630FMM*

-

-

-

-

-

Supply Voltage

(< 690 VAC)

63FE

120FEE

120FEE

200FEE

200FEE

200FEE

280FM

-

-

-

-

-

-

-

-

280FM

280FM

450FMM

450FMM

450FMM

450FMM

-

400FMM*



4.9.4 Ferraz Fuses - HSJ


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

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

1150

8000

10500

15000

15000

51200

80000

320000

1200000

1200000

2530000

4500000

4500000

6480000

12500000

125000

125000

320000

320000

320000

320000

320000

320000

Table 4.20

** Two series connected fuses required per phase


Supply Voltage

(< 440 VAC)

HSJ40**

HSJ80**

HSJ90**

HSJ110**

HSJ125**

HSJ175

HSJ175

HSJ225

HSJ250

HSJ300

HSJ350

HSJ400**

HSJ450**

Supply Voltage

(< 575 VAC)

HSJ40**

HSJ80**

HSJ90**

HSJ110**

HSJ125**

HSJ175**

HSJ175

HSJ225

HSJ250**

HSJ300

HSJ350

HSJ400**

HSJ450**

Supply Voltage

(< 690 VAC)

Not suitable

Not suitable

Not suitable

4 4



4 4

4.9.5 Ferraz Fuses - North American Style (PSC 690)


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

MCD5-0360C

MCD5-0380C

MCD5-0428C

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

1150

8000

10500

15000

15000

51200

80000

320000

1200000

1200000

2530000

4500000

4500000

6480000

12500000

125000

125000

320000

320000

320000

320000

320000

320000

Table 4.21

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

Supply Voltage

< 440 VAC

A070URD30XXX0063

A070URD30XXX0125

A070URD30XXX0125

A070URD30XXX0125

A070URD30XXX0160

A070URD30XXX0200

A070URD30XXX0200

A070URD30XXX0315

A070URD30XXX0315

A070URD30XXX0315

A070URD30XXX0450

A070URD30XXX0450

A070URD30XXX0450

A070URD33XXX0630

A070URD33XXX0700

A070URD33XXX0700

A070URD33XXX1000

A070URD33XXX1000

A070URD33XXX1400

A070URD33XXX1400

A055URD33XXX2250

A055URD33XXX2250

-

Supply Voltage

< 575 VAC

A070URD30XXX0063

A070URD30XXX0125

A070URD30XXX0125

A070URD30XXX0125

A070URD30XXX0160

A070URD30XXX0200

A070URD30XXX0200

A070URD30XXX0315

A070URD30XXX0315

A070URD30XXX0315

A070URD30XXX0450

A070URD30XXX0450

A070URD30XXX0450

A070URD33XXX0630

A070URD33XXX0700

A070URD33XXX0700

A070URD33XXX1000

A070URD33XXX1000

A070URD33XXX1400

A070URD33XXX1400

-

-

-

Supply Voltage

< 690 VAC

-

A070URD30XXX0125

A070URD30XXX0125

A070URD30XXX0125

A070URD30XXX0160

A070URD30XXX0200

A070URD30XXX0200

A070URD30XXX0315

A070URD30XXX0315

A070URD30XXX0315

A070URD30XXX0450

A070URD30XXX0450

A070URD30XXX0450

A070URD33XXX0630

-

-

A070URD33XXX1000

A070URD33XXX1000

A070URD33XXX1400

A070URD33XXX1400

-

-

-



4.9.6 UL Tested Fuses - Short Circuit Ratings

Model

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

MCD5-0360C

MCD5-0380C

MCD5-0425B

MCD5-0595C

MCD5-0619C

MCD5-0790C

MCD5-0927C

MCD5-1200C

MCD5-1410C

MCD5-1600C

Nominal Rating (A) Short Circuit Rating 480V AC (kA) Short Circuit Rating 600V AC (kA)

23 65 10

43

50

65

65

10

10

53

76

97

100

65

65

65

65

10

10

10

10

930

1200

1410

1600

430

620

650

790

220

255

360

380

105

145

170

200

65

65

65

65

65

85

85

85

85

85

85

85

85

100

100

100

10

18

18

18

18

85

85

85

85

85

85

85

85

100

100

100

Fuse Ferraz

AJT50 A070URD30XXX0063
















A4BQ800 A070URD33XXX1000


A4BQ1200 070URD33XXX1400





Table 4.22

4 4



28


4 4

4.10 Schematic Diagrams

4.10.1 Internally Bypassed Models

A

1/L1

3/L2

5/L3

E

A4

A5

A6

1

07

+

08

11

24

VDC

2

16 +

15

17

18

3

25

05

06

4

5

13

14

21

22

24

33

34

2/T1

4/T2

6/T3

Illustration 4.16

1

2

07, 08

16, 08

3

11, 16

15, 16

17, 18

25, 18

4

5

13, 14

21, 22, 24

33, 34

Table 4.23

Control supply (model dependent)

Outputs

Programmable analog output

24 VDC output

Remote control inputs

Programmable input

Start

Stop

Reset

Motor thermistor input (PTC only)

Relay outputs

Relay output A

Relay output B

Relay output C



4.10.2 Non-bypassed Models


A

E

1/L1

*

L1B

3/L2 *

L2B

5/L3

L3B

*

A4

A5

A6

1

07

+

08

11

24

VDC

2

16 +

15

17

18

3

25

05

06

4

5

2/T1

4/T2

6/T3

22

24

33

34

13

14

21

Illustration 4.17

1

2

07, 08

16, 08

3

11, 16

15, 16

17, 18

25, 18

4

5

13, 14

21, 22, 24

33, 34

Control supply (model dependent)

Outputs

Programmable analog output

24 VDC output


Programmable input

Start

Stop

Reset


Relay outputs

Relay output A

Relay output B

Relay output C

Table 4.24

NOTE

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

4 4


Application Examples MCD 500 Operating Instruction

5 5

5 Application Examples

5.1 Motor Overload Protection

The thermal model used for motor overload in the MCD

500 has two components:

• 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.

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.

• The memory function of the model means that 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.

The overload protection function provided by this model is 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.

10000

1000

100

10

3

2

1

1

100 200 300 400 500 600 700 800 900 1000

Current (%motor full load current)

Illustration 5.1

1.

MSTC 1 = 5

2.

3.

MSTC 1 = 10

MSTC 1 = 20

1 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.



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.

700%

600%

500%

400%

300%

200%

100%

3

1

2

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

Rotor speed (% full speed)

Illustration 5.2


To use AAC Adaptive Acceleration Control to control starting performance:

1.

2.

3.

4.

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.

1: 1-5 Initial current

2: 1-4 Current limit

3: Full voltage current

Table 5.1

5.3.2 Current Ramp

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).

600%

500%

400%

300%

200%

100%

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

Full Voltage Stator Current

700%

Ramp Time

(eg Par. 4 = 10 secs)

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

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

Illustration 5.3

10% 20% 30% 40% 50% 60% 70%

ROTOR SPEED (% Full Speed)

80% 90% 100%

5 5



5 5

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0

Illustration 5.4

1

2

3

Time

4

700%

600%

2

500%

400%

300%

200%

100%

6

1

4

3

5

Illustration 5.5

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

Rotor speed (% full speed)

1. Early acceleration

2. Constant acceleration

3. Late acceleration

4. 1-16 Start Ramp Time

Table 5.2 1-13 Adaptive Start Profile

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.

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 current ramp or constant current starting.

Kickstart can be useful to help start loads that require high breakaway torque but then accelerate easily (for example flywheel loads such as presses).

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

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.

5.4.2 TVR Soft Stop

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.

Timed voltage ramp stopping can be useful for applications where the stop time needs to be extended, or to avoid transients on generator set supplies.



100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

Illustration 5.6

1

Time

1: 1-11 Stop Time

Table 5.4


To use AAC Adaptive Acceleration Control to control stopping performance:

1.

2.

3.

100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

0

Illustration 5.7

Select Adaptive Control in 1-10 Stop Mode .

Set 1-11 Stop Time .

Select the required profile in 1-14 Adaptive Stop

Profile .

4

1 2

Time

3

1. Early deceleration

2. Constant deceleration

3. Late deceleration

4. 1-10 Stop Time

Table 5.5 1-14 AAC Adaptive Stop Profile

177HA509.10

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.

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.

5.4.4 Brake

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.

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.

5 5



5 5

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.

2.

Pre-brake: provides an intermediate level of braking to slow motor speed to a point where full brake can be operated successfully (approximately 70% speed).

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

To configure the MCD 500 for brake operation

1.

2.

3.

100%

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.

70%

3

30%

0%

Illustration 5.8

1: 1-11 Stop Time

2: 1-16 Brake Time

3: Coast to stop time

Table 5.6

1

2

Time

177HA511.10



100%

90%

80%

70%

60%

50%

40%

30%

20%

10%

1

Illustration 5.9

2

3

1. Jog Forward

2. Jog Reverse

3. Normal Operation

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.

177HA512.10

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.

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

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

Jog

Brake

The starter issues a warning with the error message

Unsupported Option.

The starter performs a Coast to Stop.

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.

5 5


Application Examples

5 5

Application

General & Water

Agitator

Centrifugal pump

Compressor (Screw, unloaded)

Compressor (Reciprocating, unloaded)

Conveyor

Fan (damped)

Fan (undamped)

Mixer

Positive displacement pump

Submersible pump

Metals & Mining

Belt conveyor

Dust collector

Grinder

Hammer mill

Rock crusher

Roller conveyor

Roller mill

Tumbler

Wire draw machine

Food Processing

Bottle washer

Centrifuge

Dryer

Mill

Palletiser

Separator

Slicer

Pulp and Paper

Dryer

Re-pulper

Shredder

Petrochemical

Ball mill

Centrifuge

Extruder

Screw conveyor

Transport & Machine Tool

Ball mill

Grinder

Material conveyor

Palletiser

Press

Roller mill

Rotary table

Table 5.9


Typical Start Current

4.0 x FLC

3.5 x FLC

3.0 x FLC

4.0 x FLC

4.0 x FLC

3.5 x FLC

4.5 x FLC

4.5 x FLC

4.0 x FLC

3.0 x FLC

4.5 x FLC

4.5 x FLC

4.5 x FLC

4.5 x FLC

4.0 x FLC

5.0 x FLC

4.0 x FLC

4.5 x FLC

3.5 x FLC

4.0 x FLC

4.5 x FLC

3.5 x FLC

4.5 x FLC

4.0 x FLC

4.5 x FLC

3.5 x FLC

3.0 x FLC

4.5 x FLC

4.0 x FLC

3.5 x FLC

4.5 x FLC

4.0 x FLC

5.0 x FLC

3.0 x FLC

4.0 x FLC

4.5 x FLC

4.5 x FLC

4.5 x FLC

4.5 x FLC

3.0 x FLC


Application Examples

Lumber & Wood products

Bandsaw

Chipper

Circular saw

Debarker

Edger

Hydraulic power pack

Planer

Sander

Table 5.10

Application


Typical Start Current

4.5 x FLC

4.5 x FLC

3.5 x FLC

3.5 x FLC

3.5 x FLC

3.5 x FLC

3.5 x FLC

4.0 x FLC

5 5



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).

KM1 F1

1/L1 2/T1

5 5

3/L2 4/T2

6 7

A

S1

S2

5/L3

E

A4

A5

A6

1

07

+

08

11

24

VDC

2

16 +

15

17

18

3

25

5

05

06

4

6/T3

24

33

34

13

14

21

22

KM1

Illustration 5.10

5

6

7

3

4

1

2

Table 5.11

Control voltage (model dependent)

24 VDC output



Relay outputs

3-phase supply

Motor terminals

KM1

F1

S1

S2

13, 14

21, 22, 24

33, 34

Main contactor


Start /stop

Reset contact

Relay output A

Relay output B

Relay output C

Parameter settings:

• 4-1 Relay A Function

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



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).

KM1

F1

6

A

S1

S2

S3

1/L1

L1B

3/L2

L2B

5/L3

L3B

E

A4

A5

A6

1

07

+

08

11

24

VDC

2

16 +

15

17

18

3

25

05

06

4

5

2/T1

4/T2

6/T3

22

24

33

34

13

14

21

KM1

7

Illustration 5.11

5

6

7

3

4

1

2

Table 5.12


24 VDC output



Relay outputs

3-phase supply

Motor terminals

KM1

F1

S1

S2

S3

13, 14

21, 22, 24

33, 34

Bypass contactor


Start contact

Stop contact

Reset contact

Relay output A

Relay output B

Relay output C

Parameter settings:

• 4-4 Relay B Function

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


5 5


5 5

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.

6

KM1 F1

1/L1

3/L2

A

S3

S1

S2

5/L3

E

A4

A5

A6

1

07

+

08

11

24

VDC

2

16 +

15

17

18

3

25

05

06

4

5

2/T1

4/T2

6/T3

13

14

21

22

24

33

34

7

Illustration 5.12

5

6

7

3

4

1

2

Table 5.13


24 VDC output



Relay outputs

3-phase supply

Motor terminals

S1

S2

S3

13, 14

21, 22, 24

33, 34

Start/stop contact

Reset contact

Emergency Run contact

Relay output A

Relay output B

Relay output C

Parameter settings:

• 3-3 Input A Function

• Select Emergency Run - assigns Input A to Emergency Run Function

• 15-3 Emergency Run

• Select Enable - Enables the Emergency Run mode



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.

6

KM1 F1

1/L1

3/L2

A

S3

S1

S2

5/L3

E

A4

A5

A6

1

07

+

08

11

24

VDC

2

16 +

15

17 3

18

25

05

06

4

5

2/T1

4/T2

6/T3

22

24

33

34

13

14

21

7

Illustration 5.13

3

4

1

2

5

6

7

Table 5.14


24 VDC output



Relay outputs

3-phase supply

Motor terminals

S1

S2

S3

13, 14

21, 22, 24

33, 34

Start/stop contact

Reset contact

Auxiliary trip contact

Relay output A

Relay output B

Relay output C

Parameter settings:


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

• 3-4 Input A Name

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

• 3-8 Remote Reset Logic

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

5 5



5 5

5.12 DC Brake with External Zero Speed

Sensor

For loads which may vary between braking cycles, there are benefits in using an external zero-speed sensor to interface with the MCD 500 for brake shut-off. This control method ensures that the MCD 500 braking will always shut off when the motor has reached a standstill, thus avoiding unnecessary motor heating.

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 (-

A2) is often referred to as an under-speed detector. Its internal contact is open at zero-speed and closed at any speed above zero-speed. Once the motor has reached a standstill, the MCD 500 will go into Emergency Stop mode and remain in this state until the next start command is given (i.e. next application of –KA1).

The MCD 500 must be operated in remote mode and 3-3

Input A Function must be set to emergency stop.

L1 L2 L3

4

N E

-F1

-KA1 -A2

L1 L2 L3 E

1

T1 T2 T3

A4 A5 A6

2

15 16 17 18 25

11 16

T1 T2 T3

-KA1

3

M

3

Illustration 5.14

-KA2

5

A B

-KA2 -KA1

C D

5

6

-KA1 -KA2

7

E

8

1 Soft starter

17,

18

25,

18

2 Control voltage

15,

16

Start

Stop

Reset

4 Emergency stop mode (shown on starter display)

A

B

C

D

Off (ready)

Start

Run

Stop

2 Motor E Zero speed

3 Three-phase supply 5 Start signal (2, 3, or 4-wire)

6

7

Zero speed detect

Zero speed sensor

Table 5.15

For details on configuring DC Brake, see

5.4.4 Brake

.

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 .

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 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).



Illustration 5.15

KM2

5

F1

1/L1 3/L2 5/L3

2/T1

6

4/T2 6/T3 E

A4 A5 A6

1

54 55

2

56

53

KA3 KA2

3

05 06

3

57

S3

58

33

6

4

34

KA1 KA3 S2

KM1

KT3

KA4 A2

KT2 KT1 S1 KA1 KM1 KM2 KA1 KM1 Y1

Y2

KT1 KM2 Y1

Y2

KT2 KT3

KM1 KM2 KA1 KA2 KA3 KA4

M1

5

6

A2

S1

3

4

1

2

S2

S3

Table 5.16




Relay outputs

3-phase supply

Motor terminals

Shaft rotation sensor

Start contact

Stop contact

Reset contact

KA1

KA2

KA3

KA4

KM1

KM2

KT1

KT2

KT3

Run relay

Start relay

Brake relay

Rotation sensing relay

Line contactor (Run)

Line contactor (Brake)

Run delay timer

Brake delay timer

Shaft rotation sensor delay timer

Parameter settings:


• 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.

5 5



5 5

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.



KM3

KM1

KM2

KA1

4

F1

11

16

15

1/L1

3/L2

5/L3

A4

A5

A6

1

S1

17

18

25

2

3

2/T1

4/T2

6/T3

E

21

24

22

KM2

KM1

T1

T2

T3

T4

T5

T6

5

KM3 KM1

KA2 KM2

KA1 KM3 KM1

KM3

KM2

KA2

6

KA1

KA1

7

KA2

Illustration 5.16

1

2

3

4

5

Control voltage


Relay outputs

3-phase supply

Motor terminals

6

7

KA1

KA2

KM1

Remote low-speed start input KM2 Line contactor (low speed)

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

Remote start relay (low speed) S1

Remote start relay (high speed) 21,

22, 24

Line contactor (high speed)

Reset contact

Relay output B

Table 5.17

NOTE

Contactors KM2 and KM3 must be mechanically interlocked.

Parameter settings:


• 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


5 5

Operation

46


6 Operation

6.1.2 The LCP

6 6

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:

• 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)

Illustration 6.1

®

1

2

3

4

5

3

4

1

2

5

Table 6.1

Four-line display for status and programming details.

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

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.

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).

Remote input status LEDs.

6.2 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.


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

Copy parameters

Display to starter

Starter to display

Table 6.3

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.

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

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.

S1

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.

[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.

6 6



6 6

To soft start the motor

To stop the motor

To reset a trip on the starter

Auto start/stop operation

Table 6.5

Hand On mode press [Hand On] on the LCP press [Off] on the LCP press [Reset] on the LCP

Disabled

Auto On mode activate the Start remote input activate the Stop remote input activate the Reset remote input

Enabled

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.

The temperature monitoring screen is the default status screen.

Ready

MS1

M1 000%

Table 6.6

000.0A

Primary Motor Set

S1

000.0kW

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.

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.

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.

Ready

MS1

00000 hrs

Table 6.7

000.0A

-.-- pf

S2

000.0kW

6.6.3 Average Current (S3)

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

Ready

MS1

Table 6.8

000.0A

0.0A

S3

000.0kW



6.6.4 Current Monitoring Screen (S4)

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

Ready

MS1

000.0A

Table 6.9

000.0A

Phase currents

000.0A

6.6.5 Frequency Monitoring Screen (S5)

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

S4

000.0kW

000.0A

Ready

MS1

Table 6.10

000.0A

00.0Hz

S5

000.0kW

6.6.6 Motor Power Screen (S6)

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

Ready

MS1

000.0kW

0000kVA

Table 6.11

000.0A

S6

000.0kW

0000HP

-. - - pf

6.6.7 Last Start Information (S7)

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

Last start

000 % FLC

000.0A

S7

000.0kW

000 s

Δ Temp 0%

Table 6.12

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

MS1

Table 6.13

000.0A

YYYY MMM DD

HH:MM:SS

6.6.9 SCR Conduction Bargraph

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

S8

000.0kW

Illustration 6.2


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.

6 6


Programming MCD 500 Operating Instruction

7 Programming

7 7

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

####

OK

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



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 .

Primary Mtr Set

Motor FLC

Start Mode

Current Limit

Initial Current

Start Ramp Time

Excess Start Time

Stop Mode

Stop Time

Protection

Phase Sequence

Undercurrent

Undercurrent Dly

Inst Overcurrent

Inst Overcurrent Dly

Inputs

Input A Function

Input A Name

Input A Trip

Input A Trip Dly

Input A Initial Dly

Outputs

Relay A Function

Relay A On Delay

Relay A Off Delay

Relay B Function

Relay B On Delay

Relay B Off Delay

Relay C Function

Relay C On Delay

Relay C Off Delay

Low Current Flag

High Current FLag

Motor Temp Flag

Start/Stop Timers

Auto-Start Type

Auto-Start Time

Auto-Stop Type

Auto-Stop Time

Display

Language

User Scrn Top L

User Scrn Top R

User Scrn Btm L

User Scrn Btm R

4-5

4-6

4-7

4-8

4-1

4-2

4-3

4-4

3-5

3-6

3-7

4

2-7

3

3-3

3-4

1-11

2

2-1

2-4

2-5

2-6

1

1-1

1-3

1-4

1-5

1-6

1-9

1-10

5-4

8

8-1

8-2

8-3

8-4

8-5

5

5-1

5-2

5-3

4-9

4-10

4-11

4-12

Table 7.3

7 7



7 7

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

Motor Full Load Current

Start Mode

Adaptive Start Profile

Start Ramp Time

Stop Mode

Adaptive Stop Profile

Stop Time

Pump Submersible


Start Mode


Start Ramp Time

Stop Mode


Stop Time

Fan Damped


Start Mode

Current Limit

Fan Undamped


Start Mode


Start Ramp Time

Excess Start Time

Locked Rotor Time

Compressor Screw


Start Mode

Start Ramp Time

Current Limit

Table 7.4

Suggested Value

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%

Compressor Recip


Start Mode

Start Ramp Time

Current Limit

Conveyor


Start Mode

Start Ramp Time

Current Limit

Stop Mode


Stop Time

Crusher Rotary


Start Mode

Start Ramp Time

Current Limit

Excess Start Time

Locked Rotor Time

Crusher Jaw


Start Mode

Start Ramp Time

Current Limit

Excess Start Time

Locked Rotor Time

Suggested Value

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



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.

7.3.1 Parameters

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.

7.3.2 Parameter Shortcut

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

7 7


Programming

7 7

7.3.3 Parameter List

2-3

2-4

2-5

2-6

1-16

2

2-1

2-2

1-8

1-9

1-10

1-11

1-12

1-13

1-14

1-15

1-4

1-5

1-6

1-7

1

1-1

1-2

1-3

3-2

3-3

3-4

3-5

3-6

3-7

3-8

2-7

2-8

2-9

2-10

2-11

2-12

3

3-1

Table 7.6

Primary Mtr Set

Motor FLC

Locked Rotor Time

Start Mode

Current Limit

Initial Current

Start Ramp Time

Kickstart Level

Kickstart Time

Excess Start Time

Stop Mode

Stop Time

Adaptv Control Gain

Adaptv Start Profile

Adaptv Stop Profile

Brake Torque

Brake Time

Protection

Phase Sequence

Current Imbalance

Current Imbal Dly

Undercurrent

Undercurrent Dly

Inst Overcurrent

Inst Ocrnt Dly

Frequency Check

Freq Variation

Frequency Delay

Restart Delay

Motor Temp Check

Inputs

Local/Remote

Comms in Remote

Input A Function

Input A Name

Input A Trip

Input A Trip Dly

Input A Initial Dly

Remote Reset Logic


Outputs

Relay A Function

Relay A On Delay

Relay A Off Delay

Relay B Function

Relay B On Delay

Relay B Off Delay

Relay C Function

Relay C On Delay

Relay C Off Delay

Low Current Flag

High Current FLag

Motor Temp Flag

Analog Output A

Analog A Scale

Analog A Max Adj

Analog A Min Adj

Start/Stop Timers

Auto-Start Type

Auto-Start Time

Auto-Stop Type

Auto-Stop Time

Auto-Reset

Auto-Reset Action

Maximum Resets

Reset Dly Grp A & B

Reset Delay Grp C

Secondary Mtr Set

Motor FLC-2

Lock Rotor Time-2

Start Mode-2

Current Limit-2

Initial Crnt-2

Start Ramp-2

Kickstart Lvl-2

Kickstart Time-2

Excess Strt Time-2

Stop Mode-2

Stop Time-2

5-3

5-4

6

6-1

4-16

5

5-1

5-2

4-8

4-9

4-10

4-11

4-12

4-13

4-14

4-15

4-4

4-5

4-6

4-7

4

4-1

4-2

4-3

7-5

7-6

7-7

7-8

7-9

7-10

7-11

7-1

7-2

7-3

7-4

6-2

6-3

6-4

7

Adaptv Ctrl Gain-2

Adaptv Start Prof-2

Adaptv Stop Prof-2

Brake Torque-2

Brake Time-2

Display

Language

User Scrn Top L

User Scrn Top R

User Scrn Btm L

User Scrn Btm R

Graph Timebase

Graph Max Adj

Graph Min Adj

Mains Ref Volt

Restrict Paramtr

Access Code

Adjustment Lock

Emergency Run

Current Calibrat

Main Cont Time

Bypass Cont Time

Motor Connection

Jog Torque

Protection Action

Motor Overload

Current Imbalance

Undercurrent

Inst Overcurrent

Frequency

Heatsink Overtemp

Excess Start Time

Input A Trip

Motor Thermistor

Starter Comms

Network Comms

Battery/Clock

Low Control Volts

15-1

15-2

15-3

15-4

15-5

15-6

15-7

15-8

8-7

8-8

8-9

15

8-3

8-4

8-5

8-6

7-12

7-13

7-14

7-15

7-16

8

8-1

8-2

16-8

16-9

16-10

16-11

16-12

16-13

16

16-1

16-2

16-3

16-4

16-5

16-6

16-7



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:

Model dependent

Function:

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:

Constant Current *

Adaptive Control

Function:

Selects the soft start mode. See

5.3 Starting

Modes

for more details.

1-4 Current Limit

Range:

350% * [100% -

600% FLC]

Function:

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


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


for more details.

1-7 Kickstart Level

Range:

500% * [100% -

700% FLC]

Function:

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:

0000 msecs *

[0 - 2000 msecs]

Function:

Sets the kickstart duration. A setting of 0 disables kickstart. See


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:

20 secs *

[0:00 - 4:00

(min:secs)]

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.

Set as required.

1-10 Stop Mode

Option: Function:

Selects the stop mode. See

5.4 Stopping

Modes

for more details.

Coast to Stop *

TVR Soft Stop

7 7



7 7

1-10 Stop Mode

Option:

Adaptive Control

Brake

Function:

1-11 Stop Time

Range:

0 secs * [0:00 - 4:00

(min:secs)]

Function:

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.

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.

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

7.4.1 Brake

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.

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

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:

3 secs * [0:00 - 4:00

(min:secs)]

Function:

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



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:

20% * [0% -

100%]

Function:

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:

5 secs * [0:00 - 4:00

(min:secs)]

Function:

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:

400% * [80% - 600%

FLC]

Function:

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:

Do not Check

Start Only

Start/Run *

Run Only

Function:

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:

1 sec * [0:01 - 4:00

(min:sec)]

Function:

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:

10 secs *

[00:01 -

60:00

(min:secs)]

Function:

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

7 7



7 7

7.6 Inputs

3-1 Local/Remote

Option: Function:

Lcl/Rmt anytime *

Local Control

Only

Remote Control

Only

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

Auto On modes.

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.

3-2 Comms in Remote

Option: Function:

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.

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

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

3-3 Input A Function

Option: Function:

Emergency

Run

Emergency

Stop 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 .

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.

Jog Forward Activates jog operation in a forward direction

(will operate only in Remote mode).

Jog Reverse Activates jog operation in reverse direction (will 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 * A trip can occur at any time when the soft starter is receiving power.

Operating Only A trip can occur while the soft starter is running, stopping or starting.

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



3-7 Input A Initial Delay

Range:

0 secs * [00:00 - 30:00

(min:secs)]

Function:

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:

Off Relay A 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

Selects the function of Relay A (normally open).

Trip

Warning

The relay closes when the starter changes to run state.

The relay closes when the starter trips.

Low Current

Flag

High Current

Flag

Motor Temp

Flag

The relay closes when the starter issues a 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

A.

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:

Off

Selects the function of Relay B (changeover).

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 * The relay closes when the starter changes to run state.

Trip

Warning

Low Current

Flag

High Current

Flag

Motor Temp

Flag






4-5 Relay B On Delay

Range: Function:


B.

4-6 Relay B Off Delay

Range: Function:


Relay B.

4-7 Relay C Function

Option: Function:

Trip *

Warning

Selects the function of Relay C (normally open).

Relay C is not used Off

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 The relay closes when the starter changes to run state.


Low Current

Flag

High Current

Flag

Motor Temp

Flag





7 7



7 7

4-8 Relay C On Delay

Range: Function:


C.

4-9 Relay C Off Delay

Range: Function:


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:

50% * [1% - 100%

FLC]

Function:

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.

7.7.4 Motor Temperature Flag

The MCD 500 has a motor temperature flag to give early 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 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.

4-13 Analog Output A

Option:

Current (%

FLC) *

Motor Temp

(%)

Motor kW

(%)

Motor kVA

(%)

Motor pf

Function:

Selects which information will be reported via analog output A.

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 × IFLC × pf

1000

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

Motor FLC ) multiplied by mains reference voltage

( 8-9 Mains Reference Voltage ).

3 × V × IFLC

1000

Motor power factor, measured by the soft starter.

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:

0% * [0% - 600%] Calibrates the lower limit of the analog output to match the signal measured on an external current measuring device.

7.8 Start/Stop Timers

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.

Off * The soft starter will not auto-start.

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 .



5-2 Auto-Start Time

Range:

1 min * [00:01 - 24:00

(hrs:min)]

Function:

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.

Off * The soft starter will not auto-stop.

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:

1 min * [00:01 -

24:00

(hrs:min)]

Function:

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

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

A

B

C

Current Imbalance

Phase Loss

Power Loss

Mains Frequency

Undercurrent

Instantaneous Overcurrent

Input A Trip

Motor Overload

Motor Thermistor

Starter Overtemperature

Table 7.7

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.

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:

[Motor dependent]

Function:

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

7 7



7 7

7-2 Locked Rotor Time-2

Range:

10 secs * [0:01 - 2:00

(min:secs)]

Function:

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.

7-3 Start Mode-2

Option: Function:

Selects the start mode for the secondary motor.

Constant Current *

Adaptive Control

7-4 Current Limit-2

Range:

350% * [100% - 600%

FLC]

Function:

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]

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.

7-6 Start Ramp Time-2

Range:

10 secs * [1 - 180 secs]

Function:

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.

7-9 Excess Start Time-2

Range:

20 secs *

[0:00 - 4:00

(min:secs)]

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.

Set the excess time for the secondary motor.

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:

0 secs * [0:00 - 4:00

(min:secs)]

Function:

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.

7-12 Adaptive Control Gain-2

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.



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:

English *

Chinese ( 中丈 )

Spanish (Español)

German (Deutsch)

Portuguese (Português)

French (Français)

Italian (Italiano)

Russian ( Русский )

Function:

Selects which language the LCP will use to display messages and feedback.

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:

Blank

Starter State

Motor Current

Motor pf *

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

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

The starter's operating state (starting, running, stopping or tripped). Only available for “Top L” and “Btm L”.

The average current measured on three phases.

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

Mains Frequency The average frequency measured on three phases.

Motor kW

Motor HP

Motor Temp

The motor's running power in kilowatts.

The motor's running power in horsepower.

kWh

The motor's temperature, calculated by the thermal model.

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.

8-3 User Screen - Top Right

Option: Function:

Blank *

Starter State

Motor Current

Motor pf

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






Motor kW

Motor HP

Motor Temp



kWh




7 7


7 7


8-4 User Screen - Bottom Left

Option: Function:

Blank

Starter State

Motor Current

Motor pf

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






Motor kW

Motor HP

Motor Temp



kWh



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

8-5 User Screen - Bottom Right

Option: Function:

Blank *

Starter State

Motor Current

Motor pf

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






Motor kW

Motor HP

Motor Temp



kWh





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 progressively 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:

400 V * [100 - 690

V]

Function:

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.



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 *

Allows users to alter parameter values in the

Programming Menu

Read Only Prevents users altering parameter values in the

Programming Menu. Parameter values can still be viewed.

No Access Prevents users adjusting parameters in the

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:

100% *

[85%

-

115%]

Function:

Motor Current Calibration calibrates the soft starter's current monitoring circuits to match an external current metering device.

Use the following formula to determine the necessary adjustment:

NOTE

This adjustment affects all current-based functions.

15-5 Main Contactor Time

Range:

400 msecs *

[100 -

2000 msecs]

Function:

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



7 7

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

•

16-10 Starter/Comms

•

16-11 Network/Comms

•

16-12 Battery/Clock

•

16-13 Low Control Volts

Trip Starter *

Warn and

Log

Log Only

7.14 Factory Parameters

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


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.

2.

3.

Open the Tools Menu.

Scroll to Set Date & Time .

Press [OK] to enter edit mode.

4.

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

5.

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.

2.

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

Load Defaults

Load User Set 1

Save User Set 1

Table 8.1

Load Defaults

No

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.

2.

3.

4.

Table 8.3

Open Tools.

Scroll to Reset Thermal Model and press [OK].

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

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

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



8 8

8.4 Protection Simulation

NOTE


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].

3.

4.

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

Press [OK] to simulate the selected protection.

5.

6.

7.

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

16).

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

000.0A

0000.0kW

Table 8.5

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.

8.5 Output Signal Simulation

NOTE


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

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.

3.

4.

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

On

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

8.7 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



8.8 Alarm Log

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.

3.

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].

8.8.2 Event Log

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 open the Event Log:

1.


2.

3.

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].

8.8.3 Counters

NOTE


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

The resettable counters (hours run, starts and motor kWh) can only be reset if the correct access code is entered.

To view the counters:

1.

2.

3.

4.


Scroll to Counters and press [OK].

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

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


Troubleshooting MCD 500 Operating Instruction

9 Troubleshooting

9 9

When a protection condition is detected, the MCD 500 will write this to the event log and may also trip or issue a warning. The soft starter's response to some protections may depend on the Protection Action settings (parameter group 16).

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.

mechanisms are designed to protect the soft starter, or can be caused by a fault within the soft starter.

9.1 Trip Messages

This table lists soft starter's protection mechanisms and the 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

Battery/Clock

Current Imbalance

Possible cause/Suggested solution

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 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

Excess Start Time

FLC Too High

Frequency

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

Excess start time trip can occur in the following conditions:

•

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

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

The mains frequency has gone beyond the specified range.

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


Troubleshooting

Display

Heatsink Overtemp

Input A Trip

Inst Overcurrent

Internal Fault X

L1 Phase Loss

L2 Phase Loss

L3 Phase Loss

L1-T1 Shorted

L2-T2 Shorted

L3-T3 Shorted

Low Control Volts

Motor Overload/

Motor 2 Overlaod

Motor Connection



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

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

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

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

Related Parameters.: None

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

The MCD 500 has detected a drop in the control voltage.

•

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

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

- 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


Troubleshooting

Display

Motor Thermistor

Network Comms

Parameter out of Range

Phase Sequence

9 9

Power Loss

Starter/Comms

Thermistor Cct

Time - Overcurrent

Undercurrent

Unsupported Option

Table 9.1



The motor thermistor input has been enabled and:

- The resistance at the thermistor input has exceeded 3.6 k Ω 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 k Ω resistor must be fitted across terminals 05, 06.

Related Parameters: 16-9 Motor Thermistor

The network master has sent a trip command to the starter, or there may be a network communication problem.

Check the network for causes of communication inactivity.

Related Parameters: 16-11 Network/Comms

- 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.


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.

Related Parameters: 2-1 Phase Sequence

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

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.


- There is a problem with the connection between the soft starter and the optional communications 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 thermistor input has been enabled and:

- 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.

The MCD 500 is internally bypassed and has drawn high current during running. (The 10 A protection curve trip has been reached or the motor current has risen to 600% of the motor FLC setting.)


The motor has experienced a sharp drop in current, caused by loss of load. Causes can include broken components (shafts, belts or couplings), or a pump running dry.

Related Parameters: 2-4, 2-5, and 16-3

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




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

Soft starter does not respond to commands.

The soft starter does not control the motor correctly during starting.

Motor does not reach full speed.

Probable Cause

- 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.

- 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.

- If the start current is too low, the motor will not produce enough torque to accelerate to full speed. The soft starter may trip on excess start time.

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.

Erratic motor operation.

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

- 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.

9 9



9 9

Symptom

Soft stop ends too quickly.

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.

Probable Cause

- 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.

- 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).

- Make sure you are saving the new value by pressing the [OK] button after adjusting a 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


Specifications MCD 500 Operating Instruction

10 Specifications

Supply

Mains voltage (L1, L2, L3)

MCD5-xxxx-T5

MCD5-xxxx-T7

MCD5-xxxx-T7

Control voltage (A4, A5, A6)

CV1 (A5, A6)

CV2 (A5, A6)

CV2 (A4, A6)

Current consumption (maximum)

CV1

CV2 (110 - 120 VAC)

CV2 (220 - 240 VAC)

Mains frequency

Rated insulation voltage to earth

Rated impulse withstand voltage

Form designation

200 VAC - 525 VAC (

380 VAC - 690 VAC ( ± 10%) (in-line connection)

380 VAC - 600 VAC ( ± 10%) (inside delta connection)

24 VAC/VDC (

±

±

10%)

20%)

110~120 VAC (+ 10% / - 15%)

220~240 VAC (+ 10% / - 15%)

2.8 A

1 A

500 mA

50/60 Hz ( ± 10%)

600 VAC

4 kV

Bypassed or continuous, semiconductor motor starter form 1

Short circuit capability

Coordination with semiconductor fuses

Coordination with HRC fuses

MCD5-0021B to MCD5-0215B

MCD5-0245C to MCD5-0927B

MCD5-1200C to MCD5-1600C

Type 2

Type 1 prospective current 65 kA prospective current 85 kA 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

Start (15, 16)

Stop (17, 18)

Reset (25, 18)

Programmable input (11, 16)

Motor thermistor (05, 06)

Outputs

Relay Outputs

Programmable Outputs

Relay A (13, 14)

Relay B (21, 22, 24)

Relay C (33, 34)

Analog Output (07, 08)

Maximum load

Accuracy

24 VDC Output (16, 08) Maximum load

Accuracy

Environmental

Protection

MCD5-0021B - MCD5-0105B

MCD5-0131B - MCD5-1600C

Operating temperature

Active 24 VDC, 8 mA approx

Trip >3.6 k

Normally closed

Normally closed

Ω

Normally open

Normally open

, reset <1.6k

Ω

10A @ 250 VAC resistive, 5A @ 250 VAC AC15 pf 0.3

Normally open

Changeover

Normally open

0-20 mA or 4-20 mA (selectable)

600 Ω (12 VDC @ 20 mA)

± 5%

200 mA

± 10%

IP20 & NEMA, UL Indoor Type 1

IP00, UL Indoor Open Type

-10° C to 60° C, above 40° C with derating

10 10



10 10

Storage temperature

Operating Altitude

Humidity

Pollution degree

Heat Dissipation

During start

During run

MCD5-0021B - MCD5-0053B

MCD5-0068B - MCD5-0105B

MCD5-0131B - MCD5-0215B

MCD5-0245C - MCD5-0927C

MCD5-1200C - MCD5-1600C

Certification

C ✓

UL/ C-UL

CE

CCC

Marine

(MCD5-0021B - MCD5-0215B only)

RoHS

- 25° C to + 60° C

0 - 1000 m, above 1000 m with derating

5% to 95% Relative Humidity

Pollution Degree 3

4.5 watts per ampere

= 39 watts approx

= 51 watts approx

= 120 watts approx

4.5 watts per ampere approx

4.5 watts per ampere approx

IEC 60947-4-2

UL 508

IEC 60947-4-2

GB 14048-6

Lloyds Marine No 1 Specification

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



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

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

MCD-201

●

●

The PC software available from Danfoss's website is:

MCD-202

●

●

●

MCD500

●

●

●

●

●

•

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

•

: VLT ® software for configuration and management.

10.1.4 Finger Guard Kit

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.

•

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

12kV

• 175G0100 SPD Surge protection kit for G1

• 175G0101 SPD Surge protection kit, G2-G5

• 175G0102 SPD Surge protection kit for G1

• 175G0103 SPD Surge protection kit, G1-G5

1/L1

1/L1

1/L1

E

2/T1

2/T1

2/T1

13

14

M

3 ~

KM1

Illustration 10.1

10 10


11 11

Bus Bar Adjustment Procedur...


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.


Bus Bar Adjustment Procedur...


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.

11 11

Table 11.1

NOTE

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

1.

2.

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.

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).


www.danfoss.com/drives

175R0549 MG17K402 *MG17K402* Rev. 2012–03–05

VLT MCD 500 Operating Instructions Manual

MAKING MODERN LIVING POSSIBLE

Operating Instructions

VLT

®

Soft Starter - MCD 500

Contents

1 Safety

1.1 Safety

Safety of Personnel

2 Introduction

2.1.1 Feature List

2.1.2 Type Code

MCD 5

3 Installation

3.1 Mechanical Installation

3.2 Dimensions and Weights

4 Electrical Installation

4.1 Electrical Installation

4.1.1 Control Wiring

4.1.2 Control Terminals

4.1.3 Remote Inputs

4.1.4 Serial Communication

4.1.5 Earth Terminal

4.1.6 Power Terminations

4.2 Motor Connection

4.2.1 Testing the Installation

4.2.2 In-line Installation

4.2.2.1 In-line Installation, Internally

Bypassed

4.2.2.2 In-line Installation, Non-bypassed

4.2.2.3 In-line Installation, Externally

Bypassed

4.2.3.1 Inside Delta Installation, Internally

Bypassed

4.2.3 Inside Delta Installation

4.2.3.2 Inside Delta Installation, Nonbypassed

4.2.3.3 Inside Delta Installation, Externally

Bypassed

4.3 Current Ratings

4.3.1 In-line Connection (Bypassed)

4.3.2 AC-53 Rating for Bypassed Operation

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

4.3.4 AC-53 Rating for Continuous Operation

4.3.5 Inside Delta Connection (Bypassed)

4.3.6 AC-53 Rating for Bypassed Operation

4.3.7 Inside Delta Connection (Non-bypassed/Continuous)

4.3.8 AC-53 Rating for Continuous Operation

4.4 Minimum and Maximum Current Settings

4.5 Bypass Contactor

4.6 Main Contactor

4.7 Circuit Breaker

4.8 Power Factor Correction

4.9 Fuses

4.9.1 Power Supply Fuses

4.9.2 Bussman Fuses - Square Body (170M)

4.9.3 Bussman Fuses - British Style (BS88)

4.9.4 Ferraz Fuses - HSJ

4.9.5 Ferraz Fuses - North American Style (PSC 690)

4.9.6 UL Tested Fuses - Short Circuit Ratings

4.10 Schematic Diagrams

4.10.1 Internally Bypassed Models

4.10.2 Non-bypassed Models

5 Application Examples

5.1 Motor Overload Protection

5.2 AAC Adaptive Acceleration Control

5.3 Starting Modes

5.3.1 Constant Current

5.3.3 AAC Adaptive Acceleration Control

5.3.2 Current Ramp

5.3.4 Kickstart

5.4 Stopping Modes

5.4.1 Coast to Stop

5.4.2 TVR Soft Stop

5.4.3 AAC Adaptive Acceleration Control

5.4.4 Brake

5.5 Jog Operation

5.6 Inside Delta Operation

5.7 Typical Start Currents

5.8 Installation with Main Contactor