Danfoss MCD500 Service Manual
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Danfoss MCD500 Service Manual

Vlt soft starter
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See also: Operating Instructions , Operating Manual
MAKING MODERN LIVING POSSIBLE
www.danfoss.com/drives
S S ervice Manual
VLT Soft Starter - MCD500
175R0550
MG17L402
Rev. 2010–11–05
*MG17L402*

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Summary of Contents for Danfoss MCD500

  • Page 1 MAKING MODERN LIVING POSSIBLE www.danfoss.com/drives S S ervice Manual VLT Soft Starter - MCD500 175R0550 MG17L402 Rev. 2010–11–05 *MG17L402*...

  • Page 2: Table Of Contents

    4.6 Power Assemblies 4.7 Snubber Assemblies 4.8 Fans 4.9 Current Transformers 4.10 Bypass Contactors 4.11 Plastics 4.11.1 Complete Plastics 4.12 Bus Bars 4.13 Other Spare Parts 5 Avoiding Damage 5.1 SCRs ® MG.17.L4.02 - VLT is a registered Danfoss trademark...
  • Page 3 5.2.1 Using the Soft Starter to Switch a Contactor 5.3 Control Input 6 Appendix 6.1.1 Input/Output Busbars to SCRs 6.1.2 SCRs to Heatsink 6.1.3 Bypass Contactor Connections 6.1.4 Current Transformer Busbar Assembly ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 4: Warnings

    If the starter is installed without a main according to local and currently valid contactor, the bus bar and heatsink are live whenever mains legislation. voltage is connected (including when the starter is ready or tripped). ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 5: Troubleshooting

    SCR(s) and checking for correct operation. contactors. Use this test if the starter trips with "Bypass Fail" Investigate the likely cause of SCR damage to or "Time Overcurrent". prevent a repeat SCR failure. ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 6: After Repair Tests

    Ensure that the welcome screen displays the correct Control/Mode/HMI firmware versions. Perform a Run Simulation test using both the LCP and remote switches. Connect mains supply and motor. Test that the soft starter functions as expected. ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 7: Trip Messages

    (shearpin) while running. This may indicate a jammed load. Related Pars.: 2-6, 2-7, 16-4 Internal Fault X The MCD 500 has tripped on an internal fault. Contact your local supplier with the fault code (X). Related Pars.: None ® MG.17.L4.02 - VLT is a registered Danfoss trademark...
  • Page 8 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 Par. 2-1 is suitable for the instal- lation. Related Pars.: 2-1 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...
  • Page 9 (shafts, belts or couplings), or a pump running dry. Related Pars.: 2-4, 2-5, 16-3 Unsupported Option The selected function is not available (e.g. jog is not supported in inside delta configuration). Related Pars.: None ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 10: General Faults

    - 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. ® MG.17.L4.02 - VLT is a registered Danfoss trademark...
  • Page 11 - 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. ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 12: Service Instructions

    ("frame sizes") as follows: Class MCD 500 Models 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 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 13: Mcd5-0021B - Mcd5-0053B (G1B)

    MCD 500 Service Manual 3.1.1 MCD5-0021B - MCD5-0053B (G1B) 177HA536.10 Cover Current transformers Cable guide Mounting posts Main plastic Backplane PCB Terminal blocks SCRs LCP and Main Control PCB Side plastic Model PCB ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 14: Mcd5-0068B - Mcd5-0105B (G1B)

    3.1.2 MCD5-0068B - MCD5-0105B (G1B) 177HA537.10 Cover Mounting posts Cable guide Bypass contactors Main plastic Backplane PCB Terminal blocks SCRs LCP and Main Control PCB Side plastic Model PCB Current transformers ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 15: Mcd5-0131B - Mcd5-0215B (G2B)

    3.1.3 MCD5-0131B - MCD5-0215B (G2B) 177HA538.10 Cover Model PCB Main plastic Current transformers Cable guide Bypass contactors Terminal blocks SCRs LCP and Main Control PCB Main body Bypass Driver PCB Fan and bracket Support plastic ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 16: Mcd5-0245C (G3C)

    MCD 500 Service Manual 3.1.4 MCD5-0245C (G3C) 177HA539.10 Cover Support plastic Cable guide Model PCB Main plastic Current transformers Terminal blocks SCRs LCP and Main Control PCB Main body Fan assembly ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 17: Mcd5-0360C - Mcd5-0927C (G4C)

    Module mount and spacer plastic Cable guide Fan assembly Support plastic Power assembly Model PCB Current transformer assembly Module mount and spacer plastic Main body Magnetic bypass plate (models <0595>C ~ 0927C) ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 18: Mcd5-1200C - Mcd5-1600C (G5C)

    Cover Snubber assembly Main plastic Magnetic bypass plate Cable guide Power assembly LCP and Main Control PCB Fan assembly Bypass driver PCB Current transformer assembly Support plastic Main body Model PCB ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 19: Spare Parts

    175G5601 175G5602 MCD5-0068B MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B MCD5-0195B MCD5-0215B MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C 175G5607 175G5608 175G5605 175G5606 MCD5-0595C MCD5-0619C MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C 175G5601 - 175G5604 175G5605 - 175G5608 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 20: Model Pcb

    MCD5-0089B 175G5615 MCD5-0790C 175G5627 MCD5-0105B 175G5616 MCD5-0927C 175G5628 MCD5-0131B 175G5617 MCD5-1200C 175G5629 MCD5-0141B 175G5618 MCD5-1410C 175G5630 MCD5-0195B 175G5619 MCD5-1600C 175G5631 MCD5-0215B 175G5620 175G5609 - 175G5612 175G5613 - 175G5616 175G5617 - 175G5631 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 21: Backplane Pcb

    Models MCD5-0021B - MCD5-0105B require one Backplane PCB. MCD5-0021B MCD5-0037B MCD5-0043B MCD5-0053B 175G5632 MCD5-0068B MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B MCD5-0195B MCD5-0215B MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C Not required MCD5-0595C MCD5-0619C MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C 175G5632 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 22: Bypass Driver Pcb

    MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C MCD5-0595C MCD5-0619C Not required MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C 175G5633 175G5698 Bypass contactor upgrade- Refer to Product Note PN04 MCD 500 Bypass Contactor Upgrade for more information. ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 23: Scrs And Scr Connections

    Spare part kits may onclude either Semikron or Eupec SRCs. These SCRs are fully interchangeable in MCD 500 units and can be mixed within the same soft starter. Model 0021 - 0068 SEMIKRON EUPEC ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 24: Power Assemblies

    Models MCD5-0360C - MCD5-1600C use power assemblies. Each soft starter requires two power assemblies. MCD5-0360C 175G5636 MCD5-0380C 175G5637 MCD5-0428C 175G5638 MCD5-0595C 175G5639 MCD5-0619C 175G5640 MCD5-0790C 175G5641 MCD5-0927C 175G5642 MCD5-1200C 175G5643 MCD5-1410C 175G5644 MCD5-1600C 175G5645 175G5636 - 175G5642 175G5643 - 175G5645 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 25: Snubber Assemblies

    MCD5-0619C MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C 175G5700 MCD5-1600C 175G5699 175G5700 4.8 Fans Certain models include a fan. The number of fans required differs between units and is shown in the table below. ® MG.17.L4.02 - VLT is a registered Danfoss trademark...
  • Page 26 MCD5-0043B MCD5-0053B MCD5-0068B MCD5-0084B MCD5-0089B 175G5646 MCD5-0105B MCD5-0131B MCD5-0141B Not required MCD5-0195B 175G5646 MCD5-0215B MCD5-0245C MCD5-0360C MCD5-0380C 175G5137 MCD5-0428C MCD5-0595C MCD5-0619C MCD5-0790C 175G5138 MCD5-0927C MCD5-1200C MCD5-1410C 175G5138 MCD5-1600C 175G5646, 175G5647 175G5648 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 27: Current Transformers

    MCD5-0105B MCD5-0131B MCD5-0141B MCD5-0195B 175G9048 MCD5-0215B MCD5-0245C MCD5-0360C 175G5652 MCD5-0380C 175G5653 MCD5-0428C MCD5-0595C 175G5654 MCD5-0619C MCD5-0790C 175G5655 MCD5-0927C 175G5656 MCD5-1200C 175G5657 MCD5-1410C 175G5658 MCD5-1600C 175G5659 175G9046 - 175G9048 175G5652 - 175G5659 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 28: Bypass Contactors

    MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C MCD5-0595C MCD5-0619C Not required MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C 175G5660 175G5661/175G5697 Bypass contactor upgrade. Refer to Product Note PN04 MCD 500 Bypass Contactor Upgrade for more information. ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 29: Plastics

    MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B 175G5668 MCD5-0195B MCD5-0215B 175G5669 MCD5-0245C MCD5-0360C MCD5-0380C 175G5672 Not required MCD5-0428C MCD5-0595C MCD5-0619C Not required MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C 175G5667, 175G5668 175G5671, 175G5672 175G5669 175G5670 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 30: Complete Plastics

    175G5675: 175G5672, 175G5669, support plastic Complete plastics MCD5-0021B MCD5-0037B MCD5-0043B MCD5-0053B 175G5673 MCD5-0068B MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B 175G5674 MCD5-0195B MCD5-0215B MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C MCD5-0595C MCD5-0619C 175G5675 MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 31: Bus Bars

    175G5687 (set of 6) MCD5-0360C MCD5-0380C MCD5-0428C 175G5688 175G5689 MCD5-0595C MCD5-0619C MCD5-0790C MCD5-0927C 175G5690 175G5691 MCD5-1200C 175G5692 175G5693 MCD5-1410C MCD5-1600C 175G5694 175G5695 175G5677 175G5679, 175G5681 175G5678, 175G5680, 175G5682 175G5696, 175G5684 175G5683, 175G5685 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...
  • Page 32 Spare Parts MCD 500 Service Manual 175G5686 175G5687 175G5688, 175G5690, 175G5692, 175G5694 175G5689, 175G5691, 175G5693, 175G5695 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 33: Other Spare Parts

    175G5666 (set of 3) MCD5-0068B MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B MCD5-0195B 175G5676 (set of 3) MCD5-0215B MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C Not required MCD5-0595C MCD5-0619C MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C 175G5666 175G5676 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 34: Avoiding Damage

    Semiconductor fuses reduce the potential for SCR damage caused by short circuits on the output of the starter. Protection systems such as circuit breakers or HRC fuses do not operate quickly enough to protect SCRs from short circuits. ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 35: Using The Soft Starter To Switch A Contactor

    If long cable runs are used, wiring must be twisted 1. Soft starter output relay pair or shielded cable and must be separated from 2. Slave relay coil AC power cables by at least 300 mm. 3. Contactor coil ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 36: Appendix

    Bolt size Torque (Nm) MCD5-0021B MCD5-0037B MCD5-0043B MCD5-0053B M5x12 MCD5-0068B MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B M6x16 MCD5-0141B MCD5-0195B M8x20 MCD5-0215B MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C MCD5-0595C M8x16 MCD5-0619C MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C M10x35 MCD5-1600C ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 37: Scrs To Heatsink

    MCD5-0021B MCD5-0037B M5x12 MCD5-0043B MCD5-0053B MCD5-0068B MCD5-0084B M6x12 MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B M5x12 MCD5-0195B M8x20 MCD5-0215B MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C MCD5-0595C MCD5-0619C Not required Not required MCD5-0790C MCD5-0927C MCD5-1200C MCD5-1410C MCD5-1600C ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

  • Page 38: Current Transformer Busbar Assembly

    Appendix MCD 500 Service Manual 6.1.4 Current Transformer Busbar Assembly Model Bolt size Torque (Nm) MCD5-0245C M6x16 ® MG.17.L4.02 - VLT is a registered Danfoss trademark...

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