Danfoss MCD 500 Service Manual
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Danfoss MCD 500 Service Manual

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MCD 500 Service Manual
Contents
Spare Parts
MG.17.L1.02 - VLT
®
is a registered Danfoss trademark
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Summary of Contents for Danfoss MCD 500

  • Page 1: Table Of Contents

    MCD 500 Service Manual Contents Contents 1 Warnings 2 Troubleshooting Functional Tests Power Circuit Test Start Performance Test Run Performance Test Trip Messages General Faults 3 Service Instructions Frame Sizes MCD5-0021B - MCD5-0053B (G1B) MCD5-0068B - MCD5-0105B (G1B) MCD5-0131B - MCD5-0215B (G2B)
  • Page 2 Contents MCD 500 Service Manual Using the Soft Starter to Switch a Contactor Control Input MG.17.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 3: Warnings

    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.
  • Page 4 2 Troubleshooting MCD 500 Service Manual MG.17.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 5: Troubleshooting

    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.

  • Page 6: Run Performance Test

    If the voltage starts near nominal mains voltage then falls to less than 2 VAC just before the MCD 500 reaches Run mode, the MCD 500 is operating correctly and the cause of the starting problem is not the soft starter.
  • Page 7 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.
  • Page 8 2 Troubleshooting MCD 500 Service Manual Display Possible cause/Suggested solution L1 Phase Loss During prestart checks the starter has detected a phase loss as indicated. L2 Phase Loss In run state, the starter has detected that the current on the affected phase has dropped below 3.3% of...
  • Page 9 Secondary Motor Fail Control voltage has been applied to the MCD 500 with a link across input A (11, 16). The default function for input A is Motor Set Select. Remove the link, change the setting for Par. 3-3 then replace the link.

  • Page 10: General Faults

    Erratic motor operation. - The SCRs in the MCD 500 require at least 5 A of current to latch. If you are testing the soft starter on a motor with full load current less than 5 A, the SCRs may not latch correctly.
  • Page 11 MCD 500 Service Manual 2 Troubleshooting Symptom Probable Cause A reset does not occur after an Auto-Reset, when - The remote 2-wire start signal must be removed and reapplied for a re-start. using a remote 2-wire control. Remote start/stop command is overriding Auto...
  • Page 12 3 Service Instructions MCD 500 Service Manual MG.17.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 13: Service Instructions

    3 Service Instructions 3 Service Instructions 3.1 Frame Sizes The physical layout and spare parts for MCD 500 vary according to the size of the starter. MCD 500 starters can be grouped into five classes ("frame sizes") as follows: Class...

  • Page 14: Mcd5-0021B - Mcd5-0053B (G1B)

    3 Service Instructions MCD 500 Service Manual 3.1.1 MCD5-0021B - MCD5-0053B (G1B) 177HA536.10 Cover Model PCB Cable guide Current transformers Main plastic Mounting posts Terminal blocks SCRs LCP and Main Control PCB Side plastic MG.17.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 15: Mcd5-0068B - Mcd5-0105B (G1B)

    MCD 500 Service Manual 3 Service Instructions 3.1.2 MCD5-0068B - MCD5-0105B (G1B) 177HA537.10 Cover Current transformers Cable guide Mounting posts Main plastic SCRs Terminal blocks Side plastic LCP and Main Control PCB Model PCB MG.17.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 16: Mcd5-0131B - Mcd5-0215B (G2B)

    3 Service Instructions MCD 500 Service Manual 3.1.3 MCD5-0131B - MCD5-0215B (G2B) 177HA538.10 Cover Support plastic Main plastic Model PCB Cable guide Current transformers Terminal blocks SCRs LCP and Main Control PCB Main body Bypass Driver PCB Fan and bracket MG.17.L1.02 - VLT...

  • Page 17: Mcd5-0245C (G3C)

    MCD 500 Service Manual 3 Service Instructions 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.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 18: Mcd5-0360C - Mcd5-0927C (G4C)

    3 Service Instructions MCD 500 Service Manual 3.1.5 MCD5-0360C - MCD5-0927C (G4C) 177HA540.10 Cover LCP and Main Control PCB Main plastic Magnetic bypass plate (models <0595>C - 0927C) Cable guide Fan assembly Support plastic Power assembly Model PCB Current transformer assembly...

  • Page 19: Mcd5-1200C - Mcd5-1600C (G5C)

    MCD 500 Service Manual 3 Service Instructions 3.1.6 MCD5-1200C - MCD5-1600C (G5C) Cover Magnetic bypass plate Main plastic Fan assembly Cable guide Power assembly LCP and Main Control PCB Current transformer assembly Support plastic Main body Model PCB MG.17.L1.02 - VLT ®...
  • Page 20 4 Spare Parts MCD 500 Service Manual MG.17.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 21: Spare Parts

    MCD 500 Service Manual 4 Spare Parts 4 Spare Parts 4.1.1 Spare Parts Unless otherwise indicated, spare part kits contain only one of each item. All images in this section are indicative. 4.2 Main Control PCB Each soft starter requires one Main Control PCB.

  • Page 22: Model Pcb

    4 Spare Parts MCD 500 Service Manual 4.3 Model PCB Each soft starter requires one Model PCB. MCD5-0021B 175G5609 MCD5-0245C 175G5621 MCD5-0037B 175G5910 MCD5-0360C 175G5622 MCD5-0043B 175G5611 MCD5-0380C 175G5623 MCD5-0053B 175G5612 MCD5-0428C 175G5624 MCD5-0068B 175G5613 MCD5-0595C 175G5625 MCD5-0084B 175G5614 MCD5-0619C...

  • Page 23: Backplane Pcb

    MCD 500 Service Manual 4 Spare Parts 4.4 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...

  • Page 24: Bypass Driver Pcb

    4 Spare Parts MCD 500 Service Manual 4.5 Bypass Driver PCB Models MCD5-0131B - MCD5-0215B require one Bypass Driver PCB. MCD5-0021B MCD5-0037B MCD5-0043B MCD5-0053B Not required MCD5-0068B MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B 175G5633 MCD5-0195B MCD5-0215B MCD5-0245C MCD5-0360C MCD5-0380C MCD5-0428C MCD5-0595C...

  • Page 25: Scrs And Power Assemblies

    MCD 500 Service Manual 4 Spare Parts 4.6 SCRs and Power Assemblies Models MCD5-0021B - MCD5-0245C use SCRs. Each soft starter requires three SCRs. MCD5-0021B 175G5119 MCD5-0037B 175G5120 MCD5-0043B 175G5121 MCD5-0053B 175G5122 MCD5-0068B MCD5-0084B 175G5123 MCD5-0089B 175G5124 MCD5-0105B 175G5634 MCD5-0131B...

  • Page 26: Fans

    4 Spare Parts MCD 500 Service Manual 4.7 Fans Certain models include a fan. The number of fans required differs between units and is shown in the table below. Part number Quantity MCD5-0021B MCD5-0037B Not required MCD5-0043B MCD5-0053B MCD5-0068B MCD5-0084B...

  • Page 27: Current Transformers

    MCD 500 Service Manual 4 Spare Parts 4.8 Current Transformers Each soft starter requires three current transformers. MCD5-0021B MCD5-0037B MCD5-0043B MCD5-0053B 175G5649 MCD5-0068B MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B 175G5650 MCD5-0195B MCD5-0215B MCD5-0245C 175G5650 MCD5-0360C 175G5652 MCD5-0380C 175G5653 MCD5-0428C MCD5-0595C 175G5654...

  • Page 28: Bypass Contactors

    4 Spare Parts MCD 500 Service Manual 4.9 Bypass Contactors Models MCD5-0021B - MCD5-0215B are internally bypassed. The bypass contactor for models MCD5-0021B - MCD5-0053B is included in the Model PCB. The bypass contactors for models MCD5-0068B - MCD5-0215B are shown below. Each soft starter requires three bypass contactors.

  • Page 29: Plastics

    MCD 500 Service Manual 4 Spare Parts 4.10 Plastics The following body plastic components are available for MCD-500. Cover Main plastic Cable guide Mounting posts MCD5-0021B MCD5-0037B MCD5-0043B MCD5-0053B 175G5670 175G5667 175G5671 MCD5-0068B (set of 3) MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B...

  • Page 30: Complete Plastics

    4 Spare Parts MCD 500 Service Manual 4.10.1 Complete plastics The complete plastics kit contains the following items: • 175G5673: 175G5667, 175G5671, 175G5669, 175G5670, side plastic, plastic base • 175G5674: 175G5668, 175G5672, 175G5669, support plastic • 175G5675: 175G5672, 175G5669, support plastic...

  • Page 31: Bus Bars

    MCD 500 Service Manual 4 Spare Parts 4.11 Bus Bars Each soft starter requires a total of six bus bars (three input and three output). Each kit contains three bus bars (unless otherwise stated) and fixing accessories if applicable. Input...
  • Page 32 4 Spare Parts MCD 500 Service Manual 175G5686 175G5687 175G5688, 175G5690, 175G5692, 175G5694 175G5689, 175G5691, 175G5693, 175G5695 MG.17.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 33: Other Spare Parts

    MCD 500 Service Manual 4 Spare Parts 4.12 Other Spare Parts The following spare parts are also available. Cage Clamps Connector Plugs MCD5-0021B MCD5-0037B MCD5-0043B MCD5-0053B 175G5666 (set of 3) MCD5-0068B MCD5-0084B MCD5-0089B MCD5-0105B MCD5-0131B MCD5-0141B MCD5-0195B 175G5676 (set of 3)
  • Page 34 5 Avoiding Damage MCD 500 Service Manual MG.17.L1.02 - VLT ® is a registered Danfoss trademark...

  • Page 35: Avoiding Damage

    5.2 Output Relays MCD 500 soft starters have four programmable output relays. These relays are often used to control the main contactor. The electronic contactor coils used in many contactors have a high initial inrush current, which can damage the soft starter's internal relays if the contactor coil is switched directly.
  • Page 36 A10 A1 177HA338.11 5.3 Control Input MCD 500 soft starters can be operated by external two wire or three wire control signals. External switches are configured and wired into control input terminals 01, 02. • External switches operating the control inputs must be rated for the control voltage being used and a continuous current of 100 mA.

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