MAKING MODERN LIVING POSSIBLE

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Service Manual
VLTp Soft Starter - MCD500

175R0550 MG17L402 Rev. 2010–11–05

*MG17L402*
Contents MCD 500 Service Manual

Contents

1 Warnings 3

2 Troubleshooting 4
2.1 Functional Tests 4
2.1.1 Power Circuit Test 4
2.1.2 Start Performance Test 4
2.1.3 Run Performance Test 4
2.1.4 After Repair Tests 5
2.1.5 Control Input Test 5
2.2 Trip Messages 6
2.3 General Faults 9

3 Service Instructions 11
3.1 Frame Sizes 11
3.1.1 MCD5-0021B - MCD5-0053B (G1B) 12
3.1.2 MCD5-0068B - MCD5-0105B (G1B) 13
3.1.3 MCD5-0131B - MCD5-0215B (G2B) 14
3.1.4 MCD5-0245C (G3C) 15
3.1.5 MCD5-0360C - MCD5-0927C (G4C) 16
3.1.6 MCD5-1200C - MCD5-1600C (G5C) 17

4 Spare Parts 18
4.1.1 Spare Parts 18
4.1 Main Control PCB 18
4.2 Model PCB 19
4.3 Backplane PCB 20
4.4 Bypass Driver PCB 21
4.5 SCRs and SCR Connections 22
4.6 Power Assemblies 23
4.7 Snubber Assemblies 24
4.8 Fans 24
4.9 Current Transformers 26
4.10 Bypass Contactors 27
4.11 Plastics 28
4.11.1 Complete Plastics 29
4.12 Bus Bars 30
4.13 Other Spare Parts 32

5 Avoiding Damage 33
5.1 SCRs 33

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Contents MCD 500 Service Manual

5.1.1 Typical Causes of SCR Damage 33

5.1.2 Protecting SCRs 33
5.1.3 Semiconductor Fuses 33
5.1.4 Main Contactors 33
5.2 Output Relays 33
5.2.1 Using the Soft Starter to Switch a Contactor 34
5.3 Control Input 34

6 Appendix 35
6.1.1 Input/Output Busbars to SCRs 35
6.1.2 SCRs to Heatsink 36
6.1.3 Bypass Contactor Connections 36
6.1.4 Current Transformer Busbar Assembly 37

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Warnings MCD 500 Service Manual

1 Warnings 1 1

When reading this manual you will come across different

symbols that require special attention. The symbols used are
WARNING
the following: Disconnect the soft starter from mains voltage before
carrying out repair work.
It is the responsibility of the user or person installing the soft
NOTE starter to provide proper grounding and branch circuit
Indicates something to be noted by the reader protection according to local electrical safety codes.
Do not connect power factor correction capacitors to the
CAUTION output of MCD 500 soft starters. If static power factor
correction is employed, it must be connected to the supply
Indicates a general warning
side of the soft starter.
MCD5-0021B - MCD5-0105B: After transportation,
WARNING mechanical shock or rough handling there is possibility that
the bypass contactor may have latched into the on state. To
Indicates a high voltage warning
prevent the possibility of the motor starting immediately, on
first commissioning or operation after transportation, always
The examples and diagrams in this manual are included
ensure that the control supply is applied before the power,
solely for illustrative purposes. The information contained in
so that the contactor state is initialised.
this manual is subject to change at any time and without
prior notice. In no event will responsibility or liability be
In Auto On mode, the motor can be stopped using digital or
accepted for direct, indirect or consequential damages
bus commands while the soft starter is connected to mains.
resulting from the use or application of this equipment.

NOTE CAUTION
Before changing any parameter settings, ensure that the These stop functions are not sufficient to avoid unintended
current parameter set is saved to an internal file. Refer to start.
MCD 500 Operating Instructions, MG.17.KX.YY, for more A motor that has been stopped may start if faults occur in
information. the electronics of the soft starter, or a temporary fault in the
supply mains or the motor connection ceases.

WARNING
WARNING - ELECTRICAL SHOCK HAZARD CAUTION
MCD 500 soft starters contain dangerous voltages when Use the auto-start feature with caution. Read all the notes
connected to mains voltage. Only a competent electrician related to auto-start before operation.
should carry out the electrical installation. Improper instal-
lation of the motor or the soft starter may cause equipment Equipment containing electrical
failure, serious injury or death. Follow this manual and local components may not be disposed of
electrical safety codes. together with domestic waste.
Models MCD5-0360C - MCD5-1600C: The bus bar and It must be collected separately as
heatsink are live while the unit is operating (starting, running electrical and electronic waste
or stopping). 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).

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 Troubleshooting MCD 500 Service Manual

2 Troubleshooting
2 2 When a protection condition is detected, the MCD 500 will The modern SCRs used in MCD 500 soft starters are
write this to the event log and may also trip or issue a extremely reliable and it is extremely unlikely that they will
warning. The soft starter's response to some protections may fail due to faulty manufacture. SCR damage is almost always
depend on the Protection Action settings (parameter group caused by external influences. Often these influences can be
16). identified but in other cases the identification may prove
difficult or impossible because the damaging event was
If the MCD 500 trips you will need to reset the soft starter temporary in nature. See Avoiding Damage for information
before restarting. If the MCD 500 has issued a warning, the on typical causes of SCR damage.
soft starter will reset itself once the cause of the warning has
been resolved. 2.1.2 Start Performance Test

Some protections cause a fatal trip. This response is pre- This procedure tests that the MCD 500 soft starts correctly.
defined and cannot be overridden. These protection This test is performed using an AC voltmeter. During Start
mechanisms are designed to protect the soft starter, or can mode, the On LED on the LCP should flash.
be caused by a fault within the soft starter.
1. Connect the MCD 500 to mains voltage, control
voltage and to a motor.
2.1 Functional Tests
2. Measure the voltage across each phase (L1-T1, L2-
Use the tests in this section to identify the cause of problems T2, L3-T3). This should be close to the nominal
with the soft starter. mains voltage (phase voltage for in-line connection
and line voltage for inside delta connection).
2.1.1 Power Circuit Test • If the voltage is zero, the SCR on that phase may
have failed.
This procedure tests the soft starter's power circuit, including
the SCR, Interface PCB and Main Control PCB. • If the voltage is not equivalent to the nominal
mains voltage, the bypass contactor may be
damaged and should be replaced (models
Use a 500V DC insulation tester on the 200Ω scale or a
MCD5-0021B - MCD5-0215B only).
standard multimeter (voltmeter).
3. Command the MCD 500 to start. While the MCD
500 is starting, measure the voltage across each
1. Isolate the soft starter from the incoming mains
phase. The voltage should fall to less than 2 VAC
supply and remove the control voltage.
just before the soft starter reaches Run mode.
2. Disconnect the motor cables and any external
bypass contactor cables from the soft starter. • If the voltage remains near nominal mains voltage,
the SCR is not firing correctly. Check the
3. Allow the soft starter to cool to room ambient connections between the Main Control PCB and
temperature. SCRs.
4. Using a meter, check the resistance across each • If the voltage starts near nominal mains voltage
phase of the soft starter in both directions. then falls to less than 2V AC just before the MCD
• L1 to T1, T1 to L1, L2 to T2, T2 to L2, L3 to 500 reaches Run mode, the MCD 500 is operating
T3 and T3 to L3. correctly and the cause of the starting problem is
not the soft starter.
5. If any reading is less than 200Ω, the SCR or internal
bypass relay has failed short circuit and must be
replaced. 2.1.3 Run Performance Test
NOTE Models MCD5-0021B - MCD5-0215B incorporate internal
There is no need to replace the Main Control PCB or the bypass contactors. If the internal bypass contactor does not
Backplane PCB just because an SCR has been damaged. operate, the SCRs will eventually fail due to thermal stress.
Consider replacing these parts only after first replace the This procedure tests the operation of the internal bypass
damaged SCR(s) and checking for correct operation. contactors. Use this test if the starter trips with "Bypass Fail"
6. Investigate the likely cause of SCR damage to or "Time Overcurrent".
prevent a repeat SCR failure.

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Troubleshooting MCD 500 Service Manual

This test is performed using either an AC voltmeter. To test the operation of the soft starter with a small motor (ie
a motor with a current rating which is much lower than that
of the soft starter)
1. Connect the MCD 500 to mains voltage, control
voltage and to a motor. 2 2
2. Measure the voltage across each phase (L1-T1, L2- 1. Use the tools menu to load the Factory Default
T2, L3-T3). This should be close to the nominal parameter file for the soft starter.
mains voltage (phase voltage for in-line connection 2. Disable 2-4 Undercurrent Trip.
and line voltage for inside delta connection).
3. Connect a small motor to the output terminals of
• If the voltage is zero, the SCR on that phase may the soft starter. Test that the soft starter functions
have failed. as expected.

• If the voltage is not equivalent to the nominal NOTE

mains voltage, the bypass contactor may be Ensure that 2-4 Undercurrent Trip is reset to its default value
damaged and should be replaced. after conducting tests.
3. Command the soft starter to start. After a
successful start, you should hear the bypass 2.1.5 Control Input Test
contactors close.

• If the bypass contactors do not close, the bypass This procedure tests the condition of the soft starter control
contactor, Main Control PCB, Model PCB or Bypass inputs. This test is performed using a wire link.
Driver PCB (models MCD5-0131B - MCD5-0215B 1. Disconnect all external wiring from the soft starter's
only) may be faulty or there may be a faulty control inputs.
connection between these components.
2. Control voltage must still be connected to the soft
4. When the soft starter is running, measure the starter.
voltage across each phase. This should be less than
3. Connect a wire link between each input.
0.5 VAC.
5. Command the soft starter to stop and listen for the • If the corresponding LED lights up then the input is
operating correctly
bypass contactor to open.

NOTE • If the LED does not light up, the control input is
damaged. Replace the Main Control PCB
The bypass contactors used in the MCD 5-0021B ~
MCD5-0105B are latching. The MCD 500 control circuits are
designed to open the bypass contactors even in the event of
removal or loss of control voltage. However it is still possible
that the bypass contactor may be closed when there is no
control supply to the soft starter. The bypass contactors will
open when control voltage is next applied.

2.1.4 After Repair Tests

NOTE
The servicing technician is responsible for ensuring that all
electrical safety tests have been completed in accordance
with local regulations.

To test that the soft starter functions correctly after

reassembly

1. Apply control power only to the soft starter.

2. Ensure that the welcome screen displays the
correct Control/Mode/HMI firmware versions.
3. Perform a Run Simulation test using both the LCP
and remote switches.
4. Connect mains supply and motor. Test that the soft
starter functions as expected.

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 Troubleshooting MCD 500 Service Manual

2.2 Trip Messages Protection Action, other settings are built-in system
protections and cannot be set or adjusted.
This table lists soft starter's protection mechanisms and the
2 2 probable cause of the trip. Some of these can be adjusted
using parameter group 2 Protection and parameter group 16

Display Possible cause/Suggested solution

Battery/Clock A verification error has occurred on the real time clock, or the backup battery voltage is low. If the
battery is low and the power is off, date/time settings will be lost. Reprogram the date and time.
Related Pars.: 16-12
Current Imbalance Current imbalance can be caused by problems with the motor, the environment or the installation,
such as:
- An imbalance in the incoming mains voltage

- A problem with the motor windings

- A light load on the motor

Current imbalance can also be caused by incorrect cabling between the external bypass contactor
and the soft starter or an internal problem with the soft starter, particularly an SCR that has failed
open circuit. A failed SCR can only be definitely diagnosed by replacing the SCR and checking the
starter's performance.
Related Pars.: 2-2, 2-3, 16-2
Excess Start Time 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 Pars.: 1-1, 1-6, 1-4, 1-9, 7-9, 7-1, 7-6, 7-4, 16-7
FLC Too High 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 Pars.: 1-1, 7-1
Frequency 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 Pars.: 2-8, 2-9, 2-10, 16-5
Heatsink Overtemp Check if cooling fans are operating. If mounted in an enclosure, check if ventilation is adequate.
Fans operate during Start, Run and for 10 minutes after the starter exits the Stop state.
NOTE
Models MCD5-0021B to MCD4-0053B and MCD5-0141B do not have a cooling fan. Models
with fans will operate the cooling fans from a Start until 10 minutes after a Stop.

Related Pars.: 16-6

Input A Trip Identify and resolve the condition which caused Input A to activate.
Related Pars.: 3-3, 3-4, 3-5, 3-6, 3-7, 16-8
Inst Overcurrent The motor has experienced a sharp rise in motor current, probably caused by a locked rotor condition
(shearpin) while running. This may indicate a jammed load.
Related 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

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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%
L3 Phase Loss of the programmed motor FLC for more than 1 second, indicating that either the incoming phase or 2 2
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 Pars.: None
L1-T1 Shorted During prestart checks the starter has detected a shorted SCR or a short within the bypass contactor
L2-T2 Shorted as indicated.
L3-T3 Shorted Related Pars.: none
Low Control Volts The internal 24 VDC rail has dropped below 19V. This may have been caused by a fluctuation of the
control supply. Reset the trip. If the problem persists:
• The 24 V supply in the main control PCB may be faulty; or
• the bypass driver PCB may be faulty (internally bypassed models only).

These trips cannot be reset. Contact your local supplier for advice.
Related Pars: None
Motor Overload/ The motor has reached its maximum thermal capacity. Overload can be caused by:
Motor 2 Overlaod - 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 Pars.: 1-1, 1-2, 1-3, 1-4, 7-1, 7-2, 7-3, 7-4, 16-1
Motor Connection 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 Pars.: 15-7

Motor Thermistor The motor thermistor input has been enabled and:
- The resistance at the thermistor input has exceeded 3.6 kΩ for more than one second.

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

- The motor thermistor input has been open.

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

Related Pars.: 16-9

Network Comms The network master has sent a trip command to the starter, or there may be a network communi-
cation problem.
Check the network for causes of communication inactivity.
Related Pars.: 16-11
Parameter out of Range - A parameter value is outside the valid range.

The starter will load the default value for all affected parameters. Press MAIN MENU to go to the first
invalid parameter and adjust the setting.
Related Pars.: None
Phase Sequence The phase sequence on the soft starter's input terminals (L1, L2, L3) is not valid.
Check the phase sequence on L1, L2, L3 and ensure the setting in Par. 2-1 is suitable for the instal-
lation.
Related Pars.: 2-1

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 Troubleshooting MCD 500 Service Manual

Display Possible cause/Suggested solution

Power Loss 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
2 2 end of a soft stop.
Related Pars.: 15-5
Starter/Comms - 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 Pars.: 16-10

Thermistor Cct 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 Pars.: None.
Time - Overcurrent The MCD 500 is internally bypassed and has drawn high current during running. (The 10A protection
curve trip has been reached or the motor current has risen to 600% of the motor FLC setting.)
Related Pars.: None
Undercurrent 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 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

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Troubleshooting MCD 500 Service Manual

2.3 General Faults

This table describes situations where the soft starter does not operate as expected but does not trip or give a warning.
2 2
Symptom Probable Cause

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

The soft starter may be in Auto On mode and will only accept commands from the remote
control inputs. In Auto On mode, the Auto On LED on the LCP is illuminated. Press the Hand
On or Off button to enable control via the LCP (this will also send a start or stop command to
the MCD 500).
- If the soft starter does not respond to commands from the control inputs:

The soft starter may be in Hand On mode and will only accept commands from the LCP.
When the soft starter is in Hand On control mode, the Off or Hand On LED on the LCP is
active. To change to Auto On mode, press the Auto On button once.
The control wiring may be incorrect. Check that the remote start, stop and reset inputs are
configured correctly (see Control Wiring for details).
The signals to the remote inputs may be incorrect. Test the signalling by activating each
input signal in turn. The appropriate remote control input LED should activate on the LCP.
The soft starter will only execute a start command from the remote inputs if the remote stop
input is inactive and the remote reset input is activated (the Reset LED on the starter will be
on).
- If the soft starter does not respond to a start command from either the local or remote
controls:

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

Motor does not reach full speed. - 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.

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

Erratic motor operation. - The SCRs in the MCD 500 require at least 5 A of current to latch. If you are testing the soft
starter on a motor with full load current less than 5 A, the SCRs may not latch correctly.

Soft stop ends too quickly. - The soft stop settings may not be appropriate for the motor and load. Review the
settings of Pars. 1-10, 1-11, 7-10 and 7-11.

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

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 Troubleshooting MCD 500 Service Manual

Symptom Probable Cause

AAC adaptive acceleration control, DC brake - These features are only available with in-line installation. If the MCD 500 is installed inside
2 2 and Jog functions not working delta, these features will not operate.

A reset does not occur after an Auto-Reset, - The remote 2-wire start signal must be removed and reapplied for a re-start.
when using a remote 2-wire control.
Remote start/stop command is overriding Auto - Auto Start/Stop function should only be used in HAND ON mode or in tandem with
Start/Stop settings when using remote 2-wire HAND OFF mode, 3 and 4-wire control.
control.
After selecting AAC the motor used an ordinary - The first AAC start is current limit so that the starter can learn from the motor character-
start and/or the second start was different to istics. Subsequent starts use AAC.
the first.
Non-resettable THERMISTOR CCT trip, when - The thermistor input is enabled once a link is fitted and short circuit protection has
there is a link between Thermistor input 05, 06 activated.
or when the motor thermistor connected Remove the link then load the default parameter set. This will disable the thermistor input
between 05, 06 is permanently removed. and clear the trip.
Place a 1k2 Ω resistor across the thermistor input.
Turn thermistor protection to 'Log only' (Par. 16-9).
Parameter settings cannot be stored. - 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.

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Service Instructions MCD 500 Service Manual

3 Service Instructions

3.1 Frame Sizes

3 3
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 MCD 500 Models

G1B MCD5-0021B
MCD5-0037B
MCD5-0043B
MCD5-0053B
MCD5-0068B
MCD5-0084B
MCD5-0089B
MCD5-0105B
G2B MCD5-0131B
MCD5-0141B
MCD5-0195B
MCD5-0215B
G3C MCD5-0245C
G4C MCD5-0360C
MCD5-0380C
MCD5-0428C
MCD5-0595C
MCD5-0619C
MCD5-0790C
MCD5-0927C
G5C MCD5-1200C
MCD5-1410C
MCD5-1600C

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 Service Instructions MCD 500 Service Manual

3.1.1 MCD5-0021B - MCD5-0053B (G1B)

8 9 10 11

3 3

177HA536.10
1 2 3 4 5 6 7

1 Cover 7 Current transformers

2 Cable guide 8 Mounting posts
3 Main plastic 9 Backplane PCB
4 Terminal blocks 10 SCRs
5 LCP and Main Control PCB 11 Side plastic
6 Model PCB

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Service Instructions MCD 500 Service Manual

3.1.2 MCD5-0068B - MCD5-0105B (G1B)

8 9 10 11 12 13

3 3

177HA537.10
1 2 3 4 5 6 7

1 Cover 8 Mounting posts

2 Cable guide 9 Bypass contactors
3 Main plastic 10 Backplane PCB
4 Terminal blocks 11 SCRs
5 LCP and Main Control PCB 12 Side plastic
6 Model PCB 13 Fan
7 Current transformers

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 Service Instructions MCD 500 Service Manual

3.1.3 MCD5-0131B - MCD5-0215B (G2B)

7 8 9 10 11 12 13

3 3

1 2 3 4 5 6
177HA538.10

1 Cover 8 Model PCB

2 Main plastic 9 Current transformers
3 Cable guide 10 Bypass contactors
4 Terminal blocks 11 SCRs
5 LCP and Main Control PCB 12 Main body
6 Bypass Driver PCB 13 Fan and bracket
7 Support plastic

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Service Instructions MCD 500 Service Manual

3.1.4 MCD5-0245C (G3C)

7 8 9 10 11

3 3

1 2 3 4 5 6
177HA539.10

1 Cover 7 Support plastic

2 Cable guide 8 Model PCB
3 Main plastic 9 Current transformers
4 Terminal blocks 10 SCRs
5 LCP and Main Control PCB 11 Main body
6 Fan assembly

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 Service Instructions MCD 500 Service Manual

3.1.5 MCD5-0360C - MCD5-0927C (G4C)

7 8 9 10

3 3

177HA540.10

1 2 3 4 5 6 11 12

1 Cover 8 Snubber assembly

2 Main plastic 9 Module mount and spacer plastic
3 Cable guide 10 Fan assembly
4 Support plastic 11 Power assembly
5 Model PCB 12 Current transformer assembly
6 Module mount and spacer plastic 13 Main body
7 Magnetic bypass plate (models <0595>C ~
0927C)

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Service Instructions MCD 500 Service Manual

3.1.6 MCD5-1200C - MCD5-1600C (G5C)

1 2 3 4 6 7 9 10 11

3 3

177HA541.11
5 8 12 13

1 Cover 8 Snubber assembly

2 Main plastic 9 Magnetic bypass plate
3 Cable guide 10 Power assembly
4 LCP and Main Control PCB 11 Fan assembly
5 Bypass driver PCB 12 Current transformer assembly
6 Support plastic 13 Main body
7 Model PCB

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 Spare Parts MCD 500 Service Manual

4 Spare Parts

4.1.1 Spare Parts

NOTE
Unless otherwise indicated, spare part kits contain only one of each item.
All images in this section are indicative.
4 4
4.1 Main Control PCB
Each soft starter requires one Main Control PCB.

CV1 CV2
T5 T7 T5 T7
MCD5-0021B
MCD5-0037B
MCD5-0043B
MCD5-0053B
175G5603 175G5604 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

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4.2 Model PCB

Each soft starter requires one Model PCB.

MCD5-0021B 175G5609 MCD5-0245C 175G5621

MCD5-0037B 175G5610 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 175G5626 4 4
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

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 Spare Parts MCD 500 Service Manual

4.3 Backplane PCB

Models MCD5-0021B - MCD5-0105B require one Backplane PCB.

MCD5-0021B
MCD5-0037B
MCD5-0043B
MCD5-0053B
175G5632
MCD5-0068B
4 4 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

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4.4 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 4 4
MCD5-0089B
MCD5-0105B
MCD5-0131B
MCD5-0141B 175G5633
MCD5-0195B 175G56981
MCD5-0215B
MCD5-0245C
MCD5-0360C
MCD5-0380C
MCD5-0428C
MCD5-0595C
MCD5-0619C Not required
MCD5-0790C
MCD5-0927C
MCD5-1200C
MCD5-1410C
MCD5-1600C

177HA595.10

175G5633 175G5698

1Bypass contactor upgrade- Refer to Product Note PN04 MCD

500 Bypass Contactor Upgrade for more information.

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 Spare Parts MCD 500 Service Manual

4.5 SCRs and SCR Connections

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

4 4
MCD5-0068B
MCD5-0084B 175G5123
MCD5-0089B 175G5124
MCD5-0105B
175G5634
MCD5-0131B
MCD5-0141B 175G5635
MCD5-0195B 175G5126
MCD5-0215B
175G5127
MCD5-0245C

175G5119 - 175G5122 175G5123, 175G5124, 175G5634 175G5635, 175G5126, 175G5127

NOTE
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

Yellow

Yellow
White

White
Black

Black
Red

Red

76 54 7 6 54
177HA600.10

SEMIKRON EUPEC

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Spare Parts MCD 500 Service Manual

Model 0084 - 0131

Yellow

Yellow
White

White
Black

Black
Red

Red
7 5 6 4

6 4 7 5 4 4

177HA603.10
SEMIKRON EUPEC

Model 0141 - 0245

Yellow
White
Black
Red

Yellow
White
Black
Red
7 6 5 4
7 6 5 4

177HA606.10
SEMIKRON EUPEC

4.6 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
177HA550.11

175G5636 - 175G5642 175G5643 - 175G5645

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 Spare Parts MCD 500 Service Manual

4.7 Snubber Assemblies Each snubber kit includes three snubber assemblies.

T7 (AC input) models MCD5-0360C ~ MCD5-1600C use

snubber assemblies. Each soft starter requires three snubber
assemblies.

MCD5-0360C
MCD5-0380C

4 4
MCD5-0428C
MCD5-0595C 175G5699
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.

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Spare Parts MCD 500 Service Manual

Part number Quantity

MCD5-0021B
MCD5-0037B
Not required
MCD5-0043B
MCD5-0053B
MCD5-0068B
MCD5-0084B
MCD5-0089B 175G5646 1
MCD5-0105B
MCD5-0131B 4 4
MCD5-0141B Not required
MCD5-0195B
175G5646 1
MCD5-0215B
MCD5-0245C
MCD5-0360C
MCD5-0380C 175G5137 3
MCD5-0428C
MCD5-0595C
MCD5-0619C
MCD5-0790C 175G5138 2
MCD5-0927C
MCD5-1200C
MCD5-1410C 175G5138 3
MCD5-1600C

175G5646, 175G5647 175G5648

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 Spare Parts MCD 500 Service Manual

4.9 Current Transformers

Each soft starter requires three current transformers.

MCD5-0021B
MCD5-0037B
MCD5-0043B
MCD5-0053B
175G9046
MCD5-0068B
4 4 MCD5-0084B
MCD5-0089B
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

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Spare Parts MCD 500 Service Manual

4.10 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.

MCD5-0021B
MCD5-0037B
Not required
MCD5-0043B
MCD5-0053B 4 4
MCD5-0068B
MCD5-0084B
175G5660
MCD5-0089B
MCD5-0105B
MCD5-0131B
MCD5-0141B 175G5661
MCD5-0195B 175G56971
MCD5-0215B
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

1Bypass contactor upgrade. Refer to Product Note PN04 MCD

500 Bypass Contactor Upgrade for more information.

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 Spare Parts MCD 500 Service Manual

4.11 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
4 4 MCD5-0068B
175G5667 175G5671
(set of 3)
MCD5-0084B
MCD5-0089B
MCD5-0105B
MCD5-0131B
MCD5-0141B
175G5668
MCD5-0195B
MCD5-0215B 175G5669
MCD5-0245C
MCD5-0360C
MCD5-0380C
MCD5-0428C 175G5672 Not required
MCD5-0595C
MCD5-0619C Not required
MCD5-0790C
MCD5-0927C
MCD5-1200C
MCD5-1410C
MCD5-1600C

175G5667, 175G5668 175G5671, 175G5672

175G5669 175G5670

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Spare Parts MCD 500 Service Manual

4.11.1 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

Complete plastics 4 4
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

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 Spare Parts MCD 500 Service Manual

4.12 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 Output
MCD5-0021B
MCD5-0037B
175G5677 175G5678
MCD5-0043B
4 4 MCD5-0053B
MCD5-0068B 175G5679 175G5680
MCD5-0084B
MCD5-0089B 175G5681 174G5682
MCD5-0105B
MCD5-0131B 175G5696 175G5683
MCD5-0141B
MCD5-0195B 175G5684 175G5685
MCD5-0215B
MCD5-0245C 175G5686 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

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Spare Parts MCD 500 Service Manual

4 4
175G5686 175G5687

175G5688, 175G5690, 175G5692, 175G5694 175G5689, 175G5691, 175G5693, 175G5695

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 Spare Parts MCD 500 Service Manual

4.13 Other Spare Parts

The following spare parts are also available.

Cage Clamps Connector Plugs

MCD5-0021B
MCD5-0037B
MCD5-0043B
MCD5-0053B
4 4 MCD5-0068B
175G5666 (set of 3)

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

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Avoiding Damage MCD 500 Service Manual

5 Avoiding Damage

5.1.4 Main Contactors

5.1 SCRs
SCRs are most vulnerable to overvoltage damage when
5.1.1 Typical Causes of SCR Damage voltage is applied to their input terminal while they are off. In
this condition the SCR is blocking the full line voltage. Using
SCR damage is generally caused by overcurrent, overvoltage a main contactor to remove voltage from the SCR input
or overtemperature. To prevent future damage, check that when the starter is off eliminates the risk of SCR damage due
the soft starter has been installed properly. Common causes to overvoltage.
of SCR problems include: 5 5
5.2 Output Relays
Overcurrent:
• cable fault on soft starter output MCD 500 soft starters have three programmable output
relays. These relays are often used to control external
• motor fault
contactors.
• start current and/or start time exceeds the soft
starter's rating The electronic contactor coils used in many contactors have
• starts per hour exceed the soft starter rating a high initial inrush current, which can damage the soft
starter's internal relays if the contactor coil is switched
Overvoltage:
directly.
• power supply transient or surge
• lightning strike (direct or indirect) on power supply

• motor fault

• loose connection in power circuit, before or after

the starter

• power factor correction connected to the output of

the soft starter

• over-corrected bulk power factor correction on a

lightly loaded system causing severe ringing
voltages
Overtemperature:
• blocked heatsinks or restricted ventilation
• inadequate ventilation

• excessive ambient temperatures

• bypass relay fails to close during running (internally

bypassed starters only)

5.1.2 Protecting SCRs

Modern SCRs are generally rugged and reliable. However,

the risk of SCR damage can be reduced by using semicon-
ductor fuses and/or a main contactor.

5.1.3 Semiconductor Fuses

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.

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 Avoiding Damage MCD 500 Service Manual

5.2.1 Using the Soft Starter to Switch a

Contactor

Before using the soft starter's output relay to switch an

electronic contactor coil, consult the contactor
manufacturer. Some contactor manufacturers (eg Klockner-
Moeller) state that you cannot use PCB mount relays for
direct switching of their electronic contactor coils.
A10 A1
If this is the case, there are two solutions: 1 2
A11 A2
5 5 1. Use the soft starter's output relay to control a slave
relay. This slave relay can then be used to directly
switch the electronic contactor coil circuit.

177HA338.11

1. Soft starter output relay

2. Contactor coil
1 KA1
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.

KA1 KM1 A1 • External switches operating the control inputs

must be rated for the control voltage being used
2 3 and a continuous current of 100 mA.
A2 • Incorrect configuration and wiring of the external
contacts/switches to the control input terminals
may cause damage.

•
177HA337.11
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

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Appendix MCD 500 Service Manual

6 Appendix

When assembling soft starter components, each bolt should the different types of bolts and bolt tightening torques for
be tightened using a calibrated torque driver set to the each assembly.
appropriate assembly torque. The following tables indicate
6.1.1 Input/Output Busbars to SCRs

Model Bolt size Torque (Nm)

MCD5-0021B
MCD5-0037B
MCD5-0043B
MCD5-0053B
M5x12 4

6 6
MCD5-0068B
MCD5-0084B
MCD5-0089B
MCD5-0105B
MCD5-0131B M6x16 4
MCD5-0141B
MCD5-0195B
M8x20 8
MCD5-0215B
MCD5-0245C
MCD5-0360C
MCD5-0380C
MCD5-0428C
MCD5-0595C M8x16 12
MCD5-0619C
MCD5-0790C
MCD5-0927C
MCD5-1200C
MCD5-1410C M10x35 20
MCD5-1600C

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 Appendix MCD 500 Service Manual

6.1.2 SCRs to Heatsink

Model Bolt size Torque (Nm)

MCD5-0021B
MCD5-0037B
MCD5-0043B
MCD5-0053B
M5x16 4
MCD5-0068B
MCD5-0084B
MCD5-0089B
MCD5-0105B
MCD5-0131B
MCD5-0141B
M5x20 4
MCD5-0195B
MCD5-0215B
6 6 MCD5-0245C M5x20 4
MCD5-0360C
MCD5-0380C
MCD5-0428C
MCD5-0595C
MCD5-0619C
Not required Not required
MCD5-0790C
MCD5-0927C
MCD5-1200C
MCD5-1410C
MCD5-1600C

6.1.3 Bypass Contactor Connections

Model Bolt size Torque (Nm)

MCD5-0021B
MCD5-0037B
M5x12 4
MCD5-0043B
MCD5-0053B
MCD5-0068B
MCD5-0084B
M6x12 4
MCD5-0089B
MCD5-0105B
MCD5-0131B
MCD5-0141B M5x12 4
MCD5-0195B M8x20 8
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

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Appendix MCD 500 Service Manual

6.1.4 Current Transformer Busbar Assembly

Model Bolt size Torque (Nm)

MCD5-0245C M6x16 4

6 6

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