product manual mms digital switchgear motor control unit ... · providing with redundant ethernet...

—PRODUCT MANUAL

MMS digital switchgear

Motor control unit MC510 user guide

A reliable, available, simple,

safe and powerful MNS solution

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GENERAL

The information in this document is subject to change without

notice and should not be construed as a commitment by ABB.

ABB assumes no responsibility for any errors that may appear

in this document.

In no event shall ABB be liable for direct, indirect, special, inci-

dental, or consequential damages of any nature or kind arising

from the use of this document, nor shall ABB be liable for inci-

dental or consequential damages arising from use of any soft-

ware or hardware described in this document.

This document and parts thereof must not be reproduced or

copied without ABB's written permission, and the contents

thereof must not be imparted to a third party nor be used for

any unauthorized purpose. The software described in this doc-

ument is furnished under a license and may be used, copied, or

disclosed only in accordance with the terms of such license.

All rights reserved.

Copyright © 2016 Xiamen ABB Low Voltage Equipment Co., Ltd.

GENERAL

—

Table of content

4-6 General

4 Target Group

4 Use of Warning, Caution, Information and Tip icon

5 Terminology

5 Related Documentation

6 Related System Version

6 Document Revision History

7 Product Overview

7 Introduction

7 Structure

10 Mounting

10 Mounting of MC510

11-17 Interfaces

12 Terminal Designations

16 Typical Diagram

18-88 Functionality

18 Starter Types

35 Protection Functions

72 Logic Block

79 Maintenance Function

80 Metering and Monitoring

82 Using extension modules

83 Communication interface

89 Parameterization

90-105 Accessories

90 MP51/MP52 Operator Panel

104 Parameterization Software: MConfig

106-109 Appendix A Technical Data

106 A.1 Common Technical Data

106 A.2 Technical Data of the Basic Unit MC510

109 A.3 Technical Data of the Operation panel MP51/52

109 A.4 Technical Data of the Loop Switch MS571

GENERAL

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—

General

Target Group

The manual is primarily intended for those requiring information on the applications of MC510 for the

purpose of understanding, engineering, wiring & operation.

The objective of this manual is to provide the technical functions description of MC510.This manual

should be studied carefully before installing, parameterizing or operating the motor control unit. It is

assumed that the user has a basic knowledge of physical and electrical fundamentals, electrical wiring

practices and electrical components.

This document should be used along with MC510 Parameter Description, which provides detailed

information about parameters and their applications.

Use of Warning, Caution, Information and Tip icon

The electrical warning icon indicates the presence of a hazard that could

result in electrical shock.

The warning icon indicates the presence of a hazard that could result in per-

sonal injury.

The caution icon indicates important information or warnings related to the

concept discussed in the text. It might indicate the presence of hazard that

could result on corruption of software or damage to equipment/property.

The information icon alerts the reader to pertinent facts and conditions.

The tip icon indicates advice on, for example, how to design your project or

how to use a certain function

GENERAL

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Terminology

List of the terms, acronyms, abbreviations and definitions that being used in this document.

Abbreviation Term Description

Alarm Alarm is defined as status transition from any state to ab-

normal state. Status transition to abnormal state can be

data crossing over the pre-defined alarm limit.

DCS Distributed Control

System

High level distributed control system

Local Hardwiring A Control Access term describing that MC510 accepts its

commands from the hardwired inputs, when the Local

control authority is enabled.

PCS Process Control System High level process control system

MODBUS TCP Ethernet communication protocol

PTC Positive Temperature

Coefficient

PTC thermistors are semiconductor elements with a very

high positive temperature coefficient.

RCU Remote Control Unit Local control unit with pushbutton and indicator to operate a

device (e.g. motor) from field level.

Remote Fieldbus A Control Access term describing that MC510 accepts its

commands from the fieldbus inputs, when the remote

control authority is enabled.

TOL Thermal Overload

Protection

Protection against overheated caused by overload

Trip A consequence of an alarm activated or an external trip

command from another device to stop the motor or trip the

circuit breaker.

MCC Motor Control Centre Common term for a switchgear used for motor control

and protection.

SOE Sequence of events A record of events with time stamp.

FDR Failure Device

Replacement

Maintenance method for failure device

Related Documentation

1TNC 928206M MC510 Parameter Description

1TNC 928207M MC510 Modbus/TCP Protocol Implementation

1TNC 928208M MConfig User Guide

1TNC 928238M Extension module User Guide

Related System Version

The content of this document is related to MC510 products with the following hardware and firmware

version release,

HW FW

MC510-MT-DC 1.0 1.2

GENERAL

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MC510-MT-AC 1.0 1.2

MP51 1.0 1.2

MP52 1.0 1.2

Until further notice, this document is also applicable for future firmware versions other than those

listed above.

The described functions are designed but may not be fully implemented in all details. Please refer to

the release notes regarding possible restrictions.

Document Revision History

Revision Page(s) Description of change Date

M0201 Initial Edition 12/08/2016

M0202 Update extension module description 24/08/2018

PRODUCT OVERVIEW

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—

Product Overview

Introduction

MC510 is an intelligent motor control and protection device based on current and voltage measure-

ment. It is part of low voltage system family to provide customers the intelligent system solution and

supplied as part of ABB Low Voltage switchgear MNS®.

MC510 is microprocessor-based product providing comprehensive features. Every motor starter could

be equipped with one MC510 device. By predefined parameters, MC510 will provide specific control,

monitoring and protection functions in various motor applications.

Providing with redundant Ethernet interface, MC510 could be integrated into industry control system

and plant management system efficiently and smoothly. Every MC510 device can be accessed to get

actual operating data. Fast response time for alarm and trip makes real time control of production

process possible. Statistical recording of maintenance data, like running hours and number of opera-

tions, assists with predictive maintenance scheduling.

For AC motor and the operated installation this means:

•Reliable protection

•Maximum utilization

•Continuous supervision

•Flexibility

Structure

MC510 Main unit

Main unit is constructed with two parts, the electronics of the motor control unit and the integrated

CT. Main unit is a one type device with the integrated CT range starting from 0.24 to 63A. For motor

rating larger than 63A, interposing CTs should be selected.

Main unit is designed with a mounting rail fixed to the bottom of the device for easy vertical DIN rail

mounting.

Screws and other mounting accessories are also provided for vertical and horizontal screw mounting.

Operator panel

The Operator panel is the user interface mounted on the front door or instrument plate of a drawer.

PRODUCT OVERVIEW

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With control buttons, LED, LCD module (MP51 only), MP51/MP52 provides the functions as motor con-

trol, supervision and parameterizing. One operator panel is provided for each main unit at request.

Extension modules (optional module)

All extension modules are powered by the basic unit. The type of extension modules will be automatic

detected by the basic unit after configured in parameter setting.

DIDO module (MB550/MB551)

The DIDO module MB550 provides four 24VDC digital inputs and two relay outputs.

The DIDO module MB551 provides four 110/240VAC digital inputs and two relay outputs.

AIAO module (MA552)

The AIAO module MA552 provides two RTD inputs, one 0-10V voltage input and one 0-20mA/4-20mA

current output.

Hotspots monitor module (MT561)

The hotspots monitor module MT561 supervises the temperature of power contacts in the drawer by

infrared temperature sensor.

Wireless temperature monitor module (MT564)

The wireless temperature monitor module MT564 supervises the temperature of switchgear bus-bar

by wireless temperature sensor WT01.

Note: Max. 4 extension modules can be connected with MC510 basic unit.

Material

The enclosure of MC510 is made of PA6. Flammability rating of the material is UL 94 V-2 and material is

halogen free.

Colour of the enclosure is RAL 7012.

For detail description of MP51/MP52, please refer to Chapter ‘Accessories’.

PRODUCT OVERVIEW

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Fig 1 MC510 and MP51

MOUNTING

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—

Mounting

Mounting of MC510

Basic dimension of MC510

W X H X D = 123mm X 121mm X 72mm

Typical Installation of MC510

DIN rail mounting, or screw mounting on plate

Fig 1 MC510 in 8E/2 module

Basic dimension of MP51

W X H X D = 91mm X 75mm X 29.3mm

Mounting dimension of MP51

W X H = 84mm X 68mm

Basic dimension of MP52

W X H X D = 91mm X 52mm X 29.3mm

Mounting dimension of MP52

W X H = 84mm X 45mm

The installation details of MC510 and MP5x, please see the related documentation installa-

tion manual.

INTERFACES

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Interfaces

Terminal blocks of MC510 are located on the top of the main unit for easy access. There are 3 sets of

I/O terminal blocks and 1 set of RJ12 connector as shown.

Fig 3 Top View Terminal Layout

Fig 4 Side View Terminal Layout

INTERFACES

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Terminal Designations

Terminal name Designation…

Plug/Contacts

Remark

DI0...DI7, COM Digital inputs Cross section 2.5mm2

VL1,VL2,VL3 Voltage input

I0a,I0b RCT input

CCA,CCB,CCI Control relay output

R0a,R0b,R0c,R1a,R1b Relay output

L+,M Power supply 24V DC type

L,N 110-240V AC type

ETH1 Ethernet interface 1 RJ45

ETH2 Ethernet interface 1

MP Interface of MP5x RJ12

L1-T1;L2-T2;L3-T3 Current Measurement Φ 12mm Window

IO-BUS Interface of extension modules

Table 1 Device terminals

Power Supply

Depending on different product type, three types of power supply are available, i.e. 24VDC, 110VAC &

240VAC. Power supply of the device should be always derived from uninterrupted and reliable supply

source.

Power supply Terminal Description

DC L+ 24 VDC +

M 0 VDC

AC L Line

N Neutral

Table 1 Power supply input terminals

Digital Input

MC510 has 8 DIs. Digital inputs are cyclically read. Functions of all digital inputs can be configured by

logic block.

Terminal Description

DI0 Digital Input 0

DI1 Digital Input 1

DI2 Digital Input 2

DI3 Digital Input 3

INTERFACES

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DI4 Digital Input 4

DI5 Digital Input 5

DI6 Digital Input 6

DI7 Digital Input 7

COM Common input of digital inputs

Table 3 Digital inputs with 24VDC supply

i ) For 24VDC, it is recommended to use separate supply source for power supply and digital

inputs especially in the case that DI signals are taken from the field which is located long

distance from MCCs

Fig 5 Illustration of DIs wiring to MC510

Residual Current Transformer

MC510 supports earth fault protection through external Residual Current Transformer (RCT).


I0a Residual current transformer input A

I0b Residual current transformer input B

Table 2 Residual current transformer terminals

INTERFACES

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i) Different size or types of RCT are available. Refer to MNS Digital Ordering Guide for de-

tails.

ii) It is recommended to short terminals I0a and I0b to avoid potential external disturbance in

case that RCT is not in use.

iii) It is recommended to use STP cable for RCT circuit connections.

Voltage Measurement

Voltage measurement and protections are supported in MC510.


VL3 Phase L3 voltage input



Table 5 Voltage input terminals

i)When single phase system is selected, voltage measurement is based on phase L1 - phase

L3. Connect L to VL1 and neutral to VL3.

ii)If PT is selected, according to phase sequence, connect the secondary side of PT to VL1 VL2

VL3.

iii)PT type should be single-phase voltage transformer or Yy0 connection for three-phase

voltage transformer.

Current Measurement Terminal

MC510 measures continuously three motor phase currents. The phase current data will be used by the

protection functions and reported to the fieldbus. Phase currents are reported as a value relative to

the motor nominal current In.

Current wires are lead through current sensors from either side of the terminal.

Direction can be either L->T or T->L considering that all currents must have the same direction.

Motor nominal currents above 63A are not measured directly, but instead intermediate current

transformer’s secondary side is connected through MC510 current measurement terminal.

i)When single phase system is selected, current measurement is based on phase L1.

ii)The measurement range of internal CT is from 0.08A to 63A.

Contactor Control Output

MC510 supports various motor starter types. The control of the contactor by MC510 is via internal

output relays (CCA, CCB, CCC(R1) relays) by the microprocessor. There is a interlock between CCA and

CCB to avoid closing together.

INTERFACES

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1) Relay output R0/R1 is to be set as the function of CCC in the control circuits.

2) For external connecting contactors, spark suppression is necessary for all types of

contactors except the AF types to maintain a reasonable service life of relays.


CCI Contactor control voltage input

CCA Contactor control A

CCB Contactor control B

Table 6 Contactor control terminals

Relay Output

MC510 is also equipped with two relay outputs which functions according to project specific settings.


R0a NC terminal of SPDT

R0b NO terminal of SPDT

R0c Common terminal of SPDT

R1a NO terminal of R1

R1b NO terminal of R1

Table 7 Relay output terminals

The output status of relays may change in responding to different functions assigned.

For external connecting contactors, spark suppression is necessary for all types of contac-

tors except the AF types to maintain a reasonable service life of relays.

Interface for MP51/MP52

MC510 connects with operator panel MP51/MP52 via RJ12 interface, which marked “MP”.

Ethernet communication Interface

Redundant Ethernet communication is provided, in which RJ45 interface is applied, with mark “ETH1”

and “ETH2”.

INTERFACES

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Extension module interface

IO-BUS interface is used for the extension function of basic unit for more complex application. Exten-

sion functions, such as temperature measurement, analog output etc. are implemented separately in

extension modules. IO-Bus interface provides the power supply of extension modules and the data

exchange between MC510 and extension modules.

Typical Diagram

Typical wiring diagrams of different types of MC510 are shown in this section.

MC510 110-240V AC type

Fig 6 Typical wiring diagram for MC510 110-240V AC type

INTERFACES

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MC510 24V DC type

Fig 7 Typical wiring diagram for MC510 24V DC type

Roc is the common terminal of NO and NC contact of R0 relay, output status of NO and NC

contact would change synchronously in responding to different functions assigned

FUNCTIONALIT Y

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—

Functionality

Starter Types

MC510 offers various kinds of motor starting control modes via the control of relay output. It super-

vises the operating state of the contactor according to the feedback of auxiliary contact, predefined

feedback timeout and current.

The following starting control modes are offered:

Starter type

NR-DOL

REV-DOL

NR-DOL/RCU

REV-DOL/RCU

Actuator

NR-S/D

NR-2N

NR-2N Dahlander

Autotransformer

NR_softstater

REV_softstater

Contactor Feeder

Contactor Feeder/RCU

Table 8 Starter types supported by MC510

Starter type is selected with a dedicated parameter to match the wiring for contactor and motor

control circuits.

i) Pin numbers assigned for DIs in below starters are shown as per default settings and

subject to be changed to meet different project engineering.

ii) Spark suppression is necessary for all types of connecting contactors except AF

types through MC510 output relays to maintain a reasonable service life of the output

relays. Interface relays should also be considered in engineering to increase the

FUNCTIONALIT Y

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reasonable service life. Interface relay is recommended to be used for contactor type

A210 and above.

Fig 8 Surge Suppressors on Contactor Coils

Precautious measures shall be taken in system designs to avoid potential high electromag-

netic disturbance which may result in unstable network and malfunction of MC510 relays.

For example, in applications that Variable Speed Drives are used in a large scale, harmonic

filter devices shall be required in system design to reduce the impact to the network.

NR-DOL STARTER

NR_DOL starter is a basic starter type for driving motor to one direction. When start command has

been received from field or local I/O, the contactor control output will be energized and remains this

condition until stop command has been received or any protection function activated.

Terminal Description Remark



DI5 Contactor control A feedback (F_Ca)

Table 9 NR-DOL starter contactor control interface

The definition of the terminal in the above list is only an example.

FUNCTIONALIT Y

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Fig 9 Control circuit for NR-DOL starter (for MC510)

Operating Sequence for NR-DOL:

Motor is Stopped - > Start1 - > Close CCA

Motor is Running - > Stop - > Open CCA

NR-DOL/RCU STARTER

RCU (Remote Control Unit) is a starter type where contactors are directly controlled by a special

RCU-switch located near the motor. This allows control of the motor even without MC510




R1a NO contact of R1

(CCC)

R1b


Table 10 NR-DOL/RCU starter contactor control interface


FUNCTIONALIT Y

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Fig 10 Control circuit for NR-DOL/RCU starter

Operating Sequence for NR-DOL/RCU:

Motor is Stopped - > Start1 - > Close CCA for 1s and open

Motor is Running - > Stop - > Close CCC (R1) for 1s and open

REV-DOL STARTER

REV-DOL uses contactor control output A for controlling the contactor which drives motor to

direction CW and correspondingly contactor control output B is used for direction CCW. When

starting motor to either direction contactor will be energized and is stopped (not energized) by

command (fieldbus or local I/O) or active protection function.






DI6 Contactor control A feedback (F_Cb)

Table 11 REV-DOL starter contactor control interface

FUNCTIONALIT Y

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Fig 11 Control circuit for REV-DOL starter

Operating Sequence for REV-DOL:


Motor is Stopped - > Start2 - > Close CCB

Motor is Running - > Stop - > Open CCA&CCB

REV-DOL/RCU STARTER

The functionality of this starter type is according to NR-DOL/RCU starter with support for revers-

ing use of motor.





R1a NO contact of R1 (CCC)

R1b

FUNCTIONALIT Y

23/110



Table 12 REV-DOL starter contactor control interface (for MC510)


Fig 12 Control circuit for REV-DOL/RCU starter

Operating Sequence for REV-DOL/RCU:

Motor is Stopped - > Start1 - > Close CCA for 1s and open

Motor is Stopped - > Start2 - > Close CCB for 1s and open

Motor is Running - > Stop - > Close CCC (R1) for 1s and open

Actuator STARTER

This starter type is for controlling valves and actuators by using limit switches. Limit switches

cause the motor to be stopped when activated and additionally start command is allowed only to

reverse direction. Torque switch is selectable by parameterization.





FUNCTIONALIT Y

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(CCC)

R1b

DI0 Limit position switch 1 input (Limit1)

DI1 Limit position switch 2 input (Limit2)

DI7 Torque switch input (Tor)



Table 13 Actuator starter contactor control interface


Fig 13 Control circuit for Actuator starter

Operating Sequence for Actuator:

Motor is Stopped with Limit1 and Torque inactivated - > Start1 - > Close CCA for 1s and open

Motor is Stopped with Limit2 and Torque inactivated - > Start2 - > Close CCB for 1s and open

Motor is Running CW - > Limit1 activated or Stop - > Close CCC (R1) for 1s and open CCC (R1)

Motor is Running CCW - > Limit2 activated or Stop - > Close CCC (R1) for 1s and open CCC (R1)

Motor is Running - > Torque activated - > Close CCC (R1)

FUNCTIONALIT Y

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NR-S/D STARTER

Motor start current is reduced in star connection to 1/3 rd of the current in delta connection, with

lower torque during the same time.

Start to delta starting sequence is based on the presented control logic Figure. The changeover

condition is time.

The following guideline applied for selecting parameter values:

Changeover time < Motor startup time





R1a NO contact of R1 (CCC)

R1b


DI6 Contactor control B feedback (F_Cb)

DI7 Contactor control C feedback (F_Cc)

Table 14 NR_S/D starter contactor control interface


Fig 14 Control circuit for NR-S/D starter

FUNCTIONALIT Y

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Operating Sequence for NR-S/D:

Motor is Stopped - > Start1 - > Close CCB & CCC (R1) - > Changeover Time - > Open CCB & Close

CCA

Motor is Running - > Stop - > Open CCA & CCB & CCC (R1)

NR-2N STARTER

NR-2N uses two contactors control motor rotation speed, the motor contains separate windings.

Rotation speed can be changed “on the fly” without stop command in between. Low speed (start1)

could be changed to high speed (start2) immediately, and high speed could be changed to low

speed after a changeover time.

Current measurement for NR-2N utilizes two external current transformers measuring current

from motor main supply. External current transformers can be selected separately for both

speeds.









Table 15 NR-2N starter contactor control interface


FUNCTIONALIT Y

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Fig 15 Control circuit for NR_2N starter, separate windings

Operating Sequence in NR-2N

Sending command ‘Start1’ (Low Speed N1) to close contactor CCA.

Sending command ‘Start2’ (High Speed N2) to close contactor CCB.

Contactors are latched

Stop command opens CCA or CCB.

Motor can be controlled with sequences.e.g.

Stop -> Start1-> Stop

Stop -> Start2 -> Stop

Stop -> Start1 -> Start2 ->Stop

NR-2N Dahlander STARTER

NR-2N Dahlander uses three contactors control motor rotation speed where motor is equipped

with a three phase winding. Rotation speed can be changed “on the fly” without stop command in

between. Low speed (start 1) could be changed to high speed (start 2) immediately, and high

speed could be changed to low speed after a changeover time.

Current measurement for NR-2N Dahlander utilizes two external current transformers measuring

current from motor main supply. External current transformers can be selected separately for

both speeds.

FUNCTIONALIT Y

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(CCC)

R1b



DI7 Contactor control A feedback (F_Cc)

Table 16 NR-2N Dahlander starter contactor control interface


Fig 16 Control circuit for NR_2N Dahlander starter

Operating Sequence in NR-2N Dahlander

Sending command ‘Speed1’ to close contactor CCA.

Sending command ‘Speed2’ to close contactor CCB and CCC(R1).

Contactors are latched

Sending stop command to open CCA or CCB + CCC(R1).

FUNCTIONALIT Y

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Motor can be controlled with sequences.e.g.

Stop -> Start1-> Stop

Stop -> Start2 -> Stop

Stop -> Start1 -> Start2 ->Stop

Stop -> Start2 -> Chang over delay-> Start1 -> Stop

.

AUTOTRANSFORMER STARTER

This starter type is used to control autotransformer unit in order to minimize the voltage drop

during motor startup. Autotransformer starter with three contactors supports motor starting

with reduced voltage thus providing reduced motor startup current. The starting torque will be

reduced accordingly.








(CCC)

R1b



DI7 Contactor control C feedback (F_Cc)

Table 17 Autotransformer starter contactor control interface


FUNCTIONALIT Y

30/110

Fig 17 Control circuit for Autotransformer starter

Operating Sequence for Autotransformer:

Motor is Stopped - > Start1 - > Close CCB & CCC (R1) - > Changeover Time - > Open CCB & Close

CCA

Motor is Running - > Stop - > Open CCA & CCB & CCC (R1)

NR-SOFTSTARTER

Softstarter applications are for controlling motor accessory softstarter device. MC510 gives start

and stop commands to the softstarter unit. The softstarter is set for adjusting motor voltage

with its own parameters. More information about softstarter can be found from softstarter’s

manual.

This starter type supports all protection functions during normal “Running” situation. For motor

start and stop period some of the protection functions are disabled by these parameters.





(CCC)

R1b


Table 18 NR_Softstarter starter contactor control interface

FUNCTIONALIT Y

31/110

The definition of the DI terminal in the above list is only an example.

Fig 18 Control circuit for NR-softstarter

Operating Sequence for NR-Softstarter:

Motor is Stopped - > Start1 - > Close CCA - > Close CCC (R1)

Motor is Running - > Stop - > Open CCC (R1) -> Ramp down time -> Open CCA

REV-softstarter

This starter is of similar functionality as NR-softstarter starter with additional function on sup-

porting reversing motor.






(CCC)

R1b

FUNCTIONALIT Y

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Table 19 REV-softstarter starter contactor control interface

The definition of the DI terminal in the above list is only an example.

Fig 19 Control circuit for REV-Softstarter

Operating Sequence for REV-Softstarter:

Motor is Stopped - > Start1 - > Close CCA - > Close CCC (R1)

Motor is Stopped - > Start2 - > Close CCB - > Close CCC (R1)

Motor is Running - > Stop - > Open CCC (R1) -> Ramp down time -> Open CCA & CCB

Contactor Feeder

Contactor feeder is regarded in MC510 as a specific starter type to provide measurement, control

and protection functionality to a contactor feeder circuit. When start command has been received

from field or local I/O, the contactor control output will be energized and remains this condition

until stop command has been received or any protection function activated.



FUNCTIONALIT Y

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Table 20 Contactor Feeder contactor control interface

i) The definition of the terminal in the above list is only an example.

ii) Power, energy and other parameters related to Power factor are NOT correct and

should not be refer to!

Fig 20 Control circuit for Contactor Feeder

Operating Sequence for Contactor Feeder:


Motor is Running - > Stop - > Open CCA

Contactor Feeder/RCU

The functionality of this starter type is according to NR-DOL/RCU starter with support for con-

tactor feeder.

FUNCTIONALIT Y

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(CCC)

R1b


Table 21 Contactor Feeder/RCU contactor control interface (for MC510)

i) The definition of the DI terminal in the above list is only an example.

ii) Power, energy and other parameters related to Power factor are NOT correct and should

not be refer to!

Fig 21 Control circuit for Contactor Feeder/RCU

Operating Sequence for Contactor Feeder/RCU:

Motor is Stopped - > Start1 - > Close CCA for 1s and Open CCA

Motor is Running - > Stop - > Close CCC (R1) for 1s and Open CCC (R1)

FUNCTIONALIT Y

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Protection Functions

The module provides full protection for motor by supervising three phases voltage, three phases

current, earth fault current, startup time, the state of contactors and the state of main switch.

Responding of protection functions is based on the parameters given by user. The operation of

separate functions is independent thus protection functions can be active at the same time but

the one which indicates the situation first will give a trip for motor.

According to the application, all kinds of protection can be enabled, disabled by the upper level

system or MCU parameter setting tool, also the protection characteristics can be adjusted.

MC510 offers the following protection and supervisory function.

Thermal overload protection

Stall protection

Long start protection

Phase failure protection

Unbalance protection


Noload protection

Under power protection

Over power protection

Under power factor protection

Earth fault protection

Undervoltage protection

Overvoltage protection

Phase sequence protection

Start limitation protection

Environment temperature protection*

Hotspots temperature protection*

Busbar temperature protection*

Motor temeprature protection (PTC/PT100/PT1000) *

Table 22 Protection Functions in MC510

* Extension module is required.

FUNCTIONALIT Y

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Thermal Overload protection

Thermal overload protection (TOL) protects the motor against overheating.

The motor thermal condition is simulated by a calculation. The result of the calculation is stored in a

thermal register and can be reported via operator panel or fieldbus interface.

Calculation is accomplished in a different motor operation conditions, principle presented below,

thermal increase and decrease are simulated by TOL protection function for running and stopped

motor.

Fig 22 Principle picture of motor thermal simulation

MC510 simulates thermal conditions in the motor for all operating modes (Running or Stopped).

This permits maximum utilization of an installation and assures safe protection of the motor.

Thermal overload protection simulation accounts for the temperature rise of both the stator

winding and the iron mass of the motor, it gives thorough consideration on the effect of motor

overheating due to three phase unbalance during the simulation calculation of motor thermal

overload.

There are two thermal models supported by MC510: Standard or EEx e. The standard model

makes use of parameters Trip class, t6 in thermal overload calculation. The protection of explo-

sion proof three-phase motors with type of protection ‘increased safety’ EEx e is done with two

special parameters, the Ia/In ratio (stall/nominal current ratio) and Te time.

The following diagram offers the characteristic curve of overload protection, in which the charac-

.

If EEx e thermal overload protection is required, please contact ABB for detailed clarifi-

cation.

FUNCTIONALIT Y

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Fig 23 Trip curve from cold condition

The Maximum thermal capacity level is 100%. Maximum level is reached when motor has been

running with a current 6xIn at the time t6 starting from the cold state in ambient temp. 40°C.

Trip class T6

10A 3-7

10 7-12

20 10-25

30 15-38

Table 23 IEC 60947-4-1 trip class when ambient temp. 40°C, balanced motor current

If motor is in overload condition, i.e. ILmax > 1.14 x TFLC (Thermal full load current multiplier re-

duced by motor ambient temperature), the Overload alarm is active to indicate overload.

In some applications it is beneficial to be able to bypass the TOL protection momentarily because

of the process reasons. The lifetime of the motor will be shortened but it might be more costly to

stop the process.

MC510 provides the function of TOL bypass protection. If the TOL bypass is triggered:

That is, when the motor is running, the thermal capacity value is allowed to reach 200% before a

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trip occur.

Or when the motor has been tripped due to thermal overload protection, the motor is required to

start urgently when the heat capacity is below 200%.

TOL bypass protection may cause overheating and even fire. This function can be used

only if the customer is clear about the load, even if the motor is required to operate

under overload conditions. Otherwise, it may cause equipment damage, serious injuries

or even death.

Function

Setting range 0=Disabled 1=Enabled 4=Protection bypass1

5=Enabled, and disable during motor startup

Default value 1

Step value 1

Thermal model

Setting range 0=Standard model 1=EEX e

Default value 0

Step value 1

T62

Setting range 3-40s

Default value 6s

Step value 1

Ia/In3

Setting range 1.2-8.0

Default value 5.0

Step value 0.1

Te3

Setting range 5-40s

Default value 5s

Step value 1s

Cool coe.

Setting range 1-10

Default value 4

Step value 1

TOL Alarm Level

Setting range 60-100%

Default value 90%

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Step value 1%

TOL Trip Level


Default value 100%

Step value 1%

TOL Reset Level


Default value 50%

Step value 1%

TOL bypass

Setting range 0=Disabled 1=Enabled

Default value 0

Trip Reset Mode

Setting range 1=Auto 2=Local 3=Remote 4=Remote&Local

Default value 4

Step value 1

Ambient Temperature

Setting range 0-80°C

Default value 40°C

Step value 5°C

Table 24 TOL protection parameters

1 The user can trigger the protection bypass command through the input of the digital

or the command from the fieldbus. Then all the options allow the protection bypass are

actived, even if the trip level is reached, MC510 still only sends out the corresponding

alarm information and does not execute the trip command.

2 When Standard thermal model is selected

3 When EEx e thermal model is selected

Stall Protection

Stall protection is used to protect the driven mechanical system from jams and excessive over-

load. Stall protection function uses Imax as the criterion. There are other parameters to be deter-

mined as followed.

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Function

Setting range 0=Disable 1=Enable 4=Protection bypass

Default value 0

Step value 1

Trip Level


Default value 400%

Step value 10%

Trip Delay

Setting range 0.0-25.0s

Default value 0.5s

Step value 0.1s

Trip Reset Mode

Setting range 2=Local 3=Remote 4=Remote&Local

Default value 4

Step value 1

Table 25 Stall protection parameters

The user can trigger the protection bypass command through the input of the digital




Fig 24 Stall protection

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Stall function activates after motor nominal startup time has elapsed.

The highest measured phase current (ILmax) is compared against the Trip level. When ILmax remains

over the trip level at a time longer than Trip delay, a “Stall” alarm is issued and the contactor

tripped.

Long Start protection

The long start protection protects motor against locked or stalled rotor in starting state. MC510

detects the current after a start command, and signals a fault when current continuously exceeds

a separately set threshold of the period of start time.

Fig 25 Long start protection

Function Enable/Disable


Default value 0

Step value 1

Locked rotor Level


Default value 120%

Step value 10%

Locked Rotor Delay

Setting range 0-250s

Default value 10s

Step value 1s

Trip Reset Mode


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Default value 4

Step value 1

Table 26 Long Start protection parameters

1 The user can trigger the protection bypass command through the input of the digital




Long Start protection activates during motor nominal startup time and disables automatically

after predefined startup time.

The highest measured phase current (ILmax) is compared against the Locked rotor level. When ILmax

remains over the trip level at a time longer than Locked Rotor delay, a “Long Start” alarm is issued

and the contactor tripped.

Phase failure protection

MC510 protects the motor against phase current loss condition. Phase failure protection function uses

ILmin/ILmax (the ratio of lowest ILmin and highest measured phase value ILmax) as the criterion. Function is

suppressed by parameters Motor startup time, Number of phases and Softstart ramp time.

Function


Default value 0

Step value 1

Alarm Level


Default value 80%

Step value 1%

Trip Level

Setting range 5-90%

Default value 70%

Step value 1%

Trip Delay

Setting range 0-60s

Default value 10s

Step value 1s

Trip Reset Mode

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Default value 4

Step value 1

Table 27 Phase failure parameters

The user can trigger the protection bypass command through the input of the digital or

the command from the fieldbus. Then all the options allow the protection bypass are



Fig 26 Phase failure protection

ILmin/ILmax is compared against the phase failure Alarm level. When ILmin/ILmax decreases below the Alarm

level, a “Phase failure alarm” alarm is issued.

ILmin/ILmax is compared against the phase failure Trip level. When ILmin/ILmax remains below the Trip level

at a time longer the Trip delay, a “Phase failure trip” alarm is issued and the contactor tripped.


MC510 protects the motor against unbalance condition. Unbalance protection function also uses

ILmin/ILmax as the criterion. Function is suppressed by parameters Motor startup time, Number of phas-

es and softstart ramp time.

Function

Setting range 0=Disabled 1=Enabled 3=Alarm only 4=Protection

bypass

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Default value 0

Step value 1

Alarm Level


Default value 90%

Step value 1%

Trip Level


Default value 85%

Step value 1%

Trip Delay

Setting range 0-60s

Default value 10s

Step value 1s

Trip Reset Mode


Default value 4

Step value 1

Table 28 Unbalance protection parameters

The user can trigger the protection bypass command through the input of the digital or the

command from the fieldbus. Then all the options allow the protection bypass are actived,

even if the trip level is reached, MC510 still only sends out the corresponding alarm infor-

mation and does not execute the trip command.

Fig 27 Unbalance protection

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ILmin/ILmax is compared against the unbalance Alarm level. When ILmin/ILmax decreases below the Alarm

level, a “Unbalance alarm” alarm is issued.

ILmin/ILmax is compared against the unbalance Trip level. When ILmin/ILmax remain below the Trip level at a

time longer the Trip delay, an “Unbalance Trip” alarm is issued and the contactor tripped.

Underload protection

MC510 protects the motor against underload condition. Underload protection function uses ILmax/In

(the ratio of highest measured phase value ILmax and the rated current of the motor In) as the criterion.

There are other parameters to be determined, such as alarm level, trip level and trip delay. The protec-

tion characteristic is as follows:



bypass

Default value 0

Step value 1

Alarm Level


Default value 30%

Step value 1%

Trip Level

Setting range 5-90%

Default value 20%

Step value 1%

Trip Delay


Default value 10s

Step value 1s

Trip Reset Mode


Default value 4

Step value 1

Table 29 Underload protection parameters

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1 The user can trigger the protection bypass command through the input of the digital or

the command from the fieldbus. Then all the options allow the protection bypass are ac-

tived, even if the trip level is reached, MC510 still only sends out the corresponding alarm

information and does not execute the trip command.

Fig 28 Underload protection

The ILmax/In is compared against the Underload Alarm level. When ILmax/In decreases below the

Alarm level an “Underload alarm” alarm is issued.

The ILmax/In is compared against the Underload trip level. When ILmax/In remains below the Trip level

at a time longer than underload Trip delay, a “ Underload trip” alarm is issued and the contactor

tripped.

Noload protection

MC510 protects the motor against no load condition. Practically no load protection is the same func-

tion as underload protection. The function also uses ILmax/In as the criterion.

Function


bypass

Default value 0

Step value 1

Alarm Level

Setting range 5-50%

Default value 20%

Step value 1%

Trip Level

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Setting range 5-50%

Default value 15%

Step value 1%

Trip Delay


Default value 5s

Step value 1s

Trip Reset Mode


Default value 4

Step value 1

Table 30 Noload protection parameters





Fig 29 Noload protection

The ILmax/In is compared against the Noload Alarm level. When ILmax/In decreases below the Alarm level a

“Noload alarm” alarm is issued.

The ILmax/In is compared against the Noload trip level. When ILmax/In remains below the Trip level at a

time longer than Noload Trip delay, a “Noload trip” alarm is issued and the contactor tripped.

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There are two ways of earth fault protection in MC510 protects the motor against the earth fault con-

dition.

Direct measurement of zero sequence current through an external RCT

Calculation of zero sequence current by internal calculation through measurement current values

The function is by default suppressed by parameters “Motor startup time” and “Softstarter ramp up

time” to avoid nuisance tripping due to harmonics caused by saturation of the current transformers. In

some cases, it may be required to be switched on during startup in specific project requirements.

This protection is neither intended to be used for pre-emptive isolation supervision nor for

personnel protection against electrical shock. For these applications ABB recommends the

usage of external protection devices (PRCDs / RCDs).

Earth fault protection uses parameters as in the following table.

Function


bypass3

Default value 0

Step value 1

Protection based on

Setting range 0=External RCT 1=Internal Calculation

Default valuez 0

Step value 1

Earth Fault Primary

Setting range 1000mA, 5000mA

Default value 1000mA

Step value -

Alarm Level

Setting range 100-3000mA (Earth Fault Primary = 1A) 1

500-15000mA (Earth Fault Primary = 5A) 1

20%-50% In2

Default value 500mA1

20%In2

Step value 100mA1

0.1%In2

Trip Level

Setting range 100-3000mA (Earth Fault Primary = 1A) 1

500-15000mA (Earth Fault Primary = 5A) 1

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20%-80% In2

Default value 800mA1

50%In2

Step value 100mA1

0.1%In2

Trip Delay


Default value 10.0s

Step value 0.1s

Trip Reset Mode


Default value 4

Step value 1

Earth fault protection is activated during motor startup time


Default value 0

Step value 1

Table 31 Earth fault protection parameters

1 When “Protection based on = External RCT“ is selected

2 When “Protection based on = Internal Calculation“ is selected

3 The user can trigger the protection bypass command through the input of the digital or the




Fig 30 Earth fault protection (I0 = Measured Earth Fault Current)

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I0 is compared against the earth fault current fault Alarm level. When I0 exceeds above the Alarm level,

an “Earth fault alarm” alarm is issued.

I0 is compared against the earth fault current Trip level. When I0 remains above the earth fault current

Trip level at a time longer than Trip delay, an “Earth fault trip” alarm is issued and the contactor

tripped.

Undervoltage protection

MC510 protects the motor against undervoltage condition as “voltage dip”. The undervoltage protec-

tion function uses ULmin as the criterion. There are other parameters to be determined, such as alarm

level, trip level and trip delay, reset voltage level. The protection characteristic is as follows:

3

Fig 31 Undervoltage protection

The lowest measured main line voltage (ULmin) is compared against the undervoltage alarm level. When

ULmin decreases below the undervoltage alarm level, an “Undervoltage alarm” alarm is issued.

The lowest measured main line voltage (ULmin) is compared against the undervoltage Trip level and

voltage restore level. When ULmin recovers above undervoltage Restore level before Trip delay expires

and motor continues running. If ULmin remains below the restore level at a time longer than Trip delay,

“Undervoltage trip” is issued and contactor will be opened.

When “Autorestart” function is active, “Undervoltage trip delay” will be same as “Max. power

down time” automatically.



bypass

Default value 0

FUNCTIONALIT Y

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Step value 1

Alarm Level


Default valuez 80%

Step value 1%

Trip Level


Default value 65%

Step value 1%

Trip Delay


Default value 1.0s

Step value 0.1s

Reset Level


Default value 90%

Step value 1%

Trip Reset Mode


Default value 4

Step value 1

Table 32 Undervoltage protection parameters





Overvoltage protection

MC510 protects the motor against overvoltage condition. The overvoltage protection function uses

ULmax as the criterion. There are other parameters to be determined, such as alarm level, trip level

and trip delay, reset voltage level. The protection characteristic is as follows:

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Fig 32 Overvoltage protection

The maximum measured main line voltage (ULmax) is compared against the overvoltage alarm level.

When ULmax increases bigger than the overvoltage alarm level, an “Overvoltage alarm” alarm is issued.

The maximum measured main line voltage (ULmax) is compared against the overvoltage Trip level and

voltage restore level. When ULmax recovers below overvoltage Restore level before Trip delay expires and

motor continues running. If ULmax remains bigger than the restore level at a time longer than Trip delay,

“Overvoltage trip” is issued and contactor will be opened.



bypass

Default value 0

Step value 1

Alarm Level


Default valuez 100%

Step value 1%

Trip Level


Default value 120%

Step value 1%

Trip Delay


Default value 1.0s

Step value 0.1s

Reset Level


Default value 100%

Step value 1%

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Trip Reset Mode


Default value 4

Step value 1

Table 33 Overvoltage protection parameters





Under power protection

MC510 protects the motor against under power condition. Under power protection function uses P/Pn

(the ratio of measured power value P and the rated power the motor Pn) as the criterion.

Alarm level

1. warning 2. start trip delay 3. clear trip delay 4. start trip delay

5. trip 6. trip reset

Trip level

1

.

(P / Pn)

t

Trip delay

2

. 3

. 4

. 5

. 6

.

Fig 33 Under power protection

The P/Pn is compared against the Alarm level. When P/Pn decreases below the Alarm level a “Under

power alarm” alarm is issued.

The P/Pn is compared against the trip level. When P/Pn remains below the Trip level at a time longer

than Trip delay, a “Under power trip” alarm is issued and the contactor tripped.



FUNCTIONALIT Y

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bypass

Default value 0

Step value 1

Alarm Level


Default valuez 50%

Step value 1%

Trip Level


Default value 30%

Step value 1%

Trip Delay


Default value 1.0s

Step value 0.1s

Trip Reset Mode


Default value 4

Step value 1

Table 34 Under power protection parameters





Over power protection

MC510 protects the motor against over power condition. Over power protection function uses P/Pn

(the ratio of measured power P and the rated power of the motor Pn) as the criterion.

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Fig 34 Over power protection

The P/Pn is compared against the alarm level. When P/Pn increases above the Alarm level an “Over pow-

er alarm” alarm is issued.

The P/Pn is compared against the trip level. When P/Pn remains above the Trip level at a time longer

than Trip delay, a “Over power trip” alarm is issued and the contactor tripped.





bypass

Default value 0

Step value 1

Alarm Level


Default valuez 100%

Step value 1%

Trip Level


Default value 150%

Step value 1%

Trip Delay

Setting range 0.2-50s

Default value 0.2s

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Step value 0.1s

Trip Reset Mode


Default value 4

Step value 1

Table 35 Over power protection parameters





Under power factor protection

MC510 protects the motor against underload condition based on power factor. Under power factor

protection function uses measured power factor as the criterion. The protection is masked by motor

startup time or softstarter start time. There are other parameters to be determined, such as alarm

level, trip level and trip delay. The protection characteristic is as follows:



bypass

Default value 0

Step value 1

Alarm Level


Default valuez 60%

Step value 1%

Trip Level


Default value 50%

Step value 1%

Trip Delay

Setting range 0-60s

Default value 10s

Step value 1s

Trip Reset Mode


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Default value 4

Step value 1

Table 36 Under power factor protection parameters





Alarm level

1. warning 2. start trip delay 3. clear trip delay 4. start trip delay

5. trip 6. trip reset

Trip level

1

.

Power factor

t

Trip delay

2

. 3

. 4

. 5

. 6

.

Fig 35 Under power factor protection

The power factor is compared against the Alarm level. When power factor decreases below the Alarm

level a “Under power alarm” alarm is issued.

The power factor is compared against the trip level. When it remains below the Trip level at a time

longer than Trip delay, a “Under power trip” alarm is issued and the contactor tripped.

Phase sequence protection

MC510 protects the motor against wrong phase sequence condition. The protection bases on the

sequence of voltage input while motor is stopped. And while motor is started, it bases on the se-

quence of current. The predefined phase sequence as following,

Voltage: VL1,VL2, VL3

Current: IL1, IL2, IL3

While the protection is enabled, there will be a trip while the measured phase sequence is different

from the predefined sequence.

The function is by default suppressed by parameters “Motor startup time” and “Softstarter ramp up

time” to avoid nuisance tripping due to harmonics caused by saturation of the current transformers. In

some cases, it may be required to be switched on during startup in specific project requirements.

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Setting range 0=Disabled 1=Enabled 4=Protection bypass

Default value 0

Step value 1

Trip Reset Mode


Default valuez 4

Step value 1

Table 37 Phase sequence protection parameters





Start limitation

Start limitation helps to protect the motor and also the process against excess number of starts in a

given interval. When the number of starts is reached and the motor is switched off, a new start is pre-

vented. The time interval starts from the first start. After the elapse of the time interval the counter is

reset to the pre-set value. The permissible motor starts per hour can be obtained from the manufac-

turers motor and apparatus data sheet. However, the minimum waiting time between two starts shall

be complied.

The parameterization of the protection function can be the number of starts per time interval or the

time between two consecutive starts. In the first case the user must wait after the trip for the reset to

take place before making a start.

Independent of this function, the motor is protected by TOL function and a start is possible only if the

thermal capacity is below the startup inhibit level. If motor data specifies the number of starts during

a certain time span the advantage of this protection function can be taken of supervising the number

of starts. On some other cases process may put requirements for the motor start number thus this

protection can be employed.

Functionality is presented in the following example. Fig. 36 presents the start limitation protection

with 3 starts allowed.

1) Normal situation, after stop command motor can be started normally, “Start 2”. Every start activates

an internal timer for the time defined by time interval parameter. The number of active timers are

reviewed after every stop command and compared to value of number of starts parameter. Stop

command can thus exist during active or elapsed timer.

2) Two timers are still active, thus stop command generates alarm message "Start limitation alarm"

and one more start “Start 3” is allowed.

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3) The 3rd start has been executed. A contactor trip and trip message "Start Limitation Trip" alarm will

follow when motor is stopped while there are two active timers, here starting from “Start 1”.

4) Trip can be automatically reset when the first timer from “Start 1” is finished. Motor start is possible

when all pending trips are reset. Supervision continues with a new timer from “Start 4”

Fig 36 Start limitation protection



Default value 0

Step value 1

Time interval

Setting range 1-600min

Default valuez 1min

Step value 1

Number of starts

Setting range 1-100

Default value 2

Step value 1

Trip Reset Mode

Setting range 1=Auto

Default value 1

Step value 1

Table 38 Start limitation parameters

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1 The user can trigger the protection bypass command through the input of the digital or the




Loop environment Temperature protection

MC510 extends the module hotspots module MT561 to monitor the ambient temperature inside the

drawer and prevent the drawer components from being too high, thus causing the drawer to burn

down. MC510 monitors the temperature of drawer environment to decide whether to trigger environ-

mental temperature protection alarm.

For details, please refer to the hotspots module MT561 section of the extended module user guide.

When MT561 is only used for loop environment temperature protection, there is no need to

configure hotspots temperature sensor.

Hotspots temperature protection

By extending the module hotspots module MT561, MC510 monitors the temperature of the inserting in

the drawer to prevent the temperature of the drawer from being too high, which leads to the burnout

of the drawer.

The single insertion temperature measurement is realized by inserting a fixed temperature infrared

sensor IR. MC510 monitors the temperature of one primary connector to decide whether to trigger a

temperature protection.

Fig 37 Hotspots temperature protection

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For details, please refer to the hotspots module MT561 section of the extended module user guide.

Busbar temperature protection

MC510 monitors the copper temperature in the switchgear by extending the module MT564 to moni-

tor the copper temperature in the switchgear, including the main busbar, the copper platoon of the

ACB cabinet, and the copper row of the fixed circuit.

The bus temperature measurement is realized by self-powered wireless temperature measurement

module WT01, and transmitted to MT564 through Zigbee. MC510 monitors the temperature of the bus

bar to decide whether or not to trigger the bus temperature protection.

Fig 38 WTM temperature protection

For details, please refer to the wireless temperature module MT564 in the user guide of the extended

module.

Thermal protection of motor (PTC/PT100/PT1000)

The thermal protection of the motor is used as a protective condition to determine the protection

function of the PTC/PT100/PT1000 thermistor detector, which is pre buried on the stator winding or

bearing of the motor.

MC510 realizes motor thermal protection through analog input and output module MA552. MC510

according to the measured resistance value, decide whether to turn on the corresponding motor

thermal protection.

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Fig 39 PTC/PT100/PT1000 temperature protection

For details, please refer to the MA552 section of the analog input and output module in the extended

module user guide.

Analog input signal monitoring function

MC510 monitors the input of analog input in analog input and output module MA552 in real time, and

sends out corresponding signal according to the preset alarm level value and trip level value.

For details, please refer to the MA552 section of the analog input and output module in the extended

module user guide.

Autorestart Function

The line voltage (UL1L3) is supervised continuously. It is possible to automatically restart the motor after

momentary power loss. Two alternative models of auto restart function are provided in MC510: Stand-

ard and enhanced.

When any DI is set to "main switch state" and the main switch state is not input, the auto-

matic restart function will automatically fail.



Default value 0

Step value 1

Function mode

Setting range 0=standard 1=enhanced

Default valuez 0

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Step value 1

Max. autoreclose time

Setting range 0-5000ms

Default value 200ms

Step value 100ms

Max. power down time


Default value 5s

Step value 0.1s

Staggered start delay


Default value 5s

Step value 0.1s

Table 39 Autorestart function parameters

Autorestart function (standard)

In standard mode, the reaction of the auto restart function depends on the length of the voltage dip.

The following cases show the different reactions of MC510 in different voltage dip situations.

Case 1: Voltage dip< autoreclose time

Fig 40 Autorestart (Voltage dip< autoreclose time)

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If voltage is restored within the autoreclose time, the motor will be restarted immediately.

Case 2: autoreclose time<voltage dip< Max. power down time

Fig 41 Autorestart (autoreclose time<voltage dip< Max. power down time)

If power is restored after autoreclose time but before max power down time, motor will be restarted

after the staggered start delay time.

Case 3: Voltage dip> Max. power down time

Fig 42 Restart (Voltage dip> Max. power down time)

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If supply voltage remains below restore level long enough and exceeds max power down time, no au-

tomatic restart will be initiated.

Autorestart function (enhanced)

If the voltage dip is taken more serious, the enhanced autorestart function can be applied.

In the enhanced mode, the reaction of the auto restart function not only depends on the length of the

voltage dip, but also the number of voltage dips within short period of time.

The following cases show the different reactions of MC510 in different voltage dip situations.

Case1: Voltage dip< autoreclose time

Identical to Case1 of standard mode

Case2: autoreclose time<voltage dip< Max. power down time


Case3: Voltage dip> Max. power down time


Case4: 2xdip<200ms within 1s

Fig 43 Restart (2xdip<200ms within 1s)

If the interval between two voltage dips (which length less than 200ms) is less than 1 second. Auto-

matic delay restart is triggered after second voltage restore.

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Modbus TCP Failsafe Functionality

MC510 failsafe function supervises the network interface and connection to the remote devices con-

trolling the motor/starter equipment by MC510. Remote device have to refresh the certain MC510

network input variable to indicate that the control is operating normally and the network interface is in

good condition.

If a loss of Modbus/TCP communications for preset timeout value (1-25 seconds) is detected, the

failsafe activates with the parameterized function as follows:

• No operation

• Start motor direction 1


• Stop motor

When communication failure is detected and activated by MOSBUS TCP failsafe mode, MC510 will

automatically release remote control permissions (if remote control authority has been selected).

IO BUS Failsafe Functionality

MC510 failsafe function supervises the network interface and connection to the extension modules by

MC510. Remote device have to refresh the certain MC510 network input variable to indicate that the

control is operating normally and the network interface is in good condition.

If a loss of IO BUS communications for 200ms is detected, the failsafe activates with the parameter-

ized function as follows:

• No operation



• Stop motor

Main Switch Protection Function

When ‘Main switch’ or ‘Test switch’ function is enabled, main switch protection function is enabled

accordingly. Below tables show the logic relationship of main switch protection functions:

‘Main switch’ function is enabled, and ‘Test switch’ function is disabled:

Motor status Main switch status

ON OFF OFF ON

Running Trip Remark*

Stop No operation No operation

Remark*：When main switch status is ‘OFF’, motor can’t be started, i.e. motor status couldn’t be ‘Run-

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ning’ status.

‘Main switch’ function is disabled, and ‘Test switch’ function is enabled:

Motor status Test switch status

ON OFF OFF ON

Running Stop Stop

Stop No operation No operation

Both ‘Main switch’ and ‘Test switch’ function are enabled

Motor status

Main switch status Test switch status Both main switch and

test switch are ON ON OFF OFF ON ON OFF OFF ON

Running Trip Remark* Trip Remark* Trip

Stop No operation No operation No operation No operation Trip

Remark*：When main switch status is ‘OFF’, motor can’t be started, i.e. motor status couldn’t be ‘Run-

ning’ status.

MC510 Control Authority

Control Authority

MC510 Control Authority is the term describing the privileges on allowing motor control operation

through MC510. It is also a setting parameter in MC510 to define which control access group has privi-

lege to operate the motor via MC510.

Control Access

There are three control access groups defined in MC510,

Local Hardwiring: MC510 accepts its commands from the hardwired inputs

Remote Fieldbus: MC510 accepts its commands from PLC or higher control system via fieldbus, i.e.

MODBUS/TCP.

MP Control: MC510 accepts its commands from operator panel MP5x which locates on the front panel

of each starter unit on switchgear.

CHMI Control: MC510 accepts its commands from CHMI (MV570).

Assign Control Authority

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There are several means in MC510 to assign control authority and decide which control access group

has the privilege to control.

Local/Remote control authority assignment

Parameter Setting:

Select the access group from parameter setting window (Fig 44). This is the most direct option where

control access is defined by parameterization software.

Fig 44 Parameter Setting of Local/Remote of Control Authority

Multi control access group is supported!

For MC510, only when no DI is assigned Loc/R, Soft Local/Remote could be selected.

Local/Remote Selector Switch

MC510 supports hardwired local remote selector switch function which allows selecting control access

groups via hardwired inputs. To enable this function, one of the digital inputs has to be defined as

‘Loc/R’ in MC510 (Fig45).

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Fig 45 Assign “Local/Remote” function to Digital Input

Local/Remote Selector Switch will then define if control access goes to “Local “(Local Hardwired) or

“Remote” (Remote Fieldbus). This function does not include the selection of operator panel MP control

which is independent of either “Local” or “Remote” and has to be further defined in this case.

Loc/R Selector

Switch Input

Control Authority

Local Hardwiring Remote Fieldbus MP Enabled in Local MP Enabled in Remote

False input Disabled Enabled Disabled Enabled

True input Enabled Disabled Enabled Disabled

Table 40 “Local/Remote” Selector Switch

MP control authority assignment

The selection of operator panel MP5x control which is independent of either “Local” or “Remote” and

has to be further defined in this case. There are two ways of defining MP5x control access i.e. through

“parameter setting” in parameterization software or through hardwired input.

Parameter Setting

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Fig 46 MP Control

Select the access group from parameter setting window (Fig 46). This is the most direct option where

control access is defined by parameterization software.

Hardwired Input

Use external selector switch to select MP control. Same as in Local/Remote Selector Switch function,

one of the digital inputs has to be defined as ‘MP Control” to enable the function.

Fig 47 Set DI as “MP Control”

When “MP control” is enabled in one of the DIs, the MP control access option will be gray out.

In another word, Hardwired Selection has privilege over Soft in terms of assigning control

authority.

CHMI control authority assignment

The choice of CHMI control permissions is completely independent of local / remote selection. MC510

provides 2 ways to define control permissions for CHMI human-machine interface, such as parameter

setting through software or input signals through hard wire switches.

Parameter Setting

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Fig 47-1 CHMI Control Authority

As shown in Fig 47-1, this is the most direct way to set up CHMI control permissions in the local / re-

mote switch input state.

Hardwired Input

Use external selector switch to select CHMI control. Same as in Local/Remote Selector Switch func-

tion, one of the digital inputs has to be defined as ‘CHMI Control” to enable the function.

Fig 47-2 Set DI as “CHMI Control”

When “CHMI control” is enabled in one of the DIs, the CHMI control access option will be gray

out. In another word, Hardwired Selection has privilege over Soft in terms of assigning con-

trol authority.

Main switch protection function

The main switch protection function is based on the protection function of MNS drawer handle opera-

tion. This function monitors the state of the main switch under different motor circuits and enhances

the functional safety of the MNS system.

If you want to turn on the protection, you need to connect the main switch status and the test position

status to the DI of MC510. In this case, the action performance of MC510 is as follows:

Motor

Status

Main Switch State Test Switch State* Close Main Switch &

Test position CloseOpen OpenClose Close CloseOpen OpenClose

Running

（Current

feedback）

Main switch trip -- Current

feedback

trip

Stop Stop Main switch trip

Running

（contactor

feedback）

Main swich trip -- Normal Stop Stop Main switch trip

Stop Normal Normal Normal Normal Normal Main switch trip

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When MC510 monitors the test position, the "T" will appear on the top right corner of the

MP51 LCD.

The main switch state can be individually connected to MC510 without the need to access the test

position. In this case, MC510 only monitors the state of the DI, and the performance of MC510 is as

follows:

Motor Status Main Switch State

CloseOpen OpenClose

Running（Current feedback） Main Switch trip --

Running（contactor feedback） Main Switch trip --

Stop Normal Normal

The test position state can be accessed to MC510 individually without requiring access to the main

switch state. In this case, MC510 monitors the main switch in real time. When the main switch is in the

test position, MC510 monitors the three-phase current and the "I/O" point state, and allows the con-

tactor control loop to be controlled, but all protection functions based on current and voltage are

invalid. When the input of the switch is defined as the "test position", if the input point is the same as

the set state, the main switch is in the normal working position; on the contrary, the main switch is in

the test position. For example, if the contact type is normally closed, when the input is high, the main

switch is in the normal working position and the high level is cancelled. However, when the main switch

is in the test position but MC510 detects the current (>5% Ie), all the protection functions will be au-

tomatically opened according to the set parameters, while ignoring the "test position". The action

performance of MC510 is as follows：

Motor Status

Test position

Close CloseOpen OpenClose

Running（Current

feedback）

Current feedback trip Stop Stop

Running（contactor

feedback）

Normal Stop Stop

Stop Normal Normal Normal

*When MC510 monitors the test position, the "T" will appear on the top right corner of the

MP51 LCD.

Logic Block

MC510 provides freely programmable logic block functions to carry out additional logic functions for

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your application.

Logic block function provides several logic modules:

•True table 2I/1O

The function block is used to define the logical relationship between 2 input signals and 1 output sig-

nals.

•True table 3I/1O

The function block is used to define the logical relationship between 3 input signals and 1 output sig-

nals.

•Timer

The function block consists of three modes: power delay output (TON), power off delay output (TOFF)

and pulse output (TP).

Timer Type Time sequence diagram Remark

TP

PT：the pulse time of the TP type

TON

DT：the delay time of the TON type

TOFF

DT：the delay time of the TOFF type

Fig 48 time sequence diagram of timer

•Counter

The function block will change according to the input signal, each effective count input signal, and the

counter value will be increased by 1 or reduced by 1 according to the set counter mode.

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•Flashing

When the input signal is valid, the function block will output the signal according to the set duty ratio

and frequency. For example, the duty cycle is 50%, the frequency is 0.5 Hz, the output duty cycle is

50%, and the frequency is 0.5 Hz.

Logic block function also provides below operation modules:

•F_Ca/F_Cb/F_Cc

•This function is used to monitor the feedback state of the contactor CCA/CCB/CCC (R1), and is the

level detection mode.Start1/Start2

The local control authority should be opened beforehand before use.

This function is used for hard wiring starting motor. After receiving the starting 1 instructions, the

motor will be running or running at low speed. After receiving the 2 instructions, the motor will reverse

or run at high speed. The function is an edge trigger mode.

•Stop (edge triggering) / Stop (level trigger)

The local control authority should be opened beforehand before use. This function is used for hard

wiring stop motor.Limit1/Limit2

This function is used to install the limit switch. When the function is activated, the motor stops, and

the motor can only reverse control. That is, the limit switch 1, which limits the positive or low speed

operation of the motor, and the limit switch 2, which limits the motor reversing or the high speed

operation of the motor. The function is a level trigger mode.

•Trip Reset

The local reset authority should be opened before use. This function is used to reset the tripping sig-

nal for the edge triggered mode.

•PLC Control1/2

When the function is set to "PLC control 1" or "PLC control 2", and when the action signal is monitored,

the motor will continue to run in one direction or at a given speed until the opposite stop signal is

received.

"PLC control 1" allows the motor to rotate or run at low speed.

"PLC control 2" allows the motor to reverse or run at high speed.

If you want to turn on the PLC control function, you need to set the control authority to local hard wir-

ing.

•Torque Switch

When the function is set to torque switch, when the input signal is opposite to the setting state,

MC510 will release all control relays to stop the motor. This function is a level trigger mode.

•External Trip

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This function is used to define the external tripping signal, which will cause the motor to trip. When

the signal is effective, the motor is tripped and needs to wait until the signal is lost before it can be

restarted. The signal is a level detection mode.

When the input point does not detect the external tripping input signal, MC510 will reset

automatically.

• MP Control

This function is used to decide whether the operation panel can control the motor. When the function

is set to "MP control", the control authority of MP can’t be changed by parameter settings, and is de-

termined by the state of the input signal of the function. If the input signal is effective, the operation

panel MP can control the motor and vice versa. The signal is a level detection mode.

• Loc/R

This function is used for local / remote state control.

For MC510, if the local / remote input function is valid, the control permissions are local hard wiring; if

the signal is invalid, it is a remote bus. The signal is a level detection mode.

• Test Switch

This function is used to monitor whether the main switch is in the test position. If the main switch is in

the test position, MC510 monitors the three-phase voltage and the various "I/O" point states. MC510

can control contactors, but all protection functions based on current and voltage are automatically

closed, and only the control loop is tested.

When the current value of the monitor is not 0, all protection functions set by the parameter will au-

tomatically turn on. This function protects the motor in the case of contact failure.

The contact is a level trigger mode.

Opening the "test position" function will trigger the monitoring function of the main switch to turn on.

The function of the main switch can be seen in detail as the main switch protection function.

• Main Switch

When the function is set to "main switch state", the monitoring and protection functions of the main

switch will be switched on immediately. The input is the level detection mode.

• Process Interlock1

The process interlock 1 function is used to specify the time to allow the interlocking switch state to

change.

When the motor starts, if MC510 detects that there is no interlocking signal input, and the duration

exceeds the set time, MC510 will operate according to the defined execution mode. When this parame-

ter is set to 0, the interlocking signal must be active before starting the motor. The signal is a level

trigger mode.

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Fig 49-1 Process interlock1

Case 1: When t1>t2, motor can run normally.

Case 2: When t1<t2, a trip or stop will be performed according to the predefined operation.

If the signal is detected active, the trip will be reset automatically.

• Process Interlock2

The process interlock 2 function is used to specify the time to allow the interlocking switch state to

change.

When the motor starts, if MC510 detects interlocking signal input, and the duration exceeds the time

set by this parameter, MC510 will operate according to the defined execution mode. When this param-

eter is set to 0, the interlocking signal must be inactive before starting the motor.

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Fig 49-2 Process interlock2

Case 1: when t1>t2, motor can run normally.

Case 2: when t1<t2, a trip or stop will be performed according to the predefined operation.

If the signal is detected active, the trip will be reset automatically.

• Emergency Stop

It is used to define the emergency stop device. When the motor is running, once the emergency shut-

down input is effective, the motor will stop running or trip immediately according to the set execution

mode. The motor is not allowed to restart until the input point is cancelled.

The input signal is a level trigger mode.

1）Emergency stop function is not used for functional safety.

2）When the function block does not detect the emergency stop input signal, MC510 will

reset automatically.

•CHMI Control

This function is used to decide whether CHMI can control the motor. When the function is set to "CHMI

control", the control authority of CHMI can’t be changed by the parameter settings, and is determined

by the state of the input signal of the function. If the input signal is effective, CHMI can control the

motor and vice versa. The signal is a level detection mode.

•TOL Bypass

If the thermal overload bypass function is selected and the signal input function block is detected by

MC510, the thermal overload bypass instruction of the motor is issued.

When the TOL bypass function is activated, MC510 allows the thermal capacity trip level to rise to

200% temporarily, that is, the motor can run continuously when the heat capacity is less than 200%,

and does not trip the motor, or allows the motor to start immediately when the heat capacity is less

than 200%.

If the TOL bypass function is to be activated, TOL bypass function must be enabled at TOL protection

window in MCUSetup, and then TOL bypass signal should be given to TOL bypass function block or

from fieldbus. The signal is a level detection mode.

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TOL bypass function increases the thermal capacity trip level value, which may cause the

equipment to overheat or even burn down.

• Protection Bypass

If the protection bypass function is selected, MC510 will detect the signal input function block and

issue the protection bypass instruction. At this time:

Motor is running. When MC510 detects the protection bypass signal input, all protection functions that

allow the protection bypass are switched to alarm only mode automatically. When the protection by-

pass signal disappears, all the protection functions that allow the protection bypass are restored.

Protection with protection bypass is during trip delay time. When MC510 detects the protection by-

pass signal input, the delay calculation will stop immediately. When the protection bypass signal is

lost, the delay calculation will restart if trip signal is still available.

The motor is tripped, but the trip is not cleared. When MC510 detects the protection bypass signal

input, the trip will be reset immediately. When the protection bypass signal disappears, the trip infor-

mation is redisplayed if the judgment condition of the trip is still available.

After the bypass is protected, the motor may run under dangerous conditions. Please be

careful when using it.

•Digital output relay

This function maps the signal status to the output relay of MC510, and the digital output relay will be

ON or OFF according to the state of the input signal.

All kinds of signals/variables are provides for the input signals of logic modules and operation mod-

ules:

•True/False

•Clock signal

•DI status

•Output of Truth2I1O

•Output of Truth3I1O

•Output of Counter

•Output of Timer

•Output of Flashing

•Alarm signal

•Trip signal

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•Control authority status

•Motor status

•Switch position

Logic block function could be edited in MConfig and CHMI. Below picture shows an example of logic

block function. For more details of logic block, please refer the ‘MC510 parameter description’ docu-

ment.

Fig 50 Example of Logic Block Program

Maintenance Function

MC510 provides maintenance function for motor by supervising running hours, start numbers, trip

numbers and SOE.

When the maintenance parameter over the predefined alarm level, MC510 will trigger an alarm signal

accordingly. The operation of separate maintenance functions is independent thus these functions can

be active and given an alarm at the same time.

Number of Starts

MC510 counts number of starts. For each startup, MC510 updates the number of starts in memory

map. When start number alarm level exceeds, MC510 will issues an alarm.

Motor running time

MC510 counts motors running hours. When running hours exceeds, MC510 will issue a “running time”

alarm.

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Insertion cycles

MC510 gets the value of insertion cycles via counting control power cycles. When times of

Insertion cycles exceeds alarm level, MC510 issues an alarm.

MC510 also provides some other maintenance information of motor, which will convenience users to

get the report of motor.

Number of Trips

MC510 counts number of trips and updates in memory map.

Parameter change counters

MC510 counts times of parameter change and updates them in a memory map.

SOE

MC510 provides event recorder data for up to 256 events with time stamp.

Metering and Monitoring

MC510 provides an extensive range of motor operation supervisory functions. Supervisory data are

transmitted via MODBUS TCP to the upper level system for centralized management and also can

directly displayed on the operator panel MP51 if installed on the front of the motor starter module.

Metering and Monitoring

Power Information

Current L1,L2,L3 (A)

Current L1,L2,L3 (%)1

Current Unbalance(%)2

Thermal Capacity (%)

Power Factor

Line Voltages (V)

Frequency (Hz)

Earth Fault Current (A)

Active Power (kW)

Apparent Power (kVA)

Energy (kWh)

Time to TOL trip

Time to TOL reset

Actual Startup Time

Contactor Temperature3

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Environment Temperature3

Busbar Temperature4

PTC Resistance5

PT100/PT1000 Temperature Value5

Analog input (0-10V) 5

Analog output5

Motor status

Motor status

DI status

Diagnosis

Alarm/Trip for each function

Maintenance

Motor Running Hours

Motor Stop Time

Number of Starts

Number of trips

Number of insertion cycles

Parameter change counter

Pre Trip Phase A/B/C current

Pre Trip Earth Fault Current

SOE

Table 41 Monitoring and metering by MC510

1)Current% measured current compares with nominal current.

For expmple, Current% of L1 = IL1 / In*100%

2)Current Unbalance measured the max. difference between current and average current

with average current. The formula is :

Iave=(IL1+IL2+IL3)/3

Current Unbalance = max(IL1- Iave , IL2- Iave , IL3- Iave )/ Iave *100%

3)Need extended MT561 module.

4)Need extended MT564 module.

5)Need extended MA552 module.

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Extension modules

Max.4 extension modules are allowed to connect with MC510 basic unit. All extension modules have

the same enclosure dimension design. All extension modules are powered from the basic unit. The

type of extension modules will be automatic detected by the basic unit after they are configured in

parameter setting. The following extension modules are available:

1）DIDO modules MB550/MB551 —— DI/DO extension

2）AIAO module MA552 ¬—— AI/AO extension or motor thermal protection (PTC/PT100/PT1000)

3）Hotspots module MT561 ¬—— Contactor and Environment Temperature Supervision

4）Wireless temperature module MT564 ¬—— Bus bar Temperature Supervision

Fig 51 Max.4 extension modules with MC510 module

For more details, please refer to the document ‘Extension Module User Manual’.

The extension module connected the closest to the basic unit via IO-BUS will be identified as

extension module 1. The modules that follow behind will be identified as extension module 2,

extension module 3, and extension module 4.

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Communication

MC510 provides two 10/100Mbps Ethernet interfaces. Several protocols are supported, such as Mod-

bus/TCP, SNMP, SNTP, HTTP, TFTP and MRP etc.

Communication interface

Designation Description

Physical interface 10/100 BASE-T

Connector RJ45

Speed 10 /100Mbps

(Yellow LED of RJ45 connector lighted means

communication speed =100Mbps)

Table 42 Ethernet interface

Fig 52 RJ45 pin assignment

Pin no. Signal Description

1 TD+ Transmit +

2 TD- Transmit -

3 RD+ Receive+

4 No connection -

5 No connection -

6 RD- Receive-

7 No connection -

8 No connection -

Table 43 RJ45 pin assignment

Pin 4, 5 are internally shorted, Pin 7, 8 are internally shorted.

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MODBUS/TCP

MODBUS/TCP is MODBUS over TCP/IP protocol. It is mainly used the monitoring and control of auto-

mation.

MODBUS/TCP implemented in MC510 follows the specification below,

- Modbus application protocol V1.1b

- Modbus Messaging on TCP/IP Implementation Guide V1.0b

Refer to 1TNC928207M0201 for the MODBUS command supported by MC510.

MC510 supports 4 ODBUS/TCP master at the same time.

Modbus/TCP connection

Two-port Ethernet switches are integrated inside MC510. It makes system integration flexible and

econic. Three topologies are supported,

-Start

-Daisy chain

-Ring

Network characteristics

Designation Description

Type of cable Straight or crossed category 5 shielded twisted

pair

Maximum cable length between two adjacent devices 100 m

Maximum number of devices per network segment 160

Maximum number of devices per ring 50

Table 44 Network characteristics

The same network segment must have the same network identifier. For example,

192.168.1.x is in the same network segment, while 192.168.1.x and 192.168.2.x are not in the

same network segment.

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Topologies

Following figure illustrate the typical topology support by MC510.

Fig 53 Topology

Using ring topology in withdrawable cubicle

The drawers have the characteristics of low downtime. In the low voltage switchgear, the protection

and control equipment of a motor starter are all installed in the same drawer. When the circuit fails, the

user can replace the equipment quickly and conveniently to reduce maintenance hours. Moreover, ring

topology will ensure that replacing any one drawer will not affect the communication quality of the

whole system.

But if two drarwes are withdrawn, as shown in right part of fig 54, even if the system has MRP redun-

dancy function, the situation is totally different. Devices between these two drawers cannot be ac-

cessed anymore.

Here MS571 should be used to ensure stable communication even if two or more drawers are with-

drawn, as shown in left part of fig 54.The MS571 is mounted in the cable compartment instead of

mounted inside the drawer. When draws are withdrawn, MS571 will bypass the withdrawn drawer au-

tomatically to keep communication working in ring.

When the drawer withdraws, the network will spend less than 200ms to re-organize a new

network.

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Fig 54 Ring topology in withdrawable cubicle

No more than 5 consecutive drawers can be withdrawn in the same ring, otherwise, the

quality of communication will be affected.

Loop switch MS571

The loop switch is used for keeping the Ethernet loop healthy while the withdrawable module with

MC510 is removed. As shown in left part of fig 55, there are 4 RJ45 ports in MS571, 2 ports with MCU

mark are MCU interface to connect to MC510, 2 ports with BUS mark are BUS interface to connect in

Ethernet loop. The principle is shown as right part of fig 55, MC510 is introduced into the Ethernet

loop via MS571. When MC510 is removed, MC510 will be auto bypassed by MS571, so that the ring

Ethernet loop is still available.

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Fig 55 Loop switch MS571

The power supply of MS571 is provided from the BUS interface. As shown in fig 54, TA60

should be use for connecting the first and last MS571 to external device in one loop. Directly

connecting MS571 to external device may damage the device!

Accessary TA60

Fig 56 TA60

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The power supply of MS571 can be provided via TA60, there are 3 ports in TA60: RJ45 modular

plug, RJ45 modular jack, and two pair’s redundancy power cables. RJ45 modular plug is used to

connect to external device. RJ45 modular jack is used to connect to MS571 to provide power sup-

ply and Ethernet loop signals. Two power cables should be connected to two redundancy 24VDC

power supplies. The red core is 24VDC+ while the black core is 24VDC-. In case there is only one

power supply, both power cables should be connected to this power supply.

SD card interface

If SD card is detected during MC510 power up, below operation will be executed according to the

preset function in SDFunction.INI file, which is stored in SD card.

Function code Description File name

0x00000000 No operation

0x00000001 Upgrade MC510 boot firmrware from SD card Boot.bin

0x00000002 Upload parameter from MC510 module to SD

card

Para_upload.csv

0x00000004 Upgrade MC510 application firmrware from

SD card

User.bin

0x00000008 No operation

0x00000010 Upgrade extention module firmware of slot1

from SD card Hotspotsmeasurement.bin

/PT100.bin

/PTC.bin

/AIAO.bin

/DIDO.bin


from SD card


from SD card


from SD card

0x00000100 Upgrade operator panel firmware from MP.bin

Table 45 Function code of SD card

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—

Parameterization

MC510 can be configured with MP51 or MP52 operator panel keypad, via MCUSetup software, and

through fieldbus if the communication network is available.

Parameterization via MP51

By pressing keypad on MP51 panel, most of the parameters can be set or changed through operator

panel MP51. Details of the parameters menu structure, please refer to “MP51/MP52 Operator Panel’

Chapter.

Parameterization via MConfig Software

Via mini USB-Pin physical interface on MP51 or MP52, users can connect MC510 with computer where

MConfig software is installed and running to complete the parameters setting.

Parameterization via CHMI

All parameters of MC510 are stored in registers, and users can set parameters through CHMI (human

machine interface).

Parameterization via Fieldbus

MC510 parameters are listed in the memory map. The user can parameterize MC510 by MODBUS/TCP

refer to the “MC510 MODBUS/TCP Protocol Implementation”.

MC510 Parameters

MC510 Parameters are listed together with explanations, ranges and default values in separate docu-

ment “MC510 Parameter Description”.

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—

Accessories

MP51/MP52 Operator Panel

Overview

MC510 device provides an operator panel as optional accessory for local operating and parameters

setting to individual motor starter. There are two types of operator panels available, i.e. MP51 and

MP52. MP51 is the operator panel with control buttons, LED indicators and LCD display. MP52 is more

compact in size with control buttons and LED indicators only. Both operator panel types are equipped

with communication port (mini USB connector) in the front for remote parameterizing via engineering

station.

Operator panel is connected to main MC510 device via RJ12 interface (RS485 port) which is located on

the back of the panel.

Fig 57 MP51 Operator Panel

Fig 58 MP52 Operator Panel

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LED Indicators

There are 4 sets of LEDs available in the front of MP5x panel. All LEDs’ color are configurable. Following

table describes LEDs functions and configuration.

LEDs Configurable color Configurable functions

LED1

Power, Running, Stop, Fault, Start1, Start2, Ready to Start,

DI0, DI1, DI2, DI3, DI4, DI5, DI6, DI7, ready/fault(default, color

can’t be configured), temperature

LED2

Power, Running, Stop, Fault, Start1(default), Start2, Ready to

Start, DI0, DI1, DI2, DI3, DI4, DI5, DI6, DI7, ready/fault, tem-

perature (default)

LED3

Power, Running, Stop, Fault, Start1, Start2(default), Ready to

Start, DI0, DI1, DI2, DI3, DI4, DI5, DI6, DI7, ready/fault, tem-

perature (default)

LED4 Power, Running, Stop, Fault, Start1, Start2, Ready to Start,

DI0, DI1, DI2, DI3, DI4, DI5, DI6, DI7, ready/fault, tempera-

ture(default, color can’t be configured)

Table 46 LED configuration

LED functions Meaning of the function

Power MC510 unit is powered up and ready for operation

Running Motor is running CW/N1 or CCW/N2 or feeder is closed.

Stop Motor is stopped or feeder is open

Fault Motor is in faulty status

Start1 Motor is running CW/N1

Start2 Motor is running CCW/N2

Ready to Start Motor is ready to start, i.e. there is no active internal or external trip, motor is not

under emergency stop state (if defined) & Main Switch is ON (if defined)

DIx The status of DIx

Ready/fault LED color for ‘Ready/fault’ function can’t be configured. When motor is ready to

start, the LED turns green; When motor is in faulty status, the LED turns yellow.

Temperature LED color for ‘Temperature’ function can’t be configured. When the temperature

measured by hotspots monitor is in normal range, the LED turns green; Once the

temperature is above the alarm level or MT561 communication failure with the

Basic Unit, the LED turns yellow; once the temperature is above trip level the LED

turns red. If MC510 does not configure hotspot monitoring module MT561, LED

does not display.

Table 47 LED indicator function definition

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LED Status Explanation

On Assigned function is activated.

Wink Alarm active or device is initializing

Off Inactive or off power

Table 48 LED indicator message

i)If MP5x is under parameterization with parametering cable plugged on or scrolling

through setting menus, all LEDs in the front panel wink at the same time.

ii)Additional label of LED should be prepared, if LED is not assigned to default function.

Control Buttons

MP51 provides 7 buttons and MP52 provides 3.

Customer could control motor via buttons on MP51 and MP52. And customer can control motor, do

monitoring and parameterization via buttons on MP51.

Button Function Remark

Start 1 button, to Start motor CW/N1

Start 2 button, to Start motor CCW/N2

Stop button, to Stop motor Also used to reset fault trip

Enter button, to enter selected menu Only in MP51

Down button, to show next messages or menus Only in MP51

Up button, to show past messages or menus Only in MP51

Back button, to exit selected menu or go back one step. Only in MP51

Table 49 MP51/52 Button Icons

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Monitoring value display

After power on, MP51 initially enters Monitoring Values display stage, during which all values, alarms,

trips and control authority can be displayed here.

Fig 59 View of monitoring value display window

•Page Title: At the top of the LCD to show the tag name.

•Main display Area: Main display area to display process data.

•Test Switch: show test switch is active.

•Indication Type: At the left side of the bottom of the LCD to show the type of the indication

(Alarm/Trip).

•Indication text: Following Indication Type to show the detail alarm/trip message

•Control Authority: show control access

Icon Meaning

Alarm

Trip

Local control is active

Remote control is active

Test switch is active

01, highlighted, DI1* status is closed

02, not highlighted, DI2* status is open

Table 50 Description of icons displayed on MP51

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*) The number stands for the port of DI. Status of each DI is available on MP51.

Displaying parameters

MP51 supports up to 16 running parameter windows/pages. Users are free to choose any or all of the

parameters to be shown on MP panel and masked out unwanted information.

User can navigate through displaying pages by pressing “Up” or “Down” button.

Page No. Meaning

1 Current (A)

2 Current (%)

3 Line Voltage

4 Power Related (include Power, Apparent Power, Power factor)

5 Thermal Capacity

6 Frequency

7 Energy

8 Ground Current

9 Time to TOL Trip/Reset

10 DI Status

11 Startup Time

12 Current Unbalance

13 Extension Module 1




Table 51 Parameters on different displaying page

i)“Enter” button is NOT active when scrolling through running parameter windows.

ii) Table 51 shows the actual sequence of displaying pages on MP51.

Alarm message

Alarm message will come up on the bottom of the display window as shown in fig 59 with indication

icon whenever there is an alarm active. Possible alarm messages include the following,

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Thermal Capacity Overload Phase Failure

Phase unbalance Underload Noload

Earth Fault Undervoltage Overvoltage

Autoreclose Feedback Welded Contactor

Start limitation Communication failure Running time

Start number Watchdog Ready to trip reset

Hotspots Temperature Drawer Environment Temperature WTM CH1 Temperature

WTM CH2 Temperature WTM CH3 Temperature WTM CH4 Temperature

More detail alarm information, please refer to 1TNC928207M MC510 Modbus TCP Protocol

Implementation.

Trip message

Trip message will come up on the bottom of the display window as shown in fig 59 with indication icon

whenever there is a trip active. Possible trip messages include the following,

TOL Stalled rotor Phase Failure

Phase unbalance Underload Noload

Earth fault Undervoltage Overvoltage

Feedback Communication failure Start Limitation

Feeder Trip Long start Emergency Stop

External Trip Current Feedback Main switch off

Hotspots Temperature WTM CH1 Temperature WTM CH2 Temperature

WTM CH3 Temperature WTM CH4 Temperature

More detail trip information, please refer to 1TNC928207M MC510 Modbus TCP Protocol

Implementation.

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The Menu Tree

Press “Back" button at monitoring value display window to enter the main configuration menu

Fig 60 View of menu

Press “Back" button at the main configuration menu to enter running parameter window.

•Page Title: At the top of the LCD to show the tag name or submenu table

•Highlighted Item: The current active menu item

•Current Number: At the right of the top of the LCD to show the number of the current selected menu

item

•Total Number: At the right of the top of the LCD to show total menu item numbers in the current

page.

•Hint: At the bottom of the LCD to describe the current highlighted item or the related value of the

highlighted item.

Press Up/Down button, could move the highlight to previous/next items.

Press “Enter” button to enter next level of menu.

Press “Back” button to go back to previous level of menu.

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Fig 61 View of main configuration menu tree

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•Parameter

Within this submenu all motor related parameters can be configured.

More details about parameter, please refer to “MC510 parameter description” document.

•Operator Panel

Within this submenu LCD display and LED indication can be configured.

More details about parameter, please refer to “MC510 parameter description” document.

•Time Setting

Within this submenu actual time can be configured. Below table shows the organization of the

different parameter masks in the menu tree.

Level 1 Level 2

Time Setting Year

Month

Day

Hour

Minute

Second

Week

Table 52 Menu tree of time setting

•Maintenance

Within this submenu all motor related maintenance can be configured. Below table shows the

organization of the different parameter masks in the menu tree.

Level 1 Level 2

Maintenance SOE

Running Time

Stop Time

Start Number

Stop Number

Trip Number

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Last Trip Current (%)

Last Trip Current (A)

Last Earth Fault Trip Current

Insertion cycle counters

Parameter change counters

Table 53 Menu tree of maintenance

•Product Info.

Within this submenu, information of MC510 and MP51 can be read. Below table shows the organization

of the different parameter masks in the menu tree.

Level 1 Level 2

Maintenance MC510 Firmware version

MP51 Firmware version

IP Address

Subnet Mask

Gateway Address

Type of Extension Module 1

Firmware Version of Extension Module 1







Table 54 Menu tree of product info

•Backup & Download

“Backup” feature is to read the parameters from MC510 device and create a backup file in MP panel.

“Download’ feature is to download the backup file from MP panel to MC510 device.

This feature can be quite useful when similar parameters are required for several MC510 devices. It is

easy to operate on site.

Table 57 shows the organization of the different parameter masks in the menu tree.

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Level 1 Level 2

Backup & download Backup Parameter

Download Default Parameter

Download Backup1

Table 55 Menu tree of backup & download

1)Download Backup' option will not be available until the 'Backup Parameter' function has

been executed.

2)Remember to change slave address after copying parameters from other device to avoid

communication problem.

Backup Parameter: save current parameter to backup register in MP51.

Download Backup: download the parameter in backup register into MC510

•Test

Select this submenu, MC510 will test itself for a few seconds and feedback.

Test function is only for manufactory.

Adjusting Parameters

Select the item at the last level of Parameter and press enter, a window for password input will appear.

Input the correct password to enter the parameter adjusting window.

Fig 62 Process of enter parameter adjusting window

1)Default password is 1111.

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It is recommended to change the default password after first login.

There are two types of parameter adjusting window: Numerical Value adjusting window

and Option Selecting window.

When finish, press “Back" button to confirm window. Then select confirm and press enter to download

new parameter to MC510.

Fig 63 Process of confirm parameter adjusting

The slave address could be revised and downloaded to MC510 via MP51.

•Adjusting a Numerical Value

This type of window allows a numerical value to be specified within the given limits. Press up/down

button will increase/decrease the digit. Once the value is set, press “enter” button to acknowledge it.

i)The information of given limits of parameters is provided in ‘MC510 parameter

description’ document.

ii) Keep pressing up/down button will changing the speed of increase/decrease the digits.

iii)When the value reaches the limit, it will automatically count backwards even if the same

button is pressed.

The following example shows how to set the startup time to 10s.

Fig 64 Example of numerical value adjusting

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Start editing the value by pressing the “Up” button. If reach 10, press enter button.

•Selecting an Option from a List

This type of window allows an item to be selected from a given list of options. With the up/down keys

you can scroll through the list. The highlighted selection shows current position within the list.

Pressing “Enter” button to confirm and then press ‘Back’ button to exit.

Pressing ‘Back’ button exits the dialog and discards the selection.

i)The details of given options of parameter are available in ‘MC510 parameter description’

document.

The following example shows how to set the starter type to NR_2N Dahlander

Fig 65 Example of options selecting

Parameterization port

The parameterization port on MP5x panel is a mini USB type of interface. Once this port is connected

with parametering cable, the communication between MC510 main device and MP5x panel is

temporarily stopped with a ‘parameterizing’ status message shown on LCD. No operation is allowed

during parameterizing.

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Fig 66 Parameterizing message

MC510 parameters can be uploaded and downloaded from the parameterization device via the

interface.

Rememer to cover up the mini USB port after parameterization finished.

Connection

Operator panel is connected to the terminal on MC510 via RJ12 interface. The connection shown below

includes power supply and communication.

Fig 67 Connection between MC510 and MP5x

If MP51 can’t get information from MC510, “No Comm.” will be shown in LCD the window.

Fig 68 No Communication message

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If MP51 does not get correct information from MC510, “Comm. Error” will be shown in LCD the window.

Fig 69 Communication error message

Parameterization Software: MConfig

MConfig software is used to set parameter. It exchanges data with MC510 via RS485.

Fig 70 Parameterization interface

Fig 71 MConfig window

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The parameterization software available with following function:

•Edit parameters

•Export parameter to a file

•Import parameter from a file

•Update MC510’s parameters

•Download MC510’s parameters

•Read MC510’s parameters

•User management

The parameterization software can run on all of the following PC operation system:

Windows 2000, Windows XP, Win 7 and Win 8.

For more information on how to do the parameter setting through MConfig software,

please refer to separate document “MConfig User Guide“

APPENDI A TECHNICA L DATA

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—

Appendi A Technical Data

A.1 Common Technical Data

Environmental conditions

Installation DIN rail, or M4 screwing mounting

Storage -40 ~ +85℃

Operation -10 ~ +60℃

Humidity 15% up to 95% without dew

Degree of protection IP20

Derating accepted operating altitude 4500m

Without derating operating altitude 2000m

EMC Environment 1) Equipments in the system comply with EMC requirement of

CE / CCC certificate.

2) Power supply system complies with IEC61000-2-1,

IEC61000-2-2, especially the system in which VSD / Frequency

Converters are used.

EMC Standards

Electrostatic discharge IEC61000-4-2 Level 3

Electromagnetic field immunity IEC61000-4-3 Level 3

Electrical fast transient/burst immunity IEC61000-4-4

Power supply, Level 4

Others, Level 3

Surge immunity IEC61000-4-5 Level 3

Conducted disturbance immunity IEC61000-4-6 Level 3

Radiated disturbance EN55011/CISPR 11, Class A

A.2 Technical Data of the Basic Unit MC510

Low voltage switchgears

IEC60947-1 Low voltage switchgear and controlgear” Part1: General rules

IEC60947-4-1 Low voltage switchgear and controlgear” Part4: Contactors

and motor-starters, Section one-Electromechanical

contactors and motor-starters


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Main circuit

Rated operation voltage (Ue) up to 400/690VAC

Rated insulation voltage (Ui) 800VAC

Rated impulse withstand voltage (Uimp) 8KV, overvoltage category III

Degree of pollution 3

Rated operation current (Ie) 0.24-63A

Trip rating 115% of TFLC

Rated frequency 50/60Hz

Control circuit

Rated operational voltage (Ue) 24V DC ,110 or 240 VAC

Rated insulation voltage (Ui) 250VAC

Rate impulse withstand voltage (Uimp) 4kV for AC circuit

Rated operational current (Ie)

relay output 2A /24VDC(DC-13)

4A/120VAC(AC-15)

2A/240VAC(AC-15)

Rated frequency 50/60Hz

Response timing accuracy

TOL protection ±5% of tripping time (I≤3Ie)

±20% of tripping time (I>3Ie)

Stall protection 200 ~ 350ms


Others

-30 ~ +30ms

0 ~ 150ms

Power supply

Rated operational voltage (Ue) 24VDC , 110 or 240VAC

Voltage operation range 85%-110% Ue

Power consumption

24VDC 110VAC 240VAC

Typical 3W 6VA 16VA

Maximum starting current 600mA


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Digital input(DC)

Number of digital input 8 with one common connection

Logic 1 15…30V

Logic0 0…5V

Digital input (AC)

Number of digital input 8 with one common connection

Logic 1 110VAC type, 79…110V

240VAC type, 164…240V

Logic0 110VAC type, 0…20V

240VAC type, 0…40V

Communication interface

Protocol Modbus/TCP

Baud-rate 10/100M bps

Installation

Mounting DIN rail: On TS35 DIN

Screw: with 3 rolling screws M4 (max. tightening torque

2Nm)

Dimension 123mm(W) X 121mm(H) X 72mm(D)

Terminal wiring size 0.2…2.5mm2

Terminal tightening torque M3 /0.5…0.6Nm

Metering accuracy

Phase current Range: 0.4-8 ×phase CT primary amps

Accuracy: ±2% or ±0.01A, whichever is greater

Earth fault current Measurement:

Full scale: 1.2 × RCT nominal current

Accuracy: ±2% RCT primary

Internal Calculation:

Full scale: 2 × In

Accuracy: ±2% In

Line voltage Voltage metering range: 110V - 690V

Accuracy: ±2%

Power Accuracy: ±5% or ±0.1kW, whichever is greater


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A.3 Technical Data of the Operation panel MP51/52

Installation Front panel or door installation

Degree of protection IP54 from front

LEDs 4, function and color configurable

Buttons MP51: 7

MP52: 3

A.4 Technical Data of the Loop Switch MS571

Installation DIN rail

Max. continuous bypass number 5

Power supply 24VDC, through TA60

Power consumption 0.1W

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