Danfoss Vlt aqua Bedienungsanleitung

MAKING MODERN LIVING POSSIBLE

VVLTpAQUA Drive

Cascade Controller Options MCO 101/102

Operating Instructions

www.danfoss.com/drives

*MI38C402*

130R0345 MI38C402 Rev. 2012-08-21

Safety

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when

connected to AC mains input power. Qualified personnel

only should perform installation, start up, and

maintenance. Failure to perform installation, start up,

and maintenance by qualified personnel could result in

death or serious injury.

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains,

the motor may start at any time. The frequency

converter, motor, and any driven equipment must be in

operational readiness. Failure to be in operational

readiness when the frequency converter is connected to

AC mains could result in death, serious injury,

equipment, or property damage.

WARNING

DISCHARGE TIME

Frequency converters contain DC-link capacitors that can

remain charged even when the frequency converter is

not powered. To avoid electrical hazards, disconnect AC

mains, any permanent magnet type motors, and any

remote DC-link power supplies, including battery back-

ups, UPS, and DC-link connections to other frequency

converters. Wait for the capacitors to fully discharge

before performing any service or repair work. The

amount of wait time is listed in the Discharge Time table.

Failure to wait the specified time after power has been

removed before doing service or repair could result in

death or serious injury.

Voltage

[V]

Minimum Waiting Time (Minutes)

4 15 20 30 40

200-240 0.25-3.7

5.5-45 kW

380-480 0.37-7.5

11-90 kW 110-250

315-1000

525-600 0.75-7.5

11-90 kW

525-690 11-37 kW 45-400

450-1200

1400 kW

High voltage may be present even when the warning

LED display lights are off.

Discharge Time

Symbols

The following symbols are used in this manual.

WARNING

Indicates a potentially hazardous situation which could

result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which can

result in minor or moderate injury. It can also be used to

alert against unsafe practices.

CAUTION

Indicates a situation that could result in equipment or

property-damage-only accidents.

NOTICE

Indicates highlighted information to regard with

attention to avoid mistakes or operate equipment at less

than optimal performance.

Approvals

NOTICE

The T7 (525-690 V) frequency converters are not certified

for UL.

Safety VLT®AQUA Drive MCO 101/MCO 102

MI38C402 - VLT®is a registered Danfoss trademark

Safety VLT®AQUA Drive MCO 101/MCO 102

MI38C402 - VLT®is a registered Danfoss trademark

Contents

1 Introduction 3

1.1 Purpose of these Operating Instructions 3

1.1.1 Software Version 3

2 Application Types 5

2.1 Overview 5

2.2 Supported Configurations 5

2.2.1 Extension of Basic Cascade - Parameter Group 25** Control Mode 5

2.2.2 Master-Follower Configuration 7

2.2.3 Mixed Pump Configuration 8

2.2.3.1 Unequal Size Pump Configuration 8

2.2.3.2 Mixed Pump Configuration with Alternation 9

2.2.4 Using Soft Starters for Fixed Speed Pumps 10

2.3 Sleep Mode 10

2.3.1 Basic Cascade Controller 11

2.3.2 Master/Follower and Mixed Pump Configurations 11

3 Installation 12

3.1 Mechanical and Electrical Installation 12

3.1.1 Before Start 12

3.1.2 Extended Cascade Controller

MCO 101 12

3.1.3 Advanced Cascade Controller

MCO 102 14

4 Configuring the System 16

4.1 Configuring the Extended and Advanced Cascade Controller 16

4.1.1 Setting-up the Cascade Parameters 16

4.1.2 Configuration of Multiple Frequency Converters 16

4.1.3 Closed Loop Control 17

4.1.4 Staging/De-staging of Variable Speed Pumps 17

4.1.5 Staging/De-staging of Fixed Speed Pumps 17

4.2 Operation 18

4.2.1 Pump Status and Control 18

4.2.2 Manual Pump Control 18

4.2.3 Runtime Balancing 19

4.2.4 Pump Spin for Unused Pumps 19

4.2.5 Total Lifetime Hours 19

4.2.6 Alternation of the Lead Pump 19

4.2.7 Staging/De-staging in Mixed Pump Configurations 20

4.2.8 Override Staging/De-staging 20

Contents VLT®AQUA Drive MCO 101/MCO 102

MI38C402 - VLT®is a registered Danfoss trademark 1

4.2.9 Minimum Speed De-staging 20

4.2.10 Fixed Speed only Operation 20

4.2.11 Flow Compensation for Applications with Cascade Controller 21

5 Parameter Descriptions 22

5.1 Cascade Controller Parameters 22

5.1.1 Cascade CTL Option, 27-** 24

5.1.3 Control & Status, 27-0* 25

5.1.4 Configuration, 27-1* 26

5.1.5 Bandwidth Settings, 27-2* 26

5.1.6 Staging Speed, 27-3* 28

5.1.7 Staging Settings, 27-4* 29

5.1.8 Alternation Settings, 27-5* 30

5.1.9 Digital Inputs, 27-6* 31

5.1.10 Connections, 27-7* 35

5.1.11 Readouts, 27-9* 36

5.2 Parameter Lists 37

5.2.1 25-** Cascade Controller 37

5.2.2 27-** Cascade CTL Option 38

6 Configuration Examples 41

6.1 Master/Follower 41

6.1.1 Basic Settings 41

6.1.2 Master Drive Settings 41

6.1.3 Follower Drive Settings 42

Index 43

Contents VLT®AQUA Drive MCO 101/MCO 102

2 MI38C402 - VLT®is a registered Danfoss trademark

1 Introduction

1.1 Purpose of these Operating Instructions

The purpose of these operating instructions is to describe

the Danfoss Cascade Controller Options MCO 101 and

MCO 102.

The operating instructions contain information about:

•Application types

•Installation

•Configuring the system

•Parameters

•Configuration examples

These operating instructions are intended for use by

qualified personnel. Read these operating instructions in

full in order to use the Cascade Controller Options safely

and professionally and pay particular attention to the

safety instructions and general warnings.

1.1.1 Software Version

Extended Cascade Controller Option for

VLT®AQUA Drive

Software version: 1.9x

Table 1.1 Software Version

NOTICE

MCO 101/102 is software supported from version 1.24

onwards.

1.1.2 Cascade Control

The Cascade Controller consists of an option board

containing 3 relays that is installed in option slot B. Once

options are installed the parameters needed to support the

Cascade Controller functions will be available through the

control panel in parameter group 27-**.

MCO 101 and 102 are add-on options extending the

supported number of pumps and the functionalities of the

built-in Cascade Controller in the VLT®AQUA Drive.

The following options for cascade control are available for

the VLT®AQUA Drive:

•Built-in Basic Cascade Controller (standard

Cascade Controller)

•MCO 101 (Extended Cascade Controller)

•MCO 102 (Advanced Cascade Controller)

For further information, see 2 Application Types.

The Extended Cascade Controller can be used in two

different modes:

•with the extended features controlled by

parameter group 27-**

•to extend the number of available relays for the

Basic cascade controlled by parameter

group 25-**

With MCO 101, a total of 5 relays can be used for cascade

control and with MCO 102, a total of 8 pumps can be

controlled. The options are able to alternate the lead

pump with 2 relays per pump.

NOTICE

If MCO 102 is installed, the relay option MCB 105 can

extend the number of relays to 13.

Application

Cascade control is a common control system used to

control parallel pumps or fans in an energy efficient way.

The Cascade Controller option enables control of multiple

pumps configured in parallel by:

•Automatically turning individual pumps on/off

•Controlling the speed of the pumps

When using Cascade Controllers, the individual pumps are

automatically turned on (staged) and turned off (de-

staged) as needed in order to satisfy the required system

output for flow or pressure. The speed of pumps

connected to the VLT®AQUA Drive is also controlled to

provide a continuous range of system output.

Designated use

The Cascade Controller options are designed for pump

applications, however, it is also possible to use Cascade

Controllers in any application requiring multiple motors

configured in parallel.

Operating principle

The Cascade Controller software runs from a single

frequency converter with Cascade Controller option

(master drive). It controls a set of pumps, each controlled

Introduction VLT®AQUA Drive MCO 101/MCO 102

MI38C402 - VLT®is a registered Danfoss trademark 3

by a frequency converter or connected to a contactor or a

soft starter.

Additional frequency converters in the system (follower

drives) do not need any Cascade Controller option card.

They are operated in open loop mode and receive their

speed reference from the master drive. Pumps connected

to follower drives are referred to as variable speed pumps.

Pumps connected to mains through a contactor or

through a soft starter are referred to as fixed speed

pumps.

Each pump, variable speed or fixed speed, is controlled by

a relay in the master drive.

The Cascade Controller options can control a mix of

variable speed and fixed speed pumps.

Other resources are available to understand advanced

functions and programming.

•The VLT

AutomationDrive FC 302Operating

Instructions provide details on installation and

operation of the frequency converter.

•The VLT

AutomationDrive FC 302 Programming

Guide provides greater detail on working with

parameters and many application examples.

•The VLT

AutomationDrive FC 302 Design Guide

provides detailed capabilities and functionality to

design motor control systems.

•Supplemental publications and manuals are

available from Danfoss.

See www.danfoss.com/BusinessAreas/DrivesSo-

lutions/Documentations/Technical

+Documentation.htm for listings.

•Optional equipment may change some of the

procedures described. Reference the instructions

supplied with those options for specific

requirements. Contact the local Danfoss supplier

or visit the Danfoss website: www.danfoss.com/

BusinessAreas/DrivesSolutions/Documentations/

Technical+Documentation.htm, for downloads or

additional information.

Introduction VLT®AQUA Drive MCO 101/MCO 102

4 MI38C402 - VLT®is a registered Danfoss trademark

2 Application Types

2.1 Overview

100% 100% 200% 200%

130BA594.12

Relay 1

Relay 2

Relay 10

Built-

1 VSP + 2 FSP

parameter group 25-** Cascade

Controller

- -

MCO

101

1 VSP + 5 FSP

parameter group 25-** Cascade

Controller

1 to 6 VSP + 1 to 5 FSP

(max. 6 pumps)

parameter group 27-** Cascade

CTL Option

6 VSP

parameter group 27-** Cascade

CTL Option

MCO

102

1 VSP + 8 FSP

parameter group 25-** Cascade

Controller

1 to 8 VSP + 1 to 7 FSP

(max. 8 pumps)

parameter group 27-** Cascade

CTL Option

8 VSP

parameter group 27-** Cascade

CTL Option

Table 2.1 Application Overview

VSP = Variable Speed Pump (directly connected to the frequency

converter)

FSP = Fixed Speed Pump (the motor could be connected via

contactor, soft starter or star/delta starter)

2.2 Supported Configurations

When setting-up the system, create a hardware configu-

ration, which communicates the number of connected

pumps and frequency converters to the master. The

necessary hardware is explained in the following hardware

configuration examples.

2.2.1 Extension of Basic Cascade -

Parameter Group 25** Control Mode

Use of the extended cascade option MCO 101 as an

extension of the built-in basic cascade in the frequency

converter

In applications already controlled by the built-in Cascade

Controller in parameter group 25-**, the option card can

be used to extend the numbers of relays for cascade

control. For instance if a new pump is added to the

system.

Enable the Basic Cascade Controller in 27-10 Cascade

Controller by selecting [3] Basic Cascade Ctrl. Refer to VLT

AQUA Drive Programming Guide for further programming

with parameter group 25-** settings.

Illustration 2.1 and Illustration 2.2 show the external wiring

needed for systems with alternating lead pump of 4

pumps using basic cascade and MCO 101 as relay

extension.

Application Types VLT®AQUA Drive MCO 101/MCO 102

MI38C402 - VLT®is a registered Danfoss trademark 5

Illustration 2.1 Control Circuit Alternating Lead Pump (4 Pumps)

Illustration 2.2 Mains Circuit Alternating Lead Pump (4 Pumps)

The fixed speed pump configuration provides a cost

effective method for controlling up to 9 pumps. It is able

to control system output by controlling the number of

running pumps as well as the speed of the single variable

speed pump.

In this configuration the VLT®AQUA Drive controls one

variable speed pump and up to 8 fixed speed pumps. The

fixed speed pumps are staged and de-staged as needed

through contactors direct online. The variable speed pump

provides the finer level of control needed between the

stages.

The direct online pumps are staged or de-staged

depending on the feedback.

130BA592.12

Illustration 2.3 Fixed Speed Pump Configuration Example

Application Types VLT®AQUA Drive MCO 101/MCO 102

6 MI38C402 - VLT®is a registered Danfoss trademark

NOTICE

If the pumps are not equal in size or if 2 relays per

pump are used, a Mixed Pump Configuration has to be

chosen.

For the configuration shown in Illustration 2.3, relay

selections in parameter group 27-7* Connections are as

follows

27-70.0 RELAY 1→[73] Pump 2 to Mains

27-70.1 RELAY 2 →[74] Pump 3 to Mains

27-70.9 RELAY 10 →[75] Pump 4 to Mains

27-70.10 RELAY 11→[0] Standard Relay

27-70.11 RELAY 12→[0] Standard Relay

NOTICE

Pressure fluctuations during staging/de-staging

transitions may occur and it may be less energy efficient

than the master-follower configurations.

2.2.2 Master-Follower Configuration

The master-follower cascade control mode offers the best

performance, the most precise control and maximum

energy savings. It controls multiple equal sized pumps in

parallel, running all pumps at the same speed and stages

the pumps on and off according to system requirements.

Compared to traditional cascade control the number of

running pumps is controlled by speed instead of feedback.

To obtain the highest energy saving the stage on and off

speed must be set correctly according to the system. In

this example terminal 27 of the master drive is used as

pulse output for the reference and the terminals 29 of the

follower drives are used as pulse input for this reference.

While the master drive is running in closed loop, the

followers are running in open loop. All follower drives are

connected to mains and motor in the same way as the

master drive.

Motor / Pump 1Motor / Pump 2 Motor / Pump 3

Master

with

MCO 101/ 102 Follower 1 Follower 2

DI 18

DI 18 DI 29 DI 29

DO 27

R 1

R 2

100% 100%

100%

PU / I

T 54

T 55 T 20

Pressure

Transmitter

0 - 10 V

0 - 20 mA or

4 - 20 mA

T 12

DI18

Start

130BD072.10

Illustration 2.4 Basic Wiring Principle (Example)

Application Types VLT®AQUA Drive MCO 101/MCO 102

MI38C402 - VLT®is a registered Danfoss trademark 7

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