Danfoss VLT series Manuel utilisateur

Contents

1 Extended and Advanced Cascade Controller Option

How to read these Operating Instructions 3

High Voltage Warning 3

Safety Instructions 3

Avoid unintended Start 3

Software Version 3

Symbols 4

Safety 4

Caution 5

Introduction to MCO 101 and 102 5

Extended Cascade Controller MCO 101 7

Advanced Cascade Controller MCO 102 8

Supported Configurations 10

Extension of Basic Cascade - Parameter group 25** control mode 11

Fixed Speed Pump Configuration 12

Master-Follower Configuration 13

Mixed Pump Configuration 14

Unequal Size Pump Configuration 15

Mixed Pump Configuration with Alternation 17

Soft Starters 18

Configuring the System 18

Setting-up the cascade parameters 18

Additional configuration for Multiple Drives 19

Closed Loop Control 20

Staging / De-staging of variable speed pumps based on Drive Speed 20

Staging / De-staging of fixed speed pumps based on Pressure Feedback 21

Control 21

Cascade Controller Features 21

Pump Status and Control 21

Manual Pump Control 22

Runtime Balancing 22

Pump Spin for unused pumps 23

Total lifetime hours 23

Alternation of the Lead Pump 23

Staging / Destaging in Mixed Pump Configurations 23

Override Staging /Destaging 24

Minimum Speed Destaging 24

Fixed speed only operation 24

Cascade Controller Parameters 25

VLT

Operating Instructions Contents

MI.38.C3.02 - VLT®is a registered Danfoss trademark

Cascade CTL Option, 27-** 25

Control & Status, 27-0* 25

Configuration, 27-1* 26

Bandwidth Settings, 27-2* 27

Staging Speed, 27-3* 30

Staging Settings, 27-4* 31

Alternation Settings, 27-5* 33

Connections, 27-7* 34

Readouts, 27-9* 35

Master/Follower Application Note 38

Index

Contents VLT

Operating Instructions

MI.38.C3.02 - VLT®is a registered Danfoss trademark

1 Extended and Advanced Cascade Controller Option

1.1 How to read these Operating Instructions

1.1.1 High Voltage Warning

The voltage of the frequency converter and the MCO 101 option card is dangerous whenever it is connected to mains. Incorrect

installation of the motor or frequency converter may cause damage to the equipment, serious injury or death. Consequently, it is

essential to comply with the instructions in this manual as well as local and national rules and safety regulations.

1.1.2 Safety Instructions

Prior to using functions directly or indirectly influencing personal safety (e.g. Safe Stop or other functions either forcing the motor to

stop or attempting to keep it functioning) a thorough risk analysis and system test must be carried through. The system tests

must include testing failure modes regarding the control signalling (analog and digital signals and serial communication.

• Make sure the frequency converter is properly connected to earth.

• Do not remove mains connections, motor connections or other power connections while the frequency converter is connected to power.

• Protect users against supply voltage.

• Protect the motor against overloading according to national and local regulations.

• The earth leakage current exceeds 3.5 mA.

• The [OFF] key is not a safety switch. It does not disconnect the frequency converter from mains.

1.1.3 Avoid unintended Start

While the frequency converter is connected to mains, the motor can be started/stopped using digital commands, bus commands, references or via the

Local Control Panel.

• Disconnect the frequency converter and the MCO 101 option card from mains whenever personal safety considerations make it necessary to

avoid unintended start of any motors.

• To avoid unintended start, always activate the [OFF] key before changing parameters.

1.1.4 Software Version

Extended Cascade Controller Option for

VLT AQUA Drive FC 200

Operating Instructions

Software version: 1.33

These Operating Instructions can be used with all Extended Cascade Controller options with software version 1.33.

VLT

Operating Instructions 1 Extended and Advanced Cascade Controller

Option

MI.38.C3.02 - VLT®is a registered Danfoss trademark

NB!

MCO 101/102 is software supported from version 1.24 onwards.

1.1.5 Symbols

When reading through this Operating Instructions, you will come across various symbols that require special attention.

The symbols used are the following:

Indicates a general warning.

NB!

Indicates something to be noted by the reader.

Indicates a high-voltage warning.

1.2 Safety and Caution

1.2.1 Safety

Rotating shafts and electrical equipment can be hazardous. Therefore, it is strongly recommended that all electrical work conform to

National Electrical Code (NEC) and all local regulations. Installation, start-up and maintenance should be performed only by qualified

personnel.

Factory recommended procedures, included in this manual, should be followed. Always disconnect electrical power before working on the unit. Although

shaft couplings or belt drives are generally not furnished by the manufacturer, rotating shafts, couplings and belts must be protected with securely

mounted metal guards that are of sufficient thickness to provide protection against flying particles such as keys, bolts and coupling parts. Even when the

motor is stopped, it should be considered “alive” as long as its controller is energized. Automatic circuits may start the motor at any time. Keep hands

away from the output shaft until the motor has completely stopped and power is disconnected from the controller.

Motor control equipment and electronic controls are connected to hazardous line voltages. When servicing drives and electronic controls, there will be

exposed components at or above line potential. Extreme care should be taken to protect against shock. Stand on an insulating pad and make it a habit

to use only one hand when checking components. Always work with another person in case of an emergency. Disconnect power whenever possible to

check controls or to perform maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electric control or rotating

equipment.

Safety Guidelines

1. The drive must be disconnected from the AC line before any service work is done.

2. The “Stop/Off” key on the of the drive does not disconnect the equipment from the AC line and is not to be used as a safety switch.

3. Correct protective grounding of the equipment must be established. The user must be protected against supply voltage and the motor must be

protected against overload in accordance with applicable national and local regulations.

4. Ground currents are higher than 3 mA.

1 Extended and Advanced Cascade Controller

Option VLT

Operating Instructions

MI.38.C3.02 - VLT®is a registered Danfoss trademark

Warning against Unintended Start

1. While the drive is connected to the AC line, the motor can be brought to a stop by means of external switch closures, serial bus commands or

references. If personal safety considerations make it necessary to ensure that no unintended start occurs, these stops are not sufficient.

2. During programming of parameters, the motor may start. Be certain that no one is in the area of the motor or driven equipment when changing

parameters.

3. A motor that has been stopped may start unexpectedly if faults occur in the electronics of the drive, or if an overload, a fault in the supply AC

line or a fault in the motor connection or other fault clears.

4. If the “Local/Hand” key is activated, the motor can only be brought to a stop by means of the “Stop/Off” key or an external safety interlock

NB!

It is responsibility of user or person installing drive to provide proper grounding and branch circuit protection for incoming power and

motor overload according to National Electrical Code (NEC) and local codes.

The Electronic Thermal Relay (ETR) in UL listed VLTs provides Class 20 motor overload protection in accordance with NEC in single motor applications,

when par. is set for ETR TRIP 1, ETR TRIP 2, ETR TRIP 3, or ETR TRIP 4, and par. is set for rated motor (nameplate) current.

1.2.2 Caution

The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard,

disconnect the frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on

the frequency converter:

Voltage (V) Min. Waiting Time (Minutes)

415 20 30 40

200 - 240 0.25 - 3.7 kW 5.5 - 45 kW

380 - 480 0.37 - 7.5 kW 11 - 90 kW 110 - 250 kW 315 - 1000 kW

525-600 0.75 kW - 7.5 kW 11 - 90 kW 315 - 1200 kW

525-690 11 - 90 kW 45 - 400 kW 450 - 1200 kW

Be aware that there may be high voltage on the DC link even when the LEDs are turned off.

1.3 Introduction to MCO 101 and 102

MCO 101 and 102 are add-on options extending the supported number of pumps and the functionalities of the in-built cascade controller in the VLT®

AQUA Drive.

The extended cascade controller can be used in two different modes.

It can either be used with the extended features controlled by parameter group 27** or it can be used to extend the number of available relays for the

Basic cascade controlled by parameter group 25**.

When one of the cascade options are installed only group 27** will appear. In case the option is supposed to extend the relays in the in-built cascade

controller group 25**, the basic cascade can be enabled in par. 27-10, where after group 25** will be visible in the main menu again. If par. 27-10 is

set to Basic Cascade only, the basic cascade functionality will be available, only extended with 3 relays to a total of 5 relays.

When using group 27** Extended / Advanced Cascade Control, the systems with pump alternation can be set-up with 2 relays per pump, which reduces

the need for external equipment.

With MCO 101, a total of 5 relays can be used for cascade and with MCO 102, a total of 8 pumps can be controlled.

VLT

Operating Instructions 1 Extended and Advanced Cascade Controller

Option

MI.38.C3.02 - VLT®is a registered Danfoss trademark

NB!

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 provides the capability to control multiple pumps configured in parallel in a way that makes them appear as a single larger

pump.

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 VLT AQUA Drives is also controlled to provide a continuous range of

system output.

Illustration 1.1: Cascade control of multiple pumps

The Cascade Controllers are optional hardware and software components that can be added to the VLT AQUA Drive. It consists of an option board

containing 3 relays that is installed in the B option location on the Drive. Once options are installed the parameters needed to support the Cascade

Controller functions will be available through the control panel in the 27-** parameter group. The Extended Cascade Controller offers more functionality

than the Basic Cascade Controller. It can be used to extend the Basic Cascade with 3 relays and even to 8 relays with the Advanced Cascade Control card

installed.

While the Cascade controller is designed for pumping applications and this document describes the cascade controller for this application, it is also possible

to use the Cascade Controllers for any application requiring multiple motors configured in parallel.

Master/Follower Operation

The Cascade Controller software runs from a single VLT AQUA Drive with the Cascade Controller option card installed. This frequency converter is referred

to as the Master Drive. It controls a set of pumps each controlled by a frequency converter or connected directly to mains through a contactor or through

a soft starter.

Each additional frequency converter in the system is referred to as a Follower Drive. These frequency converters do not need the Cascade Controller

option card installed. They are operated in open loop mode and receive their speed reference from the Master Drive. The pumps connected to these

frequency converters are referred to as Variable Speed Pumps.

Each additional pump connected to mains through a contactor or through a soft starter is referred to as a Fixed Speed Pump.

Each pump, variable speed or fixed speed, is controlled by a relay in the Master Drive. The frequency converter with the Cascade Controller option card

installed has five relays available for controlling pumps. Two (2) relays are standard in the FC and additional 3 relays are found on the option card MCO

101 or 8 relays and 7 digital inputs on option card MCO 102.

1 Extended and Advanced Cascade Controller

Option VLT

Operating Instructions

MI.38.C3.02 - VLT®is a registered Danfoss trademark

The difference between MCO 101 and MCO 102 is mainly the number of optional relays being made available for the FC. When MCO 102 is installed, the

relays option card MCB 105 may be mounted in the B-slot.

The Cascade Controller is capable of controlling a mix of variable speed and fixed speed pumps. Possible configurations are described in more detail in

the next section. For simplicity of description within this manual, Pressure and Flow will be used to describe the variable output of the set of pumps

controlled by the cascade controller.

1.3.1 Extended Cascade Controller MCO 101

The MCO 101 option includes 3 pieces of change-over contacts and can be fitted into option slot B.

Electrical Data:

Max terminal load (AC) 240 V AC 2A

Max terminal load (DC) 24 V DC 1 A

Min terminal load (DC) 5 V 10 mA

Max switching rate at rated load/min load 6 min-1/20 sec-1

Illustration 1.2: Mounting of B-options

Warning Dual supply

NB!

The label MUST be placed on the LCP frame as shown (UL approved).

How to add the MCO 101 option:

• The power to the frequency converter must be disconnected.

• The power to the live part connections on relay terminals must be disconnected.

• Remove the LCP, the terminal cover and the cradle from the FC 202.

• Fit the MCO 101 option in slot B.

VLT

Operating Instructions 1 Extended and Advanced Cascade Controller

Option

MI.38.C3.02 - VLT®is a registered Danfoss trademark

• Connect the control cables and relief the cables by the enclosed cable strips.

• Various systems must not be mixed.

• Fit the extended cradle and terminal cover.

•ReplacetheLCP

• Connect power to the frequency converter.

Wiring the Terminals

Do not combine low voltage parts and PELV systems.

1.3.2 Advanced Cascade Controller MCO 102

The MCO 102 option supports a maximum of 8 pumps and is able to alternate the lead pump with 2 frequency converter relays per pump. This reduces

the need for external auxiliary switches as well as cost of installation.

When MCO 102 (C-option) is used, the number of relays can be increased to a total of 13 by adding the MCB 105 (B-option).

NB!

Before start, interrupt the power supply to the frequency converter. Never install an option card into the frequency converter during

operation.

Electrical Data:

Max terminal load (AC) 240 V AC 2A

Max terminal load (DC) 24 V DC 1 A

Min terminal load (DC) 5 V 10 mA

Max switching rate at rated load/min load 6 min-1/20 sec-1

1 Extended and Advanced Cascade Controller

Option VLT

Operating Instructions

MI.38.C3.02 - VLT®is a registered Danfoss trademark

Illustration 1.3: Enclosure A2, A3 (and B3) 40 mm (only one C option).

Illustration 1.4: Enclosures B (except B3) and C.

VLT

Operating Instructions 1 Extended and Advanced Cascade Controller

Option

MI.38.C3.02 - VLT®is a registered Danfoss trademark

How to add the MCO 102 option:

• The power to the frequency converter must be disconnected.

• The power to the live part connections on relay terminals must be disconnected.

• Remove the LCP, the terminal cover and the cradle from the FC 202.

• Fit the MCO 102 option in slot B.

• Connect the control cables and relief the cables by the enclosed cable strips.

• Various systems must not be mixed.

• Fit the extended cradle and terminal cover.

•ReplacetheLCP

• Connect power to the frequency converter.

The VLT Advanced Cascade Control Card MCO 102 option is exclusively intended for use in option slot C1. The mounting position of C1 options is shown

in the drawing below.

Wiring the Terminals:

8 relays 7 digital inputs

Table 1.1: Advanced Cascade Controller MCO 102 terminal connections

Some items are needed for the installation of a C-option mounting kit (depending on the enclosure):

Type Description Ordering number

Options:

MCF 105 Mounting Kit frame size A2 and A3 (40mm for one C

Option) 130B7530

MCF 105 Mounting Kit Frame size A5 130B7532

MCF 105 Mounting Kit Frame size B,C,D,E ,F1 and F3 (Except B3) 130B7533

MCF 105 Mounting Kit frame size B3 (40mm for one C Option) 130B1413

Accessory Bag:

MCO 102 Accessory Bag 130B0152

1.4 Supported Configurations

The Extended- and Advanced Cascade Controller support a variety of different pump and Drive configurations. All of these configurations must have at

least one variable speed pump, controlled by a VLT AQUA Drive, with the Extended- and Advanced Cascade Controller option card installed. They support

from 1 to 8 additional pumps each connected to either a Danfoss VLT Drive with Master / Follower or to mains through a contactor or soft starter for a

direct online system.

When setting-up the system, it is necessary to create a hardware configuration, which communicate to the Master, how many pumps and drives are

connected. The necessary hardware is explained in the following hardware configuration examples.

The following describes the features and how to use the extended cascade by means of parameters in group 27:

1 Extended and Advanced Cascade Controller

Option VLT

Operating Instructions

MI.38.C3.02 - VLT®is a registered Danfoss trademark

Autres manuels pour VLT series

Table des matières

Autres manuels Danfoss Entraînement CC

Danfoss

Danfoss VLT 5000 Series Manuel utilisateur

Danfoss

Danfoss VLT AutomationDrive FC 301 Mode d'emploi

Danfoss

Danfoss NEMA-3R Manuel utilisateur

Danfoss

Danfoss VFD500 Series Manuel utilisateur

Danfoss

Danfoss VLT AutomationDrive FC 360 Manuel utilisateur

Danfoss

Danfoss VLT Decentral FCD 300 Mode d’emploi

Danfoss

Danfoss VLT HVACDrive Manuel utilisateur

Danfoss

Danfoss FC 300 Mode d'emploi

Danfoss

Danfoss VLT CDS 303 Manuel utilisateur

Danfoss

Danfoss VLT AutomationDrive FC 301 Mode d’emploi

Danfoss

Danfoss VLT AutomationDrive FC 302 Mode d'emploi

Danfoss

Danfoss RAVV Manuel utilisateur

Danfoss

Danfoss VLT CDS 803 Manuel utilisateur

Danfoss

Danfoss VLT HVAC Drive FC 102 Manuel utilisateur

Danfoss

Danfoss VLT HVAC Drive FC 102 Mode d’emploi

Danfoss

Danfoss VLT Midi Drive FC 280 Manuel utilisateur

Danfoss

Danfoss VLT Flow Drive FC 111 Mode d'emploi

Danfoss

Danfoss vlt aqua Manuel utilisateur

Danfoss

Danfoss VLT PROFINET MCA 120 Manuel utilisateur

Danfoss

Danfoss VLT AutomationDrive FC 360 Mode d'emploi

Danfoss

Danfoss VLT Midi Drive FC 280 Manuel utilisateur

Danfoss

Danfoss FC 300 Manuel utilisateur

Danfoss

Danfoss VLT CDS 803 Mode d’emploi

Danfoss

Danfoss VLT Automation Drive FC 360 Mode d'emploi

Manuels Entraînement CC populaires d'autres marques

Vincent Associates

Vincent Associates UNIBLITZ ED12DSS Manuel utilisateur

EKSMA OPTICS

EKSMA OPTICS DQ-100-4 Manuel de la liste des pièces

Chamberlain Garog

Chamberlain Garog D Series Manuel utilisateur

Parker

Parker PDS Series Manuel utilisateur

Festo

Festo DGC G Series Guide de configuration

Binks

Binks QS-5012-1-CE Manuel utilisateur

ABB

ABB ACQ580-01 Series Manuel d'installation

YASKAWA

YASKAWA CANopen SI-S3 Manuel utilisateur

GE D20A6 Manuel utilisateur

Unex

Unex MC-D-250-1000-050W-TW Manuel utilisateur

Geckodrive

Geckodrive G213V Manuel utilisateur

ABB

ABB RSYC-01 Manuel utilisateur

Rockwell Automation

Rockwell Automation PowerFlex 700S Manuel du propriétaire

WEG

WEG DeviceNet CFW500 Manuel utilisateur

Siemens

Siemens SINAMICS G Fiche technique

Siemens

Siemens SINAMICS SM150 6SL3815-7NP41-0AA1 Mode d'emploi

SOMFY

SOMFY JR RU 30 Manuel utilisateur

Beckhoff

Beckhoff AX8911 Manuel de l'opérateur