Danfoss Cascade Operating Instructions Manual

Contents

■

Cascade Controller Option

Safety

Safety regulations ................................................................................................... 4

Warning against unintended start ........................................................................... 4

Operation m odes

Cascade Control Operation ................................................................................... 6

Standa

Master/Slave Cascade Control Mode .................................................................... 8

Instal

Installing the cascade controller option card .......................................................... 9

Standard cascad e control wiring diagram .............................................................. 17

Option

Master drive in master/slave control wiring diagram .............................................. 19

Slave drive in master/slave control wiring diagram ................................................. 20

Changed Drive functions

Introduction ............................................................................................................ 21

Changed

Serial communications(parameter 500) .................................................................. 22

and precautions

............................................................................................ 6

rd Cascade Control Mode .......................................................................... 7

lation and Wiring Instructions

al Hand/Off/Auto Switch .............................................................................. 18

systemstop functions .............................................................................. 22

................................................................................ 3

..................................................... 9

............................................................................ 21

User Int

How to use the LCP for programming ................................................................... 23

Control keys for parameter setup .......................................................................... 23

Indicat

Drive Control .......................................................................................................... 23

Display modes ....................................................................................................... 24

Changin

Parameter setting procedure .................................................................................. 26

Example of how to change parameter data ........................................................... 26

Manual in

VLT D rive and Cascade Controller Setup

Introduc

Quick Menu Summary ........................................................................................... 29

Language ............................................................................................................... 29

Motor nam

Relay outputs ......................................................................................................... 32

Alternate programming ........................................................................................... 36

Standard Cascade Controller Setup

Introduction ............................................................................................................ 38

Initial S

Alternate programming ........................................................................................... 45

erface

or lamps ...................................................................................................... 23

g data ....................................................................................................... 25

itialization ................................................................................................ 26

tion ............................................................................................................ 28

eplate data ............................................................................................ 30

etup ............................................................................................................ 39

................................................................................................... 23

........................................... 28

..................................................... 38

Master/S

Introduction ............................................................................................................ 46

Initial Setup ............................................................................................................ 46

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lave Cascade Control Setup

................................................... 46

Cascade Controller Option

Step 1: Master drive programming ........................................................................ 46

Step 2: Slave drive programming .......................................................................... 49

ate programming: .......................................................................................... 50

Altern

System Optimisation

System

Best efficiency frequency ....................................................................................... 52

Optimization of the process regulator .................................................................... 53

start up and final adjustments ................................................................... 52

Feedback Transmitter Wiring

Connecting feedback transmitters ......................................................................... 54

Single 0

Two 0 - 10 V feedback transmitter connections: ................................................... 54

Two 4 - 20 mA feedback transmitters connection: ................................................ 55

Two feed

Programming example ........................................................................................... 55

Paramet

Parameter group 700 d efinitions ............................................................................ 57

Service

Display information ................................................................................................. 58

Relay status ........................................................................................................... 59

- 10 V feedback transmitter connection: .................................................. 54

back signals and two setpoints: .............................................................. 55

er group 700, all parameters

parameters

.................................................................................... 52

................................................................... 54

................................................... 57

........................................................................................ 58

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Safety and precautions

■

Cascade Controller Option

175ZA677.11

for

VLT 6000 HVAC

and

Safety and precautions

VLT 8000 AQUA

Operating Instructions

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.

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Cascade Controller Option

The voltage of the frequency converter is dangerous whenever the equipment is

connec of the motor or the frequency converter may cause damage to the equipment, serious personal injury

th. Consequently, the instructions in this

or dea manual, as well as national and local rules and safety regulations, must be complied with.

NB!:

UsingtheVLTDialogSoftwareorthe FC protocol for serial communication can cause unintended behaviour of motors

and plant and must be avoided.

Safety regulations

■

1. The VLT frequency converter must be

on-nected from mains if repair work is to be

disc carried out.Check that the mains supply has been disconnected and that the necessary time has

sed before removing motor and mains plugs.

pas

2. The [OFF/STOP] key on the control panel of the

VLT frequency converter does n

equipment from mains and is thus n

the to be used as a safety switch.

ted to mains. Incorrect instal-lation

ot disconnect

necessary time has passed before removing motor and mains plugs.

7. Reliab

8. Please note that the VLT frequency converter

Warning against unintended start

■

1. The motor can be brought to a stop by

2. While parameters are being changed, the

le galvanic isolation (PELV) is not complied with if the RFI switch is placed in OFF position. This means that all control in- and outputs

ly be considered low-voltage terminals

can on with basic galvanic isolation.

has mo the DC-bus terminals are used. Check that all voltage inputs have been disconnected and that t repair w o rk is commenced.

means of digital commands, bus commands, references or a local stop, while the frequency converter is connected to mains. If personal safety considerations make it necessary to ensure that no unintended start occurs, t stop functions are not sufficient.

motor may start. Consequently, [OFF/ STOP] must always be activated, after which data can be modified.

re voltage inputs than L1, L2, L3 when

he necessary time has passed before

the stop key

hese

NB!:

The IMMEDIATE STOP function will release all slave relays a switch. The SEQUENCED STOP will stage off

the slave relays a

3. Correct protective earthing of the equipment st be established, the user must be protected

mu against supply voltage, and the motor must be protected against overload in accordance with

plicable national and local regulations.

4. The earth leakage currents are higher than 3.5 mA.

5. Protection against motor overload is included

the factory setting. Parameter 117, Motor

in thermal protection, default value is ETR trip

1. For the North American market: The ETR unctions ensure overload protection of the motor,

f Class 20, in accordance with NEC.

NB!:

Motor Thermal Protection is initialised at 1.0 x rated motor current and rated motor frequency (see parameter 117, Motor thermal protection).

nd can not be used as a safety

nd can not be used as a safety switch

6. Do n

ot remove the plugs for the motor and mains supply while the VLT frequency converter is connected to mains. Check that the mains supply has been disconnected and that the

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Cascade Controller Option

Warning:

Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. 200-240 and 380-480 V: wait at least 15 minutes 550-600 V: VL T 6002/8002 - 6027/8027: wait at least 15 minutes 550-600 V: VL T 6032/8032 - 6300/8300: wait at least 30 minutes

175ZA678.11

Safety and precautions

MG.60.I3.02 - VLT is a registered Danfoss trademark

Operation modes

■

Cascade Control Operation

■

With the cascade controller option card, the frequency converter can automatically control up to five motors. Staging motors on or off is done cyclically, in accordance with operating hours. This function assures equal use over time and eliminates concern about starting a seldom used motor. The cascade controller includes four Form C relays having contacts rated 250 V, 2 A (non-inductive) that are used to control the motor con tactors. The controller option card installs in the frequency converter control card cassette and can be ordered factory installed. The cascade controller is effective in applications where multiple motors are used to control a common flow, level or pressure involving pumps, fans, and blowers.

eedback Signals

F An important advantage to the cascade controller option is that it is based upon the VLTs advanced PID controller. This means that programming is done in selected units of measurement appropriate to the application and that the feedback and setpoints can be displayed. Unlike drives that base staging upon frequency, feedback allows precise control in response to actual system demand. The VLTs PID controller accommodates two feedback signals and two setpoints which allows regulating a system with different setpoint zones.

Cascade Controller Option

In pumping applications, when a pressure feedback signal is not practical, the feedback signal may be taken near the pump by measuring flow. When the flow rate is low, the pressure needed is low. At increased flow, the pumps need to provide greater pressure to compensate for the increased pressure drop in the piping. The setpoint should be adjusted to match the flow in these cases. While difficult to accomplish with standard PID controllers, the cascade controller provides an easy solution. By programming one setpoint for minimum flow and the other for maximum flow, the VLT calculates intermediate setpoints based on the flow required.

Cascade control operation depends on the general system design. Two operational modes are available:

1. Standard Cascade Control, with one speed controlled pump/fan and up to four fixed speed pumps/fans. Programming for this mode is described in Chapter 6, Standard Cascade Control Mode Setup.

2. Master / Slave Cascade Control has all pumps/fans speed controlled through the Master drive. Programming is described in Chapter 7, Master/Slave Cascade Control Mode Setup.

Standard Cascade Control Mode

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Standard Cascade Control Mode

■

In standard cascade control, a frequency converter

e Cascade Controller option card installed

with th controls a variable speed motor and is used to stage additional constant speed motors on and

y varying the speed of the initial motor,

off. B variable speed control is provided for the system. This maintains constant pressure while eliminating

ure surges, resulting in reduced system

press stress and quieter operation.

The motors can be of equal or differing sizes. The controller offers a selection of eight pre-defined pump combinations. Selections allow mixing pumps of 100%, 200% and 300% capacity. This provides a dynamic capacity range of 9 to 1. The VLT drives internal PID controller directs the cascade option card based upon the feedback signal. The cascade controller will continue operation of the constant speed motors to meet demand should the drive trip.

Cascade Controller Option

When the master drive is the only one running, the drives sleep mode can discontinue system operation when not needed while staying ready to start on demand. Variable speed control with fixed speed motors optimizes energy consumption and avoids damaging a pump running at near no flow condition

evel Control With level control, multiple pumps can be used to keep a constant level in applications such as a buffer tank. Typically, a water level sensor provides a feedback signal for the VLT’s built-in PID controller. Precise level control is maintained in response to the system setpoint. With a cascade controller, additional fixed speed pumps will be staged on or off, as required, to maintain level control.

stage Timer

eA de-stage timer takes effect in standard control when the drive runs continuously at minimum speed

h one or more constant speed motors running.

wit Since a variable speed pump at minimum speed adds no or very limited flow to the system, it is

visable to stop a constant speed motor and

ad allow the drive to provide the required flow. The de-stage timer is programmable to avoid frequent

taging of the constant speed motors.

Operation modes

Level Control in Standard Cascade Control Mode

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Master/Slave Cascade Control Mode

■

Master/slave systems control multiple pumps in

el at the same output frequency. Pumps are

parall staged on and off as required to meet the systems demand. The master/slave control mode of operation

des maximum system efficiency.

provi In master/salve control, each motor has its own

adjustable frequency drive which responds to control from a master drive which contains the cascade option card. The master drive sends a pulse speed reference signal to the drives under control to ensure that all operate at the same speed. The motors must be of equal size. In some applications, it may be advisable for a second drive with a cascade card to act as an auxiliary controller.

Sequential staging of drives on or off is provided by

master drive in response to system feedback,

the maintaining precise setpoint control. Pressure surge and water hammer are eliminated. Because all

he operating pumps run at the same speed,

of t the possibility of running a pump continuously into a closed check valve is all but eliminated. This

duces pump maintenance by minimizing the

re wear on pump seals and bearings.

Cascade Controller Option

Danfoss has available the Multiple Unit Staging Efficiency Calculator (MUSEC), a free software program available on the Danfoss website. By entering pump and system data, MUSEC provides the programmer with master drive on and off staging frequencies at optimal efficiency for each pump: for example, three motors providing flow at reduced speed rather than two at full speed. This often results in 10% to 15% additional savings over similar control systems. For a free download, go to www.danfoss.com and enter MUSEC in the search box.

Best efficiency is attained when a pressure transmitter is placed at the farthest significant load in the system. If this is not practical and the pressure transmitter is placed close to the discharge of the pumps, or when pump data and system characteristics are not accessible, alternative ways of programming the cascade controller are provided.

Master/Slave Cascade Control Mode

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Installation and Wiring Instructions

■

Installing the cascade controller option card

■

This chapter provides instructions for installing the cascade controller option card into a VLT adjustable frequency drive. In Standard cascade control mode, the option card installs into the VLT controlling up to four additional motors. In Master/Slave mode, the option card installs in the Master drive controlling up to four additional slave drives.

Cascade Controller Option

DANGER VLT adjustable frequency drive contains dangerous voltages when

connected to line voltage. After disconnecting from line, wait at least 14 minutes before touching any electrical components.

Relay o utput connections vary according to the mode of operation and configuration of the system. Typical wiring diagrams are also provided in this chapter.

Adhere to all safety guidelines provided in the VLT Operating Instructions. See the VLT Operating Instructions for details and for instructions on drive operation.

orque tightening requirements

T Tighten all fittings described in this chapter to 7.1 in-lbs (0.8 Nm), unless specified otherwise.

ptional transmitter connections VLT drive terminals12 and 13 provide a 24 VDC, 200 mA power supply. This supply can be used to power remote transmitters without need for an external power supply. See wiring instructions in Chapter 10, Feedback Transmitter Wiring.

WARNING Only a competent electrician should carry out electrical installation.

Improper installation of motor or VLT can cause equipment failure, serious injury or death. Follow this manual and National Electrical Code and local safety codes.

CAUTION

Electronic components of VLT

adjustable frequency drive are

sensitive to electrostatic discharge (ESD). ESD can reduce performance or destroy sensitive electronic components. Follow proper ESD procedures during installation or servicing to prevent damage.

Installation and

Wiring Instructions

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Cascade Controller Option

1. Access to Control Card Cassette

■

•

Remove Local Control Panel (LCP) keypad by

g out from top by hand. LCP connector

pullin on panel back will disconnect.

•

Remove terminal protective cover by gently prying with screw driver at top notch and lift cover o

•

Open access cover to internal VLT components. (Drive configurations vary.)

ut of guide pin fittings.

2. Disconnect VLT Drive Control Wiring

■

Touching electrical parts may be fatal – even after equipment has been

disconnected from AC line. To be sure that capacitors have fully discharged, wait 14 minutes after power has been removed before touching any internal component.

•

Remove control wiring by unplugging connector terminals.

•

Remove wiring clamp by removing two screws. Save for reassembly.

•

Loosen two captive screws securing control board cassette to VLT chassis.

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Cascade Controller Option

3. Remove VLT Cassette and Ribbon Cables

■

•

Lift control board cassette from bottom.

•

4. Remove LCP Keypad Cradle

■

•

nect two ribbon cables from VLT

Discon control board.

Push tabs at side of LCP cradle to release clips. Pull out to disengage and lift cradle free.

•

Unhinge cassette at top to remove.

Installation and

Wiring Instructions

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5. Cascade OptionCard Ribbon Cable Routing

■

Electronic components of VLT and

cascade controller option card are

sensitive to electrostatic discharge (ESD). Follow proper ESD procedures to prevent component damage. ESD procedures to prevent component damage.

Cascade Controller Option

•

6. Secure Option Card

■

•

ribbon cables from cascade controller

Route option card through slot at side of VLT control board cassette. Option card mounts

component side down.

with Feed plastic option card insulation pad through terminal opening in control board cassette.

rt edge of option card into slot (A)

Inse in side of cassette. Align opposite side of card with mounting

s (B) provided.

hole

Secure option card to control board cassette with 3 self-tapping screws and washers provided. Use a Torx T-10 screw driver.

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7. Connect Option Card Ribbon Cable to

■

VLT Control Board

•

Pull up cable socket.

•

DO NOT remove blue insulation on end of option into corresponding socket (B) on VLT control board and push collar closed. Be sure not to cri

•

Repeat procedure for all ribbon cables.

collar (A) of control board ribbon

card ribbon cable. Insert ribbon cable

mp ribbon cables.

Cascade Controller Option

Installation and

Wiring Instructions

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Cascade Controller Option

8. Chassis Ground Connection

■

•

Location of holes to mount grounding strips in VLT chassis can vary with drive configuration.

•

When applicable, remove mounting screws located in chassis using Torx T-20 screw driver and save for reassembly. Otherwise, grounding strips attach with screws provided.

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9. Install Chassis Ground Connections

■

•

Align ground strips over corresponding screw

(Strip with fewest contact points mounts

holes. on right side of chassis.)

•

Replace screws removed and add additional screws Torx T-20 screw driver.

10. Replace VLT Control Board Cassette

■

•

Attach LCP keypad craddle to VLT control board cassette removed in step 4. Ensure not to crimp option card ribbon cables.

•

Connect two ribbon cables to control board in corresonding connectors as removed in step 3.

•

Hinge VLT cassette at top of VLT chassis and reposition into place. Use Torx T-20 screwdriver to fasten two captive screws. Ensure not to crimp control board ribbon cables.

provided, as necessary. Use a

Cascade Controller Option

11. Relay Output Connection

■

•

Connect relay output cables to terminal blocks provided as required by application. (See wiring diagrams in this chapter.)

•

Insert relay terminal blocks firmly into corresponding terminal sockets on control board.

•

Secure relay wiring with bottom right wiring clamp and fasten.

Relay 6-9: A-B make, A-C break Max. 240 VAC, 2 A Max. cross-section: 1.5 mm Torque: 0.22 - 0.25 Nm

(28-16 AWG)

Installation and

Wiring Instructions

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12. Remove Wiring Clamp Mounting Fixture

■

•

Option card insulation pad is designed to use top most ca

•

Use screw driver to remove top most wiring clamp.

13. Reconnect VLT Control Terminals and

■

Secure Option Card InsulationPad

•

Reconnect VLT control terminals removed in step 2bypressingfirmlyintocorresponding terminal socket.

•

Crease option card insulation pad flap and insert into slot in side of control card cassette.

•

Attach insulation pad to top most clamp position with one screw from removed wiring clamp.

•

Route VLT control terminal wiring through bottom left wiring clamp and fasten.

ble wiring clamp screw hole for attaching.

Cascade Controller Option

14. Final Reassembly

■

•

Secure access cover to internal VLT components.

•

Replace LCP keypad by positioning guide slots at bottom of cradle and snaping into place.

•

Attach terminal protective cover by positioning guide pins at bottom of cover into control card cassette and snaping into place.

Transmitter wiring

■

Please refer to chapter 10, Feedback Transmitter Wiring.

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Standard cascade control wiring diagram

■

The wiring diagram shows an example for a

rd cascade control system with 4 fixed

standa speed motors, a 4-20 mA pressure transmitter, and external safety interlock.

Cascade Controller Option

Power terminal connections Control board terminal

connections

Option card terminal connections

Installation and

Wiring Instructions

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Optional Hand/Off/Auto Switch

■

ptional Hand/Off/Auto Switch

dard cascade control mode, an optional

In stan Hand/Off/Auto switch on the constant speed motor starter is common. During normal operation, the switch automatic start and stop commands to the motor. The HAND position allows manual operation of the motor switch to OFF. For a motor in the OFF position, the

is set to AUTO and the drive will signal

. The motor can be disabled by setting the

Cascade Controller Option

cascade controller will try to start it by triggering its relay. Since no contribution will occur, the next pump will be switched on. The relay timer will, however, assume operation for a disabled motor. See Chapter 12, Service Parameters.

The diagram below provides wiring instructions for an optional Hand/Off/Auto switch.

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Cascade Controller Option

Master drive inmaster/slave control wiring diagram

■

The wiring diagram below shows an example of a Master system demonstrates a 4-20 mA pressure transmitter,

drive in Master/Slave cascade control. The

Power terminal connections Control board terminal

connections

an external safety interlock and four slave drives. The slave drive speed reference is provided from terminal 17 as a p used for the Start/Stop command to the slave drives.

ulse signal. The relays on the option card are

Option card terminal connections

Master Drive

Installation and

Wiring Instructions

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Cascade Controller Option

Slave drive in master/slave control wiring diagram

■

Each slave drive is wired in the same way, receiving the Sta from the master drive. The speed reference and its common are typically looped from Slave-to-Slave.

Power terminal connections Control board terminal connections

rt/Stop command and a pulse speed reference

Slave Drive

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Cascade Controller Option

Changed Drive functions

■

Introduction

■

Installation of the Cascade Controller Option card into the VLT adjustable frequency drive overrides some existing drive functions. Changes to the default parameter setting are shown in the tables below. Data entered into the drive parameters are used to program the drive and cascade controller for system operation. The modified parameter default settings make programming the cascade controller easier. See Chapter 5, User Interface, for instructions on programming drive parameters.

Changed Default Settings with the Cascade Controller Option Card

Parameter Description Previous default New default

100 Configuration Open loop Closed loop 201 Minimum output freq. 0.0 Hz 40% of nominal frequency

205 Maximum reference 60 Hz 100% 206 Ramp-up time Varies with unit See table below 207 Ramp-down time Varies with unit See table below 304 Terminal 27 (digital input) Safety interlock Coasting stop, inverse 308 Terminal 53 (analog in V) Reference No operation 314 Terminal 60 (analog in A) Reference Feedback (4 20 mA) 318 Function after time out No function Stop (sequence stop) 417 Feedback Function Maximum Virtual Control Curve 427 PID lowpass filter time 0.01 sec. 0.20 sec.

In addition, parameters that need to be programmed for cascade control operation are assembled sequentially in a new and expanded 39 item Quick Menu. Programming is simplified by following the

Quick Menu items in sequence for either Standard cascade control or Master/Slave cascade control. The new Quick Menu is described in Chapter 6, VLT

Drive and Cascade Controller Card Setup.

New options are also available to stop pumps or fans controlled in cascade operation. A summary of VLT changed functionality is presented in this chapter.

(24 Hz)

VLT Type Ramp Up (parameter

206)

Ramp Down(parameter

207)

8005/6002 8011/6011 1 sec. 1sec. 8016/6016 8062/6062 3 sec. 2sec. 8072/6072 8300/6275 5 sec. 3sec. 8350/6350 8600/6550 8 sec. 5sec.

Changed Drive functions

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Changed systemstop functions

■

Two stop functions are provided by the cascade

ller option. One function quickly stops a

contro system. The other stages off pumps in a sequence, allowing for a controlled pressure stop.

Do not use these functions as emergency

stops. Some functions do not turn

off all pumps.

Standard cascade control mode Stop functions in Standard cascade control are described in the table below. In a sequenced stop, there is a one ramp-down time delay between each staging off of motors.

Standard Cascade Control

Function Description

OFF/STOP key Provides a sequenced stop

for all constant speed motors in opposite order as staged on. Controller decelerates its

motortoastop. STOP via Terminals 16 and 17 (parameters 300 and 301)

Controller decelerates its

motortoastop.Withmotor

stopped, controller provides

sequenced stop for constant

speed motors. STOP via Terminal 18 (parameter 302)

Constant speed motors

continue to operate normally

with feedback signal from

drive. Controller decelerates

its motor to a stop. STOP via Terminal 27 Coast Inverse

Constant speed motors stop

immediately. Controller coasts

its motor to a stop. (parameter 304) STOP via Terminal 27 Safety Interlock

Constant speed motors stop

immediately. Controller coasts

its motor to a stop. (parameter 304)

Cascade Controller Option

Master/Slave cascade control mode Stop fu are described in the table below.

OFF/STOP key Provides a sequenced

STOP vi and 17 (parameters 300 and 301)

STOP via Terminal 18 (parameter 302)

STOP v 27 Coast Inverse (parameter 304) STOP via Terminal 27 Safety Interlock (parameter 304)

Serial communications(parameter 500)

■

The Danfoss FC protocol may be used only with VLT Dialog software for programming and setting up drive and cascade controller parameters.

nctions in Master/Slave cascade control

Master/Slave Cascade Control

Function Description

stop for all slave motors in opposite order as staged on. Master decelerates its motortoastop.

aTerminal16

Slave m

otors all stop together. Master decelerates its motor to

astop Slave motors all stop together. Master decelerates its motor to astop.

ia Terminal

motors all stop

Slave together. Master coasts its motor to a stop. Slave motors all stop together. Master coasts its motor to a stop.

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User Interface

■

How to use the LCP for programming

■

The combined display and keypad on the front of the VLT is called the Local Control Panel (LCP). The LCP is the user interface to the VLT adjustable frequency drive.

The LCP has several user functions: programming the VLT; displaying operational data, along with warnings and cautions; to reset the drive after a fault; and, in local control, to start/stop and control the speed of the drive.

Control keys for parameter setup

■

Each parameter determines an operational function the drive. Many parameters are used in combinations with others. The keys shown below are used for programming the drive by selecting from parameter options or entering data in the parameter, as applicable. The LCP keys are also used for selecting the data displayed during normal operation of the drive.

Cascade Controller Option

[+/-] are used to scroll through parameters and for changing a selected parameter. These keys can also be used to change the drive speed as a function of the local reference. In addition, the keys are used in Display mode to switch between readouts.

[<>] are used when selecting a parameter group and for moving the cursor to the desired digit when changing numerical values.

Indicator lamps

■

At the bottom of the control panel are three indicator lamps: a red alarm lamp, a yellow warning lamp, and a green voltage (power on) lamp.

If pre-determined threshold values are exceeded, the alarm and/or warning lamp is activated, and a status or alarm text is displayed. The power-on light is activated when the VLT adjustable frequency drive receives voltage.

[DISPLAY/MODE] is used to change display modes or to return to the Display mode from either the Quick Menu or the Extend Menu mode.

[QUICK MENU] gives access to the programming parameters in the Quick Menu. These are the most commonly used parameters in setting up the drive functions.

[EXTEND MENU] gives access to all drive parameters, including Quick Menu items.

[CHANGE DATA] is used for changing a parameter setting selected in either the Extend Menu or the Quick Menu mode.

[CANCEL] is used if a change to a selected parameter is not to be carried out.

[OK] is used for confirming a change to a selected parameter.

Drive Control

■

Keys for control of the drive are described below.3

[HAND START] is used if the VLT drive is to be started and controlled from the LCP. The VLT drive will start the motor when [HAND START] is pressed.

NB!:

The motor will start when [HAND START] is activated if parameter 201, Output frequency low limit, is set to an output

frequency greater than 0 Hz. The following control signals are active on the control

terminals when [HAND START] is activated:

•

Hand Start - Off Stop - Auto Start - Reset

•

Safety interlock

•

Coasting stop inverse

•

Reversing

User Interface

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Cascade Controller Option

•

Setup select lsb - Setup select msb

•

Jog

•

Run per

•

Lock for data change

•

Stop command from serial communication

missive

[OFF/STOP] is used for stopping the connected motor in Hand or Auto mode. This key can be diabled in parameter 013. If the stop function is activated, the main display will flash.

[AUTO START] is used if the VLT is to be controlled through the control terminals. When a start signal is act ive on the control terminals and/or serial bus, the VLT drive will start.

NB!:

Drive can start at anytime with a start signal through digital inputs. Digital inputs have higher priority than control keys [HAND

START] and [AUTO START]. [RESET] is used for manually resetting the drive after

a fault trip (alarm). In this case, the top line of the display will show TRIP (RESET). If the top line of the display shows TRIP (AUTO START), the drive will automatically restart. If the top line of the display shows TRIPLOCK (DISC. MAINS), input power to the drive must be removed before the trip can be reset.

Display modes

■

In Auto operational mode, information is displayed in any of three programmable displays. Pressing the [DISPLAY MODE] key enters display mode and toggle between modes I and II. In Display mode, the [+] and [-] keys scroll through all data display options. When in Mode II, holding down the [DISPLAY MODE] key identifies the units the display is showing on the top line. Mode IV is available only in local Hand operation.

In normal operation, three data readouts can be shown on the first (top) line of the display. One readout is available for line 2 (the large display). Parameters 008, 009 and 010 select the data displayed on the top line. Parameter 007, Large Display Readout, selects the data displayed on line 2.

The list on the next page defines the operating data that can be selected for the display readouts. Line 4 (bottom line) automatically displays the operating status of the drive.

The active setup number and an arrow indicating the direction of motor rotation is shown on the right side of the large display. Clockwise indicates forward and counterclockwise indicates reverse. The arrow

body is removed if a stop command is given or if the output frequency falls below 0.01 Hz.

Warnings and alarms (fault trips) will also be displayed. During an alarm, ALARM and the alarm number is shown on the large display. An explanation is given in line 3 or in lines 3 and 4. For a warning, WARN. and the warning number is shown with an explanation in line 3 and/or 4. Both alarms and warnings cause the display to flash.

VAR 1.1 VAR 1.2 VAR 1.3

VAR 2

SETUP

STATUS

The list below gives the operating data options for the first and second line of the LCP display.

Data Item: Unit: Resulting reference, % [%] Resulting reference, unit [unit] Frequency [Hz] %ofmaximumoutput frequency Motor current [A] Power [kW] Power Power [HP] Output energy [kWh] Hours run [hours] User-defined readout [unit] Setpoint 1 [unit] Setpoint 2 [unit] Feedback 1 [unit] Feedback 2 [unit] Feedback [unit] Motor voltage [V] DC-link voltage [V] Thermal load on motor [%] Thermal load on VLT [%] Input status, digital input [binary code] Input status, analog terminal 53 Input status, analog terminal 54 Input status, analog terminal 60 Output status, relay status [binary code] Pulse reference [Hz] External reference [%] Heat sink temperature [ User-defined text [-]

[%]

[V]

[mA]

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Cascade Controller Option

Three operating data values can be shown in the first display line and one in the large display line,

mmed via parameters 007, 008, 009, and 010.

progra D

isplay mode I InDisplaymodeI,thedriveisinAutomodewith reference and control determined via t he control terminals. Below is an example in which the drive is running in setup 1, in Auto mode, with a remote reference, and at an output frequency of 40 Hz.

The text in line 1, FREQUENCY, describes the

r shown in the large display. Line 2 (large

mete display) shows the current output frequency (40.0 Hz), direction of rotation (reverse arrow), and active

p (1). Line 3 is blank. Line 4 is the status line

setu and the information is automatically generated for display by the drive in response to its operation. It

ws that the drive is in auto mode, with a remote

sho reference, and that the motor is running.

FREQUENCY

40.0Hz40.0Hz

40.0Hz

40.0Hz40.0Hz

AUTO REMOTE RUNNING

SETUP

175ZA683.10

The last part of line 4 indicates the drive’soperational status, for example: RUNNING, STOP, or ALARM.

isplay mode II This display mode shows three operating data values in the top line programmed v ia parameters 007, 008, and 009. Pressing the [DISPLAY MODE] key toggles between Display modes I and II.

100% 7.8A 5.9kW

SETUP

50.0Hz

AUTO REMOTE RUNNING

Display mode III Press and hold the [DISPLAY MODE] key while in Mode II. Mode III is visible as long as the key is depressed. The top line changes to identify the data names and units displayed. Lines 2 and 4 are unchanged. When the key is released, the display returns to Mode II.

REF% CURR.A.POW.,KW

60.0Hz

SETUP

175ZA685.10

175ZA686.10

Status line (Line 4): Additional automatic displays forthedrivestatuslineareshownbelow.

80.0% 5.08A 2.15kW

SETUP

40.0Hz

AUTO REMOTE RUNNING

HAND LOCAL STOP

OFF RAMPING JOGGING .

. . .

STAND BY

The left indicator on the status line displays the active control mode of the VLT drive. AUTO is displayed when control is via the control terminals. HAND indicates that control is local via the keys ontheLCP.OFFindicatesthatthedriveignores all control commands and will not run.

The center part of the status line indicates the reference element that is active. REMOTE means that reference from the control terminals is active, while LOCAL indicates that the reference is determined via the [+] and [-] keys on the control panel.

175ZA684.10

AUTO REMOTE RUNNING

Display mode IV This display mode is used for local operation, where the local speed reference is given from the keypad. In this display mode, the reference is determined via the [+] and [-] keys. Control is carried out through the bottom keys on the keypad. The first line indicates the requ ired reference. The third line gives the relative value of the output frequency in the form of a bar graph in relation to the maximum frequency.

USE +/- 40Hz

40.0Hz

HAND LOCAL RUNNING

Changing data

■

Regardless of whether a parameter has been selected under the Quick Menu or the Extend Menu, the procedure for changing data is the same. Pressing the [CHANGE DATA] key gives access to changing the selected parameter. Line 3 displays the parameter

175ZA688.10

User Interface

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

number and title. The underlined function or number flashing in line 4 on the display is subject to change.

The procedure for changing data depends on whether the selected parameter represents a numerical data value or a function.

hanging numeric values

C If the chosen parameter represents a number

, the flashing digit can be changed by means

value of the [+] and [-] keys. Position the cursor by using the [<] and [>] keys, then change the data

e using the [+] and [-] keys.

valu The selected digit is indicated by a flashing cursor.

Thebottomdisplaylinegivesthedatavaluethat will be entered (saved) by pressing the [OK] button. Use [CANCEL] to ignore the change.

FREQUENCY

24.2 Hz

205 MAX. REFERENCE

000060.000 Hz

SETUP

175ZA687.10

2. Use [+] and [-] keys to find parameter

you choose to edit.

3. Press [

4. Use [+] and [-] keys to select correct parameter

5. Press [Cancel] key to disregard change, or press

Example of how to change parameter data

■

Assume Quick Menu item 9 (parameter 206, Ramp Up Time) is set at 60 seconds. Change the ramp

up time to 100 seconds as follows:

1. Press [Quick Menu] key.

2. Press [+] key until you reach Quick Menu item

3. Press < key twice hundreds digit will flash.

4. Press [+] key once to change hundreds digit to 1.

5. Press

6. Press [-] key until 6 counts down to 0 and setting

7. Press [

Change Data] key.

setting. To move to a different digit within a

c parameter, use < and > arrows. Flashing

numeri cursor indicates digit selected to change.

ey to accept change and enter new setting.

[OK] k

9of35

for Ramp Up Time reads 100 s.

(parameter 206), Ramp Up Time.

> key once to move to tens digit.

OK] key to enter new value.

Changing functional values If the selected parameter is a functional value, the selected text value can be changed by meansofthe[+]and[-]keys.

MOTOR CURRENT

SETUP

3.90 A

210 REFERENCE TYPE

SUM

The functional value flashes until signing off by pressing the [OK] button. The functional value has then been selected. Use [CANCEL] to ignore the change.

hanging listed numeric values A few parameters offer numeric lists of values that can be selected from or changed. This means that if the numeric value is not listed, a value may be entered using the procedure for changing numeric values. This applies to parameter 102, Motor power, parameter 103, Motor voltage,and parameter 104, Motor frequency.

175ZA689.10

Manual initialization

■

The drive can be initialized to return to factory default settings.

NB!:

Initializing the drive will remove all values and settings entered into drive. Some factory default

ngs may be for European applications.

setti

1. Remove AC power to drive.

2. Press and hold [DISPLAY MODE] + [CHANGE DATA]+[OK]keysdownwhileatsametime applying AC power to drive.

3. Release keys. VLT reverts to factory setting.

It is also possible to carry out initialization via parameter 620, Operating mode, by selecting Initialize.

Parameter setting procedure

■

Enter or change parameter data or settings as follows:

1. Press [Quick Menu] or [Extended Menu] key.

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Cascade Controller Option

The following parameters are not reset when using manual initialization: 500, Protocol 600, Operating hours 601, Hours run 602, kWh counter 603, Number of power-ups 604, Number of overtemperatures 605, Number of overvoltages 724 - 737, Operating hours/counters

User Interface

MG.60.I3.02 - VLT is a registered Danfoss trademark

VLT Drive and Cascade Controller Setup

■

Introduction

■

A new quick menu list is activated when a cascade controller option card is installed in the VLT adjustable frequency drive. The original 12 items are expanded to 39 quick menu items that allow programming additional drive and cascade controller functions. See Chapter 4, Changed Drive Functions.

The first 20 items on the new quick menu must be programmed in sequ ence for initial drive and cascade controller setup. (See block diagram.) These 20 items are common to both Standard cascade control mode and Master/Slave control mode. After initial setup is complete, additional quick menu items program the drive for the selected mode of operation. Those instructions are available in Chapter 7, Standard Cascade Control Mode Setup and Chapter 8, Master/ Slave Control Mode Setup.

Chapter 9, System Optimization, provides instructions for final adjustments to reach maximum drive and controller efficiency after system start up.

Cascade Controller Option

selects the mode of operation for further setup. The Quick Menu Summary table on the next page describes the menu items.

The VLT adjustable frequency drive has four independent setups that can be programmed. The initial programming in this chapter is stored as Setup 1. See Alternative Programming at the end of this chapter for instructions on using the drives multi-setup capability.

VLT drives delivered with the cascade controller option card already installed, or prepared for field installation, have been programmed with factory settings typical for operation. These settings may be satisfactory for initial start up of the system.

See Chapter 5, Use Interface, for instructions on programming the VLT drive.

Items 2 6 are motor characteristics. In Standard cascade control mode, only the motor data from the variable speed motor run by the cascade controller are entered. In Master/Slave control, only data from the motor controlled by the Master drive are entered at this time. Items 7 19 are basic cascade controller settings used in either mode of operation. Item 20

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Quick Menu Summary

■

Cascade Controller Option

Quick Menu numbe

Basic Drive Set Up parameters 001 001 Language 10 languages See VLT 6000 H VAC or VLT

002 102 Motor Power KW/HP 1.1-450/1.5-600 003 103 Motor Volta ge Volts 200 - 480 004 104 Motor Frequency Hz 50 / 60 005 105 Motor Current Amps 0-IVLT max 006 106 Rated Motor Speed RPM 0- fm,n x 60 007 201 Min. Fr equency Hz 0.0 -fmax 2/5 of fnom (NEW) 008 202 Max. Frequency Hz Fmin-120/1000 Fnom x 1.1 (NEW) 009 206 Ramp up time Seconds 1-3600 See table above in 2.4.8 010 207 Ramp down time Seconds 1-3600 011 323 Relay 1 Output Depending on cho ice See VLT 6000 HVAC Manual. 012 326 Relay 2 Output Basic Set Up for Standard Cascade and Master/Slave. 013 415 Closed loop units Selected acc or ding to your p ro cess. 014 413 Minimum Feedba ck 015 414 Maximum Feedback 016 227 Warning low Feedback Units -999,999.999- FB High -999,999.999 017 228 Warning high Feedback Units FB low- 999,999.999 999,999.999 018 204 Ref.min. Units Min. feedback - Ref.max 0 019 205 Ref.max. Units Ref.min - Max. feedback 0 020 723 Operational Mode select - Standard / M/S Stan dar d Ca scade 021 712 Pump combination 1-8 1 022 713 Staging BandW. % 1. 0 - 100.0 10.0 023 714 Destaging Delay Sec. 0.0 - 3000 15 024 715 Staging Delay Sec. 0.0 - 3000 15 025 716 Override BW %ofsetpoint 2.0 - 10 0.0 20.0 026 717 Override Timer Sec. 0.0 - 300 5 027 718 Transition frequency %offnom fmin - 120.0 60 028 418 Setpoint 1 (H0) Bar (or equiv.) Refmin - Refmax 6bar 029 419 Setpoint 2 (H1) Bar (or equiv.) Refmin - Refmax 6bar 030 721 Destage Timer Timer Sec. 0.0 - 600 30 031 722 Pump cycling Enabled/Disabled Enabled 032 319 Analog/digital outputs - [1] - [43] F out 020mA 033 739 M/S Stage on frequencies Hz Fmin-Fmax Fmin 034 740 M/S stage off frequencies Hz Fmin-Fmax Fmax PID Controller tun ing 035 420 Normal/Inverse control Normal/Inverse Normal mode 036 422 PID Start up frequency Hz Fmin-fmax 0Hz 037 427 PID Lowpass filter time Sec. 0.01 10.00 1. 00 038 423 PID Proportional Gain Factor 0.00 10.0 0. 01 039 424 PID Integrator time Sec. 0.01 9999.0 OFF

Parame-

ter nu ber

Name Units Range Factory setting

8000 AQUA manuals.

Controller Setup

VLT Drive and Cascade

Language

■

Quick Menu 001 Par. 001 Language

(LANGU

AGE)

Value:

✭English(ENGLISH)

German(DEUTSCH)

MG.60.I3.02 - VLT is a registered Danfoss trademark

French (FRANCAIS) Danish (DANSK) Spanish (ESPAÑOL) Italian(ITALIANO) Swedish (SVENSKA) Dutch (NEDERLANDS)

Cascade Controller Option

Portuguese(PORTUGUESA) Finnish (SUOMI)

Function:

This choice defines the language to be used on the display.

Description of choice:

Select the display language.

NB!:

It is important that the values set in parameters 102-106, Motor nameplate data, correspond to the nameplate data of the motor.

Motor nameplate data

■

Quick Menu 002 Par. 102 Motor power

(MOTOR POWER)

Value:

0.1/3 HP (0.25 KW)

0.5 HP (0.37 KW)

0.75 HP (0.55 KW)

1.0 HP (0.75 KW)

1.5 HP (1.10 KW) 2 HP (1.50 KW) 3 HP (2.20 KW) 4 HP (3.00 KW) 5 HP (4.00 KW)

7.5 HP (5.50 KW) 10 HP (7.50 KW) 15 HP (11.00 KW) 20 HP (15.00 KW) 25 HP (18.50 KW) 30 HP (22.00 KW) 40 HP (30.00 KW) 50 HP (37.00 KW) 60 HP (45.00 KW) 75 HP (55.00 KW) 100 HP (75.00 KW) 125 HP (90.00 KW) 150 HP (110.00 KW) 200 HP (132.00 KW) 250 HP (160.00 KW) 300 HP (200.00 KW) 350 HP (250.00 KW) 400 HP (300.00 KW) 450 HP (315.00 KW) 500 HP (355.00 KW) 600 HP (400.00 KW)

✭Depends on the unit

[000.25] [000.37] [000.55] [000.75] [001.10] [001.50] [002.20] [003.00] [004.00] [005.50] [007.50] [011.00] [015.00] [018.50] [022.00] [030.00] [037.00] [045.00] [055.00] [075.00] [090.00] [110.00] [132.00] [160.00] [200.00] [250.00] [300.00] [315.00] [355.00] [400.00]

is the full rating of the drive. The drive can operate motors undersized by up to four ratings below the

ting of the drive or oversized by one rating.

full ra

Description of choice:

Select a value that equals the nameplate data on the motor. tage

Quick Menu 003 Par. 103 Motor voltage

(MOTOR VOLTAGE)

Value:

200 V 208 V 220 V 230 V 240 V 380 V 400 V 415 V 440 V 460 V 480 V 500 V

✭Depends on motor

Function:

This is wher

Description of choice:

Select a value that equals the nameplate data on the motor, regardless of the AC input voltage of the VLT adjustable frequency drive.

Quick Menu 004 Par. 104 Motor frequency

Value:

50 Hz 60 Hz

Function:

This is where the rated motor frequency is selected.

Description of choice:

Select a value that equals the nameplate data on the motor.

e the rated motor voltage is selected.

(MOTOR FREQUENCY)

[200] [208] [220] [230] [240] [380] [400] [400] [440] [460] [480] [500]

✭ 60

Function:

This sets the power value that corresponds to the nameplate power of the motor. The default setting

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

Quick Menu 005 Par. 105 Motor current

(MOTOR CURRENT)

Value:

0.01 - Drive rating

✭ Depends on motor

Function:

The rated motor current in amps forms part of the VLT frequency converter calculations for torque and motor thermal protection.

Description of choice:

Set a value that equals the nameplate data on the motor.

NB!:

It is important to enter the correct value, since this forms part of the VVC

control feature.

Quick Menu 006 Par. 106 Rated motor speed

(MOTOR

NOM. SPEED)

Value:

100 - 60000 rpm

✭ Depends on parameter 102, Motor power

Function:

This is where the value is set that corresponds to the rated motor speed found on the nameplate data.

Description of choice:

Set a value that corresponds to the motor nameplate data.

NB!:

It is important to set the correct value, since

this forms part of the VVC

control feature.

Description of choice:

Set a value from 0.0 Hz to the Output frequency high limit set in Quick Menu item 008 (parameter 202).

Quick Menu 008 Par. 202 Output frequency

high limit

(MAX. FREQUENCY)

Value:

Para 201 setting - Para 200 limit

✭ 60 Hz

Function:

In this parameter, a maximum output frequency can be selected that corresponds with the maximum motor speed. The drive will not be able to run continuously at an output frequency above this value in any mode.

NB!:

e output frequency high limit to 60 Hz

Set th for US applications. The output frequency of the VLT frequency converter can never

e a value higher than 1/10 of the switching

assum frequency (parameter 407, Switching frequency).

Description of choice:

Enter a value between the low frequency limit, set in Quick Menu item 07 (parameter 201), and the frequency range limit, set in parameter 200.

Quick Menu 009 Par. 206 Ramp-up time

(RAMPUPTIME)

Value:

1 - 3600 sec.

✭ Depends on unit

Controller Setup

VLT Drive and Cascade

The maximum value equals frequency x 60. Frequency is set in parameter 104, Motor frequency.

Quick Menu 007 Par. 201 Output frequency

low limit

(MIN. FREQUENCY)

Value:

0.0 - Parameter 202 setting

✭ 0.0 HZ

Function:

This is where to select the minimum output frequency. The drive will be unable to run continuously below t

MG.60.I3.02 - VLT is a registered Danfoss trademark

his value in any mode.

Function:

The ramp-up time is the acceleration time from 0 Hz to the rated motor frequency (parameter 104, Motor frequency). It is assumed that the output current does not reach the current limit (set in parameter 215, Current limit). This determines the maximum acceleration rate for all modes of operation.

Description of choice:

Set the desired ramp-up time. Too long of a ramp up can cause sluggish drive operation. Too short of a ramp up can cause the drive to go into current limit during acceleration or cause unaccepta ble torque pulses in the controlled system.

Quick Menu 010 Par. 207 Ramp-down time

(RAMP DOWN TIME)

Value:

1 - 3600 sec..

Function:

The ramp-down time is the deceleration time from the rated motor frequency (parameter 104, Motor frequency) to 0 Hz. This ramp-down time may be automatically extended to prevent an overvoltage trip if the load regenerates to the drive. This determines the maximum deceleration rate for all modes of operation.

Description of choice:

Set the desired ramp-down time. Too long of a ramp down can cause sluggish operation. Too short of a ramp down can cause the drive to trip off due to high DC bus voltage or cause unacceptable torque pulses in the controlled system.

✭ Depends on unit

Cascade Controller Option

Relay 1 1 - 3 break, 1 - 2 make Max. 240 VAC, 2 Amp. The relay is with the main and motor terminals.

Relay 2 4 - 5 make Max. 50 VAC, 1 A, 60 VA. Max. 75 VDC, 1A,30W.Therelayisonthecontrolcard.

Quick Menu 011 Par. 323 Output relay 1

(RELAY 1 FUNCTION)

Value:

29 optional settings

Function:

This output activates relay switch 01. This 240 volt, Form C relay can be used for status and warnings. There are 29 optional settings. It is generally programmed to provide a remote alarm indication.

No Alarm is the default setting. This indicates the drive is operating properly and the contact is closed. The contact opens to indicate an alarm when there is a fault condition or when the drive looses power. Terminal wires 1 and 3 are wired together.

Alarm is selected when a loss of power should not cause an alarm indication. Wire terminals 1 and 2 together.

See the VLT Operating Instructionsfora detailed list of relay options.

✭ NO ALARM

Relay outputs

■

Relay outputs 1 and 2 can be used to give the present drive status or a warning.

If the output is used as a voltage output (0-10 V), a pull-down resistor of 500 terminal 39 (common for analogue/digital outputs. See chapter 10 for additional detail).

Iftheoutputisusedasacurrentoutput,the resulting impedence of the connected equipment should not exceed 500 W.

should be fitted to

Description of choice:

Select relay 1 function.

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Cascade Controller Option

Quick Menu 012 Par. 326 Output relay 2

(RELAY 2 FUNCTION)

Value:

29 optional settings

✭ RUNNING

Function:

This output activates relay switch 02. This low voltage relay is generally programmed to provide a remote run indication. There are 29 optional settings.

Running makes this relay close when the drive is running. This is the default setting.

Description of choice:

Select relay 2 function.

Quick Menu 013 Par. 415 Units relating

to closed loop

(REF. /

FDBK. UNIT)

Value:

No unit

✭%

rpm ppm pulse/s l/s l/min l/h kg/s kg/min kg/h

/min

/h m/s mbar bar Pa kPa mVS kW

C GPM gal/s gal/min gal/h lb/s lb/min lb/h CFM

/min

[10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31]

[0] [1] [2] [3] [4] [5] [6] [7] [8] [9]

/h ft/s in wg ft wg PSI lb/in HP

[32] [33] [34] [35] [36] [37] [38] [39]

Function:

This unit will be used for the reading in the Display modeandasaunitforMinimum / Maximum

Feedback, Minimum / Maximum Reference, Warning Feedback High/Low and for the H1, H0 and the calculated Hmx parameter settings/readings.

Description of choice:

Select the unit for the reference/feedback signal.

Quick Menu 014 Par. 413 Minimum feedback

(MIN. FEEDBACK)

Value:

-999,999.999 - FB

MAX

✭ 0.000

Function:

Parameters 413, Minimum feedback and 414, Maximum feedback are used to scale the feedback

signal ensuring that it shows the feedback signal proportionally to the signal at the input.

Description of choice:

Setthevaluetobeshownonthedisplaywhenthe feedback signal is at its minimum value.

Quick Menu 015 Par. 414 Maximum feedback

(MAX. FEEDBACK)

Value:

- 999,999.999

MIN

✭ 100.000

Function:

Parameters 413, Minimum feedback and 414, Maximum feedback are used to scale the feedback

signal ensuring that it shows the feedback signal proportionally to the signal at the input.

Description of choice:

Setthevaluetobeshownonthedisplaywhenthe feedback signal is at its maximum value.

Controller Setup

VLT Drive and Cascade

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

Quick Menu 016 Par. 227 Warning:

Low feedback

(WARN LOW FDBK)

Value:

-999,999.999 - FB

(parameter 228)

HIGH

✭ -999.999,999

Function:

If the feedback signal is below the limit programmed in this parameter, the display will show a flashing FEEDBACK LOW.

The warning functions in parameters 221-228 are not active during ramp up after a start command, ramp down after a stop command or while stopped. The warning functions are activated when the output frequency has reached the resulting reference. The signal output can be programmed to generate a warning signal via terminal 42 or 45 or via the relay output.

In Closed loop, the unit for the feedback is programmed in parameter 415, Units related to closed loop.

Description of choice:

Set the desired value within the feedback range between parameter 413, Minimum Feedback,and parameter 414, Maximum Feedback.

Quick Menu 018 Par. 204 Minimum reference

(MIN. REFERENCE)

Value:

Parameter 100 Configuration = Closed loop [1].

-Par.413 Minimum feedback

-par.205Ref

MAX

✭ -999.999,999

Function:

The Minimum Reference sets the minimum value of the sum of all references. If Closed loop has been selected in parameter 100, Configuration, the minimum reference is limited by parameter 413, Minimum Feedback. Minimum reference is ignored when the local reference is active. In this case, minimum reference is determined by parameter 201, Minimum Frequency.

Description of choice:

Set the desired value within the feedback range between parameter 413, Minimum Feedback and parameter 414, Maximum Feedback.

QuickMenu 017 Par. 228 Warning High feedback

(WARN. HIGH FDBK)

Value:

(parameter 227) - 999,999.999

LOW

✭ -999.999,999

Function:

If the feedback signal is above the limit programmed in this parameter, the display will show a flashing FEEDBACK HIGH.

The warning functions in parameters 221-228 are not active during ramp-up after a start command, ramp-down after a stop command or while stop-ped. The warning functions are activated when the output frequency has reached the resulting reference. The signal outputs can be prog rammed to generate a warning signal via terminal 42 or 45 and via the relay outputs.

Description of choice:

Set the Minimum Reference, which is the lowest reference value that can be set for the drive. The unit for this reference is set in parameter 415.

Quick Menu 019 Par. 205 Maximum reference

(MAX. REFERENCE)

Value:

Par. 204 Ref

- par. 414 Maximum feedback

MIN

✭ 50.000 Hz

Function:

The Maximum reference gives the maximum value that can be assumed by the sum of all references. The Maximum Reference is limited to be with the settings of Parameter 414 Maximum Feedback. The Maximum reference is ignored when the local reference is active (parameter 203 Reference site).

Description of choice:

Set the Maximum reference, which is the highest reference value that can be set for the drive.

In Closed loop, the unit for the feedback is programmed in parameter 415 Units related to closed loop.

Quick Menu 020 Par. 723 Mode Select

(MODE SELECT)

Value:

Standard Control

✭ Master/Slave

Master/Slave Control

MG.60.I3.02 - VLT is a registered Danfoss trademark

Function:

Standard cascade control mode operation is a system consisting of one adjustable speed pump and up to four constant speed pumps. Master/Slave cascade control mode operation is for a system using variable speed pumps controlled by a Master drive.

NB!:

Set the correct control option. Improper setting may result in system damage, operational errors, or wasted energy.

Description of choice:

Select Standard Control for operating the cascade controller option card in Standard control mode. Select Master/Slave Control for operating the cascade controller option card in Master/Slave control mode.

Cascade Controller Option

Controller Setup

VLT Drive and Cascade

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

Alternate programming

■

etup configuration and copying parameters

S The fre setups that can be programmed. Each setup acts independently in controlling the drive. An exampl setups for day/night or summer/winter operation. Any of the four setups can be used.

The setup is selected in Extended Menu parameter 002, Active Setup, for programming and operation. Setups are changed manually by switching between active setups in parameter 002. It is also possible to change setups through digital inputs or serial communication by selecting Multi-Setup in parameter 002 and providing an external signal.

The number of the active setup selected is show the second line of the display.

The Extended Menu is accessed by pressing the [EXTEND. MENU] key on the LCP keypad.

A short cut to programming more than one setup is pos Setup Copy. This enables copying one setup to another. After an active setup has been programmed an other setups need be changed.

All setups can be transferred from one frequency converter to another (in the same VLT series) by using the frequency converter’s removeable keypad. Extended Menu parameter 004, LCP Copy,allows this function. First, upload all parameter values to the keypad. The keypad can then be removed and plugged into another frequency converter where all parameter values can be downloaded. If motor or drive sizes differ, Download Power-independent Parameters can be selected in parameter 004 to omit downloading motor and current dependent data.

✭Setup 1 (SETUP 1)

This parameter defines the setup number that controls the drive. All parameters can be programmed in four

quency converter has four parameter

e application would be programming different

n on the keypad display under Setup in

sible by using Extended Menu parameter 003,

d copied, just those parameters unique to the

Extended Menu Par. 002 Active Setup

(ACTIVE SETUP)

Value:

Factory Setup (FACTORY SETUP)

Setup 2 (SETUP 2) Setup 3 (SETUP 3) Setup 4 (SETUP 4) Multi-Setup(MULTI SETUP)

Function:

[0] [1] [2] [3] [4] [5]

individual parameter setups: Setup 1, Setup 2, Setup 3 and Setup 4. There is also a pre-programmed

nly setup, called the Factory Setup.

read-o

Description of choice:

Factory Setup contains the parameter values preset at the factory. This setup can be used as a data source if the other setups are to be returned to a known state. Setups 1 through 4 are four individual setups that can be programmed and selected as required. Multi-Setup is used if remote switching between different setups is required. Terminals 16, 17, 29, 32, 33 and the serial communication port can be used for switching between setups.

Extended MenuExtended Par. 003 Setup Copy

(SETUP COPY)

Value:

✭No copying (NO COPY)

Copy active Setup to Setup 1 (COPY TO SETUP 1) Copy active Setup to Setup 2 (COPY TO SETUP 2) Copy active Setup to Setup 3 (COPY TO SETUP 3) Copy active Setup to Setup 4 (COPY TO SETUP 4) Copy active Setup to All (COPY TO ALL)

Function:

A copy is made from the active setup selected in parameter 002, Active Setup, to the setup or setups selected here.

NB!:

Copying is only possible when drive is stopped.

Description of choice:

The copying starts when t he required copying function has been display indicates when copying is in progress.

Extended Menu Par. 004 LCP Copy

Value:

✭No copying (NO COPY)

Upload all parameters (UPLOAD ALL PARAMET.) Download all parameters

selected and the [OK] key pressed. The

(LCP COPY)

[0]

[1]

[2]

[3]

[4]

[5]

[0]

[1]

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

(DOWNLOAD ALL PARAM.) Download power-independent parameters (DOWNLOAD SIZE INDEP.)

Function:

This parameter is used to copy all parameter setups to or from the Local Control Panel (LCP) keypad. It can be used to store a backup copy of all parameters in the LCP or to copy all setups from one drive to another.

Description of choice:

Select Upload all parameters to copy all parameter values from the drive to the LCP. Select Download all parameters to copy all parameter values from the LCP to the drive on which the keypad is mounted. Select Download power-independent parameters if only the power-independent parameters are to be downloaded. This allows the parameters from one drive to be easily copied to another drive of a different size. Settings in parameters 102, 103, 104, 105, 106, 215, 221, and 222 are not downloaded using this function.

[2]

[3]

Controller Setup

VLT Drive and Cascade

NB!:

Copying is only possible when drive is stopped.

MG.60.I3.02 - VLT is a registered Danfoss trademark

Standard Cascade Controller Setup

■

Introduction

■

In standard cascade control, a frequency converter with the cascade option card controls a motor in response to system feedback signals w hile staging additional constant speed motors on and off. By varying the speed of the initial motor, variable speed control is provided for the system.

The motors can be of equal or differing sizes. The controller offers a selection of eight pre-defined pump combinations (see parameter 712).

A de-stage timer takes effect in standard control mode when the drive runs continuously at minimum speed with one or more constant speed motors running. The de-stage timer is programmable to avoid frequent staging on and off of the constant speed motors.

Although pump applications are highlighted in this chapter, the procedures and settings are nearly identical for other applications. The feedback process setup described, assumes that a pressure feedback signal is measured at the outlet of the pumps.

rogramming instructions: Instructions for programming Quick Menu items 1-20 are presented in Chapter 5, VLT Drive and Cascade Controller Card Setup. Parameters 1-20 must be programmed before programming Standard cascade control options.

Cascade Controller Option

ensor placement: Best efficiency is attained when the pressure transmitter is placed at the farthest significant load in the system. This setup allows measurement of actual system peformance. If this is not practical, the pressure transmitter is usually placed close to the discharge of the pumps.

The cascade controller uses the feedback to estimate the setpoint required at various rates of flow. Setpoint 1 is the minimum pressure required when the system is running with only the frequency converter operating at full speed. Setpoint 2 is the maximum pressure required when the system is running with all pumps at full capacity. A theoretical value calculates pressure loss in the system under minimum and maximum loads. The controller adjusts the loading based upon the number of pumps in operation.

When the pressure transmitter is placed at the farthest significant load in the system, common in HVAC applications, see alternative ways of programming the cascade controller described in Alternate Programming at the end of this chapter.

General information on how to program the frequency converter through the local control panel keypad are presented in Chapter 4, User Interface.

The instructions in this chapter describe procedures for programming the frequency converter for standard cascade control mode operation. The Quick Menu simplifies setup since the 39 parameters are programmed in sequence. Procedures for programming are in the following order:

Initial Setup: Quick Menu items 1-20 Step 1: Standard control mode programming Step 2: Optimization of the process regulator Alternate Programming Optimizing the process regulator is performed after

system start up. The procedures are described in Chapter 9, System Optimization.

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

Initial Setup

■

Instructions for programming Quick Menu items 1-20 ar Cascade Controller Card Setup. Parameters 1-20 must be programmed before programming addit

The combinations of pumps and their rated capacities are selected in this parameter. The lead pump (or fan) with the cascade contol option must have a capacity of 100% and its speed is controlled by the VLT adjustable frequency drive. This enables the highest accuracy in regulation of the system. In Standard cascade control mode, additional pumps can be either 100%, 200% or 300% relative to the VLT driven p ump.

e presented in Chapter 5, VLT Drive and

ional options described below.

Quick Menu 021 Par. 712 Motor Pump

Combinations

(PUMP COMBINATION)

Value:

(See options in table below)

Function:

Motor Pump Combinations Value:

Additional Constant Speed Pumps Operated by Cascade Control

Display Option 100% Capacity 200% Capacity 300% Capacity

R6 @100%

1 pump controlled by relay 6

R6, R7 @100% 2 pumps controlled by

relays 6, 7

R6-R8 @100% 3 pumps controlled by

relays 6, 7, 8

R6-R9 @100% 4 pumps controlled by

relays 6, 7, 8, 9

R6 @100%, R7 @200% 1 pump controlled by

relay 6 R6 @100%, R7, R8 @200% R6, R7 @100%, R8 @300% R6, R7 @100%, R8, R9 @300%

1 pump controlled by

relay 6

2 pumps controlled by

relays 6, 7

2 pumps controlled by

relays 6, 7

Description of choice:

Select the pump combination and capacities from the choices offered.

1 pump controlled

by relay 7

2 pumps controlled

by relays 7, 8

1 pump controlled

by relay 8

2 pumps controlled

by relays 8, 9

Controller Setup

Standard Cascade

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Quick Menu 022 Par. 713 Staging Bandwidth %

(STAGING BANDW%)

Value:

1 - 100%

Function:

In cascade control systems, to avoid frequent switching of fixed speed pumps, the desired system pressure is typically kept within a bandwidth rather than at a constant level. The staging bandwidth (SBW) is programmed as a percentage of the setpoint (desired pressure). For example, if the setpoint is 5 bar and the SBW set at 10%, a system pressure between 4.5 and 5.5 bar is tolerated. No staging or destaging will occur within this bandwidth.

Description of choice:

Set the staging bandwidth percentage to accomodate

m pressure fluctuation.

syste

✭ 10%

Cascade Controller Option

Description of choice:

Set the staging bandwidth off time delay. A delay time of 30 seconds (factory setting) is sufficient in most systems. When encountering frequent staging, add to the delay time.

NB!:

Should the drive trip for any reason, the cascade controller can continue operation

with the remaining C/S pumps or fans. It is recommend, however, that the user consider a wider bandwitdth for parameter 716, Override Bandwidth. Otherwise, unnecessary staging could occure.

Quick Menu 023 Par. 714 SBW staging off time

(DESTAGING DELAY)

Value:

0 - 3000 sec.

Function:

Immediate destaging of a fixed speed pump is not desirable when a momentary pressure increase in the system that exceeds the staging bandwidth (SBW). Destaging is delayed by the length of time programmed. If the pressure decreases to within the SBW before the timer has elapsed, the timer is reset.

✭ 30 sec.

Quick Menu 024 Par. 715 SBW staging on time

(STAGING DELAY)

Value:

0 - 3000 sec.

Function:

Immediate staging of a fixed speed pump is not desirable when a momentary pressure drop in the system that exceeds the staging bandwidth (SBW). Staging on is delayed by the length of time programmed. If the pressure increases to within the SBW before the timer has elapsed, the timer is reset.

Description of choice:

Set the staging on time delay. A delay time of 30 seconds (factory setting) is sufficient in most sys tems. When encountering freq uent staging, decease delay time.

✭ 30 sec.

MG.60.I3.02 - VLT is a registered Danfoss trademark

Quick Menu 025 Par. 716 Override bandwidth

(OVERRIDE BANDW%)

Value:

2 - 100 % (100 = OFF)

Function:

When a large and quick change in the system demand (such as a sudden water demand), the system pressure rapidly changes and an immediate staging or destaging of a fixed speed pump becomes necessary to match the requirement. The override bandwidth (OBW) is programmed to override the staging/destaging timer for immediate response. The override bandwidth is a percentage of the setpoint and defines the feedback (pressure) at which the timers (set in parameters 714, 715) are overridden. For example, if the setpoint is 5 bar and the override is set to 20%, the low limit is 4 bar and the high limit 6 bar.

✭ 100 = OFF

Cascade Controller Option

Commissioning the Cascade Controller

To avoid unintended staging during the commissioning phase and fine tuning of the controller, initially leave the OBW at the factory setting of 100%. When the fine tuning is completed, the OBW should be set to the desired value. A good initial value may be 10%.

Quick Menu 026 Par. 717 Override Bandw. timer

(OVERRIDE TIMER)

Value:

0 - 300 sec.

Function:

Staging a fixed speed pump creates a momentary pressure peak in the system, which might exceed the override bandwidth (OBW). It is not desirable to destage a pump in response to a staging pressure peak. The override bandwidth timer can be programmed to prevent st aging until the system pressure has stabilized and normal control established.

✭ 10 sec.

Controller Setup

Standard Cascade

Description of choice:

The OBW must always be programmed to a higher value than the staging bandwidth (SBW) set in parameter 713. Setting the OBW too close to the SBW could defeat the purpose with frequent staging at momentary pressure changes. Setting the OBW too high might lead to unacceptably high or low pressure in the system while the SBW timers are running. The value can be optimized with increased familiarity with the system. See parameter 717, Override Bandwidth Timer.

Description of choice:

Set the timer to a value that allows the system to stabilize after staging. The 10 second factory setting is appropriate in most applications. In highly dynamic systems, a shorter time might be desirable.

Quick Menu 027 Par. 718 Transition frequency

(TRANSITION FREQ %)

Value:

0 - 120 % of F

Function:

The adjustable speed pump typically runs at maximum speed when staging on an additional fixed speed pump to match the system demand.

max

✭ 90%

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Cascade Controller Option

The instant effect of the fixed speed pump creates a momentary overpressurization until the adjustable speed pump decelerates. This is undesirable in most situations. To avoid this, this drive can be programmed to decelerate to a transition frequency before starting the fixed speed pump.

the transition frequency might cause the check valve at the discharge of a variable speed pump to close

the transition, which could add pressure in the

during system. Ensure that the transition frequency setting allows the check valve to remain open.

Example:

Maximum frequency (F

um frequency (F

Minim

max

)= 30Hz

min

) = 60Hz

Transistion frequency to be programmed exactly

nd F

max

Then, transition frequency = 45/F

min

= 45/60 =75%

max

Quick Menu 028 Par. 418 Setpoint 1

(SETPOINT 1)

Value:

Feedback Min. to Feedback Max

✭ 0.000

The opposite process occurs during destaging where a momentary pressure drop is avoided by increasing the speed of the adjustable speed pump. Therefore, set a transition frequency roughly half-way between minimum and maximum frequency.

NB!:

Ensure that the transmission frequency is set

within the minimum frequency and maximum

set in parameters 201 and 202.

Description of choice:

Adjust the transition frequency to the best compromise to prevent momentary pressure overshoot and a pressure drop during transition. A very low value for the transition frequency might cause the check valve at the discharge of a variable speed pump to close during the transition, which could add pressure in the system. Ensure that the transition frequency setting allows the check valve to remain open.

Adjust the transition frequency to the best compromise to prevent momentary pressure overshoot and a pressure drop during transition. A very low value for

Function:

The default feedback process is used when a pressure feedback signal is measured at the outlet of the pumps. The cascade controller uses the feedback to estimate the setpoint required at various rates of flow. All other reference signals are ignored. Setpoint 1 is the minimum pressure required when the system is running with only the adjustable frequency drive operating at full speed. Setpoint 1 is a theoretical value that the cascade controller uses as an internal reference to calculate pressure loss in the system under minimum load. The controller adjusts the internal reference based upon the number of pumps in operation.

The range is determined by Quick Menu item 14 (parameter 413, Minimum Feedback) and Quick Menu item 015 (parameter 414, Maximum Feedback). When the pressure feedback signal originates at the far end of the system, the drive does not need to compensate for system pressure changes

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

due to flow. For this system configuration, or for two setpoint PID control, see Alternative

mming at the end of this chapter.

Progra

Description of choice:

Set the desired feedback minimum within the programmed minimum and maximum in Quick Menu items 014 and 015. The process unit is selected in Quick menu item 013, Process Units.

NB!:

Factory setting is for a single 4 - 20 mA current

signal transmitter for process feedback. In

all other cases, see instructions in Chapter 10, Feedback Transmitter Wiring.

Quick Menu 029 Par. 419 Setpoint 2

(SETPOINT 2)

Value:

Feedback Min. to Feedback Max.

Function:

The default feedback process is used when a pressure feedback signal is measured at the outlet of the pumps. The cascade controller uses the feedback to estimate the setpoint required at various rates of flow. All other reference signals are ignored. Setpoint 2 is the maximum pressure required when the system is running with all pumps at full capacity. A theoretical value calculates pressure loss in the system under maximum load. The controller adjusts the loading based upon the number of pumps in

✭ 0.000

across the outlet of the pumps, see Alternative Programming at the end of this chapter.

Description of choice:

Set the desired feedback maximum within the programmed minimum and maximum in Quick Menu items 014 and 015. The process unit is selected in Quick menu item 013, Process Units.Inawater supply system with little leakage, the difference between Setpoint 1 (set in Quick Menu item 028) and Setpoint 2 is typically around 10% to 15%.

Quick Menu 030 Par. 721 De-stage timer

(DESTAGE TIME)

Value:

0 - 300 sec. (301= OFF)

Function:

The de-stage timer starts when the adjustable speed pump is running a minimum speed with one or more

ant speed pumps in operation and system

const requirements satisfied. In this situation, the adjustable speed pump contributes little to the system. When

rogrammed value of the timer expires, a fixed

the p speed pump is destaged and the adjustable speed pump accelerated to maintain system requirement.

saves energy and avoids dead head water

This circulation within the adjustable speed pump.

Description of choice:

Set the de-stage timer interval. When sleep mode is activated, ensure the interval is set lower or equal to the value of the sleep mode timer (parameter 403).

✭ 15 sec.

Controller Setup

Standard Cascade

The range is determined by Quick Menu item 014 (parameter 413, Minimum Feedback) and Quick Menu item 05 (parameter 414, Maximum Feedback).

When the pressure feedback signal originates at the far end of the system, the drive does not need to compensate for system pressure changes due to flow. For this system configuration, or for two setpoint PID control, or for water pumping systems where the feedback signal is measured

MG.60.I3.02 - VLT is a registered Danfoss trademark

NB!:

Sleep mode activates when the adjustable

speed p

turn off the destage timer, turn off sleep mode first. Set parameter 403, Sleep Mode to

conds (off), then parameter 721, De-stage

301 se Timer to 301 seconds (off).

Quick Menu 031 Par. 722 Pump cycling

(PUMPCYCLING)

Value:

Enabled - Disabled

Function:

To achieve equal hours of operation in the constant speed pumps, pump use can be cycled. Timers on the relay outputs (relays 6, 7, 8, and 9) monitor the running hours of each pump. In staging on, the relay (pump) with the least hours is switched on. In destaging, the relay (pump) with the most hours is switched off. Not operating a pump over long time periods can create corrosion concerns.

ump is the only pump running. To

✭ Enabled

Cascade Controller Option

If cycling is disabled, the controller follows the fixed pattern of relay activation (6, 7, 8 and

9) regardless of the running hour counters. Destaging is in the reverse order.

Description of choice:

Choosewhethertodisableorenablethefunction.

Quick Menu 035 Par. 420 PID normal/inverse

rol

cont

(PID NOR/INV. CTRL)

Value:

✭Normal (NORMAL)

Inverse(INVERSE)

Function:

This determines how the d rives PID controller responds to a difference between the setpoint and feedback. Normal is when the drive is to reduce the output frequency as the feedback signal increases. Inverse is when the drive is to increase the output frequency as the feedback signal increases.

[0] [1]

Description of choice:

Select the PID controller response op tion.

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

Alternate programming

■

In water supply systems, it is o ften impractical to place a In HVAC and other applications, however, it is often possible to place the pressure sensor(s) at the farthest signi system. In these cases, the cascade option can use the drive’s PID controller to respond to system chang on and off in response to the system feedback signal.

The most common setup for feedback response is with a single transmitter located at the farthest significant load in the system. Programming the cascade controller option in this manner is described below. It is also possible for the PID to accept two feedback signals, making two-zone regulation available. For two feedback control, and for additional setting options, see the VLT Operating Instructions.

Setup for feedback response is with a single tra the system requires programming parameter 417, Feedback Function, and parameter 418, Setpoint 1. Pa through the Extended Menu. The Extended Menu is accessed by pressing the [EXTEND. MENU] key on be accessed through either the Extended Menu or as item 28 in the Quick Menu.

pressure sensor at the far end of the system.

ficant load and measure actual pressure in the

es as programmed. Pumps or fans are staged

nsmitter located at the farthest significant load in

rameter 417, Feedback Function, is only accessible

the drive control panel. Parameter 418 may

Description of choice:

Set the feedback function to Maximum for the drive to use Setpoint 1 as the maximum reference signal for control.

Quick Menu 028 Par. 418 Setpoint 1

(SETPOINT 1)

Value:

Feedback Min. to Feedback Max.

Function:

Setpoint 1 is used to provide the setpoint reference for one setpoint PID control or for the setpoint for zone 1 in two setpoint PID control. All other reference signals are ignored.

Description of choice:

Set the required value the system is to maintain during n ormal operation. The value must be between the minimum and maximum values set in Quick Menu items 14 and 15 (parameter 413, Minimum Feedback, and parameter 414, Maximum Feedback). Setpoint 2, Quick Menu item 29, is not used in one feedback signal applications.

✭ 0.000

Controller Setup

Standard Cascade

EXTENDED MENU Par. 417 Feedback Function

(2 FEEDBACK, CALC.)

Value:

Minimum(MINIMUM) Maximum(MAXIMUM) Sum (SUM) Difference (DIFFERENCE) Average (AVERAGE) Two-zone minimum (2 ZONE MIN) Two-zone maximum (2 ZONE MAX)

✭Virtual Control Curve (VIRTUAL CTRL CURVE)

Feedback 1 Only (FEEDBACK 1 ONLY) Feedback 2 Only (FEEDBACK 2 ONLY)

Function:

This parameter sets the calculation method whenever a system feedback signal is used, or when two feedback signals (Setpoint 1 and Setpoint 2) are used.

MG.60.I3.02 - VLT is a registered Danfoss trademark

Master/Slave Cascade Control Setup

■

Introduction

■

In Master/Slave cascade control operation, the frequency converter with the cascade control option card is the Master. The Master drive controls the speed and staging on or off of up to four additional adjustable speed drives. The Master drive exports a pulse signal or analog speed signal through its output relays to the slave drives. It is recommended that a pulse signal be used for minimum electrical noise and for precise drive control.

The Master drive and the slave drives are programmed for different operation, although many parameters are set the same. The Master drive is programmed for closed loop operation and responds to system feedback signals to meet the needs of the system. The slave drives are programmed for open loop operation and receive a variable speed signal and stop/start commands from the Master drive.

rogramming instructions: Instructions for programming Quick Menu items 1-20 are presented in Chapter 6, VLT Drive and Cascade Controller Card Setup. Parameters 1-20 must be programmed before programming Master/Slave cascade control options.

The instructions in this chapter describe procedures for programming both the Master and slave drives for Master/Slave cascade control mode. Procedures for programming are in the following order:

Initial Setup: Quick Menu items 1-20

Cascade Controller Option

entering pump and system data, MUSEC provides the programmer with Master drive on and off staging frequencies for each pump at optimal efficiency. For a free download, go to www.danfoss.com and enter MUSEC in the search box.

ensor placement:

S Best efficiency is attained when the pressure transmitter is placed at the farthest significant load in the system. This setup allows measurement of actual system peformance. If this is not practical, the pressure transmitter is usually placed close to the discharge of the pumps.

The default feedback process described for setup in this chapter is used when a pressure feedback signal is measured at the outlet of the pumps. The cascade controller uses the feedback to estimate the setpoint required at various rates of flow. Setpoint 1 is the minimum pressure required when the system is running with only the adjustable frequency drive operating at full speed. Setpoin t 2 is the maximum pressure required when the system is running with all pumps at full capacity. A theoretical value calculates pressure loss in the system under minimum and maximum loads. The controller adjusts the loading based upon the number of pumps in operation.

Although pump applications are highlighted in this chapter, the procedures and setting are nearly identical for fan applications, such as controlling multiple cooling tower fans. Differences between fan and pump settings are described in the procedures.

Step 1: Master drive programming Step 2: Slave drive programming Step 3: Optimization of the process regulator Alternate Programming Optimizing the process regulator is performed after

system start up. The procedures are described in Chapter 9, System Optimization.

est efficiency: Danfoss has available the Multiple Unit Staging Efficiency Calculator (MUSEC), a free software program available on the Danfoss website. By

General information on how to program the adjustable frequency drive through the local control panel keypad are presented in Chapter 4, User Interface.

Initial Setup

■

Instructions for programming Quick Menu items 1-20 are presented in Chapter 5, VLT Drive and Cascade Controller Card Setup. Parameters 1-20 must be programmed into the Master drive before programming additional Master/Slave cascade control options described below.

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

Step 1: Master drive programming

■

The following drive parameters are used in

mming the Master drive. Note that while

progra the menu items are in sequence, not each menu item in the Quick Menu is programmed.

Quick Menu 021 Par. 712 Motor Pump

Combinations

(PUMP COMBINATION)

Value:

R6 @100%

R6, R7 @100%

R6-R8 @100%

R6-R9 @100%

Function:

The number of slave pumps or fans is selected in this parameter. In Master/Slave operation, all motors are the same size. R6 @100% = one slave controlled by relay 6. R6, R7 @100% = two slaves controlled by relays 6 and 7. R6-R8 @100% = three slaves controlled by relays 6, 7, and 8. R6-R9 @100% = four slaves controlled by relays 6, 7, 8, and 9.

Description of choice:

Select the number of slave pumps or fans.

Quick Menu 023 Par. 714 SBW staging off time

(DESTAGING DELAY)

Value:

0 - 3000 sec.

✭ R6 @100%

✭ 30 sec.

Quick Menu 024 Par. 715 SBW staging on time

(STAGING DELAY)

Value:

0 - 3000 sec.

Function:

Staging delay time is used to prevent the fast cycling on of the slave pumps or fans. Increase the time if frequent switching is encountered.

Description of choice:

Set staging on delay time. In Master/Slave operation, 3 secon

The default feedback process is used when a pressure feedback signal is measured at the outlet of the pumps. The cascade controller uses the feedback to estimate the setpoint required at various rates of flow. Setpoint 1 is the minimum pressure required when the system is running with only the adjustable frequency drive operating at full speed. Setpoint 1 is a theoretical value that the cascade controller uses as an internal reference to calculate pressure loss in the system under minimum load. The controller adjusts the internal reference based upon the number of pumps in operation.

dsisatypicalvalue.

Quick M

Value:

Feedback Min. to Feedback Max.

Function:

enu 028 Par. 418 Setpoint 1

(SETPOINT 1)

✭ 30 sec.

✭ 0.000

Control Setup

Master/Slave Cascade

Function:

Destaging delay time is used to prevent the fast cycling off of the slave pumps or fans. Increase the time if frequent switching is encountered.

Description of choice:

Set staging off delay time. In Master/Slave operation, 3secon

MG.60.I3.02 - VLT is a registered Danfoss trademark

ds is a typical value.

The range is determined by Quick Menu item 14 (parameter 413, Minimum Feedback) and Quick Menu item 15 (parameter 414, Maximum Feedback). When the pressure feedback signal originates at the far end of the system, the drive does not need to compensate for system pressure changes due to flow. For this system configuration, or for two setpoint PID control, see Alternative Programming at the end of this chapter.

Cascade Controller Option

Description of choice:

Set the desired feedback minimum within the programmed minimum and maximum in Quick Menu items 14 and 15. The process unit is selected in Quick menu item 13, Process Units.

NB!:

Factory setting is for a single 4 - 20 mA current signal transmitter for process feedback. In all other cases, see instructions in Chapter

10, Feedback Transmitter Wiring.

Quick Menu 029 Par. 419 Setpoint 2

(SETPOINT 2)

Value:

Feedback Min. to Feedback Max.

Function:

The default feedback process is used when a pressure feedback signal is measured at the outlet of the pumps. The cascade controller uses the feedback to estimate the setpoint required at various rates of flow. Setpoint 2 is the maximum pressure required when the system is running with all pumps at full capacity. A theoretical value calculates pressure loss in the system under maximum load. The controller adjusts the loading based upon the number of pumps in operation.

✭ 0.000

items 14 and 15. The process unit is selected in Quick menu item 13, Process Units.

Quick Menu 031 Par. 722 Pump cycling

(PUMP C YCLING)

Value:

Enabled - Disabled

Function:

To achieve equal hours of operation, use of pumps or fans can be cycled. Timers on the relay outputs (relays 6, 7, 8, and 9) monitor the running hours of each pump. In staging on, the relay with the least hours is switched on. In destaging, the relay with the most hours is switched off. Not operating a pump over long time periods can create corrosion concerns.

If cycling is disabled, the controller follows the fixed pattern of relay activation (6, 7, 8 and 9) regardless of the running hours. Destaging is in the reverse order.

Description of choice:

Choose whether to enable or disable the function.

Quick Menu 032 Par. 319 Analog output,

terminal 42

(AO 42 FUNCTION)

Value:

Output, terminal 42

✭ Output current 4-20 mA

✭ Enabled

The range is determined by Quick Menu item 14 (parameter 413, Minimum Feedback) and Quick Menu item 15 (parameter 414, Maximum Feedback).

When the pressure feedback signal originates at the far end of the system, the drive does not need to compensate for system pressure changes due to flow. For this system configuration, or for two setpoint PID control, see Alternative Programming at the end of this chapter.

Description of choice:

Set the desired feedback maximum within the programmed minimum and maximum in Quick Menu

Function:

An analog/digital output is available through terminal 42 and can be programmed to show a status or an analog value such as frequency. For the analog output, there are three types of output signals: 0 to 20 mA, 4 to 20 mA, or 0 to 32000 pulses. The pulse rate is set by parameter 320, Terminal 42, Output, Pulse Scaling.

Description of choice:

Set the output of terminal 42 to Output Frequency (pulse sequence), (OUT.FREQ.PULSE) for Master/Slave

operation as shown in the wiring diagram in Chapter

4. Using frequency pulse is a reliable way of providing the same speed reference to all slave drives. Current output is limited to two slave drives.

System pressure and flow requirements can often be generated using parallel pumps at different efficiencies. The cascade controller can automatically configure the number of pumps in operation to achieve the highest system efficiency. Running three pumps at full

MG.60.I3.02 - VLT is a registered Danfoss trademark

Cascade Controller Option

speed, for example, may satisfy system requirements, while running four pumps at a lower speed meets

ements and achieves higher efficiency.

requir Danfoss has available the Multiple Unit Staging

Efficiency Calculator (MUSEC), a free software program available on the Danfoss website. By entering pump and system data, MUSEC provides the programmer with on and off staging frequencies for each pump at optimal efficiency. Enter the data for each pump in Extended Menu parameters 739 and

740. For a free download, go to www.danfoss.com and enter MUSEC in the search box.

Quick Menu 033 Par. 739 Master/Slave

staging on frequencies

(M/S STAGE FREQ)

Value:

Min. freq - Max. freq

(Par. 201 - 202)

Function:

Best efficiency staging on frequency can be calculated for the cascade controller based on pump and system curves to meet feedback requirements. Use the MUSEC software program to determine the most efficient staging on frequency for each pump.

Description of choice:

Enter the staging on frequency for each pump. After pressing the CHANGE DATA key in parameter 739, use the (+) and (-) keys to scroll through all four slave settings.

Ifthepumporsystemdataisunknown,refer to the section Alternative Programming at

end of this chapter.

the

✭ Min. freq.

Description of choice:

Enter the staging off frequency for each pump. After pressing the CHANGE DATA key in parameter 740, use the (+) and (-) keys to scroll through all four slave settings.

If the pump or system data is unknown, refer to the section Alternative Programming at the end of this chapter.

Step 2: Slave drive programming

■

The slave drives run in open loop mode and recieve stop/start and speed reference commands from the Master drive. Each slave drive must be programmed with the nameplate data from the motor it controls. All other applicable parameter settings must match the settings in the Master drive.

All parameter settings can be transferred from one VLT drive to another by using the r emoveable keypad. Parameter 004, LCP Copy, allows this function. First, upload all parameter values to the Local Control Panel (LCP) keypad. The keypad can then be removed and plugged into another VLT drive where all parameter values can be downloaded. If motor or drive sizes differ, Download Power-independent Parameters can be selected in parameter 004 to omit downloading motor and current dependent data.

Manual programming of slave drives is also possible following the procedure described for Master drive programming. To copy required Master drive parameter settings manually into each slave drive, enter Master drive settings for Quick Menu items 7-13 and 18-19 into each slave drive.

Commisioning slave drives is done in the following sequence of events:

Control Setup

Master/Slave Cascade

ck Menu 034 Par. 740 Master/Slave

Qui

staging off frequencies

(M/S DESTAGE FREQ)

Value:

Min. freq - Max. freq

(Par. 201 - 202)

Function:

Best efficiency staging off frequency can be calculated for the cascade controller based on pump and system curves to meet feedback requirements. Use the MUSEC software program to determine the most efficient staging off frequency for each pump.

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✭ Min. freq.

nter Motor Nameplate Data Enter the nameplate data from each motor into its associated drive in accordance with Quick Menu items 001 - 006 in Chapter 6, VLT Drive and Cascade Control Card Setup.

ownload master drive programming data Use the Master LCP to download parameter settings into the slave drives in accordance with procedures in Extended Menu parameter 004, LCP Copy. The Extended Menu is accessed by pressing the [EXTEND. MENU] key on the LCP keypad.

Cascade Controller Option

Extended Menu Par. 004 LCP Copy

(LCP COPY)

Value:

✭No copying (NO COPY)

Upload all parameters (UPLOAD ALL PARAMET.) Download all parameters (DOWNLOAD ALL PARAM.) Download power-independent parameters (DOWNLOAD SIZE INDEP.)

Function:

Description of choice:

NB!:

Copying is only possible when drive is stopped.

Alternate programming:

■

ump/system data for MUSEC unavailable:

P In cases where the pump or system data points are not known, the best efficiency staging and destaging frequencies are difficult to calculate. Operation of the system is possible with an approximation of the best efficiency function.

1. Set staging on frequency in Quick Menu item 33 (parameter 739, Master/Slave staging on frequency), to the maximum frequency set in Quick Menu item 08 (parameter 202, Output frequency high limit).

2. For an approximation of best efficiency, set the destaging frequences in Quick Menu item 34 (parameter 740, Master/Slave staging off frequency), to half of the frequency set between Quick Menu item 08 (parameter 202)

[0]

[1]

[2]

[3]

and Quick Menu item 07 (parameter 201, Output frequency low limit).

lternate Feedback Programming : In water supply systems, it is often impractical to placeapressuresensoratthefarendofthesystem. In HVAC and other applications, however, it is often possible to place the pressure sensor(s) at the farthest significant load and measure actual pressure in the system. In these cases, the cascade option can use the drive’s PID controller to respond to system changes as programmed. Pumps or fans are staged on and off in response to the system feedback signal.

The most common setup for feedback response

th a single transmitter located at the farthest

is wi significant load in the system. Programming the cascade controller option in this manner is described

ow. It is also possible for the PID to accept

bel two feedback signals, making two-zone regulation available. For two feedback control, and for additional

ting options, see the VLT Operating Instructions.

set Setup for feedback response is with a single

transmitter located at the farthest significant load in the system requires programming parameter 417, Feedback Function, and parameter 418, Setpoint 1. Parameter 417, Feedback Function, is only accessible through the Extended Menu. The Extended Menu is accessed by pressing the [EXTEND. MENU] key on the drive control panel. Parameter 418 may be accessed through either the Extended Menu or as item 28 in the Quick Menu.

xtended Menu Par. 417 Feedback Function

(2 FEEDBACK, CALC.)

Value:

Minimum(MINIMUM) Maximum (MAXIMUM) Sum (SUM) Difference (DIFFERENCE) Average (AVERAGE) Two-zone minimum (2 ZONE MIN) Two-zone maximum (2 ZONE MAX)

✭Virtual Control Curve (VIRTUAL CTRL CURVE)

Feedback 1 Only (FEEDBACK 1 ONLY) Feedback 2 Only (FEEDBACK 2 ONLY)

Function:

This parameter sets the calculation method whenever a system feedback signal is used, or when two feedback signals (Setpoint 1 and Setpoint 2) are used.

Description of choice:

Select the feedback calculation method required. Maximum uses Setpoint 1 as the maximum

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reference signal for control. See the VLT Operating Manual for additional information.

Quick Menu 028 Par. 418 Setpoint 1

(SETPOINT 1)

Value:

Feedback Min. to Feedback Max.

Function:

Setpoint 1 is used to provide the setpoint reference for one setpoint PID control or for the setpoint for zone 1 in two setpoint PID control.

Description of choice:

Set the required value the system is to maintain during normal operation. The value must be between the minimum and maximum values set in Quick Menu items 14 and 15 (parameter 413, Minimum Feedback, and parameter 414, Maximum Feedback). Setpoint 2, Quick Menu item 29, is not used in one feedback signal applications.

✭ 0.000

Cascade Controller Option

Control Setup

Master/Slave Cascade

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System Optimisation

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System start up and final adjustments

■

After Master drive and slave programming is complete, and after all system safety procedures have been ensured and the system is operational, final adjustments can be made to reach maximum efficiency for drive and cascade controller operation.

Final adjustments involves the following: a. Setting the best efficiency frequency in the cascade

controller for staging and destaging pumps and fans

b. Optimization of the process regulator

Best efficiency frequency

■

Quick Menu 036 Par. 422 PID start-up frequency

(PID START VALUE)

Value:

MIN-fMAX

(parameters 201 and 202)

Cascade Controller Option

✭ 0Hz

Function:

Each time the drive is given a start command, the start up frequency is the speed the drive accelerates to before PID control is activated. The drive will follow the acceleration ramp when a start signal is received as if in open loop. When the programmed start frequency is reached, it will change to closed loop operation.

ription of choice:

Desc

Set the required start frequency. A setting near the operating speed will enable the system to stabilize more quickly. For pump applications, set this high enough to ensure flow from the pump.

Quick Menu 037 Par. 427 PID lowpass filter time

(PID FILTER TIME)

Value:

0.01 - 10.00

Function:

Noise on the feedback signal can be reduced with the lowpass filter.

✭ 1.00

The PID controller will then only respond to changes in the feedback signal whose frequency is less than 1.6 Hz.

Description of choice:

Select the desired time constant (t). The cut off

frequency equals of 0.1 s is programmed, the cut off frequency for the lowpass filter will be 1/[2

t. For example, if a time constant

(.1)] = 1.6 Hz.

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Optimization of the process regulator

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Quick Menu 038 Par. 423 PID proportional gain

(PID PROP. GAIN)

Value:

0.00 - 10.00

Function:

Determines how fast the system responds to a change in feedback.

Description of choice:

Quick regulation is obtained by a high gain, but if the ga unstable. See Optimization of the Process Regulator for information on proper adjustment.

in is too high, the process may become

Quick Menu 039 Par. 424 PID integration time

(PID INTEGR.TIME)

Value:

0.01 - 9999.00 sec. (OFF)

✭ 0.01

✭ OFF

Cascade Controller Option

PID equation:

The VLT PID controller operates in accordance to the following equation:

PID out = P[e(t) + 1/ l f e(t) dt] + D e(t)/dt

Function:

Theintegratoraddstheerrorsignalovertimeand uses this to correct the speed of the drive. The integration time is the time needed by the integrator to have the same effect as the proportional gain.

Description of choice:

Fast regulation is obtained by setting a short integration time. However, if this time is too short, the pro See Optimization of the Process Regulator for information on p roper adjustment.

P The process regulator is set by Quick Menu items 38 and 39 (parameters 423 and 424). To optimize the proportional gain and integration time, in most processes, this can be done as follows:

1. Start

2. Set parameter 423, PID Proportional Gain,to0.3

3. Set p

cess will overcorrect and become unstable.

rocedure for Optimization of the Process Regulator

the motor.

and increase it until the feedback signal becomes

able. Then reduce the value until the feedback

unst signal has stabilized. Now lower the proportional gain by about half (40% to 60%).

arameter 424, PID Integration Time,to20 seconds and reduce the value until the feedback signal becomes unstable. Increase the integration

until the feedback signal stabilizes. Now

time increase the integration time from 15% to 50%.

System Optimisation

Starting and stopping the drive will produce the necessary error signal in the process to set the PID.

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Feedback Transmitter W iring

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Connecting feedback transmitters

■

Terminal 12 and 13 of the VLT provide access to a 24 VDC, 200 mA power supply. This can be used to power remote transmitters, so an external power supply is generally not needed. The diagrams below show how to wire two- and three-wire transmitters.

ingle 4 - 20 mA feedback transmitter connection:

Programming: Parameter Parameter Parameter Number Description Value 415 REF./FDBK UNIT Process unit 413 MIN. FEEDBACK Transmitter low limit 414 MAX. FEEDBACK Transmitter high limit 308 AI [V] 53 FUNCT. NO OPERATION 311 AI [V] 54 FUNCT. NO OPERATION 314 AI [mA] 60 FUNCT FEEDBACK 315 AI 60 SCALE LOW 4 mA 316 AI 60 SCALE HIGH 20 mA

Cascade Controller Option

Single 0 - 10 V feedback transmitter connection:

Programming: Parameter Parameter Paramet er Number Description Value 415 REF./FDBK UNIT Process unit 413 MIN. FEEDBACK Transmitter low limit 414 MAX. FEEDBACK Transmitter high limit 308 AI [V] 53 FUNCT. FEEDBACK 309 AI 53 SCALE LOW 0 V 310 AI 53 SCALE HIGH 10 V 314 AI [mA] 60 FUNCT NO FUNCTION

Two 0 - 10 V feedback transmitter connections: When two feedback signals are used with the VLT, both signals must be voltage signals. Both transmitters must also have the same range.

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Cascade Controller Option

Programming: Parameter Parameter Par ameter Number D escription Value 415 Ref./FDBK UNIT Process unit 413 MIN. FEEDBACK Transmitter low limit 414 MAX. FEEDBACK Transmitter high limit 417 2 FEEDBACK CALC. Desired operation 308 AI [V] 5 3 FUNCT. FEEDBACK 309 AI 53 SCALE LOW 0V 310 AI 53 SCALE HIGH 10V 311 AI [V] 5 4 FUNCT. FEEDBACK 312 AI 54 SCALE LOW 0V 313 AI 54 SCALE HIGH 10V 314 AI [mA] 60 FUNCT. NO OPERATION

Two 4 - 20 mA feedback transmitters connection: When two feedback signals are used, the VLT requires that they both be connected to its analog voltage inputs, terminals 53 and 54. Transmitters that produce a current signal can be used by adding two resistors.

Two feedback signals and two setpoints: Similar to two feedback signals and one setpoint, the need fo

r two feedback signals with two setpoints is frequently encountered. Whenever two critical zones do not have the same setpoint value, two feedback

wo setpoint control is required. Many pumping

with t systems require the monitoring and control of two loads that differ in size and pressure drop. Or this can be

effective when controlling different temperature

zones in cooling or heating applications.

If the transmitter is capable of producing 10V at 20 mA, the value of the resistor to use is:

The input scaling of the VLT analog inputs in this case would have to be 2 - 10 Volt.

Programming: Parameter Parameter Parameter Number Description Value 415 Ref./FD BK UNIT Process unit 413 MIN . FEEDBACK Transmitter low limit 414 MAX. FEEDBACK Transmitter high limit 417 FEE D BACK CALC. Desired operation 308 AI [V] 53 FUNCT. FEEDBACK 309 AI 53 SCA LE LOW 2V 310 AI 53 SCALE HIGH 10V 311 AI [54] 54 FUNCT. FE EDBACK 312 AI 54 SCA LE LOW 2V 313 AI 54 SCALE HIGH 10V 314 AI [mA] 60 FUNCT. NO OPERATION

To enable this setup, the feedback function in parameter 417, Feedback Function, is selected. When selecting 2-zone Minimum in parameter 417, the drive will regulate the system so the feedbacks are equal to or greater than their associated setpoints. If 2-zone Maximum is selected, the feedbacks will be equal to or less than their associated setpoints.

Feedback 1 is associated with Setpoint 1 and Feedback 2 is associated with Setpoint 2. The two independent groupings are continuously monitored to satisfy both zones requirements.

Transmitter connection to the VLT: The transmitters are connected to the VLT in the same way as shown above with 1 setpoint and 2 feedbacks. The feedback connected to terminal 53 is assigned to setpoint 1 and the one connected to terminal 54 to setpoint 2. Both transmitters must have the same output signal and range.

rogramming example for 2 feedback and

2 setpoint controls:

Wiring

Feedback Transmitter

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Transmitter ratings:

Supply: 15 - 30 VDC Output: 0 - 10 V Range: 0 - 100 Pa

The VLT is programmed to match its input to follow the specification of the transmitter:

Programming: Parameter Parameter Parameter Number Description Value 100 CONFIG. MODE CLOSED LOOP 415 Ref./FDBK UNIT Pa 413 MIN. FEEDBACK 0 414 MAX. FEEDBACK 100 308 AI [V] 53 FUNCT. FEEDBACK 309 AI 53 SCALE LOW 0 310 AI 53 SCALE HIGH 100 311 AI [54] 54 FUNCT. FEEDBACK 312 AI 54 SCALE LOW 0 313 AI 54 SCALE HIGH 100 314 AI [mA] 60 FUNCT. NO OPERATION

Cascade Controller Option

The reference range is generally set to equal the range of the transmitter. In this way, the setpoint (reference) can be set to any value that the transmitter can produce. If required, the reference range can be set to a range that is narrower than the transmitters range, but it cannot be set to a wider range.

Parameter Parameter Parameter Number Description Value 204 MIN. REFERENCE 0 205 MAX. REFERENCE 100

In this example, load 1 requires a pressure of at least 30 Pa and load 2 at least 60 Pa.

Parameter Parameter Par ameter Number D escription Value 417 2 FEEDBACK CALC. 2 ZONE M IN 418 SETPOINT 1 30 419 SETPOINT 2 60

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Parameter group 700 definitions

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Cascade Controller Option

Para Name Description Unit Range Factory

Setti

712 PUMP COMBINA-

TION

713 STAGING BANDW.%Pump Staging Bandwidth in

714 DESTAGING DELAY Pump Staging Bandwidth off Sec. 0.0 - 3000.0 10 sec. Yes 6 -1 715 STAGI 716 OVERRIDE

717 OVERRIDE TIMER Over-ride Bandwidth

718 STAGING FREQ% VLT Frequency at staging

721 DESTA 722 PUMP CY CLING Enable or disable pump

723 OPERATIONAL

724 PUMP 2 ON TIME Hour meter for pump 2 Hrs 0 - 130000 0.0 Yes 7 -1 725 PUMP 3 ON TIME Hour meter for pump 3 Hrs 0 - 130000 0.0 Yes 7 -1 726 PUMP 4 ON TIME Hour meter for pump 4 Hrs 0 - 130000 0.0 Yes 7 -1 727 PUMP 5 ON TIME Hour meter for pump 5 Hrs 0 - 130000 0.0 Yes 7 -1 728 PUMP 2 CYCLES Cycle counter for pump 2 No. 0 - 130000 0.0 Yes 7 0 729 PUMP 3 CYCLES Cycle counter for pump 3 No. 0 - 130000 0.0 Yes 7 0 730 PUMP 4 CYCLES Cycle counter for pump 4 No. 0 - 130000 0.0 Yes 7 0 731 PUMP 5 CYCLES Cycle counter for pump 5 No. 0 - 130000 0.0 Yes 7 0 736 RELAY ON TIME Relay hour meter, relay R6 -R9Hrs 0 - 130000 0.0 No 7 -1

NG DELAY

BANDW.%

GE T IME

MODE SELECT

Selects number and size of slave pumps

tpoint

%ofse

taging Bandwidth on

Pump S Over-ride Bandwidth % 2.0 - 100.0 100% Yes 6 -1

hysteresis time

transition in % of max speed

ge timer

Desta

cycling Selects either Standard or Master/Slave control

No. 1-8 R6@100 No 5 0

% 1.0 - 100.0 5.0% Yes 6 -1

Sec. 0.0 - 3

Sec. 0.0 - 300 10 sec. Yes 6 -1

% 0.0 - 100.0 90% Yes 6 -1

Sec. Para 4

000.0

03 - 600

Enabled/Disabled Enable No 5 0

Standard/Master Slave

10 sec

OFF Yes 6 0

Standard No 5 0

Change

Durin Operation

Yes 6 -1

Data Type Conversion

Index

all parameters

Parameter group 700,

737 RELAY CY 738 SETPOINTS HM 1- 7 Ca lculate d intermediate

739 M/S STAGE FREQ M/S Stage on frequency, relay

740 M/S DESTAGE FREQ M/SStage off frequency, relay

CLES

cle c ounter, r ela

Relay Cy

setpoint, relay (Hm1-Hm7)

(1-4)

No. 0 - 13000 Para

H0 - H1 0.000 No 4 -3 415 Hz Para 201-202 Para 202 Yes 6 -1

Hz Para 201-202 Para 201 Yes 6 -1

Conversion Index Factors

Conversion Index Conversion Factor 74 3.6

2100.0

110.0

01.0

-1 0.1

-2 0.01

-3 0.001

-4 0.0001

0.0 No 7 -1

DataType Descriptions

Data type Description 3 Integer 16 4 Integer 32 5 Unsigned 8 6 Unsigned 16 7 Unsigned 32 9Textstring

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Service parameters

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Cascade Controller Option

Display information

■

Parameters 724 through 738 provide operational information including the number of hours run, cycles, and the state of the relay for each pump.

Par. 724 - 727 Pump-on time (PUMP x ON TIME) Parameter number Pump number

724 Pump 2 725 Pump 3 726 Pump 4

727 Pump 5 Value: h 0 - 130000 Function: The relay timer accumulates the hours (h) the pump has run (the relay switched on). The counter is updated 10 times per hour which means that cycles less than 6 minutes are not registered. The hours can be reset to zero when a pump is replaced since the cascade controller uses parameter 736, Relay On Time, to determine cycling patterns.

Par. 728 - 731 Pump cycles (PUMP x CYCLES) Parameter number Pump number

728 Pump 2

729 Pump 3

730 Pump 4

731 Pump 5 Value: No. 0 - 130000 Function: The cascade controller counts the number (No.) of times each relay (pump) is switched on. The cycle c

ounter can be reset to zero when a pump

is replaced.

Par. 737 Relay cycles

(RELAY CYCLES)

Value:

No. 0 - 130000

Function:

The relay timer accumulates the number (No.) of

each relay has been switched on and is used

times by the cascade controller to determine the cycling pattern. This counter cannot be reset.

Par. 738 Calculated intermediate setpoint

(SETPOINTS HM 1 - 7)

Value:

(set by Par. 415) sp 1 - sp 2

Function:

The intermediate setpoint is used internally by the cascade controller to calculate the system setpoint. This parameter displays the setpoint for information. Setpoint data is entered in parameters 418, Setpoint 1, and 419, Setpoint 2.

Par. 736 Relay-on time

(RELAY ON TIME)

Value:

h 0 - 130000

Function:

The relay timer accumulates the hours (h) each relay has been switched on and is used by the cascade controller to determine the cycling pattern. This counter cannot be reset. A new pump will not compensate for older pumps. The new pump will cycle in regular rotation.

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Relay status

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The display panel on the VLT allows reading the sta

Press the [DISPLAY MODE] key. Use the [+] and [-] keys to scroll through the list to RELAY STATUS. The relay status readout consists of 8 binary digits. The first digit (starting from left) indicates the status of Relay 01 which is located in the power section of the VLT. The second digit i s Relay 02 which is located on the VLT control card. Digits 3 - 6 indicate the four relays of the cascade controller, relays 06, 07, 08 and 09 which are located on the option board. Digits 7-8 are reserved for future use.

The r to see how many fixed speed or slave pumps are in operation.

tus of the relays.

eadout c an be very useful during commissioning

RELAY STATUS

1001010010010100

10010100

1001010010010100

SETUP

Cascade Controller Option

175ZA690.10

AUTO REMOTE RUNNING

Value: Relay open [0] Relay closed [1]

NB!:

For readout via serial communication, parameter 537 must be used.

Bit 7 = Relay 01, Bit 6 = Relay 02, Bits 5-2 = Relays 06 - 09.

Service parameters

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Danfoss Cascade Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual