Danfoss FC 202 Application guide

Application Guide

Multi-Master Cascade Control

VLT® AQUA Drive FC 202

drives.danfoss.com

Multi-Master Cascade Control

Application Guide

Contents

1

Before You Begin 5

1.1

Version History 5

Purpose of the Guide 5

1.2

Additional Resources 5

1.3

Introduction to Multi-Master Cascade Control 6

2

An Overview 6

2.1

System Requirements and Compatibility 7

2.2

Identifying Control Card 7

2.2.1

Ordering Multi-Master Cascade Control 7

2.3

Ordering from Factory 7

2.3.1

Ordering Retrofit on Existing VLT® Product 7

2.3.2

Identifying License Key for Cascade Control 8

2.3.3

Contents

Loading new software to AC drives 8

2.4

Installing Modbus Multi-Master Cascade Control 9

3

3.1

Wiring the Daisy Chain Module 9

4

Multi-Master Cascade Control Parameter Setup 10

4.1

Multi-Master Cascade Control Parameter Setup 10

4.2

Assigning Correct Addresses for Modbus Multi-Master Cascade Control System 10

4.3

Maintenance and Replacement Scenario 10

4.4

Parameter Setup for Master Drive(s) – Basic Setup 11

4.5

Parameter Setup for Followers (Basic Setup) 12

4.6

Copy settings 13

5

Staging Parameter Setup 14

5.1

Staging Parameter Setup 14

5.2

Stage-On Speed 14

5.3

Stage-Off Speed 14

5.4

General Staging Parameters 15

6

Sleep Mode Parameter Overview 16

6.1

Sleep Mode Parameter Setup 16

6.2

Entering Sleep Mode 16

6.3

Activating Drives from Sleep Mode 16

7

Cascading Operation and Settings 17

7.1

Cascading Operation 17

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Multi-Master Cascade Control

Application Guide

7.2

Local Control Panel (LCP) Readings 18

8

Maintenance Scenarios 20

8.1

Service on Primary Master (Address 1) 20

8.2

Service on Backup Master running as a Follower 20

8.3

Service on Follower 21

9

Alarms, Warnings, and Defects 22

9.1

System Setups and Actions to Alarms, Warnings 22

Water Features with Multi-Master Cascade 24

10

Water Features 24

10.1

Check Valve Ramp 24

10.2

Sleep Mode 24

10.3

Deragging 25

10.4

10.5

Dry Pump 25

Contents

10.6

End of Curve Detection 26

10.7

Flow Compensation 26

10.8

Pipefill 27

10.9

Flow Confirmation 27

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Manual Version

Remarks

M00342, doc version 01

Information in this version of the manual corresponds to software version 4.11

Multi-Master Cascade Control

Application Guide

Before You Begin

1 Before You Begin

1.1 Version History

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.
The original language of this manual is in English.

1.2 Purpose of the Guide

This Application Guide is intended for qualified personnel such as

•

Automation engineers

•

Configurators who has experience operating with parameters and basic knowledge of AC drives

The Application Guide provides information on the functions and features of the Multi-Master Control using the built-in Modbus
RTU for communication between multiple FC 202 drives. The guide covers information on ordering, installation, parameter setups
and maintenance use cases.

1.3 Additional Resources

Additional resources are available with related information.

•

VLT® AQUA Drive FC 202 Programming Guide.

•

VLT® AQUA Drive Cascade Controller Options MCO 101/102 Operating guide offers more information on advanced and flexible
options.

Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation when not avoided, results in death or serious injury.

W A R N I N G

Indicates a hazardous situation when not avoided, could result in death or serious injury.

C A U T I O N

Indicates a hazardous situation when not avoided, could result in minor or moderate injury.

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

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1

1 2 3 4

2 3 4

Line supply

LXX1 LXX1

68 69 68 68 6869 69 69

100% 100% 100% 100%

1

1 2 3 4

2 3 4

Line supply

LXX1 LXX1

68 69 68 68 6869 69 69

100% 100% 100% 100%

e30bi493.10

Multi-Master Cascade Control

Introduction to Multi-Master

Application Guide

Cascade Control

2 Introduction to Multi-Master Cascade Control

2.1 An Overview

Benefits of Multi-Master Cascade Control setup

•

Easy installation using daisy-chain Modbus connection terminal 68/69

•

Easy commissioning using dialog based Smart Start

•

True multi-master functionality for cascade redundancy

•

Improved system performance

Significant reduced wiring complexity as the drive communication is daisy-chain using the on-board RS485 communication termi­nals. The communication protocol is Modbus RTU and requires an absolute minimum setup of parameters. The dialog-based Smart
Start makes configuration easy and trouble-free.

The automatic drive detection supports hot-swap providing a rigid system setup against loose connection or cable failure. In case of
master drive failure, the system automatically reallocates the master functionality.

In water distribution systems, it is usually the requirement that the cascade system has a redundant master functionality, this func­tionality is now an integrated solution in the drives. Multi-Master Cascade comes with improved functionalities and system perform­ance, as the master knows the status and performance of the individual drives and pumps.

Example

The illustration shows a system with 4 AC Drives, where 2 are allocated Master recognized by License Code LXX1. In case of defect
on Master Drive ID 1, the master automatically changes to ID 2 for full functionality until replaced on site. This example is considered
to explain the different phases such as installation, commissioning, and troubleshooting.

Illustration 1: Illustration Example

Application setups supported by Modbus Multi-Master Cascade

Following are the six setups supported by Modbus Multi-Master Cascade

•

Supports only Master Follower cascade.

•

Equal sized pumps.

•

A maximum of 8 pumps in cascade system.

•

A master drive requires a license code (LXX1 or LX11) to unlock the master functionality and Parameter Group 27-*.

•

A minimum of 1 master for Modbus Cascade.

•

A minimum of 2 masters for accomplishing Multi-Master Cascade.

Setup 3 and Setup 4 are not available in Modbus Multi-Master Cascade in software versions 3.91 or older versions. Setups 1 and 2

are assigned for Multi-Master. Flexibility in assigning different setups for different scenarios is limited.

For use of digital cascade without multi-master and available in setup 3 and 4, use parameter 8–30[22] Modbus Cascade Master in

software version 3.40.

N O T I C E

N O T I C E

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•

•

•

•

•

•

VLT® Product

Minimum Software Compatibility Version

VLT® AQUA Drive FC 202

Software version 4.11 and higher on all drives in cascade system.

Control Card Version

Identification of Control Card Version

Production Identification

MKII

White USB

CW18 Y2018 or later.

Sce­nario

Con­trol
Card

Parame­ter 15–
43

Action

1

MKII

3.91

Order license code. See 2.3 Ordering Multi-Master Cascade Control Flash software version 4.11 or
newer.

2

MKII

3.80 or
older

Flash software version 4.11 or newer.

Order license code for master drive(s). See 2.3 Ordering Multi-Master Cascade Control.

3

MKI

Order new control card.

Order license Code for master drive(s). See 2.3 Ordering Multi-Master Cascade Control.

Replace old control card with new Mk II control card. Ensure to upgrade to software version

4.11.

Enable license code for master drive(s).

Note: It is not possible to order an MKII control card with pre-initialized license code activated.
Activation must take place on site.

Multi-Master Cascade Control

Introduction to Multi-Master

Application Guide

Cascade Control

2.2 System Requirements and Compatibility

VLT® products and software compatibility for Multi-Master Cacade Control

To enable and effective functioning of Multi-Master Cascade Control, verify the following software compatibility and system-re­quirements.

Table 1: VLT® Product and Software Compatibility for Multi-Master Cascade Control

Table 2: Control Card Compatibility for Multi-Master Cascade Control

Retrofit existing VLT® AQUA Drive FC 202

Following are the 3 scenarios and actions to retrofit an existing drive.

Table 3: Retrofit Existing VLT® AQUA Drive FC 202

2.2.1 Identifying Control Card

2.3 Ordering Multi-Master Cascade Control

Modbus multi-master is enabled with license codes. The license codes can be installed from the factory or retrofit to an existing
VLT® AQUA Drive FC 202.

2.3.1 Ordering from Factory

Procedure

1.

Select the license code character [12]. For example, LXX1 replaces SXXX.

2.3.2 Ordering Retrofit on Existing VLT® Product

To proceed with creation of unique license code, it is required to obtain the S/N number of each VLT® AQUA Drive FC 202 which is
intended as master. After generating unique license code(s), the list is shared for activating the feature in the drives.

Procedure

1.

Order a retrofit license key via local Danfoss sales office contact.

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Parameter Number

Factory delivered license code

Retrofit license code

15–44 Ordered Typecode String

LXX1

SXXX

15-45 Actual Typecode String

LXX1

LXX1

50-00 License Installed

Cascade 2.0

Cascade 2.0

Multi-Master Cascade Control

Application Guide

2.

Obtain the S/N number of each VLT® AQUA Drive FC 202 which is intended as master. Send the S/N information to the local
Danfoss contact.

S/N can be obtained in different ways:

•

On invoice with specific drive

•

Value is identified in parameter 15-51 using LCP or MCT-10

•

Product label

3.

Enter the license key in parameter 50-01.

After the drive accepts the license key, parameter 50-01 displays 0000-0000-0000-0000.

Power cycle the drive.

4.

2.3.3 Identifying License Key for Cascade Control

Procedure

To identify license key for cascade control, verify the typecode using the following parameters.

1.

Introduction to Multi-Master

Cascade Control

The ordered type code string is not changed when activating a retrofit license in the drive.

2.4 Loading new software to AC drives

Procedure

1.

Create a back-up of the parameters.

•

Copy parameters to project in MCT-10.

•

Save project.

2.

Load the software into AC drives.

•

Remove the Modbus Connector (plug 61, 68, 69) before loading the software via the USB port.

•

After connecting the USB port, right-click on the USB 1 in the software tray on the PC.

•

Click Drive Software Upgrader. (requires Service Level 1 access). Contact Danfoss if needed.

•

Locate the required file and click Start Upgrade.

3.

After uploading the software to the drive, perform the following:

•

Connect Modbus Connector (plug 6, 68, 69) again.

•

Write parameters from the project back to AC drive.

•

Power cycle AC drive.

N O T I C E

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68 696120

1 2 3 4

18 68 68 6869 69 69

6161

20 18

LXX1 LXX1

Pressure

transmitter

Pressure

transmitter

Start signal

e30bi494.10

e30bf146.10

BUS TER.

OFF-ON

A53 A54

U- I U- I

1
2

N O

1
2

N O

1
2

N O

1
2

N O

Multi-Master Cascade Control

Installing Modbus Multi-Master

Application Guide

3 Installing Modbus Multi-Master Cascade Control

3.1 Wiring the Daisy Chain Module

Ensure to install the drive using the instructions provided in VLT® AQUA Drive FC 202 Operating Guide.

Procedure

1.

Wire Modbus in Daisy Chain Terminal 68 and Terminal 69, and Terminal 61.

Cascade Control

Illustration 2: Wiring Daisy Chain Modbus

N O T I C E

Each assigned master requires a start signal and feedback. For example, pressure transmitter and PID must be set up

and tuned.

2.

Terminate first and last drive by S801 ON.

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