Danfoss MCO 101, MCO 102 Operating guide

0 (0)
Danfoss MCO 101, MCO 102 Operating guide

Operating Guide

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

VLT® AQUA Drive FC 202

drives.danfoss.com

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

 

Operating Guide

Contents

Contents

1 Introduction

6

1.1

Purpose of the Operating Guide

6

1.2

Trademarks

6

1.3

Additional Resources

6

1.4

Document and Software Version

6

1.5

Product Overview

6

 

1.5.1 Intended Use

7

2 Safety

8

2.1

Safety Symbols

8

2.2

Quali€ed Personnel

8

2.3

Safety Precautions

8

3 Applications

11

3.1

Application Overview

11

3.2

Supported Con€gurations

12

 

3.2.1 Hardware Con€guration for Expanding of Basic Cascade

12

 

3.2.2 Hardware Con€guration for Master/Follower Cascade Control

14

 

3.2.3 Hardware Con€guration for Mixed Pumps

15

 

3.2.3.1 Unequal-sized Pumps Con€guration

16

 

3.2.3.2 Mixed-pump Con€guration with Alternation

18

 

3.2.4 Using Soft Starters for Fixed-speed Pumps

20

3.3

Sleep Mode

20

 

3.3.1 Basic Cascade Controller

20

 

3.3.2 Master/Follower and Mixed-pump Con€gurations

20

 

3.3.3 Temporary Boost of the Setpoint Before Sleep Mode

21

4 Installation

22

4.1

Before Start

22

4.2

VLT® Extended Cascade Controller MCO 101

22

 

4.2.1 Installing the VLT® Extended Cascade Controller MCO 101

22

 

4.2.2 Electrical Data, VLT® Extended Cascade Control MCO 101

24

4.3

VLT® Advanced Cascade Controller MCO 102

24

 

4.3.1 Installing the VLT® Advanced Cascade Controller MCO 102

24

 

4.3.2 Electrical Data, VLT® Advanced Cascade Control MCO 102

26

5 Configuration of the System

27

5.1 Con€guration of the Extended and Advanced Cascade Controllers

27

 

 

Danfoss A/S © 2020.08

AQ326832164524en-000101/130R0345 | 3

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

 

Operating Guide

Contents

 

 

 

 

 

 

 

5.1.1

Basic Con€guration of the Extended and Advanced Cascade Controllers

27

 

 

5.1.2

Con€guring Multiple Drives

28

 

 

5.1.3

Con€guring Closed-loop Control

28

 

 

5.1.4

Staging/Destaging of Variable-speed Pumps

28

 

 

5.1.5

Staging/Destaging of Fixed-Speed Pumps

29

 

5.2

Operation

30

 

 

5.2.1

Checking Pump Status and Controlling Pumps

30

 

 

5.2.2

Manual Pump Control

30

 

 

5.2.3

Run-time Balancing

30

 

 

5.2.4

Pump Spin for Unused Pumps

31

 

 

5.2.5

Total Lifetime Hours

31

 

 

5.2.6

Alternation of the Lead Pump

31

 

 

5.2.7

Staging/Destaging in Mixed-pump Con€gurations

31

 

 

5.2.8

Override Staging/Destaging

32

 

 

5.2.9

Minimum Speed Destaging

32

 

 

5.2.10

Fixed-speed-only Operation

32

 

 

5.2.11

Flow Compensation for Applications with Cascade Controller

32

6

Parameter Descriptions

34

 

6.1 Parameter Group 27-**, Cascade CTL Option

34

 

 

6.1.1

Parameter Group 27-0*, Control & Status

34

 

 

6.1.2

Parameter Group 27-1*, Con€guration

35

 

 

6.1.3

Parameter Group 27-2*, Bandwidth Settings

37

 

 

6.1.4

Parameter Group 27-3*, Staging Speed

40

 

 

6.1.5

Parameter Group 27-4*, Staging Settings

41

 

 

6.1.6

Parameter Group 27-5*, Alternation Settings

44

 

 

6.1.7

Parameter Group 27-6*, Digital Inputs

45

 

 

6.1.8

Parameter Group 27-7*, Connections

47

 

 

6.1.9

Parameter Group 27-9*, Readouts

50

 

6.2

Parameter Lists

51

 

 

6.2.1

25-** Cascade Controller

51

 

 

6.2.2

27-** Cascade CTL Option

53

7

Configuration Example

56

 

7.1

Master/Follower

56

 

 

7.1.1

Basic Settings

56

 

 

 

7.1.1.1 Basic Settings, Master and Follower

56

 

 

 

7.1.1.2 Display Settings, Master and Follower

56

 

 

7.1.2

Master Drive Settings

57

 

 

4 | Danfoss A/S © 2020.08

AQ326832164524en-000101/130R0345

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

 

Operating Guide

 

Contents

 

 

 

 

 

7.1.2.1

Con€guration Settings

57

 

7.1.2.2

Bandwidth Settings

57

 

7.1.2.3

Staging Speed Settings

57

 

7.1.2.4

Alternate Settings

58

 

7.1.2.5

Connection Settings

58

7.1.3

Follower Drive Settings

58

 

7.1.3.1

Open-loop Settings

58

 

7.1.3.2

Digital In/Out Settings

58

7.1.4

Con€guring Sleep Mode

59

Danfoss A/S © 2020.08

AQ326832164524en-000101/130R0345 | 5

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Introduction

 

 

1 Introduction

1.1 Purpose of the Operating Guide

The purpose of this Operating Guide is to describe the VLT® Extended Cascade Controller MCO 101 and VLT® Advanced Cascade Controller MCO 102. The Operating Guide contains information about:

Applications for cascade control.

Installation.

Con€guration of the system.

Parameters.

Con€guration examples.

The Operating Guide is intended for use by quali€ed personnel. To use the cascade controller options safely and professionally, read this Operating Guide thoroughly and pay particular attention to the safety instructions and general warnings.

1.2 Trademarks

VLT® is a registered trademark for Danfoss A/S.

1.3 Additional Resources

Various resources are available to understand advanced drive operation, programming, and directives compliance.

The VLT® AQUA FC 202 Operating Guide provides detailed information for the installation and start-up of the drive.

The VLT® AQUA FC 202 Programming Guide provides greater detail on how to work with parameters. It also contains application examples.

The VLT® AQUA FC 202 Design Guide provides detailed information about capabilities and functionality to design motor control systems.

Supplemental publications, drawings, and manuals are available at www.danfoss.com.

Contact a Danfoss supplier or visit www.danfoss.com for more information.

1.4 Document and Software Version

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

Table 1: Document and Software Version

Edition

Remarks

Software version

 

 

 

AQ326832164524, version 0101

• Editorial update.

VLT® Extended Cascade Controller MCO 101: 2.6X

 

 

VLT® Advanced Cascade Controller MCO 102: 1.2X

 

 

 

N O T I C E

The Cascade Controller options for the VLT® AQUA Drive FC 202 are supported in the VLT® AQUA Drive software version 1.24 and onwards.

1.5 Product Overview

The VLT® Extended Cascade Controller MCO 101 and VLT® Advanced Cascade Controller MCO 102 are add-on options extending the supported number of pumps and the functionalities of the built-in Cascade Controller in the VLT® AQUA Drive FC 202.

The MCO 101 consists of an option board with 3 relays and is installed in slot B. Once the options are installed, the parameters supporting the Cascade Controller functions are available via the LCP in parameter group 27-** Cascade CTL Option.

The following options for cascade control are available in the VLT® AQUA Drive FC 202:

Built-in Basic Cascade Controller (standard Cascade Controller)

VLT® Extended Cascade Controller MCO 101

VLT® Advanced Cascade Controller MCO 102

The MCO 101 and MCO 102 can be used in 2 different modes:

6 | Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Introduction

 

 

With the extended features controlled by parameter group 27-** Cascade CTL Option.

Extending the number of available relays for the Basic Cascade Controller via parameter group 25-** Cascade Controller.

With MCO 101, a total of 5 relays can be used for cascade control. With MCO 102, a total of 8 pumps can be controlled. The options are able to alternate the lead pump with 2 relays per pump.

N O T I C E

If the MCO 102 is installed, the VLT® Relay Card MCB 105 can extend the number of relays to 13.

1.5.1 Intended Use

Cascade control is a common control system used to control parallel pumps or fans in an energy-efficient way.

The VLT® Extended Cascade Controller MCO 101 and the VLT® Advanced Cascade Controller MCO 102 are designed for pump applications, however, it is also possible to use Cascade Controllers in any application requiring multiple motors con€gured in parallel.

The MCO 101 and MCO 102 enable control of multiple pumps con€gured in parallel by:

Automatically turning individual pumps on/off.

Controlling the speed of the pumps.

When using Cascade Controllers, the individual pumps are automatically turned on (staged) and turned off (destaged) as needed to meet the required system output for flow or pressure. The speed of pumps connected to the VLT® AQUA Drive FC 202 is also controlled to provide a continuous range of system output.

The Cascade Controller software runs from a single drive with a Cascade Controller option installed (master drive). It controls a set of pumps, each controlled by a drive or connected to a contactor or a soft starter.

Other drives in the system (follower drives) do not need to have a Cascade Controller option card installed. They are operated in open-loop mode and receive the speed reference from the master drive. Pumps connected to drives are referred to as variablespeed pumps. Pumps connected to mains through a contactor or through a soft starter are referred to as €xed-speed pumps.

Each pump, variable speed or €xed speed, is controlled by a relay in the drive. The MCO 101 and MCO 102 can control a mix of variable-speed and €xed-speed pumps.

N O T I C E

VLT® Digital Cascade can be used instead of MCO 101 and MCO 102 for master/follower applications for full redundant system. The VLT® Digital Cascade control is unlocked with a license code. Installation is easy using embedded Modbus RTU and multimaster ability makes system redundant. Example: If the master breaks down, the back-up master takes its place until a replacement takes place.

Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345 | 7

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Safety

 

 

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

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

C A U T I O N

Indicates a hazardous situation which, if 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).

2.2 Quali€ed Personnel

To allow trouble-free and safe operation of the unit, only quali€ed personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

Are quali€ed electrical engineers, or persons who have received training from quali€ed electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

Are familiar with the basic regulations concerning health and safety/accident prevention.

Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in the Operating Guide.

Have good knowledge of the generic and specialist standards applicable to the speci€c application.

2.3 Safety Precautions

W A R N I N G

HIGH VOLTAGE

AC drives contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation, start-up, and maintenance by quali€ed personnel can result in death or serious injury.

-Only quali€ed personnel must perform installation, start-up, and maintenance.

W A R N I N G

UNINTENDED START

When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death, serious injury, and equipment or property damage. The motor may start by activation of an external switch, a €eldbus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condition.

-Press [Off] on the LCP before programming parameters.

-Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended motor start.

-Check that the drive, motor, and any driven equipment are in operational readiness.

8 | Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Safety

 

 

W A R N I N G

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning indicator lights are off.

Failure to wait the speci€ed time after power has been removed before performing service or repair work could result in death or serious injury.

-Stop the motor.

-Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and DC-link connections to other drives.

-Wait for the capacitors to discharge fully. The minimum waiting time is speci€ed in the table Discharge time and is also visible on the nameplate on top of the drive.

-Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors are fully discharged.

Table 2: Discharge Time

Voltage

Minimum waiting time (minutes)

 

 

 

 

[V]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

7

15

20

30

40

 

 

 

 

 

 

 

200–240

0.25–3.7 kW (0.34–

5.5–45 kW (7.5–60

 

5 hp)

 

hp)

 

 

 

 

 

 

 

 

 

 

380–480

0.37–7.5 kW (0.5–

11–90 kW (15–125

110–250 kW

315–1500 kW

 

10 hp)

 

hp)

(150–335 hp)

 

(425–2000 hp)

 

 

 

 

 

 

 

525–600

0.75–7.5 kW (1.0–

11–90 kW (15–125

 

10 hp)

 

hp)

 

 

 

 

 

 

 

 

 

 

525–690

1.1–7.5 kW

11–90 kW (15–125

45–400 kW (60–

450–1200 kW

1400 kW

 

 

(1.5–10 hp)

hp)

540 kW)

(600–1600 hp)

(1875 hp)

 

 

 

 

 

 

 

W A R N I N G

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.

-Ensure the correct grounding of the equipment by a certi€ed electrical installer.

W A R N I N G

ROTATING SHAFTS

Contact with rotating shafts and electrical equipment can result in death or serious injury.

-Ensure that only trained and quali€ed personnel perform installation, start-up, and maintenance.

-Ensure that electrical work conforms to national and local electrical codes.

-Follow the procedures in this guide.

W A R N I N G

UNINTENDED MOTOR ROTATION WINDMILLING

Unintended rotation of permanent magnet motors creates voltage and can charge the unit, resulting in death, serious injury, or equipment damage.

-Ensure that permanent magnet motors are blocked to prevent unintended rotation.

Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345 | 9

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Safety

 

 

C A U T I O N

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

-Ensure that all safety covers are in place and securely fastened before applying power.

10 | Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Applications

 

 

3 Applications

3.1 Application Overview

<![if ! IE]>

<![endif]>Relay 1

<![if ! IE]>

<![endif]>Relay 2

<![if ! IE]>

<![endif]>Relay 10

<![if ! IE]>

<![endif]>e30ba594.12

1

1

2

3

 

4

100%

100%

100%

 

100%

 

<![if ! IE]>

<![endif]>Relay 1

<![if ! IE]>

<![endif]>Relay 2

<![if ! IE]>

<![endif]>Relay 10

<![if ! IE]>

<![endif]>e30ba593.12

Built-in

MCO 101

MCO 102

1 VSP(1) + 2

1 VSP + 5 FSP, parame-

1 VSP + 8 FSP, parame-

FSP(2), pa-

ter group 25-** Cas-

ter group 25-** Cas-

rameter

cade Controller

cade Controller

group 25-**

 

 

Cascade

 

 

Controller

 

 

1–6 VSP + 1–5 FSP

1–8 VSP + 1–7 FSP

 

(maximum 6 pumps),

(maximum 8 pumps),

 

parameter group 27-**

parameter group 27-**

 

Cascade CTL Option

Cascade CTL Option

1

2

1

2

3

4

100%

100%

200%

200%

1

VSP=Variable-speed pump (directly connected to the drive).

 

 

2

FSP=Fixed-speed pump (the motor could be connected via contactor, soft starter, or star/delta starter).

 

 

 

 

 

 

 

 

 

Built-

MCO 101

MCO 102

 

 

in

 

 

 

 

 

 

 

Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345 | 11

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Applications

 

 

Line supply

 

 

 

R1

R2

R10

 

1

2

3

4

1

2

3

4

100%

100%

100%

100%

<![if ! IE]>

<![endif]>e30ba595.12

6 VSP, parameter group 27-** Cascade CTL Option

8 VSP, parameter group 27-** Cascade CTL Option

3.2 Supported Con€gurations

When setting up the system, create a hardware con€guration which communicates the number of connected pumps and drives to the master. The necessary hardware is explained in the hardware con€guration examples.

3.2.1 Hardware Con€guration for Expanding of Basic Cascade

In applications already controlled by the built-in Cascade Controller in parameter group 25-** Control Mode, the option cards can be used to extend the number of relays for cascade control, for example, if a new pump is added to the system.

To enable the basic Cascade Controller in parameter 27-10 Cascade Controller, select [3] Basic Cascade Ctrl. Refer to VLT® AQUA Drive FC 202 Programming Guide for further programming with settings from parameter group 25-** Control Mode.

Refer to Illustration 1 and Illustration 2 for examples of external wiring required for systems with alternating lead pump of 4 pumps using basic cascade and VLT® Extended Cascade Controller MCO 101 as relay extension.

<![if ! IE]>

<![endif]>e30ba876.11

R1

R2

Drive

R10

R11

K3

K3

K5

K7

K2

K1

K1

K5

K7

K4

K1

K1

K3

K7

K6

K1

K1

K3

K5

K8

K5

 

 

 

 

K5

 

 

 

 

K3

 

 

 

 

K3

 

 

 

 

K7

 

 

 

 

K7

 

 

 

 

K7

 

 

 

 

K5

 

 

 

 

K2

K1

 

 

 

K4

K3

 

 

 

K6

K5

 

 

 

K8

K7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

K1

K2

 

 

 

K3

K4

 

 

 

K5

K6

 

 

 

K7

K8

 

 

 

Illustration 1: Control Circuit Alternating Lead Pump (4 Pumps)

12 | Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

 

Operating Guide

Applications

 

 

 

<![if ! IE]>

<![endif]>e30ba875.11

FC

 

K1

K2

K3

K4

K5

K6

K7

K8

 

M

 

M

 

M

 

M

Illustration 2: Mains Circuit Alternating Lead Pump (4 Pumps)

The €xed-speed pump con€guration provides a cost-effective method for controlling up to 9 pumps. It is able to control system output by controlling the number of running pumps and the speed of the single variable-speed pump.

In this con€guration, the VLT® AQUA Drive FC 202 with a VLT® Advanced Cascade Controller MCO 102 controls 1 variable-speed pump and up to 8 €xed-speed pumps. The €xed-speed pumps are staged and destaged as needed through contactors direct online. The variable-speed pump provides the €ner level of control needed between the stages.

The direct online pumps are staged or destaged depending on their feedback.

<![if ! IE]>

<![endif]>Relay 1

<![if ! IE]>

<![endif]>Relay 2

<![if ! IE]>

<![endif]>Relay 10

<![if ! IE]>

<![endif]>e30ba592.13

1

1

2

3

4

100%

100%

100%

100%

Illustration 3: Fixed-speed Pump Configuration Example

N O T I C E

If the pumps are not equal in size or if 2 relays per pump are used, a mixed-pump con€guration must be selected in parameter 27-10 Cascade Controller. For the con€guration shown in Illustration 3, relay selections in parameter group 27-7* Connections are as follows:

-27-70.0 Relay 1 [73] Pump 2 to mains

-27-70.1 Relay 2 [74] Pump 3 to mains

-27-70.9 Relay 10 [75] Pump 4 to mains

-27-70.10 Relay 11 [0] Standard relay

-27-70.11 Relay 12 [0] Standard relay

Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345 | 13

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Applications

 

 

N O T I C E

Pressure fluctuations during staging/destaging transitions may occur and it may be less energy-efficient than the master/follower con€gurations.

3.2.2 Hardware Con€guration for Master/Follower Cascade Control

The master/follower cascade control mode offers the best performance, the most precise control, and maximum energy savings. It controls multiple equally sized pumps in parallel, running all pumps at the same speed, and stages the pumps on and off according to system requirements. Compared to traditional cascade control, the number of running pumps is controlled by speed instead of feedback. To obtain the highest energy saving, staging speed on and off must be set correctly according to the system. In this example, terminal 27 of the master drive is used as pulse output for the reference, and terminals 29 of the follower drives are used as pulse input for this reference. While the master drive is running in closed loop, the follower drives are running in open loop. All follower drives are connected to mains and motor in the same way as the master drive.

Master with

Follower 1

Follower 2

MCO 101/102

<![if ! IE]>

<![endif]>e30bd072.11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DO 27

 

 

DI18

 

 

DI 29

 

 

DI 18

 

 

DI 29

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

2

 

 

 

 

R 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T 12

 

T 54

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T 20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DI18

 

T 55

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Start

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P

U / I

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Motor / Pump 1

 

 

 

 

 

 

Motor / Pump 2

 

 

 

 

 

 

Motor / Pump 3

 

 

 

 

Transmitter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0 - 10 V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0 - 20 mA or

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4 - 20 mA

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

100%

 

 

 

100%

 

 

 

100%

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Illustration 4: Basic Wiring Principle for a Master/Follower Configuration (Example)

14 | Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Applications

 

 

In this con€guration, each pump is controlled by a drive. All pumps and drives must be of the same size. Staging and destaging decisions are made based on the speed of the drive. The constant pressure is controlled by the master drive operating in closed loop. The speed is the same in all running pumps.

In the master/follower mode, VLT® Extended Cascade Controller MCO 101 supports up to 6 pumps, while VLT® Advanced Cascade Controller MCO 102 supports up to 8 pumps.

Con€guring as in Illustration 4 requires the following settings in parameter group 27-7* Connections:

27-70.0 Relay 1 [1] Drive 2 enable

27-70.1 Relay 2 [2] Drive 3 enable

27-70.9 Relay 10 [0] Standard relay

27-70.10 Relay 11 [0] Standard relay

27-70.11 Relay 12 [0] Standard relay

The system run-time balances all pumps automatically depending on the pump prioritization made in parameter 27-16 Runtime Balancing. The master/follower system provides a certain level of redundancy. If the master drive trips, it continues to control the follower drives.

N O T I C E

VLT® 24 V DC Supply MCB 107 can be added to increase the level of system redundancy.

Relays set to [0] Std. Relay can be used as general purpose relay controlled by parameter group 5-4* Relays.

3.2.3 Hardware Con€guration for Mixed Pumps

This con€guration combines some of the bene€ts of the master/follower con€guration with some of the initial cost savings of the €xed-speed con€gurations. It is a good choice when the extra capacity of the €xed pumps is rarely needed.

The mixed-pump con€guration supports a mix of variable-speed pumps connected to drives and also some €xed-speed pumps. First, the variable-speed pumps are staged and destaged based on the drive speed. The €xed-speed pumps are staged and destaged last based on the feedback pressure.

N O T I C E

The variable-speed pumps and the drives must be of the same size. Fixed-speed pumps may be of different size.

<![if ! IE]>

<![endif]>Relay 1

<![if ! IE]>

<![endif]>Relay 2

<![if ! IE]>

<![endif]>Relay 10

<![if ! IE]>

<![endif]>e30ba593.12

1

2

1

2

3

4

100%

100%

200%

200%

Illustration 5: Mixed-pump Configuration Example

For this con€guration, set the relays as follows in parameter group 27-7* Connections:

27-70.0 Relay 1 [1] Drive 2 enable

27-70.1 Relay 2 [74] Pump 3 to mains

27-70.9 Relay 10 [75] Pump 4 to mains

Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345 | 15

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Applications

 

 

27-70.10 Relay 11 [0] Standard relay

27-70.11 Relay 12 [0] Standard relay

3.2.3.1 Unequal-sized Pumps Con€guration

The unequal-sized pumps con€guration supports a limited mix of €xed-speed pumps in different sizes. It provides for the largest range of system output with the smallest number of pumps.

<![if ! IE]>

<![endif]>Relay 1

<![if ! IE]>

<![endif]>Relay 2

<![if ! IE]>

<![endif]>Relay 10

<![if ! IE]>

<![endif]>e30bh880.10

1

1

2

3

4

100%

100%

200%

200%

Illustration 6: Example of a Configuration with Unequal-sized Pumps

For this con€guration, set the relays as follows in parameter group 27-7* Connections:

27-70.0 Relay 1 [73] Pump 2 to mains

27-70.1 Relay 2 [74] Pump 3 to mains

27-70.9 Relay 10 [75] Pump 4 to mains

27-70.10 Relay 11 [0] Standard relay

27-70.11 Relay 12 [0] Standard relay

For a con€guration to be valid, it must be possible to stage pumps in increments of 100% of the size of the variable-speed pump of the master drive. The variable-speed pump must control the output between the €xed-speed stages, see Illustration 7.

100% is de€ned as the maximum flow produced by the pump connected to the master drive. The €xed-speed pumps must be multiples of this size.

N O T I C E

Other valid con€gurations than the ones shown in Table 3 are possible.

Table 3: Valid Configurations

Variable speed

Fixed speed

 

 

 

 

 

100%

100%

+ 200% (see Illustration 7)

 

 

 

 

100%

100%

+ 200% + 200%

 

 

 

 

 

100%

100%

+ 100% + 300%

 

 

 

 

 

 

100%

100%

+ 100%

+ 300%

+ 300%

 

 

 

 

 

100%

100%

+ 200%

+ 400%

 

 

 

 

 

 

100% + 100%

200%

 

 

 

 

 

 

 

 

100% + 100%

200%

+ 200%

 

 

 

 

 

 

 

16 | Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Applications

 

 

C

 

 

<![if ! IE]>

<![endif]>e30bd073.11

400 %

 

 

 

 

 

300 %

 

 

100 %

 

 

 

200 %

 

100 %

100 %

 

 

 

100 %

100 %

 

 

 

 

 

100 %

100 %

200 %

200 %

1

2

3

4

Illustration 7: Example of a Valid Configuration

N O T I C E

Invalid con€gurations, as in Illustration 8, will still run, but will have a poor control performance. This allows only limited operation if a pump fails or is interlocked.

Table 4: Invalid Configurations

Variable speed

Fixed speed

 

 

 

 

 

100%

200%

 

No control between 100% and 200%

 

 

 

 

100%

100%

+ 300%

No control between 200% and 300%, see Illustration 8

 

 

 

 

100%

100%

+ 200% + 600%

No control between 400% and 600 %

 

 

 

 

Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345 | 17

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Applications

 

 

C

 

 

<![if ! IE]>

<![endif]>e30bd074.11

 

 

 

400%

 

 

100%

 

 

 

300%

 

100%

100%

 

 

 

200%

 

 

 

100%

100%

 

 

 

 

 

100%

100%

300 %

300 %

 

 

 

1

2

3

4

Illustration 8: Example of an Invalid Configuration

3.2.3.2 Mixed-pump Con€guration with Alternation

In this con€guration, the drive alternates between 2 pumps and controls the other as extra €xed-speed pumps. The Cascade Controller attempts to balance the running hours of the pumps.

<![if ! IE]>

<![endif]>Relay 10

<![if ! IE]>

<![endif]>Relay 1

<![if ! IE]>

<![endif]>Relay 2

<![if ! IE]>

<![endif]>Relay 12

<![if ! IE]>

<![endif]>e30ba602.12

 

 

1

 

 

1

2

Illustration 9: Example 1

In Illustration 9, the 2 pumps are operated either as variable-speed pumps or as €xed-speed pumps. For this con€guration, set the relay selection as follows in parameter group 27-7* Connections:

18 | Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Applications

 

 

27-70.0 Relay 1 [8] Pump 1 to drive 1

27-70.1 Relay 2 [16] Pump 2 to drive 1

27-70.9 Relay 10 [72] Pump 1 to mains

27-70.10 Relay 11 [73] Pumps 2 to mains

27-70.11 Relay 12 [0] Standard relay

<![if ! IE]>

<![endif]>Relay 10

<![if ! IE]>

<![endif]>Relay 1

<![if ! IE]>

<![endif]>Relay 2

<![if ! IE]>

<![endif]>Relay 11

<![if ! IE]>

<![endif]>Relay 12

<![if ! IE]>

<![endif]>e30ba601.12

 

 

1

 

 

 

1

2

3

Illustration 10: Example 2

In Illustration 10, 2 pumps are operated either as variable-speed pumps or as €xed-speed pumps. The 3rd pump is an extra €xedspeed pump.

For this con€guration, set the relays as follows in parameter group 27-7* Connections:

27-70.0 Relay 1 [8] Pump1 to drive 1

27-70.1 Relay 2 [16] Pump2 to drive 1

27-70.9 Relay 10 [72] Pump 1 to mains

27-70.10 Relay 11 [73] Pump 2 to mains

27-70.11 Relay 12 [74] Pump 3 to mains

<![if ! IE]>

<![endif]>Relay 1

<![if ! IE]>

<![endif]>Relay 2

<![if ! IE]>

<![endif]>Relay 10

<![if ! IE]>

<![endif]>Relay 11

<![if ! IE]>

<![endif]>Relay 12

<![if ! IE]>

<![endif]>e30ba600.12

 

1

 

 

 

 

1

2

3

4

5

Illustration 11: Example 3

Danfoss A/S © 2020.08

AQ326832164524en-000101 / 130R0345 | 19

Loading...
+ 43 hidden pages