Danfoss MCO 101, MCO 102 Operating guide

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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

Introduction 6

1.1

Purpose of the Operating Guide 6

Trademarks 6

1.2

Additional Resources 6

1.3

1.4

Document and Software Version 6

1.5

Product Overview 6

1.5.1

Intended Use 7

Safety 8

Safety Symbols 8

2.1

Qualied Personnel 8

2.2

Safety Precautions 8

2.3

Applications 11

Contents

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

3.2.3.2

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

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

Unequal-sized Pumps Conguration 16

Mixed-pump Conguration with Alternation 18

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

Conguration of the System 27

5.1

Conguration of the Extended and Advanced Cascade Controllers 27

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

Operating Guide

5.1.1

5.1.2

5.1.3

5.1.4

5.1.5

5.2

Operation 30

5.2.1

5.2.2

5.2.3

5.2.4

5.2.5

5.2.6

5.2.7

5.2.8

Contents

Basic Conguration of the Extended and Advanced Cascade Controllers 27

Conguring Multiple Drives 28

Conguring Closed-loop Control 28

Staging/Destaging of Variable-speed Pumps 28

Staging/Destaging of Fixed-Speed Pumps 29

Checking Pump Status and Controlling Pumps 30

Manual Pump Control 30

Run-time Balancing 30

Pump Spin for Unused Pumps 31

Total Lifetime Hours 31

Alternation of the Lead Pump 31

Staging/Destaging in Mixed-pump Congurations 31

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

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

Conguration Example 56

7.1

Master/Follower 56

7.1.1

Basic Settings 56

7.1.1.1

7.1.1.2

7.1.2

Master Drive Settings 57

Basic Settings, Master and Follower 56

Display Settings, Master and Follower 56

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

Operating Guide

7.1.3

7.1.4

Contents

7.1.2.1

7.1.2.2

7.1.2.3

7.1.2.4

7.1.2.5

Follower Drive Settings 58

7.1.3.1

7.1.3.2

Conguring Sleep Mode 59

Conguration Settings 57

Bandwidth Settings 57

Staging Speed Settings 57

Alternate Settings 58

Connection Settings 58

Open-loop Settings 58

Digital In/Out Settings 58

•

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

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

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 dierent modes:

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

Operating Guide

•

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.

Introduction

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-ecient way. The VLT® Extended Cascade Controller MCO 101 and the VLT® Advanced Cascade Controller MCO 102 are designed for pump appli-

cations, 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/o.

•

Controlling the speed of the pumps.

When using Cascade Controllers, the individual pumps are automatically turned on (staged) and turned o (destaged) as needed to meet the required system output for ow 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 multi-

master ability makes system redundant. Example: If the master breaks down, the back-up master takes its place until a replace-

ment takes place.

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

Operating Guide

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).

Safety

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 condi-

tion.

Press [O] 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.

Voltage [V]

Minimum waiting time (minutes) 47152030

200–240

0.25–3.7 kW (0.34– 5 hp)

–

5.5–45 kW (7.5–60 hp)

–––

380–480

0.37–7.5 kW (0.5– 10 hp)

–

11–90 kW (15–125 hp)

110–250 kW (150–335 hp)

–

315–1500 kW (425–2000 hp)

525–600

0.75–7.5 kW (1.0– 10 hp)

–

11–90 kW (15–125 hp)

–––

525–690

–

1.1–7.5 kW (1.5–10 hp)

11–90 kW (15–125 hp)

45–400 kW (60– 540 kW)

450–1200 kW (600–1600 hp)

1400 kW (1875 hp)

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 o.

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

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.

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

Operating Guide

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.

Safety

Built-in

MCO 101

MCO 102

100% 100% 100% 100%

e30ba594.12

Relay 1

Relay 2

Relay 10

1 2 3 4

1 VSP

(1)

+ 2

FSP

(2)

, pa-

rameter group 25-** Cascade Controller

1 VSP + 5 FSP, parameter group 25-** Cascade Controller

1 VSP + 8 FSP, parameter group 25-** Cascade Controller

100% 100% 200% 200%

e30ba593.12

Relay 1

Relay 2

Relay 10

2 3 4

–

1–6 VSP + 1–5 FSP (maximum 6 pumps),

parameter group 27-** Cascade CTL Option

1–8 VSP + 1–7 FSP (maximum 8 pumps),

parameter group 27-** Cascade CTL Option

Builtin

MCO 101

MCO 102

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

Operating Guide

3 Applications

3.1 Application Overview

Applications

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

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

Line supply

R1 R2

R10

e30ba595.12

100%

–

6 VSP, parame-

ter group 27-** Cascade CTL Option

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

Drive R10

R11

K1K5K5

K7 K4

K6K5

e30ba876.11

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

Operating Guide

Applications

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 using basic cascade and VLT® Extended Cascade Controller MCO 101 as relay extension.

Illustration 1 and Illustration 2 for examples of external wiring required for systems with alternating lead pump of 4 pumps

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

e30ba875.11

e30ba592.13

Relay 1

Relay 2

Relay 10

100%

100% 100%

100%

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

Operating Guide

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

Applications

The xed-speed pump conguration provides a cost-eective 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.

Illustration 3: Fixed-speed Pump Conguration 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

Motor / Pump

Motor / Pump 2

Motor / Pump 3

DI 18

DI 18 DI

DI 29

R 1

R 2

100%

U / I

T 54

T 55

T 20

Pressure Transmitter 0 - 10 V 0 - 20 mA or 4 - 20 mA

T 12

DI18

Start

Master with MCO 101/102

Follower 1

Follower 2

e30bd072.11

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

Operating Guide

Applications

N O T I C E

Pressure uctuations during staging/destaging transitions may occur and it may be less energy-ecient than the master/follower

congurations.

3.2.2 Hardware Conguration for Master/Follower Cascade Control

The master/follower cascade control mode oers 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 o 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 o 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.

Illustration 4: Basic Wiring Principle for a Master/Follower Conguration (Example)

100% 100% 200% 200%

e30ba593.12

Relay 1

Relay 2

Relay 10

2 3 4

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 Bal- ancing. 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 dierent size.

Illustration 5: Mixed-pump Conguration 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

100% 100% 200% 200%

e30bh880.10

Relay 1

Relay 2

Relay 10

1 2 3 4

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%

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

Operating Guide

•

27-70.10 Relay 11 → [0] Standard relay

•

27-70.11 Relay 12 → [0] Standard relay

Applications

3.2.3.1 Unequal-sized Pumps Conguration

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

Illustration 6: Example of a Conguration 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 ow produced by the pump connected to the master drive. The xed-speed pumps must be mul- tiples 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 Congurations

100 %

200 % 200 %

100 %

200 %

300 %

400 %

e30bd073.11

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 %

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

Operating Guide

Applications

Illustration 7: Example of a Valid Conguration

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 Congurations

e30bd074.11

100 %

300 %

100 %

300 %

100 %

200 %

300 %

400 %

2 3 4

e30ba602.12

Relay 10

Relay 1

Relay 2

Relay 12

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

Operating Guide

Applications

Illustration 8: Example of an Invalid Conguration

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.

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:

e30ba601.12

Relay 10

Relay 1

Relay 2

Relay 11

Relay 12

e30ba600.12

Relay 1

Relay 2

Relay 10

Relay 11

Relay 12

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

Operating Guide

•

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

Applications

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

Illustration 11: Example 3

Stage ON [Hz]

Stage OFF [Hz]

Stage 1

48.5 (parameter 2732.1)

30 (parameter 2734.1)

Stage 2

48.5 (parameter 2732.2)

40 (parameter 2734.2)

Stage 3

48.5 (parameter 2732.3)

42 (parameter 2734.3)

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

Operating Guide

In Illustration 11, either pump 1 or pump 2 is connected to the drive. The pump for the connection to the drive can be selected either automatically for balancing the running hours or forced by the congured alternation event. The xed-speed pumps 3, 4, and 5 are turned on and o as required.

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

•

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 → [74] Pump 3 to mains

•

27-70.10 Relay 11 → [75] Pump 4 to mains

•

27-70.11 Relay 12 → [76] Pump 5 to mains

Applications

3.2.4 Using Soft Starters for Fixed-speed Pumps

Soft starters can be used instead of contactors for any conguration using xed-speed pumps.

N O T I C E

Mixing soft starters and contactors prevents control of output pressure during staging and destaging transitions. The use of soft

starters delays the staging due to the ramp time of the xed-speed pump.

3.3 Sleep Mode

If the load on the multi-pump system allows it, it can be stopped by activating the sleep mode function. When in sleep mode, certain congurable conditions are monitored to nd out when load has been applied again and the system has to be restarted.

Depending on the system, sleep mode can be activated either from the low-power detection/low-speed detection or via an external signal applied to 1 of the digital inputs (must be programmed via parameter group 5-1* Digital Inputs). Using, for example, an electromechanical ow switch to detect a no-ow condition, activates sleep mode at the raising edge of the external signal applied.

Implementation and conguration of sleep mode depend on the hardware conguration and the requirements.

3.3.1 Basic Cascade Controller

For Basic Cascade Controller applications, sleep mode can be used and congured exactly as it is described for single-pump applica- tions in the parameter groups 22-2* to 22-4* in the VLT® AQUA Drive FC 202 Programming Guide.

Low-speed detection and low-power detection combined with the timers for minimum run-time, minimum sleep time, and the boost feature are supported. The feedback from the pressure transducer is monitored and when this pressure has dropped with a set percentage below the normal setpoint for pressure (parameter 22-44 Wake-up Ref./FB Dierence), the motor ramps up again, and pressure is controlled for reaching the set value.

3.3.2 Master/Follower and Mixed-pump Congurations

In multiple-drive applications, sleep mode can be used in 2 dierent ways:

•

Low-speed detection for applications with multiple drives can be enabled by a selection in parameter 22-22 Low Speed Detection.

•

Using the Stage O-speeds in parameter group 27-3* Staging Speed.

In the following example, sleep mode is entered at 30 Hz in a master/follower application.

This mode is activated by programming the corresponding speed in parameter 27-33 Stage O Speed [RPM] or parameter 27-34 Stage O Speed [Hz].

The value for this speed has to be higher than the minimum speed in parameter 4-11 Motor Speed Low Limit [RPM] or parameter 4-12 Motor Speed Low Limit [Hz].

The value for the override limit in parameter 27-21 Override Limit causes the drive to wake up again. The value is entered as a % of the maximum reference as programmed in parameter 3-03 Maximum Reference.

Output speed

No/low flow detection speed

Reference and feedback

7654

321 0

e30bh881.10

System is going into a no-ow condition

Conditions for pulse are present

Pulse equals boost

Boost setpoint is reached

Pressure loss due to back-ow to close no-return valve5No-return valve is closed and there is no load

PID, bring output frequency to minimum speed due to FB>Ref

Delay time for no-ow has expired. Sleep mode

Drive stop, sleep

Load return to system

Conditions for wake-up are present

System running normally

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

Operating Guide

Applications

3.3.3 Temporary Boost of the Setpoint Before Sleep Mode

In some applications, it can be dicult to detect the no-ow conditions in a reliable way with a xed setpoint. This may be the case in applications with varying inlet pressure or if the closure of a non-return valve causes a pressure loss.

In these cases, a temporary boost of the setpoint can force the PID to reduce speed. See parameter 22-22 Low Speed Detection in the VLT® AQUA Drive FC 202 Programming Guide for further details.

Illustration 12: Temporary Boost of Setpoint

Voltage [V]

Minimum waiting time (minutes) 47152030

200–240

0.25–3.7 kW (0.34– 5 hp)

–

5.5–45 kW (7.5–60 hp)

–––

380–480

0.37–7.5 kW (0.5– 10 hp)

–

11–90 kW (15–125 hp)

110–250 kW (150–335 hp)

–

315–1500 kW (425–2000 hp)

525–600

0.75–7.5 kW (1.0– 10 hp)

–

11–90 kW (15–125 hp)

–––

525–690

–

1.1–7.5 kW (1.5–10 hp)

11–90 kW (15–125 hp)

45–400 kW (60– 540 kW)

450–1200 kW (600–1600 hp)

1400 kW (1875 hp)

e30ba607.11

MCO 101

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

Operating Guide

4 Installation

4.1 Before Start

W A R N I N G

Never install an option card in a drive during operation.

Interrupt the power supply to the drive before starting the installation. Note that high voltage may be present, even when

the warning LED display lights are o.

Table 5: Discharge Time

Installation

4.2 VLT® Extended Cascade Controller MCO 101

4.2.1 Installing the VLT® Extended Cascade Controller MCO 101

The VLT® Extended Cascade Control MCO 101 includes 2 changeover contacts and can be tted into option slot B.

Illustration 13: Mounting of B Options

Procedure

Disconnect power to the drive.

Disconnect power to the live part connections on the relay terminals.

Remove the LCP, the terminal cover, and the cradle from the drive.

Relay 10

NC NCNC

Relay 12Relay 11

1 2 3 12

e30ba606.10

754 6 8 9 10 11

e30ba177.10

8-9mm

2mm

1 1 1

1102 3

4 5 6 7 8 9 1211

2 2 3

1 1 1

1102

4 5

6 7 8 9 1211

3 3

1 1 1

1 10

2 3

5 6 7 8 9 1211

e30ba176.11

1NC2

Live part

PELV

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

Operating Guide

4.5.Fit the MCO 101 option in slot B.

Connect the control cables and relieve the cables with the enclosed cable strips.

Illustration 14: Wiring of Connections

Installation

Illustration 15: Mounting of Cables

Illustration 16: Incorrect and Correct Relay Wiring

Do not combine low-voltage parts and PELV systems.

N O T I C E

Maximum terminal load (AC)

240 V AC, 2 A

Maximum terminal load (DC)

24 V DC, 1 A

Minimum terminal load (DC)

5 V, 10 mA

Maximum switching rate at rated load/minimum load

6 min-1/20 s

-1

Type

Description

Order number

Options

MCF 105

Mounting kit, enclosure sizes A2 and A3 (40 mm for 1 C option)

130B7530

MCF 105

Mounting kit, enclosure size A5

130B7532

MCF 105

Mounting kit, enclosure sizes B (except B3), C, D, E, F1, and F3

130B7533

MCF 105

Mounting kit, enclosure size B3 (40 mm for 1 C option)

130B1413

Accessory bag

MCO 102

Accessory bag

130B0152

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

Operating Guide

Fit the extended cradle and terminal cover.

Remount the LCP.

Connect power to the drive.

Installation

4.2.2 Electrical Data, VLT® Extended Cascade Control MCO 101

4.3 VLT® Advanced Cascade Controller MCO 102

4.3.1 Installing the VLT® Advanced Cascade Controller MCO 102

The VLT® Advanced Cascade Controller MCO 102 is exclusively intended for use in option slot C1.

Some items are required for the installation of a C option mounting kit. The items required depend on the drive enclosure.

Table 6: Order Numbers for Mounting Kits and Accessory Bag

A4 does not support C options. If the VLT® Advanced Cascade Controller MCO 102 is needed, select an A5 enclosure.

e30ba946.10

RemoveJumper to activate Safe Stop

12 13 18 19 27 29 32 33 20

e30ba945.10

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

Operating Guide

Installation

Illustration 17: Enclosure Sizes A2, A3, and B3, 40 mm (only 1 C option)

Illustration 18: Enclosure Sizes B (except B3) and C

Procedure

Disconnect power to the drive.

e30bb025.11

e30bb026.11

Maximum terminal load (AC)

240 V AC, 2 A

Maximum terminal load (DC)

24 V DC, 1 A

Minimum terminal load (DC)

5 V, 10 mA

Maximum switching rate at rated load/minimum load

6 min-1/20 s

-1

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

Operating Guide

Disconnect power to the live part connections on the relay terminals.

Remove the LCP, the terminal cover, and the cradle from the drive.

Fit the MCO 102 in slot C1.

Connect the control cables and relieve the cables with the enclosed cable strips.

Illustration 19: Terminal Connections, 8 Relays

Installation

Illustration 20: Terminal Connections to 7 Digital Inputs and Access to Internal 24 V DC

Fit the extended cradle and terminal cover.

Remount the LCP.

Connect power to the drive.

4.3.2 Electrical Data, VLT® Advanced Cascade Control MCO 102

Parameter

Description

27-10 Cascade Controller

This parameter is used for enabling or disabling the Extended/Advanced Cascade Controllers. It is also used to extend the number of pumps in Basic Cascade Control applications. In this case, the parameters in Parameter Group 25-** Cascade Controller must be used for the conguration details. The mixed-pump selection is the general selection for the Cascade Controller. If using 1 drive per pump, select the master/follower conguration.

27-11 Number Of Drives

Set the number of drives.

27-12 Number Of Pumps

Set the number of pumps. Default is the number of drives.

Parameter 27-13 Max Number of Pumps Running

This parameter makes it possible to force pumps to stay idle. Example: In a cascade system where 3 pumps are necessary in normal operation, but 4 pumps are installed due to legislation, it is possible to allow only 3 pumps running in parallel to avoid high pressure spikes. Default always equals the number of pumps.

27-14 Pump Capacity

Pump capacity for each pump (indexed parameter). If all pumps are the same size, use the default values. To adjust the setting, select the pump, press [OK], and adjust the capacity.

27-16 Runtime Balancing

Run-time balancing for each pump (indexed parameter). If the system should balance the running hours equally between the pumps, use the default values.

27-17 Motor starters

All xed-speed pumps must be the same size.

27-18 Spin Time for Unused Pumps

The spin time depends on the size of the pumps.

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

Operating Guide

Conguration of the System

5 Conguration of the System

5.1 Conguration of the Extended and Advanced Cascade Controllers

The Extended and Advanced Cascade Controllers, MCO 101 and MCO 102, can be congured quickly using many of the default parameters. For more information about application types and on how to use advanced features of the Cascade Controllers, refer to

3 Applications.

N O T I C E

To avoid miscongurations, check the settings even if the parameters are set to their default values.

5.1.1 Basic Conguration of the Extended and Advanced Cascade Controllers

N O T I C E

Any unused relays are available for other functions via parameter group 5-4* Relays.

Procedure

Select the values for the parameters in parameter group 27-1* Conguration.

Dene the relays in parameter group 27-7* Connections.

Assign 1 relay for each follower drive in the system.

Assign the relays for the xed-speed pumps.

If a single drive is connected to 2 pumps (alternation), congure more relays accordingly.

Pin 27

Pin 29

e30ba608.11

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

Operating Guide

Conguration of the System

5.1.2 Conguring Multiple Drives

If more than 1 drive is used with the Cascade Controller, the master drive sets the speed reference for all drives via a digital pulse signal.

Illustration 21: Multiple Drives Congured for Cascade Control

Procedure

Set the basic cascade parameters, see 5.1.1 Basic Conguration of the Extended and Advanced Cascade Controllers.

Set parameter 5-01 Terminal 27 Mode to [1] Output, parameter 5-30 Terminal 27 Digital Output to [55] Pulse Output, and parameter 5-60 Terminal 27 Pulse Output Variable to [116] Cascade Ref.

Set each follower drive to open loop, set parameter 1-00 Conguration Mode to [0] Open Loop, parameter 3-15 Reference 1 Source to [7] Pulse Input 29, and parameter 5-13 Terminal 29 Digital Input to [32] Pulse Input.

Set the ramps fast enough to enable the PID controller to maintain control of the system.

N O T I C E

Ramp-up times and ramp-down times must be the same for the master drive and for all the follower drives in the sys-

tem.

5.1.3 Conguring Closed-loop Control

The master drive is the primary controller for the system. It monitors the output pressure, adjusts the speed of the drive, and decides when to add or remove stages.

Procedure

Set up the master drive to closed-loop mode with a feedback sensor connected to an analog input of the drive.

Set up the PID controller of the master drive to match the requirements of the installation.

For further information on setting up the PID parameters, see the VLT® AQUA Drive FC 202 Programming Guide.

5.1.4 Staging/Destaging of Variable-speed Pumps

Staging occurs when the speed on the drive has reached the value in parameter 27-31 Stage On Speed [RPM] (parameter 27-32 Stage on Speed [Hz]). At this speed, the system pressure is still maintained, but the pumps start to operate outside of their peak eciency points. Staging on another pump lowers the speed of all running pumps and provides a more energy-ecient operation.

In master/follower congurations and mixed-pump congurations, the variable-speed pumps are staged and destaged based on the speed of the drives.

Destaging occurs when the speed of the drives drops below the value in parameter 27-33 Stage O Speed [RPM] (parameter 27-34 Stage O Speed [Hz]). At this speed, the system pressure is still maintained, but the pumps are beginning to operate below their peak eciency points. Destaging a pump causes the speed of the drive to increase into a more energy-ecient range.

tot

1 2

e30bb024.11

1 pump running

2 pumps running

Incorrect stage on speed adjustment

Correct stage on speed adjustment

Stage on speed pump 2

Parameter

Range

Default

27-30 Auto Tune Staging Speeds

{[0] Disabled, [1] Enabled}

[1] Enabled

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

Operating Guide

Conguration of the System

Parameter 27-31 Stage On Speed [RPM] (parameter 27-32 Stage On Speed [Hz]) and parameter 27-33 Stage O Speed [RPM] (parameter 27-34 Stage O Speed [Hz]) are installation dependent. These parameters are indexed parameters with 1 set of entries for each pump

stage. The stage on and destage o speed can be autotuned during operation or set manually. If Auto tune is enabled, the system starts

operation using default settings or the presettings programmed in parameter 27-31 Stage On Speed [RPM] (parameter 27-32 Stage on Speed [Hz]) and parameter 27-33 Stage O Speed [RPM] (parameter 27-34 Stage O Speed [Hz]).

The tuning ensures optimum energy eciency of the system.

Illustration 22: Optimum Energy Eciency

During operation, the system monitors the actual energy consumption and optimizes every time a stage or destage takes place.

5.1.5 Staging/Destaging of Fixed-Speed Pumps

Fixed-speed pumps are staged or destaged based on system pressure. To avoid turning on and o the pumps too often, dene an acceptable range of system pressure along with a period where the

pressure is allowed to be outside of this band before staging or destaging occurs. Set the values via:

•

Parameter 27-20 Normal Operating Range

•

Parameter 27-23 Staging Delay

•

Parameter 27-24 Destaging Delay

The parameters are installation dependent.

N O T I C E

Stage/destage threshold

The speed of the variable-speed pump at the point of staging or destaging is dened by a stage or destage threshold. These settings prevent overshoot or undershoot in the pressure at staging or destaging.

The optional auto tune of staging and destaging threshold monitors the feedback at the point of staging or destaging and adjusts the settings every time a staging takes place.

Parameter

Range

Default

27-40 Auto Tune Staging Settings

{[0] Disabled, [1] Enabled}

[1] Enabled

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

Operating Guide

Conguration of the System

5.2 Operation

When the Cascade Controller is enabled, it controls system pressure by varying the speed of the drive and by staging pumps on and

o.

The Cascade Controller provides 2 stop functions. One function quickly stops the system. The other function destages the pumps in a sequence, resulting in a pressure-controlled stop. For a VLT® AQUA Drive FC 202 equipped with STO, terminal 37 turns o all relays and coasts the master drive. If any of the digital inputs are set to [8] Start, and the corresponding terminal is used to control start and stop of the drive, setting the terminal to 0 V will turn o all relays and coast the master drive. Pressing [O] on the LCP causes a sequenced destaging of running pumps.

5.2.1 Checking Pump Status and Controlling Pumps

Select parameter group 27-0* Control & Status to check on the status of the Cascade Controller and to control individual pumps. Select a specic pump to view the status, the current running hours, and the total lifetime hours.

Procedure

Navigate to parameter group 27-0* Control & Status. Press [▵] and [▿] on the LCP to select the pump.

Press [▵] and [▿] on the LCP to select the parameter.

5.2.2 Manual Pump Control

Use the Extended/Advanced Cascade Controllers for complete control of each pump in the system, for example for maintenance purposes. Use parameter 27-02 Manual Pump Control to control individual pumps through their relays.

This parameter diers from other value-related parameters as selecting 1 of these options causes the action to occur and then the parameter reverts to its default state.

The selections are as follows:

•

[0] No Operation - Default value.

•

[1] Online - Makes the pump available to the VLT® Extended Cascade Controller MCO 101.

•

[2] Alternate On - Forces the selected pump to be the lead pump.

•

[3] Oine-O  - Turns o the pump and makes it unavailable for cascading.

•

[4] Oine-On - Turns on the pump and makes it unavailable for cascading.

•

[5] Oine-Spin - Initiates a pump spin.

If any of the Oine selections are selected, the pump is no longer available to the Cascade Control until Online is selected.

If a pump is taken oine through parameter 27-02 Manual Pump Control, the Cascade Controller attempts to compensate for the oine pumps as follows:

•

If [3] Oine-O is selected for a pump that is running, another pump is staged on to compensate for the loss of output.

•

If [4] Oine-On is selected for a pump that is o, another pump is staged o to compensate for the excess output.

5.2.3 Run-time Balancing

The Extended/Advanced Cascade Controllers are designed to balance the running hours of the available pumps, but parameter 27-16 Runtime Balancing also provides an optional balancing priority for each pump in the system.

Three levels of priority are available:

•

[0] Balanced Priority 1

•

[1] Balanced Priority 2

•

[2] Spare Pump

The Cascade Controller selects a pump to be staged or destaged based on the maximum capacity of the pump (parameter 27-14 Pump Capacity), parameter 27-03 Current Runtime Hours, and parameter 27-16 Runtime Balancing.

During staging, the Cascade Controller balances the current running hours for all pumps set to [0] Balanced Priority 1 in parameter 27-16 Runtime Balancing.

If all priority 1 pumps are running, the Cascade Controller balances the pumps set to [1] Balanced Priority 2.

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

Operating Guide

If all priority 1 and 2 pumps are running, pumps set to [2] Spare Pump are selected. During destaging, the reverse occurs. Spare pumps are destaged rst, followed by priority 2 pumps, followed by priority 1 pumps. At

each priority level, the pump with the highest current run-time hours is destaged rst.

Conguration of the System

N O T I C E

In mixed-pump congurations with more than 1 drive, all variable-speed pumps are staged or destaged before xed-speed

pumps.

Select parameter 27-19 Reset Current Runtime Hours to reset the current run-time hours and restart the balancing process. This parameter does not aect the total lifetime hours (parameter 27-04 Pump Total Lifetime Hours) for each pump. The total lifetime hours- function is not used for run-time balancing.

5.2.4 Pump Spin for Unused Pumps

If a pump is used only occasionally, the Cascade Controller balances the running hours of the pumps via alternation. If a pump is not used for 72 hours, a pump spin can be triggered.

The spin time can be set in parameter 27-18 Spin Time for Unused Pumps. The spin time should be long enough to ensure that the pump stays in good working condition, but short enough not to overpressure the system. To disable the function, set parameter 27-18 Spin Time for Unused Pumps to 0.

N O T I C E

The Cascade Controller does not compensate for the extra pressure generated during a pump spin. Keep the spin time as short as

possible to prevent damage caused by overpressuring the output.

5.2.5 Total Lifetime Hours

The VLT® Extended Cascade Controller MCO 101 and the VLT® Advanced Cascade Controller MCO 102 track the total lifetime hours for each controlled pump.

Parameter 27-04 Pump Total Lifetime Hours shows a running total of the operating hours for each pump. The total lifetime hours are saved in the non-volatile memory once every hour.

This parameter can also be set to an initial value that reects the hours of operation for a pump before it was added to the system.

5.2.6 Alternation of the Lead Pump

The Cascade Controller can be congured for lead pump alternation, see also examples in 3.2.3.2 Mixed-pump Conguration with

Alternation.

In a conguration with multiple drives, the lead pump is dened as the last variable-speed pump running. In a conguration with only 1 drive, the lead pump is dened as the pump connected to the drive. During start-up and normal staging/destaging, the Cascade Controller balances the running hours by alternating the lead pump.

Alternation of lead pumps can also be forced manually, for example, via parameter 27-54 Alternation At Time of Day, via a digital input, or by alternation time parameters.

5.2.7 Staging/Destaging in Mixed-pump Congurations

Two methods are used to decide when pumps should be staged or destaged:

Speed of the drives.

•

Feedback pressure exceeding the normal operating range.

•

In a mixed-pump conguration with more than 1 drive, both methods are used. In the following example, feedback is referred to as pressure.

Staging

When the master drive receives a start command, a variable-speed pump is selected and starts using 1 of the available drives. If the system pressure drops, the speed of the drive increases to meet the demand for more ow. While maintaining the pressure, if

the drive exceeds parameter 27-31 Stage On Speed [RPM] (or parameter 27-32 Stage On Speed [Hz]) and remains above that speed for the time specied in parameter 27-33 Stage O Speed [RPM] (parameter 27-34 Stage O Speed [Hz], the next variable-speed pump is staged on.

If the Cascade Controller is unable to maintain the system pressure with all variable-speed pumps running at maximum, it stages on xed-speed pumps. If pressure goes below the setpoint with the percentage set in parameter 27-20 Normal Operating Range and stays below the setpoint for the time specied in parameter 27-23 Staging Delay, a xed-speed pump stages on.

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

Operating Guide

Destaging

If the system pressure increases, the speed of the drive decreases. If the drive drops below the values specied in parameter 27-33

Stage O Speed [RPM] (or parameter 27-32 Stage O Speed [Hz] and stays there for the time specied in parameter 27-24 Destaging Delay, a variable-speed pump is staged o.

If the system pressure is still too high with only 1 drive running at minimum speed, it destages xed-speed pumps. A xed-speed pump is destaged when the pressure exceeds the setpoint in parameter 27-20 Normal Operating Range and stays there for the time specied in parameter 27-24 Destaging Delay. If the system demand continues to drop, the system enters sleep mode.

Conguration of the System

5.2.8 Override Staging/Destaging

Normal staging and destaging handle most of the situations in typical applications. However, when rapid response to changes in system pressure is required, the Cascade Controller is equipped to stage and destage pumps immediately.

Staging

When the system pressure drops below the override limit (parameter 27-21 Override Limit), the Cascade Controller immediately stages on a pump to meet the demand.

If the system pressure continues to stay below parameter 27-21 Override Limit for the time specied in parameter 27-25 Override Hold Time, the Cascade Controller stages on the next pump. This behavior is repeated until all pumps are on or until system pressure drops below the override limit.

Destaging

When the system pressure exceeds parameter 27-21 Override Limit, the Cascade Controller immediately destages a pump to reduce the pressure.

If the system pressure continues to stay above the value in parameter 27-21 Override for the time specied in parameter 27-25 Over- ride Hold Time, the Cascade Controller destages another pump. This behavior is repeated until only the lead pump is left on or until the pressure stabilizes.

Parameter 27-21 Override Limit is set as a % of the maximum reference. It denes a point above and below the system setpoint where override staging and destaging occur.

5.2.9 Minimum Speed Destaging

To reduce energy usage, the Cascade Controller can destage a xed-speed pump if the lead pump is running at minimum speed for the time set in parameter 27-27 Min Speed Destage Delay.

5.2.10 Fixed-speed-only Operation

Fixed-speed-only operation keeps critical systems operating even if all variable-speed pumps are unavailable to the Cascade Controller. In this situation, the Cascade Controller maintains system pressure by turning on and o xed-speed pumps.

Staging

If all the variable-speed pumps are unavailable and the system pressure drops below the limit in parameter 27-22 Fixed Speed Only Operating Range for the time specied in parameter 27-23 Staging Delay, a xed-speed pump is turned on.

Destaging

If all variable-speed pumps are unavailable and the system pressure exceeds the limit set in parameter 27-22 Fixed Speed Only Oper- ating Range for the time specied in parameter 27-24 Destaging Delay, a xed-speed pump is turned o.

5.2.11 Flow Compensation for Applications with Cascade Controller

Flow compensation allows placing the pressure sensor close to the drive, even if it is not the place for the wanted pressure setpoint. It adjusts the setpoint automatically according to the pressure drop in the system which depends on the system ow. In Cascade Controller applications, this is done step-wise based on the number of pumps in operation.

It uses the feedback to estimate the setpoint required at various rates of ow. The calculation of the theoretical curve results in step- wise adjusted setpoints following this curve. Setpoint 1 is the minimum pressure required when the system is running with only 1 pump operating and under minimum load conditions. Setpoint 2 is used when all pumps are running.

Theoretical

Setpoint

Pump 1

2 3

e75za642.11

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

Operating Guide

Illustration 23: Calculation of Theoretical Curve

Conguration of the System

The range of the curve is determined by the no/low ow point and the uncompensated setpoint (for example, in parameter 20-21 Setpoint 1).

Besides the conguration of the Cascade Controller, the required programming steps are:

•

Enable ow compensation in parameter 22-80 Flow Compensation.

•

Program the pressure at no-ow speed in parameter 22-87 Pressure at No-Flow Speed.

•

Program the uncompensated setpoint (for example, in parameter 20-21 Setpoint 1).

If 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 ow, and the default feedback process can be used.

Option

Function

Pump Status is a readout parameter showing the status of each pump in the system.

[0]

Ready

The pump is available for use by the Cascade Controller.

[1]

On Drive

The pump is controlled by the Cascade Controller, the pump is connected to a drive and running.

[2]

On Mains

The pump is controlled by the Cascade Controller, the pump is connected to mains and running.

[3]

Oine - O

The pump is not available for use by the Cascade Controller, and the pump is o.

[4]

Oine - On Mains

The pump is not available for use by the Cascade Controller, and the pump is connected to mains and running.

[5]

Oine - On Drive

The pump is not available for use by the Cascade Controller, and the pump is connected to mains and running.

[6]

Oine - Fault

The pump is not available for use by the Cascade Controller, and the pump is connected to mains and running.

[7]

Oine - Hand

The pump is not available for use by the Cascade Controller, and the pump is connected to mains and running.

[8]

Oine - External Interlock

The pump has been externally interlocked and is o.

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

Operating Guide

Parameter Descriptions

6 Parameter Descriptions

6.1 Parameter Group 27-**, Cascade CTL Option

N O T I C E

If 1 of the Cascade Controller options is used to extend the number of pumps in a Basic Cascade, use the parameters in parameter

group 25-** Cascade Controller. See VLT® AQUA Drive FC 202 Programming Guide for further information.

For the following array parameters, the index refers to the number of the (specic) pump. For stage on/stage o speeds, the index reects the number of pumps in operation.

•

Parameter 27-01 Pump Status

•

Parameter 27-02 Manual Pump Control

•

Parameter 27-03 Current Runtime Hours

•

Parameter 27-04 Pump Total Lifetime Hours

•

Parameter 27-14 Pump Capacity

•

Parameter 27-16 Runtime Balancing

•

Parameter 27-31 Stage On Speed [RPM]

•

Parameter 27-32 Stage On Speed [Hz]

•

Parameter 27-33 Stage O Speed [RPM]

•

Parameter 27-34 Stage O Speed [Hz]

N O T I C E

For parameter 27-70 Relay, index 0 refers to relay 1, index 1 refers to relay 2, index 2 refers to relay 3 … index 19 refers to relay 20.

6.1.1 Parameter Group 27-0*, Control & Status

Control and status parameters are for monitoring and manual control of the pumps. Press [▵] and [▿] to select a pump. Press [▵] and [▿] to change settings.

Table 7: Parameter 27-01 Pump Status

•••

•

Option

Function

[9]

Spinning

The Cascade Controller is executing a spin cycle for the pump.

[10]

No Relay Connection

The pump is not directly connected to a drive, and no relay has been assigned to the pump.

Range

Function

0 h*

[0-2147483647 h]

Current Runtime Hours is a readout parameter showing the total number of hours each pump has been running since the last reset. This time is used to balance the running hours between the pumps. The times may all be reset to 0 via parameter 27-91 Cascade Reference.

Range

Function

0 h*

[0-2147483647 h]

N O T I C E

This parameter may be set individually to any value for maintenance purposes.

Pump Total Lifetime Hours is the total operating hours for each connected pump.

Option

Function

Cascade Controller Mode sets the operating mode.

[0]

Disabled

[1]

Master/Follower

[2]

Mixed Pumps

[3]

Basic Cascade Ctrl

Range

Function

Size related*

[1-8]

Number of drives to be controlled by the Cascade Controller.

MCO 101: 1–6

MCO 102: 1–8

Range

Function

[0-Number of Drives]

Number of pumps to be controlled by the Cascade Controller.

MCO 101: 0–6

MCO 102: 0–8

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

Operating Guide

Table 8: Parameter 27-03 Current Runtime Hours

Table 9: Parameter 27-04 Pump Total Lifetime Hours

Parameter Descriptions

6.1.2 Parameter Group 27-1*, Conguration

Use the conguration parameters for setting, for example, cascade control mode, number of pumps, number of drives, and pump capacity.

Table 10: Parameter 27-10 Cascade Controller Mode

Table 11: Parameter 27-11 Number of Drives

Table 12: Parameter 27-12 Number of Pumps

Range

Function

Parameter 27-12 Number of Pumps*

[1-8]

Limit the maximum number of pumps running simultaneously to prevent overpressure. Default is always equal to parameter 27-12 Number of Pumps. Any change to parameter 27-12 Number of Pumps forces a change to parameter 27-13 Max Number of Pumps Running.

Range

Function

100%*

[10-800%]

Pump Capacity sets the capacity of each pump in the system relative to the 1st pump. This is an indexed parameter with 1 entry per pump. The capacity fo the 1st pump is always considered to be 100%.

Option

Function

Runtime Balancing sets the priority of each pump for balancing its running hours. The pumps with the higest priority are operated before the lower-prioritized pumps. Pumps with the same priority are staged/destaged based on the running hours.

[0]

Balanced Priority 1

Turned on rst, turned o last.

[1]

Balanced Priority 2

Turned on if no priority 1 pumps are available. Turned o before priority 1 pumps are turned o.

[2]

Spare Pump

Turned on last, turned o rst.

Option

Function

Motor Starters selects the type of mains starters used on the xed-speed pumps. All xed-speed pumps must be congured in the same way.

[0]

Direct Online

[1]

Soft Starter

Adds a delay when staging and destaging corresponding to the soft starter ramp time, see parameter 27-41 Ramp Down Delay and parameter 27-42 Ramp Up Delay.

[2]

Star/Delta

Adds a delay at staging, controlled by parameter 27-42 Ramp Up Delay.

Range

Function

Size related*

[0-99 s]

N O T I C E

Setting this parameter too high may cause overpressure to some systems.

Spin Time for Unused Pumps

sets the length of time to spin unused pumps. If a xed-speed pump has not been run in the last 72 hours, it is turned on for the time set in this parameter. This is to prevent damage caused by leaving the pump o too long. The spin feature may be disabled by setting the value of this parameter to 0.

Option

Function

Reset Current Runtime Hours is used for resetting all current runtime hours to 0. This time is used for runtime balancing.

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

Operating Guide

Table 13: Parameter 27-13 Max Number of Pumps Running

Table 14: Parameter 27-14 Pump Capacity

Table 15: Parameter 27-16 Runtime Balancing

Parameter Descriptions

Table 16: Parameter 27-17 Motor Starters

Table 17: Parameter 27-18 Spin Time for Unused Pumps

Table 18: Parameter 27-19 Reset Current Runtime Hours

Option

Function

[0]

Do not reset

[1]

Do reset

Range

Function

Size related*

[1-100%]

Normal Operating Range is the allowed oset from the setpoint before a pump may be added or removed. The system must be outside this limit for the time specied in parameter 27-23 Staging Delay or in parameter 27-24 Destaging Delay before a cascade operation takes place. Normal refers to the system operating with at least 1 variable-speed pump available. This value is entered as a % of maximum reference, see parameter 21-12 Ext. 1 Maximum Reference in the VLT® AQUA Drive FC 202 Programming Guide for further information.

SBW (27-20)

Setpoint

SBW staging delay (27-23)

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e75za671.12

(27-24) SBW destage delay

SBW

Setpoint

(27-20)

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

Operating Guide

6.1.3 Parameter Group 27-2*, Bandwidth Settings

Parameters for conguring control response.

Table 19: Parameter 27-20 Normal Operating Range

Parameter Descriptions

Illustration 24: SBW Staging Delay

Illustration 25: SBW Destage Delay

Range

Function

100%*

[1-100%]

Override Limit is the allowed oset from the setpoint before a pump immediately is added or removed (for example, if a re tab is turned on). Normal operating range includes a delay that limits the system response to transients. This makes the system respond too slowly to large demand changes. The override limit causes the drive to respond immediately. The value is entered as a % of maximum reference (parameter 21-12 Ext. 1 Maximum Reference). Override operation may be disabled by setting this parameter to 100%.

N O T I C E

In master/follower applications, the override limit is used as wake-up condition.

Setpoint

SBW (27-70)

OBW (27-71)

SBW (27-70)

OBW (27-71)

Actual head

OBW timer (27-25)

e30ba370.12

Range

Function

Size related*

[0- Par 27-21 %]

Fixed Speed Only Operating Range is the allowed oset from the setpoint before a pump may be added or removed when there are no operational variable-speed pumps. The system must be outside this limit for the time specied in parameter 27-23 Staging Delay or parameter 27-24 Destaging Delay before a cascade operation may take place. The value is entered as a % of maximum reference. When there are no operational variable-speed pumps, the system tries to maintain control with the remaining xed-speed pumps.

SBW (27-20)

Setpoint

SBW staging delay (27-23)

e75za672.13

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

Operating Guide

Table 20: Parameter 27-21 Override Limit

Parameter Descriptions

Illustration 26: Override Bandwidth

Table 21: Parameter 27-22 Fixed Speed Only Operating Range

Illustration 27: SBW Staging Delay

e75za671.12

(27-24) SBW destage delay

SBW

Setpoint

(27-20)

Range

Function

15 s*

[0-3000 s]

Staging Delay is the time that the system feedback must remain below the operating range before a pump may be turned on. If the system is operating with at least 1 variable-speed pump available, parameter 27-20

Normal Operating Range is used. If there are no variable-speed pumps available, parameter 27-22 Fixed Speed Only Operating Range is used.

Range

Function

15 s*

[0-3000 s]

Destaging Delay is the time that the system feedback must remain above the operating range before a pump may be turned o. If the system is operating with at least 1 variable-speed pump available, parameter 27-20

Normal Operating Range is used. If there are no variable-speed pumps available, parameter 27-22 Fixed Speed Only Operating Range is used.

Range

Function

10 s*

[0-300 s]

Override Hold Time is the minimum time that must elapse after a stage or destage before a stage or destage may take place due to the system exceeding the override limit (parameter 27-21 Override Limit). The override hold time is designed to allow the system to stabilize after a pump is turned on or o. If this delay is not long enough, the transients caused by turning a pump on or o may cause the system to add or remove another pump when it should not.

Range

Function

15s*[0-300 s]

Min-Speed Destage Delay is the time that the lead pump must be running at minimum speed while the system feedback is still inside the normal operating band before a pump is turned o to save energy. Energy savings may be realized by turning o a pump if the variable-speed pumps are operating at minimum speed but the feedback is still in band. Under these conditions, a pump may be turned o and the system is still able to maintain control. The pumps that remain on will then be operating more eciently.

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

Operating Guide

Illustration 28: SBW Destage Delay

Table 22: Parameter 27-23 Staging Delay

Parameter Descriptions

Table 23: Parameter 27-24 Destaging Delay

Table 24: Parameter 27-25 Override Hold Time

Table 25: Parameter 27-27 Min-Speed Destage Delay

e75za640.12

(4-12)

(27-27)

min

VLT pump

Destage

timer period

Pump

switch-off

Option

Function

[0]

Disabled

[1]

Enabled

Parameters 27-31 to 27-34 are kept up-to-date with new automatically calculated values. If parameters 27-31 to 37-34 are modied from the bus or LCP, the new values are used but continue to be tuned automatically. Values

are recalculated and the parameters are updated when staging occurs.

Range

Function

Size related*

[0-par. 4-13 RPM]

To be used if RPM is selected. If the lead pump is operating above stage on speed for the time specied in parameter 27-23 Staging Delay and a variable-speed pump is available, it is turned on.

SBW (27-20)

Setpoint

SBW staging delay (27-23)

e75za672.13

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

Operating Guide

Illustration 29: Destage Timer Period

6.1.4 Parameter Group 27-3*, Staging Speed

Use these parameters for conguring master/follower control response.

Table 26: Parameter 27-30 Auto Tune Staging Speeds

Parameter Descriptions

Table 27: Parameter 27-31 Stage On Speed [RPM]

Illustration 30: SBW Staging Delay

e75za671.12

(27-24) SBW destage delay

SBW

Setpoint

(27-20)

Range

Function

Size related*

[0-par. 4-14 Hz]

To be used if Hz is selected. If the lead pump is operating above stage on speed for the time specied in parameter 27-23 Staging Delay and a variable-speed pump is available, it is turned on.

Range

Function

Size related*

[0-1500 RPM]

If the lead pump operates below stage o speed for the time specied in parameter 27-24 Destag- ing Delay and more than 1 variable-speed pump is on, another variable-speed pump is turned o.

Range

Function

Size related*

[0-50 Hz]

If the lead pump operates below stage o speed for the time specied in parameter 27-24 Destaging Delay and more than 1 variable-speed pump is on, another variable-speed pump is turned o.

Option

Function

[0]

Disabled

Staging or destaging threshold.

[1]

Enabled

Staging and destaging threshold are auto tuned during operation. The auto tuning optimizes the settings and thereby prevents pressure overshoot and undershoot when staging and destaging.

Range

Function

10 s*

[0-120 s]

Ramp Down Delay sets the delay between turning on a soft starter-controlled pump and ramping down a drive-controlled pump. This is only used for soft starter and star/delta-controlled pumps.

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

Operating Guide

Illustration 31: SBW Destage Delay

Table 28: Parameter 27-32 Stage On Speed [Hz]

Parameter Descriptions

Table 29: Parameter 27-33 Stage O Speed [RPM]

Table 30: Parameter 27-34 Stage O Speed [Hz]

6.1.5 Parameter Group 27-4*, Staging Settings

Use these parameters for conguring staging transitions.

Table 31: Parameter 27-40 Auto Tune Staging Settings

Table 32: Parameter 27-41 Ramp Down Delay

(27-41)

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Speed

Ramp down delay

Ramping starts

Soft starter controlled pump

Lead pump variable speed

Staging starts

Time

Range

Function

2 s*

[0-12 s]

Sets the delay between turning o a soft starter-controlled pump and ramping up the drive-controlled pump. This is only used for soft starter-controlled pumps.

N O T I C E

Not used with star/delta-controlled pumps.

(27-42)

e30ba599.12

Speed

Ramp-up delay

Ramping starts

Lead pump variable speed

Soft starter controlled speed

Time

Staging starts

Range

Function

Size related*

[0-100%]

Staging threshold is the speed in the staging ramp at which the xed-speed pump should be turned on. Set as a percentage of the maximum pump speed. If parameter 27-40 Auto Tune Staging Settings is [1] Enabled, parameter 27-43 Staging Threshold and parameter 27-44 Destaging Threshold are kept up-to-date with new automatically calculated values. If parameter 27-43 Staging Threshold and parameter 27-44 Destaging Thresh- old are modied from the bus or LCP, the new values are used but continue to be tuned automatically.

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

Operating Guide

Illustration 32: Ramp-down Delay

Table 33: Parameter 27-42 Ramp Up Delay

Parameter Descriptions

Illustration 33: Ramp-up Delay

Table 34: Parameter 27-43 Staging Threshold

e30bd075.12

Motor s

peed

igh

Motor s

pee

Staging spe

Vari

able sp

eed pump

Fixed speed pump

Monitor feedback and

change to closed loop if

Closed loo

Time

(27-43)

setpoint is reached

Range

Function

Size related*

[0-100%]

Destaging threshold is the speed in the staging ramp at which the xed-speed pump should be turned on. Set as a percentage of the maximum pump speed. If parameter 27-40 Auto Tune Staging Settings is [1] Ena- bled, parameter 27-43 Staging Threshold and parameter 27-44 Destaging Threshold are kept up-to-date with new automatically calculated values. If parameter 27-43 Staging Threshold and parameter 27-44 Destaging Threshold are modied from the bus or LCP, the new values are used but continue to be tuned automatical- ly.

e30bd076.12

Motor speed

high

Motor speed

low

Destaging

speed

Variable speed

pum

Fixed speed pum

Closed loo

Monitor feedback and

change to closed loop if

Time

(27-44)

setpoint is reached

Range

Function

0 RPM*

[0-0 RPM]

Staging Speed is a readout parameter that shows the actual staging speed based on the staging threshold.

Range

Function

0 Hz*

[0-0 Hz]

Staging Speed is a readout parameter that shows the actual staging speed based on the staging threshold.

Range

Function

0 RPM*

[0-0 RPM]

Destaging Speed is a readout parameter that shows the actual staging speed based on the destaging threshold.

Range

Function

0 Hz*

[0-0 Hz]

Destaging Speed is a readout parameter that shows the actual staging speed based on the destaging threshold.

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

Operating Guide

Illustration 34: Staging Speed, Master/follower Conguration

Table 35: Parameter 27-44 Destaging Threshold

Parameter Descriptions

Illustration 35: Destaging Speed, Master/follower Conguration

Table 36: Parameter 27-45 Staging Speed [RPM]

Table 37: Parameter 27-46 Staging Speed [Hz]

Table 38: Parameter 27-47 Destaging Speed [RPM]

Table 39: Parameter 27-48 Destaging Speed [Hz]

Option

Function

Select the staging principle for the staging of xed-speed pumps (direct online mode).

[0]*

Normal

[1]

Rapid Staging

The drive returns to closed-loop operation immediately after a pump was staged or destaged. Use this setting in systems with rapid demand changes.

Option

Function

[0]O[1]

At destage

Range

Function

0 min*

[0-10080 min]

Use this parameter for setting the time between alternations. Disable the function by setting the parameter to 0. To see the time remaining until the next alternation occurs, check parameter 27-53 Alternation Timer Value.

Range

Function

0 min*

[0-10080 min]

Alternation Timer Value is a readout parameter that shows the time remaining before an interval-based alternation takes places. Parameter 27-52 Alternation Time Interval sets the time interval.

Option

Function

Alternate at Time of Day allows selecting a specic time of day for alternating pumps. The time is set in parameter

27.55 Alternation Predened Time. Alternation at Time of Day requires the real-time clock to be set.

[0]

Disabled

[1]

Enabled

Range

Function

Size related*

[0-0]

Alternation Predened Time is the time of day for pump alternation. This parameter is only available if parameter 27-54 Alternation At Time of Day is enabled.

Range

Function

0%*

[0-100%]

Alternate Capacity is < requires the lead pump to be operating below this capacity before time-based alternation is allowed to take place. This feature ensures that alternation only takes place when the pump is running below a speed where interruption in operation will not aect the process. This minimizes the system disturbance caused by alternations. The value is entered as a % of the capacity of pump 1. To disable operation with Alternate Capacity is <, set this parameter to 0%.

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

Operating Guide

Table 40: Parameter 27-49 Staging Principle

6.1.6 Parameter Group 27-5*, Alternation Settings

Use these parameters for conguring alternations.

Table 41: Parameter 27-51 Alternation Event

Table 42: Parameter 27-52 Alternation Time Interval

Parameter Descriptions

Table 43: Parameter 27-53 Alternation Timer Value

Table 44: Parameter 27-54 Alternation at Time of Day

Table 45: Parameter 27-55 Alternation Predened Time

Table 46: Parameter 27-56 Alternate Capacity is <

Range

Function

0.1 s*

[0.1-5 s]

Run Next Pump Delay is a delay between stopping the current lead pump and starting the next lead pump when alternating lead pumps. This provides time for the contactors to switch while both pumps are stopped.

(27-58)

Speed

Current lead pump New lead pump

Run next pump delay

Time

e30ba597.12

Option

Function

[0]

No operation

[1]

Reset

[2]

Coast inverse

[3]

Coast and reset inv

[5]

DC-brake inverse

[6]

Stop inverse

[7]

External interlock

[8]

Start

[9]

Latched start

[10]

Reversing

[11]

Start reversing

[14]

Jog

[15]

Preset reference on

[16]

Preset ref bit 0

[17]

Preset ref bit 1

[18]

Preset ref bit 2

[19]

Freeze reference

[20]

Freeze output

[21]

Speed up

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

Operating Guide

Table 47: Parameter 27-58 Run Next Pump Delay

Illustration 36: Run Next Pump Delay

6.1.7 Parameter Group 27-6*, Digital Inputs

Table 48: Parameter 27-60 Terminal X66/1 Digital Input

Parameter Descriptions

Option

Function

[22]

Speed down

[23]

Set-up select bit 0

[24]

Set-up select bit 1

[34]

Ramp bit 0

[36]

Mains failure inverse

[51]

Hand/Auto start

[52]

Run permissive

[53]

Hand start

[54]

Auto start

[55]

DigiPot increase

[56]

DigiPot decrease

[57]

DigiPot clear

[62]

Reset counter A

[65]

Reset counter B

[66]

Sleep mode

[78]

Reset preventive maintenance word

[80]

PTC card 1

[85]

Latched pump derag

[120]

Lead pump start

[121]

Lead pump alternation

[130]

Pump 1 interlock

[131]

Pump 2 interlock

[132]

Pump 3 interlock

[133]

Pump 4 interlock

[134]

Pump 5 interlock

[135]

Pump 6 interlock

[136]

Pump 7 interlock

[137]

Pump 8 interlock

[138]

Pump 9 interlock

Option

Function

The options of this parameter are the same as for parameter 27-60 Terminal X66/1 Digital Input.

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

Operating Guide

Parameter Descriptions

Table 49: Parameter 27-61 Terminal X66/3 Digital Input

Option

Function

The options of this parameter are the same as for parameter 27-60 Terminal X66/1 Digital Input.

Option

Function

The options of this parameter are the same as for parameter 27-60 Terminal X66/1 Digital Input.

Option

Function

The options of this parameter are the same as for parameter 27-60 Terminal X66/1 Digital Input.

Option

Function

The options of this parameter are the same as for parameter 27-60 Terminal X66/1 Digital Input.

Option

Function

The options of this parameter are the same as for parameter 27-60 Terminal X66/1 Digital Input.

Option

Function

This parameter is an array parameter used to set up the function of the option relays. Depending on which option is installed, only the available relays are visible. If VLT® Extended Cascade Controller MCO 101 is installed, relays 10–12 are visible. If VLT® Advanced Cascade Controller MCO 102 is installed, relays 13–20 are visible. In both cases, the standard relays (relay 1 and relay 2) are accessible as well as the relays in the B option VLT® Relay Card MCB 105 (if that option is installed in combination with advanced cascade). To set up the function of each relay, select the specic relays and then select the function. If the function option [0] Standard Relay is selected, the relay can be used as general purpose relay and the wanted function can then be set up in parameter group 5-4* Relays.

[0]

Standard Relay

Enable follower drive X

[1]

Drive 2 Enable

[2]

Drive 3 Enable

[3]

Drive 3 Enable

[4]

Drive 3 Enable

[5]

Drive 3 Enable

[6]

Drive 3 Enable

[7]

Drive 3 Enable

[8]

Pump 1 to Drive 1

[9]

Pump 1 to Drive 2

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

Operating Guide

Table 50: Parameter 27-62 Terminal X66/5 Digital Input

Table 51: Parameter 27-63 Terminal X66/7 Digital Input

Table 52: Parameter 27-64 Terminal X66/9 Digital Input

Table 53: Parameter 27-65 Terminal X66/11 Digital Input

Parameter Descriptions

Table 54: Parameter 27-66 Terminal X66/13 Digital Input

6.1.8 Parameter Group 27-7*, Connections

Table 55: Parameter 27-70 Relay

Option

Function

[10]

Pump 1 to Drive 3

[11]

Pump 1 to Drive 4

[12]

Pump 1 to Drive 5

[13]

Pump 1 to Drive 6

[14]

Pump 1 to Drive 7

[15]

Pump 1 to Drive 8

[16]

Pump 2 to Drive 1

[17]

Pump 2 to Drive 2

[18]

Pump 2 to Drive 3

[19]

Pump 2 to Drive 4

[20]

Pump 2 to Drive 5

[21]

Pump 2 to Drive 6

[22]

Pump 2 to Drive 7

[23]

Pump 2 to Drive 8

[24]

Pump 3 to Drive 1

[25]

Pump 3 to Drive 2

[26]

Pump 3 to Drive 3

[27]

Pump 3 to Drive 4

[28]

Pump 3 to Drive 5

[29]

Pump 3 to Drive 6

[30]

Pump 3 to Drive 7

[31]

Pump 3 to Drive 8

[32]

Pump 4 to Drive 1

[33]

Pump 4 to Drive 2

[34]

Pump 4 to Drive 3

[35]

Pump 4 to Drive 4

[36]

Pump 4 to Drive 5

[37]

Pump 4 to Drive 6

[38]

Pump 4 to Drive 7

[39]

Pump 4 to Drive 8

[40]

Pump 5 to Drive 1

[41]

Pump 5 to Drive 2

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

Operating Guide

Parameter Descriptions

Option

Function

[42]

Pump 5 to Drive 3

[43]

Pump 5 to Drive 4

[44]

Pump 5 to Drive 5

[45]

Pump 5 to Drive 6

[46]

Pump 5 to Drive 7

[47]

Pump 5 to Drive 8

[48]

Pump 6 to Drive 1

[49]

Pump 6 to Drive 2

[50]

Pump 6 to Drive 3

[51]

Pump 6 to Drive 4

[52]

Pump 6 to Drive 5

[53]

Pump 6 to Drive 6

[54]

Pump 6 to Drive 7

[55]

Pump 6 to Drive 8

[56]

Pump 7 to Drive 1

[57]

Pump 7 to Drive 2

[58]

Pump 7 to Drive 3

[59]

Pump 7 to Drive 4

[60]

Pump 7 to Drive 5

[61]

Pump 7 to Drive 6

[62]

Pump 7 to Drive 7

[63]

Pump 7 to Drive 8

[64]

Pump 8 to Drive 1

[65]

Pump 8 to Drive 2

[66]

Pump 8 to Drive 3

[67]

Pump 8 to Drive 4

[68]

Pump 8 to Drive 5

[69]

Pump 8 to Drive 6

[70]

Pump 8 to Drive 7

[71]

Pump 8 to Drive 8

[72]

Pump 1 to Mains

[73]

Pump 2 to Mains

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

Operating Guide

Parameter Descriptions

Option

Function

[74]

Pump 3 to Mains

[75]

Pump 4 to Mains

[76]

Pump 5 to Mains

[77]

Pump 6 to Mains

[78]

Pump 7 to Mains

[79]

Pump 8 to Mains

Range

Function

0%*

[-200 200%]

Cascade Reference is a readout parameter that shows the reference output for use with the follower drives. This reference is available even when the master drive is stopped. This is the speed that the drive operates at or would be operating at if it was on. It is scaled as a percentage of parameter 4-13 Motor Speed High Limit [RPM] or parameter 4-14 Motor Speed High Limit [Hz].

Range

Function

0%*

[0-0%]

% of Total Capacity is a readout parameter that shows the system operating point as a % capacity of total system capacity. 100% means that all pumps are on at full speed.

Option

Function

[0]

Disabled

The cascade option is not used.

[1]O[2]

Running

[3]

Running at FSBW

[4]

Jogging

[5]

In open loop

[6]

Freezed

[7]

Coast

[8]

Alarm

[9]

Staging

[10]

Destaging

[11]

Alternating

[12]

All oine

[13]

Cascade CTL sleep

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

Operating Guide

6.1.9 Parameter Group 27-9*, Readouts

Table 56: Parameter 27-91 Cascade Reference

Parameter Descriptions

Table 57: Parameter 27-92 % Of Total Capacity

Table 58: Parameter 27-93 Cascade Option Status

Range

Function

[0-25]

Cascade System Status is a readout parameter that shows the status of each individual pump.

Range

Function

[0-255]

Advanced Cascade Relay Output [bin] is a readout parameter that shows the status of each individual relay. From left to right, the bits correspond to the relays 13, 14, 15, 16, 17, 18, 19, 20, respectively.

Parameter number

Parameter description

Default value

4 setup

Change during operation

Conversion index

Type 25-0* System Settings

25-00

Cascade Controller

ExpressionLimit

2 setups

FALSE

–

Uint8

25-02

Motor Start

[0] Direct on line

2 setups

FALSE

–

Uint8

25-04

Pump Cycling

ExpressionLimit

All setups

TRUE–Uint8

25-05

Fixed Lead Pump

ExpressionLimit

2 setups

FALSE

–

Uint8

25-06

Number of Pumps

2 N/A

2 setups

FALSE

Uint8

25-2* Bandwidth Settings

25-20

Staging Bandwidth

ExpressionLimit

All setups

TRUE0Uint8

25-21

Override Bandwidth

100%

All setups

TRUE0Uint8

25-22

Fixed Speed Bandwidth

casco-staging-bandwidth (P2520)

All setups

TRUE0Uint8 25-23

SBW Staging Delay

15 s

All setups

TRUE0Uint16

25-24

SBW Destaging Delay

15 s

All setups

TRUE0Uint16

25-25

OBW Time

10 s

All setups

TRUE0Uint16

25-26

Destage at No-ow

[0] Disabled

All setups

TRUE–Uint8

25-27

Stage Function

ExpressionLimit

All setups

TRUE–Uint8

25-28

Stage Function Time

15 s

All setups

TRUE0Uint16

25-29

Destage Function

ExpressionLimit

All setups

TRUE–Uint8

25-30

Destage Function Time

15 s

All setups

TRUE0Uint16

25-4* Staging Settings

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

Operating Guide

Table 59: Parameter 27-94 Cascade System Status

Table 60: Parameter 27-95 Advanced Cascade Relay Output [bin]

Parameter Descriptions

6.2 Parameter Lists

N O T I C E

Parameter group 25-** Cascade Controller is only to be used for the Basic Cascade Controller or if 1 of the options is used for ex-

tending the number of pumps of the Basic Cascade Controller. In all other cases, use parameter group 27-** Cascade CTL Option.

6.2.1 25-** Cascade Controller

Table 61: Parameter List, 25-** Cascade Controller

Parameter number

Parameter description

Default value

4 setup

Change during operation

Conversion index

Type

25-40

Ramp Down Delay

10 s

All setups

TRUE-1Uint16

25-41

Ramp Up Delay

2 s

All setups

TRUE-1Uint16

25-42

Staging Threshold

ExpressionLimit

All setups

TRUE0Uint8

25-43

Destaging Threshold

ExpressionLimit

All setups

TRUE0Uint8

25-44

Staging Speed [RPM]

0 RPM

All setups

TRUE67Uint16

25-45

Staging Speed [Hz]

0 Hz

All setups

TRUE-1Uint16

25-46

Destaging Speed

0 RPM

All setups

TRUE67Uint16

25-47

Destaging Speed

0 Hz

All setups

TRUE-1Uint16

25-5* Alternation Settings

25-50

Lead Pump Alternation

ExpressionLimit

All setups

TRUE–Uint8

25-51

Alternation Event

[0] External

All setups

TRUE–Uint8

25-52

Alternation Time Interval

24 h

All setups

TRUE74Uint16

25-53

Alternation Timer Value

0 N/A

All setups

TRUE0VisStr[7]

25-54

Alternation Predened Time

ExpressionLimit

All setups

TRUE0TimeOfDayWoDate

25-55

Alternate if Load < 50%

[1] Enabled

All setups

TRUE–Uint8

25-56

Staging Mode at Alternation

[0] Slow

All setups

TRUE–Uint8 25-58

Run Next Pump Delay

0.1 s

All setups

TRUE-1Uint16

25-59

Run on Mains Delay

0.5 s

All setups

TRUE-1Uint16

25-8* Status

25-80

Cascade Status

0 N/A

All setups

TRUE0VisStr[25]

25-81

Pump Status

0 N/A

All setups

TRUE0VisStr[25]

25-82

Lead Pump

0 N/A

All setups

TRUE0Uint8

25-83

Relay Status

0 N/A

All setups

TRUE0VisStr[4]

25-84

Pump ON Time

0 h

All setups

TRUE74Uint32

25-85

Relay ON Time

0 h

All setups

TRUE74Uint32

25-86

Reset Relay Counters

[0] Do not reset

All setups

TRUE–Uint8

25-9* Service

25-90

Pump Interlock

[0] O

All setups

TRUE–Uint8

25-91

Manual Alternation

0 N/A

All setups

TRUE0Uint8

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

Operating Guide

Parameter Descriptions

Parameter number

Parameter description

Default value

4 setup

Change during operation

Conversion index

Type 27-0* Control & Status

27-01

Pump Status

[0] Ready

All setups

TRUE–Uint8

27-02

Manual Pump Control

[0] No Operation

2 setups

TRUE–Uint8

27-03

Current Runtime Hours

0 h

All setups

TRUE74Uint32

27-04

Pump Total Lifetime Hours

0 h

All setups

TRUE74Uint32

27-1* Conguration

27-10

Cascade Controller

null

2 setups

FALSE

–

Uint8

27-11

Number of Drives

ExpressionLimit

2 setups

FALSE

Uint8

27-12

Number of Pumps

ExpressionLimit

2 setups

FALSE

Uint8

27-14

Pump Capacity

100%

2 setups

FALSE

Uint16

27-16

Runtime Balancing

[0] Balanced Priority 1

2 setups

TRUE–Uint8 27-17

Motor Starters

[0] Direct Online

2 setups

FALSE

–

Uint8

27-18

Spin Time for Unused Pumps

ExpressionLimit

All setups

TRUE0Uint16

27-19

Reset Current Runtime Hours

[0] Do not reset

All setups

TRUE–Uint8

27-2* Bandwidth Settings

27-20

Normal Operating Range

ExpressionLimit

All setups

TRUE0Uint8

27-21

Override Limit

100%

All setups

TRUE0Uint8

27-22

Fixed Speed Only Operating Range

ExpressionLimit

All setups

TRUE0Uint8 27-23

Staging Delay

15 s

All setups

TRUE0Uint16

27-24

Destaging Delay

15 s

All setups

TRUE0Uint16

27-25

Override Hold Time

10 s

All setups

TRUE0Uint16

27-27

Min Speed Destage Delay

ExpressionLimit

All setups

TRUE0Uint16

27-3* Staging Speed

27-30

Auto Tune Staging Speeds

[1] Enabled

All setups

TRUE–Uint8

27-31

Stage On Speed [RPM]

ExpressionLimit

All setups

TRUE67Uint16

27-32

Stage On Speed [Hz]

ExpressionLimit

All setups

TRUE-1Uint16

27-33

Stage O Speed [RPM]

ExpressionLimit

All setups

TRUE67Uint16

27-34

Stage O Speed [Hz]

ExpressionLimit

All setups

TRUE-1Uint16

27-4* Staging Settings

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

Operating Guide

6.2.2 27-** Cascade CTL Option

Table 62: Parameter List, 27-** Cascade CTL Option

Parameter Descriptions

Parameter number

Parameter description

Default value

4 setup

Change during operation

Conversion index

Type

27-40

Auto Tune Staging Settings

[0] Disabled

All setups

TRUE–Uint8

27-41

Ramp Down Delay

10.0 s

All setups

TRUE-1Uint6

27-42

Ramp Up Delay

2.0 s

All setups

TRUE-1Uint16

27-43

Staging Threshold

ExpressionLimit

All setups

TRUE0Uint8

27-44

Destaging Threshold

ExpressionLimit

All setups

TRUE0Uint8

27-45

Staging Speed [RPM]

0 RPM

All setups

TRUE67Uint16

27-46

Staging Speed [Hz]

0.0 Hz

All setups

TRUE-1Uint16

27-47

Destaging Speed [RPM]

0 RPM

All setups

TRUE67Uint16

27-48

Destaging Speed [Hz]

0.0 Hz

All setups

TRUE-1Uint16

27-5* Alternate Settings

27-50

Automatic Alternation

[0] Disabled

All setups

FALSE

–

Uint8

27-51

Alternation Event

Null

All setups

TRUE–int8

27-52

Alternation Time Interval

0 min

All setups

TRUE70Uint16

27-53

Alternation Timer Value

0 min

All setups

TRUE70Uint16

27-54

Alternation At Time of Day

[0] Disabled

All setups

TRUE–Uint8

27-55

Alternation Predened Time

ExpressionLimit

All setups

TRUE0TimeOfDayWoDate

27-56

Alternate Capacity is <

All setups

TRUE0Uint8

27-58

Run Next Pump Delay

0.1 s

All setups

TRUE-1Uint16

27-6* Digital Inputs

27-60

Terminal X66/1 Digital Input

[0] No operation

All setups

TRUE–Uint8

27-61

Terminal X66/3 Digital Input

[0] No operation

All setups

TRUE–Uint8

27-62

Terminal X66/5 Digital Input

[0] No operation

All setups

TRUE–Uint8

27-63

Terminal X66/7 Digital Input

[0] No operation

All setups

TRUE–Uint8

27-64

Terminal X66/9 Digital Input

[0] No operation

All setups

TRUE–Uint8

27-65

Terminal X66/11 Digital Input

[0] No operation

All setups

TRUE–Uint8

27-66

Terminal X66/13 Digital Input

[0] No operation

All setups

TRUE–Uint8

27-7* Connections

27-70

Relay

[0] Standard Relay

2 setups

FALSE

–

Uint8

27-9* Readouts

27-91

Cascade Reference

0.0%

All setups

TRUE-1Int16

27-92

% Of Total Capacity

All setups

TRUE0Uint16

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

Operating Guide

Parameter Descriptions

Parameter number

Parameter description

Default value

4 setup

Change during operation

Conversion index

Type

27-93

Cascade Option Status

[0] Disabled

All setups

TRUE–Uint8

27-94

Cascade System Status

0 N/A

All setups

TRUE0VisStr[25]

27-95

Advanced Cascade Relay Output [bin]

0 N/A

All setups

TRUE0Uint16

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

Operating Guide

Parameter Descriptions

Basic settings (master and follower)

Example/remarks

Parameter 0-02 Motor Speed Unit

[1] Hz

Parameter 1-20 Motor Power [kW]

–

Parameter 1-22 Motor Voltage [V]

–

Parameter 1-23 Motor Frequency [Hz]

Parameter 1-24 Motor Current [A]

–

Parameter 1-25 Motor Nominal Speed [RPM]

–

Parameter 1-29 Automatic Motor Adaptation (AMA)

–

Parameter 3-41 Ramp 1 Ramp Up Time [s]

The settings must be the same for master and follower.

Parameter 3-42 Ramp 1 Ramp Down Time [s]

Parameter 4-11 Motor Speed Low Limit [RPM]

Parameter 4-12 Motor Speed Low Limit [Hz]

Parameter 4-13 Motor Speed High Limit [RPM]

Parameter 4-14 Motor Speed High Limit [Hz]

Display settings - master drive

Example

Parameter 0-20 Display Line 1.1 Small

[1601] Reference

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

Operating Guide

Conguration Example

7 Conguration Example

7.1 Master/Follower

In this example of a master/follower conguration with 3 variable-speed pumps, it is assumed that the pressure transmitter is used as feedback sensor and has a range from 0–10 bar. Furthermore, an internal reference is used.

For more detailed information on the master/follower application and on the staging/destaging principle, see 3.2.2 Hardware Con-

guration for Master/Follower Cascade Control and 5.1 Conguration of the Extended and Advanced Cascade Controllers.

The required steps for the conguration are:

•

Basic settings for the master and for the follower (motor data, display, and so on).

•

Conguration of the master.

•

Conguration of 1 of the followers.

•

Copying the setting with the LCP from this follower to the other follower.

7.1.1 Basic Settings

The basic settings of master/follower congurations consist of:

•

Basic motor settings for master and follower drives, see 7.1.1.1 Basic Settings, Master and Follower.

•

Display settings for master and follower drives, see 7.1.1.2 Display Settings, Master and Follower.

7.1.1.1 Basic Settings, Master and Follower

Table 63: Basic Settings

Ensure that the motor is running properly before setting the master drive to closed-loop operation.

7.1.1.2 Display Settings, Master and Follower

Table 64: Display Settings

N O T I C E

Display settings - master drive

Example

Parameter 0-21 Display Line 1.2 Small

[1652] Feedback

Parameter 0-22 Display Line 1.3 Small

[1614] Motor Current

Parameter 0-23 Display Line 2 Large

[1613] Frequency

Parameter 0-24 Display Line 3 Large

[2794] Cascade System Status

Display settings - follower drives

Parameter 0-20 Display Line 1.1. Small

[1650] External Reference

Parameter 0-24 Display Line 3 Large

[1613] Frequency

27-1* Conguration

Example

Parameter 27-10 Cascade Controller

[1] Master/Follower

Parameter 27-11 Number of Drives

Parameter 27-16 Runtime Balancing

[0] Array, Balanced Priority 1

Parameter 27-18 Spin Time for Unused Pumps

0 [s], O

Parameter 27-19 Reset Current Runtime Hours

[1] Do reset

27-2* Bandwidth settings

Example

Parameter 27-21 Override Limit

100 [%]

Parameter 27-23 Staging Delay

15 (s)

Parameter 27-23 Destaging Delay

15 (s)

27-3* Staging Speeds

Example/Remarks

Parameter 27-30 Auto Tune Staging Speeds

[1] Enabled

Parameter 27-31 Stage On Speed [RPM]

Arrays for the staging speeds.

Parameter 27-32 Stage On Speed [Hz]

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

Operating Guide

7.1.2 Master Drive Settings

The master drive settings for master/follower congurations consist of:

•

Conguration settings, see 7.1.2.1 Conguration Settings

•

Bandwidth settings, see 7.1.2.2 Bandwidth Settings

•

Staging speed settings, see 7.1.2.3 Staging Speed Settings

•

Alternate settings, see 7.1.2.4 Alternate Settings

•

Connection settings, see 7.1.2.5 Connection Settings

Conguration Example

7.1.2.1 Conguration Settings

Table 65: Master Drive Settings, Conguration

7.1.2.2 Bandwidth Settings

Table 66: Master Drive Settings, Bandwidth Settings

7.1.2.3 Staging Speed Settings

Table 67: Master Drive Settings, Staging Speeds

27-3* Staging Speeds

Example/Remarks

Parameter 27-33 Stage O Speed [RPM]

Parameter 27-34 Stage O Speed [Hz]

27-5* Alternate Settings

Example

Parameter 27-52 Alternation Time Interval

0 (min), Disabled

Parameter 27-54 Alternation At Time of Day

[0] Disabled

Parameter 27-56 Alternate Capacity is <

0 (s), O

27-7* Connections

Example

Parameter 27-70.0 Relay 1

[1] Drive 2 Enable

Parameter 27-70.1 Relay 2

[2] Drive 3 Enable

Open-loop settings

Example/remarks

Parameter 1-00 Congurations Mode

[0] Open loop

Parameter 3-02 Minimum Reference

Parameter 3-03 Maximum Reference

50 [Hz]

Parameter 3-15 Reference 1 Source

[7] Pulse Input 29

5-** Digital in/out (follower)

Example/remarks

Parameter 5-02 Terminal 29 Mode

[0] Input

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

Operating Guide

Conguration Example

7.1.2.4 Alternate Settings

Table 68: Master Drive Settings, Alternate Settings

7.1.2.5 Connection Settings

N O T I C E

An array parameter is used for conguring the output of the master drive for the start signal of the follower drives.

Table 69: Master Drive Settings, Connections

7.1.3 Follower Drive Settings

Follower drive must be congured for open-loop operation with basic settings as described in of the followers and copy the settings via the LCP.

Terminal 29 is used as a pulse input for the reference signal and must be scaled. The settings of the follower drives consist of:

•

Open-loop settings, see 7.1.3.1 Open-loop Settings

•

Digital in/out settings, see 7.1.3.2 Digital In/Out Settings

7.1.3.1 Open-loop Settings

Table 70: Open-loop Settings, Follower Drive

7.1.1 Basic Settings. Congure only 1

7.1.3.2 Digital In/Out Settings

Table 71: Follower Drive Settings, Digital In/Out

5-** Digital in/out (follower)

Example/remarks

Parameter 5-13 Terminal 29 Digital Input

[32] Pulse Input

Parameter 5-50 Terminal 29 Low Frequency

0 [Hz]

Parameter 5-51 Terminal 29 High Frequency

6000 [Hz]

Parameter 5-52 Terminal 29 Low Ref. Value

Parameter 5-53 Terminal 29 High Ref. Value

50 [Hz]

Parameter 5-10 Terminal 18 Digital Input

[8] Start

Stage

Stage ON [Hz]

Stage OFF [Hz]

48.5 (parameter 2732.1)

30 (parameter 2734.1)

48.5 (parameter 2732.2)

40 (parameter 2734.2)

– (parameter 2732.3)

42 (parameter 2734.3)

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

Operating Guide

Conguration Example

7.1.4 Conguring Sleep Mode

This procedure describes how to congure the drive for destaging the last variable-speed pump in applications with more than 1 drive.

Procedure

Set parameter 27-34.01 higher than the minimum speed in parameter 4-11 Motor Speed Low Limit [RPM]/parameter 4-12 Motor Speed Low Limit [Hz] to enable the sleep function (setting it to 0 disables the function).

Set parameter 27-21 Override Limit to wake up the application.

After wake-up, the pump with the least running hours starts.



N O T I C E

If the master drive does not wake up properly, the drive is not able to reach its destaging speed and the delays in

parameter group 27-** Cascade CTL Option have to be adjusted.

Example

This is an example of an application with 3 pumps with sleep mode enabled.

Table 72: Example Settings for Parameter Group 27-3* Staging Speeds

•

Stage refers to the stage the cascade is running in (stage 1 ⇒ cascade is running in stage 1, only 1 pump is running).

Pumps 1 and 3 are started on 48.5 Hz.

•

Pump 3 is stopped on 42 Hz, pump 2 is stopped on 40 Hz, and pump 1 is stopped on 30 Hz.

•

It might be necessary to ne-adjust the stage on/o speeds to optimize the energy consumption if not autotuned. It is recommended to enable Auto Tune Staging Speeds in parameter 27-30 Auto Tune Staging Speeds.

Parameter 2732.3 is irrelevant in this case because there is nothing left to stage on in stage 3.

Alternatively, the sleep mode can also be congured by using parameter 22-22 Low Speed Detection and parameter group 22-4*

Sleep Mode.

N O T I C E

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

Operating Guide

Index

Alternation

Mixed-pump conguration.............................................................18

Lead pump.............................................................................................31

Settings...................................................................................................44

Bandwidth settings......................................................................................37

Basic cascade controller......................................................................12, 20

Cascade control options...............................................................................6

Closed-loop control.....................................................................................28

Conguration settings................................................................................35

Critical systems..............................................................................................32

Destaging

Master/follower....................................................................................14

Variable-speed pumps...................................................................... 28

Fixed-speed pumps............................................................................29

Mixed-pump conguration.............................................................31

Override..................................................................................................32

in xed-speed operation.................................................................. 32

Extension, relays........................................................................................... 12

Feedback

Pressure.......................................................................................15,31,33

Sensor................................................................................................28,56

Flow compensation.....................................................................................32

Installation

Qualied personnel.............................................................................. 8

Lead pump......................................................................................................31

Index

Leakage current.................................................................................................

Lifetime hours................................................................................................30

Lifetime hours, total..............................................................................31, 31

Multiple drives...............................................................................................28

Pump spin....................................................................................................... 31

Qualied personnel........................................................................................8

Run-time balancing..................................................................................... 30

Spin time......................................................................................................... 31

Staging

Master/follower....................................................................................14

Variable-speed pumps...................................................................... 28

Fixed-speed pumps............................................................................29

Mixed-pump congurations........................................................... 31

Override..................................................................................................32

in xed-speed operation.................................................................. 32

Switches

Disconnect..................................................................................................

Symbols..............................................................................................................8

Unintended start...............................................................................................

Voltage

Safety warning..........................................................................................

Wiring

Master/follower....................................................................................14

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

Operating Guide

Index

Danfoss A/S

Ulsnaes 1 DK-6300 Graasten vlt-drives.danfoss.com

Danfoss can accept no responsibility for possible errors in catalogs, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

*130R0345*

AQ326832164524en-000101 / 130R0345

*M0021901*

Danfoss MCO 101, MCO 102 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Introduction

Safety

Applications

Installation

Parameter Descriptions

Cascade Controller

Open-loop settings

Index