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 |
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Operating Guide |
Contents |
Contents
1 Introduction |
6 |
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1.1 |
Purpose of the Operating Guide |
6 |
1.2 |
Trademarks |
6 |
1.3 |
Additional Resources |
6 |
1.4 |
Document and Software Version |
6 |
1.5 |
Product Overview |
6 |
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1.5.1 Intended Use |
7 |
2 Safety |
8 |
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2.1 |
Safety Symbols |
8 |
2.2 |
Quali€ed Personnel |
8 |
2.3 |
Safety Precautions |
8 |
3 Applications |
11 |
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3.1 |
Application Overview |
11 |
3.2 |
Supported Con€gurations |
12 |
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3.2.1 Hardware Con€guration for Expanding of Basic Cascade |
12 |
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3.2.2 Hardware Con€guration for Master/Follower Cascade Control |
14 |
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3.2.3 Hardware Con€guration for Mixed Pumps |
15 |
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3.2.3.1 Unequal-sized Pumps Con€guration |
16 |
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3.2.3.2 Mixed-pump Con€guration with Alternation |
18 |
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3.2.4 Using Soft Starters for Fixed-speed Pumps |
20 |
3.3 |
Sleep Mode |
20 |
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3.3.1 Basic Cascade Controller |
20 |
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3.3.2 Master/Follower and Mixed-pump Con€gurations |
20 |
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3.3.3 Temporary Boost of the Setpoint Before Sleep Mode |
21 |
4 Installation |
22 |
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4.1 |
Before Start |
22 |
4.2 |
VLT® Extended Cascade Controller MCO 101 |
22 |
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4.2.1 Installing the VLT® Extended Cascade Controller MCO 101 |
22 |
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4.2.2 Electrical Data, VLT® Extended Cascade Control MCO 101 |
24 |
4.3 |
VLT® Advanced Cascade Controller MCO 102 |
24 |
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4.3.1 Installing the VLT® Advanced Cascade Controller MCO 102 |
24 |
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4.3.2 Electrical Data, VLT® Advanced Cascade Control MCO 102 |
26 |
5 Configuration of the System |
27 |
5.1 Con€guration of the Extended and Advanced Cascade Controllers |
27 |
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VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102 |
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Operating Guide |
Contents |
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5.1.1 |
Basic Con€guration of the Extended and Advanced Cascade Controllers |
27 |
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5.1.2 |
Con€guring Multiple Drives |
28 |
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5.1.3 |
Con€guring Closed-loop Control |
28 |
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5.1.4 |
Staging/Destaging of Variable-speed Pumps |
28 |
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5.1.5 |
Staging/Destaging of Fixed-Speed Pumps |
29 |
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5.2 |
Operation |
30 |
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5.2.1 |
Checking Pump Status and Controlling Pumps |
30 |
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5.2.2 |
Manual Pump Control |
30 |
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5.2.3 |
Run-time Balancing |
30 |
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5.2.4 |
Pump Spin for Unused Pumps |
31 |
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5.2.5 |
Total Lifetime Hours |
31 |
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5.2.6 |
Alternation of the Lead Pump |
31 |
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5.2.7 |
Staging/Destaging in Mixed-pump Con€gurations |
31 |
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5.2.8 |
Override Staging/Destaging |
32 |
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5.2.9 |
Minimum Speed Destaging |
32 |
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5.2.10 |
Fixed-speed-only Operation |
32 |
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5.2.11 |
Flow Compensation for Applications with Cascade Controller |
32 |
6 |
Parameter Descriptions |
34 |
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6.1 Parameter Group 27-**, Cascade CTL Option |
34 |
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6.1.1 |
Parameter Group 27-0*, Control & Status |
34 |
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6.1.2 |
Parameter Group 27-1*, Con€guration |
35 |
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6.1.3 |
Parameter Group 27-2*, Bandwidth Settings |
37 |
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6.1.4 |
Parameter Group 27-3*, Staging Speed |
40 |
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6.1.5 |
Parameter Group 27-4*, Staging Settings |
41 |
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6.1.6 |
Parameter Group 27-5*, Alternation Settings |
44 |
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6.1.7 |
Parameter Group 27-6*, Digital Inputs |
45 |
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6.1.8 |
Parameter Group 27-7*, Connections |
47 |
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6.1.9 |
Parameter Group 27-9*, Readouts |
50 |
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6.2 |
Parameter Lists |
51 |
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6.2.1 |
25-** Cascade Controller |
51 |
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6.2.2 |
27-** Cascade CTL Option |
53 |
7 |
Configuration Example |
56 |
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7.1 |
Master/Follower |
56 |
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7.1.1 |
Basic Settings |
56 |
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7.1.1.1 Basic Settings, Master and Follower |
56 |
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7.1.1.2 Display Settings, Master and Follower |
56 |
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7.1.2 |
Master Drive Settings |
57 |
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VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102 |
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Operating Guide |
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Contents |
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7.1.2.1 |
Con€guration Settings |
57 |
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7.1.2.2 |
Bandwidth Settings |
57 |
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7.1.2.3 |
Staging Speed Settings |
57 |
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7.1.2.4 |
Alternate Settings |
58 |
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7.1.2.5 |
Connection Settings |
58 |
7.1.3 |
Follower Drive Settings |
58 |
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7.1.3.1 |
Open-loop Settings |
58 |
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7.1.3.2 |
Digital In/Out Settings |
58 |
7.1.4 |
Con€guring Sleep Mode |
59 |
Danfoss A/S © 2020.08 |
AQ326832164524en-000101/130R0345 | 5 |
VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Introduction |
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1 Introduction
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.
VLT® is a registered trademark for Danfoss A/S.
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.
This manual is regularly reviewed and updated. All suggestions for improvement are welcome. The original language of this manual is English.
Table 1: Document and Software Version
Edition |
Remarks |
Software version |
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AQ326832164524, version 0101 |
• Editorial update. |
VLT® Extended Cascade Controller MCO 101: 2.6X |
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VLT® Advanced Cascade Controller MCO 102: 1.2X |
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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.
The VLT® Extended Cascade Controller MCO 101 and VLT® Advanced Cascade Controller MCO 102 are add-on options extending the supported number of pumps and the functionalities of the built-in Cascade Controller in the VLT® AQUA Drive FC 202.
The MCO 101 consists of an option board with 3 relays and is installed in slot B. Once the options are installed, the parameters supporting the Cascade Controller functions are available via the LCP in parameter group 27-** Cascade CTL Option.
The following options for cascade control are available in the VLT® AQUA Drive FC 202:
•Built-in Basic Cascade Controller (standard Cascade Controller)
•VLT® Extended Cascade Controller MCO 101
•VLT® Advanced Cascade Controller MCO 102
The MCO 101 and MCO 102 can be used in 2 different modes:
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VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Introduction |
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•With the extended features controlled by parameter group 27-** Cascade CTL Option.
•Extending the number of available relays for the Basic Cascade Controller via parameter group 25-** Cascade Controller.
With MCO 101, a total of 5 relays can be used for cascade control. With MCO 102, a total of 8 pumps can be controlled. The options are able to alternate the lead pump with 2 relays per pump.
N O T I C E
If the MCO 102 is installed, the VLT® Relay Card MCB 105 can extend the number of relays to 13.
Cascade control is a common control system used to control parallel pumps or fans in an energy-efficient way.
The VLT® Extended Cascade Controller MCO 101 and the VLT® Advanced Cascade Controller MCO 102 are designed for pump applications, however, it is also possible to use Cascade Controllers in any application requiring multiple motors con€gured in parallel.
The MCO 101 and MCO 102 enable control of multiple pumps con€gured in parallel by:
•Automatically turning individual pumps on/off.
•Controlling the speed of the pumps.
When using Cascade Controllers, the individual pumps are automatically turned on (staged) and turned off (destaged) as needed to meet the required system output for flow or pressure. The speed of pumps connected to the VLT® AQUA Drive FC 202 is also controlled to provide a continuous range of system output.
The Cascade Controller software runs from a single drive with a Cascade Controller option installed (master drive). It controls a set of pumps, each controlled by a drive or connected to a contactor or a soft starter.
Other drives in the system (follower drives) do not need to have a Cascade Controller option card installed. They are operated in open-loop mode and receive the speed reference from the master drive. Pumps connected to drives are referred to as variablespeed pumps. Pumps connected to mains through a contactor or through a soft starter are referred to as €xed-speed pumps.
Each pump, variable speed or €xed speed, is controlled by a relay in the drive. The MCO 101 and MCO 102 can control a mix of variable-speed and €xed-speed pumps.
N O T I C E
VLT® Digital Cascade can be used instead of MCO 101 and MCO 102 for master/follower applications for full redundant system. The VLT® Digital Cascade control is unlocked with a license code. Installation is easy using embedded Modbus RTU and multimaster ability makes system redundant. Example: If the master breaks down, the back-up master takes its place until a replacement takes place.
Danfoss A/S © 2020.08 |
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VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Safety |
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2 Safety
The following symbols are used in this manual:
D A N G E R
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
W A R N I N G
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
C A U T I O N
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
N O T I C E
Indicates information considered important, but not hazard-related (for example, messages relating to property damage).
2.2 Quali€ed Personnel
To allow trouble-free and safe operation of the unit, only quali€ed personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.
Persons with proven skills:
•Are quali€ed electrical engineers, or persons who have received training from quali€ed electrical engineers and are suitably experienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.
•Are familiar with the basic regulations concerning health and safety/accident prevention.
•Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in the Operating Guide.
•Have good knowledge of the generic and specialist standards applicable to the speci€c application.
W A R N I N G
HIGH VOLTAGE
AC drives contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation, start-up, and maintenance by quali€ed personnel can result in death or serious injury.
-Only quali€ed personnel must perform installation, start-up, and maintenance.
W A R N I N G
UNINTENDED START
When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death, serious injury, and equipment or property damage. The motor may start by activation of an external switch, a €eldbus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condition.
-Press [Off] on the LCP before programming parameters.
-Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended motor start.
-Check that the drive, motor, and any driven equipment are in operational readiness.
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VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Safety |
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W A R N I N G
DISCHARGE TIME
The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be present even when the warning indicator lights are off.
Failure to wait the speci€ed time after power has been removed before performing service or repair work could result in death or serious injury.
-Stop the motor.
-Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and DC-link connections to other drives.
-Wait for the capacitors to discharge fully. The minimum waiting time is speci€ed in the table Discharge time and is also visible on the nameplate on top of the drive.
-Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors are fully discharged.
Table 2: Discharge Time
Voltage |
Minimum waiting time (minutes) |
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[V] |
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4 |
7 |
15 |
20 |
30 |
40 |
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200–240 |
0.25–3.7 kW (0.34– |
– |
5.5–45 kW (7.5–60 |
– |
– |
– |
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5 hp) |
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hp) |
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380–480 |
0.37–7.5 kW (0.5– |
– |
11–90 kW (15–125 |
110–250 kW |
– |
315–1500 kW |
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10 hp) |
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hp) |
(150–335 hp) |
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(425–2000 hp) |
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525–600 |
0.75–7.5 kW (1.0– |
– |
11–90 kW (15–125 |
– |
– |
– |
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10 hp) |
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hp) |
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525–690 |
– |
1.1–7.5 kW |
11–90 kW (15–125 |
45–400 kW (60– |
450–1200 kW |
1400 kW |
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(1.5–10 hp) |
hp) |
540 kW) |
(600–1600 hp) |
(1875 hp) |
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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.
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AQ326832164524en-000101 / 130R0345 | 9 |
VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Safety |
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C A U T I O N
INTERNAL FAILURE HAZARD
An internal failure in the drive can result in serious injury when the drive is not properly closed.
-Ensure that all safety covers are in place and securely fastened before applying power.
10 | Danfoss A/S © 2020.08 |
AQ326832164524en-000101 / 130R0345 |
VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Applications |
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3 Applications
<![if ! IE]> <![endif]>Relay 1 |
<![if ! IE]> <![endif]>Relay 2 |
<![if ! IE]> <![endif]>Relay 10 |
<![if ! IE]> <![endif]>e30ba594.12 |
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2 |
3 |
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4 |
100% |
100% |
100% |
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100% |
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<![if ! IE]> <![endif]>Relay 1 |
<![if ! IE]> <![endif]>Relay 2 |
<![if ! IE]> <![endif]>Relay 10 |
<![if ! IE]> <![endif]>e30ba593.12 |
Built-in |
MCO 101 |
MCO 102 |
1 VSP(1) + 2 |
1 VSP + 5 FSP, parame- |
1 VSP + 8 FSP, parame- |
FSP(2), pa- |
ter group 25-** Cas- |
ter group 25-** Cas- |
rameter |
cade Controller |
cade Controller |
group 25-** |
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Cascade |
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Controller |
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– |
1–6 VSP + 1–5 FSP |
1–8 VSP + 1–7 FSP |
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(maximum 6 pumps), |
(maximum 8 pumps), |
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parameter group 27-** |
parameter group 27-** |
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Cascade CTL Option |
Cascade CTL Option |
1 |
2 |
1 |
2 |
3 |
4 |
100% |
100% |
200% |
200% |
1 |
VSP=Variable-speed pump (directly connected to the drive). |
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2 |
FSP=Fixed-speed pump (the motor could be connected via contactor, soft starter, or star/delta starter). |
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Built- |
MCO 101 |
MCO 102 |
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VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Applications |
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Line supply |
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R1 |
R2 |
R10 |
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1 |
2 |
3 |
4 |
1 |
2 |
3 |
4 |
100% |
100% |
100% |
100% |
<![endif]>e30ba595.12
–6 VSP, parameter group 27-** Cascade CTL Option
8 VSP, parameter group 27-** Cascade CTL Option
3.2 Supported Con€gurations
When setting up the system, create a hardware con€guration which communicates the number of connected pumps and drives to the master. The necessary hardware is explained in the hardware con€guration examples.
3.2.1 Hardware Con€guration for Expanding of Basic Cascade
In applications already controlled by the built-in Cascade Controller in parameter group 25-** Control Mode, the option cards can be used to extend the number of relays for cascade control, for example, if a new pump is added to the system.
To enable the basic Cascade Controller in parameter 27-10 Cascade Controller, select [3] Basic Cascade Ctrl. Refer to VLT® AQUA Drive FC 202 Programming Guide for further programming with settings from parameter group 25-** Control Mode.
Refer to Illustration 1 and Illustration 2 for examples of external wiring required for systems with alternating lead pump of 4 pumps using basic cascade and VLT® Extended Cascade Controller MCO 101 as relay extension.
<![if ! IE]><![endif]>e30ba876.11
R1 |
R2 |
Drive |
R10 |
R11 |
K3 |
K3 |
K5 |
K7 |
K2 |
K1 |
K1 |
K5 |
K7 |
K4 |
K1 |
K1 |
K3 |
K7 |
K6 |
K1 |
K1 |
K3 |
K5 |
K8 |
K5 |
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K5 |
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K3 |
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K3 |
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K7 |
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K7 |
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K7 |
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K5 |
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K2 |
K1 |
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K4 |
K3 |
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K6 |
K5 |
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K8 |
K7 |
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K1 |
K2 |
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K3 |
K4 |
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K5 |
K6 |
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K7 |
K8 |
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Illustration 1: Control Circuit Alternating Lead Pump (4 Pumps)
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VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102 |
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Operating Guide |
Applications |
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<![if ! IE]> <![endif]>e30ba875.11 |
FC |
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K1 |
K2 |
K3 |
K4 |
K5 |
K6 |
K7 |
K8 |
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M |
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M |
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M |
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M |
Illustration 2: Mains Circuit Alternating Lead Pump (4 Pumps)
The €xed-speed pump con€guration provides a cost-effective method for controlling up to 9 pumps. It is able to control system output by controlling the number of running pumps and the speed of the single variable-speed pump.
In this con€guration, the VLT® AQUA Drive FC 202 with a VLT® Advanced Cascade Controller MCO 102 controls 1 variable-speed pump and up to 8 €xed-speed pumps. The €xed-speed pumps are staged and destaged as needed through contactors direct online. The variable-speed pump provides the €ner level of control needed between the stages.
The direct online pumps are staged or destaged depending on their feedback.
<![if ! IE]> <![endif]>Relay 1 |
<![if ! IE]> <![endif]>Relay 2 |
<![if ! IE]> <![endif]>Relay 10 |
<![if ! IE]> <![endif]>e30ba592.13 |
1
1 |
2 |
3 |
4 |
100% |
100% |
100% |
100% |
Illustration 3: Fixed-speed Pump Configuration Example
N O T I C E
If the pumps are not equal in size or if 2 relays per pump are used, a mixed-pump con€guration must be selected in parameter 27-10 Cascade Controller. For the con€guration shown in Illustration 3, relay selections in parameter group 27-7* Connections are as follows:
-27-70.0 Relay 1 →[73] Pump 2 to mains
-27-70.1 Relay 2 →[74] Pump 3 to mains
-27-70.9 Relay 10 →[75] Pump 4 to mains
-27-70.10 Relay 11 →[0] Standard relay
-27-70.11 Relay 12 →[0] Standard relay
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VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Applications |
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N O T I C E
Pressure fluctuations during staging/destaging transitions may occur and it may be less energy-efficient than the master/follower con€gurations.
3.2.2 Hardware Con€guration for Master/Follower Cascade Control
The master/follower cascade control mode offers the best performance, the most precise control, and maximum energy savings. It controls multiple equally sized pumps in parallel, running all pumps at the same speed, and stages the pumps on and off according to system requirements. Compared to traditional cascade control, the number of running pumps is controlled by speed instead of feedback. To obtain the highest energy saving, staging speed on and off must be set correctly according to the system. In this example, terminal 27 of the master drive is used as pulse output for the reference, and terminals 29 of the follower drives are used as pulse input for this reference. While the master drive is running in closed loop, the follower drives are running in open loop. All follower drives are connected to mains and motor in the same way as the master drive.
Master with |
Follower 1 |
Follower 2 |
MCO 101/102 |
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DO 27 |
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T 12 |
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T 54 |
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T 20 |
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DI18 |
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T 55 |
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U / I |
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Pressure |
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0 - 10 V |
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0 - 20 mA or |
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4 - 20 mA |
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100% |
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Illustration 4: Basic Wiring Principle for a Master/Follower Configuration (Example)
14 | Danfoss A/S © 2020.08 |
AQ326832164524en-000101 / 130R0345 |
VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Applications |
|
|
In this con€guration, each pump is controlled by a drive. All pumps and drives must be of the same size. Staging and destaging decisions are made based on the speed of the drive. The constant pressure is controlled by the master drive operating in closed loop. The speed is the same in all running pumps.
In the master/follower mode, VLT® Extended Cascade Controller MCO 101 supports up to 6 pumps, while VLT® Advanced Cascade Controller MCO 102 supports up to 8 pumps.
Con€guring as in Illustration 4 requires the following settings in parameter group 27-7* Connections:
•27-70.0 Relay 1 →[1] Drive 2 enable
•27-70.1 Relay 2 →[2] Drive 3 enable
•27-70.9 Relay 10 →[0] Standard relay
•27-70.10 Relay 11 →[0] Standard relay
•27-70.11 Relay 12 →[0] Standard relay
The system run-time balances all pumps automatically depending on the pump prioritization made in parameter 27-16 Runtime Balancing. The master/follower system provides a certain level of redundancy. If the master drive trips, it continues to control the follower drives.
N O T I C E
VLT® 24 V DC Supply MCB 107 can be added to increase the level of system redundancy.
Relays set to [0] Std. Relay can be used as general purpose relay controlled by parameter group 5-4* Relays.
3.2.3 Hardware Con€guration for Mixed Pumps
This con€guration combines some of the bene€ts of the master/follower con€guration with some of the initial cost savings of the €xed-speed con€gurations. It is a good choice when the extra capacity of the €xed pumps is rarely needed.
The mixed-pump con€guration supports a mix of variable-speed pumps connected to drives and also some €xed-speed pumps. First, the variable-speed pumps are staged and destaged based on the drive speed. The €xed-speed pumps are staged and destaged last based on the feedback pressure.
N O T I C E
The variable-speed pumps and the drives must be of the same size. Fixed-speed pumps may be of different size.
<![if ! IE]> <![endif]>Relay 1 |
<![if ! IE]> <![endif]>Relay 2 |
<![if ! IE]> <![endif]>Relay 10 |
<![if ! IE]> <![endif]>e30ba593.12 |
1 |
2 |
1 |
2 |
3 |
4 |
100% |
100% |
200% |
200% |
Illustration 5: Mixed-pump Configuration Example
For this con€guration, set the relays as follows in parameter group 27-7* Connections:
•27-70.0 Relay 1 →[1] Drive 2 enable
•27-70.1 Relay 2 →[74] Pump 3 to mains
•27-70.9 Relay 10 →[75] Pump 4 to mains
Danfoss A/S © 2020.08 |
AQ326832164524en-000101 / 130R0345 | 15 |
VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Applications |
|
|
•27-70.10 Relay 11 →[0] Standard relay
•27-70.11 Relay 12 →[0] Standard relay
3.2.3.1 Unequal-sized Pumps Con€guration
The unequal-sized pumps con€guration supports a limited mix of €xed-speed pumps in different sizes. It provides for the largest range of system output with the smallest number of pumps.
<![if ! IE]> <![endif]>Relay 1 |
<![if ! IE]> <![endif]>Relay 2 |
<![if ! IE]> <![endif]>Relay 10 |
<![if ! IE]> <![endif]>e30bh880.10 |
1
1 |
2 |
3 |
4 |
100% |
100% |
200% |
200% |
Illustration 6: Example of a Configuration with Unequal-sized Pumps
For this con€guration, set the relays as follows in parameter group 27-7* Connections:
•27-70.0 Relay 1 →[73] Pump 2 to mains
•27-70.1 Relay 2 →[74] Pump 3 to mains
•27-70.9 Relay 10 →[75] Pump 4 to mains
•27-70.10 Relay 11 →[0] Standard relay
•27-70.11 Relay 12 →[0] Standard relay
For a con€guration to be valid, it must be possible to stage pumps in increments of 100% of the size of the variable-speed pump of the master drive. The variable-speed pump must control the output between the €xed-speed stages, see Illustration 7.
100% is de€ned as the maximum flow produced by the pump connected to the master drive. The €xed-speed pumps must be multiples of this size.
N O T I C E
Other valid con€gurations than the ones shown in Table 3 are possible.
Table 3: Valid Configurations
Variable speed |
Fixed speed |
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100% |
100% |
+ 200% (see Illustration 7) |
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100% |
100% |
+ 200% + 200% |
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100% |
100% |
+ 100% + 300% |
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100% |
100% |
+ 100% |
+ 300% |
+ 300% |
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100% |
100% |
+ 200% |
+ 400% |
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100% + 100% |
200% |
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100% + 100% |
200% |
+ 200% |
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16 | Danfoss A/S © 2020.08 |
AQ326832164524en-000101 / 130R0345 |
VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Applications |
|
|
C |
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<![if ! IE]> <![endif]>e30bd073.11 |
400 % |
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300 % |
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100 % |
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200 % |
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100 % |
100 % |
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100 % |
100 % |
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100 % |
100 % |
200 % |
200 % |
1 |
2 |
3 |
4 |
Illustration 7: Example of a Valid Configuration
N O T I C E
Invalid con€gurations, as in Illustration 8, will still run, but will have a poor control performance. This allows only limited operation if a pump fails or is interlocked.
Table 4: Invalid Configurations
Variable speed |
Fixed speed |
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100% |
200% |
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No control between 100% and 200% |
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100% |
100% |
+ 300% |
No control between 200% and 300%, see Illustration 8 |
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100% |
100% |
+ 200% + 600% |
No control between 400% and 600 % |
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Danfoss A/S © 2020.08 |
AQ326832164524en-000101 / 130R0345 | 17 |
VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Applications |
|
|
C |
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<![if ! IE]> <![endif]>e30bd074.11 |
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400% |
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100% |
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300% |
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100% |
100% |
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200% |
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100% |
100% |
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100% |
100% |
300 % |
300 % |
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1 |
2 |
3 |
4 |
Illustration 8: Example of an Invalid Configuration
3.2.3.2 Mixed-pump Con€guration with Alternation
In this con€guration, the drive alternates between 2 pumps and controls the other as extra €xed-speed pumps. The Cascade Controller attempts to balance the running hours of the pumps.
<![if ! IE]> <![endif]>Relay 10 |
<![if ! IE]> <![endif]>Relay 1 |
<![if ! IE]> <![endif]>Relay 2 |
<![if ! IE]> <![endif]>Relay 12 |
<![if ! IE]> <![endif]>e30ba602.12 |
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1 |
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1 |
2 |
Illustration 9: Example 1
In Illustration 9, the 2 pumps are operated either as variable-speed pumps or as €xed-speed pumps. For this con€guration, set the relay selection as follows in parameter group 27-7* Connections:
18 | Danfoss A/S © 2020.08 |
AQ326832164524en-000101 / 130R0345 |
VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102
Operating Guide |
Applications |
|
|
•27-70.0 Relay 1 →[8] Pump 1 to drive 1
•27-70.1 Relay 2 →[16] Pump 2 to drive 1
•27-70.9 Relay 10 →[72] Pump 1 to mains
•27-70.10 Relay 11 →[73] Pumps 2 to mains
•27-70.11 Relay 12 →[0] Standard relay
<![if ! IE]> <![endif]>Relay 10 |
<![if ! IE]> <![endif]>Relay 1 |
<![if ! IE]> <![endif]>Relay 2 |
<![if ! IE]> <![endif]>Relay 11 |
<![if ! IE]> <![endif]>Relay 12 |
<![if ! IE]> <![endif]>e30ba601.12 |
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1 |
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1 |
2 |
3 |
Illustration 10: Example 2
In Illustration 10, 2 pumps are operated either as variable-speed pumps or as €xed-speed pumps. The 3rd pump is an extra €xedspeed pump.
For this con€guration, set the relays as follows in parameter group 27-7* Connections:
•27-70.0 Relay 1 →[8] Pump1 to drive 1
•27-70.1 Relay 2 →[16] Pump2 to drive 1
•27-70.9 Relay 10 →[72] Pump 1 to mains
•27-70.10 Relay 11 →[73] Pump 2 to mains
•27-70.11 Relay 12 →[74] Pump 3 to mains
<![if ! IE]> <![endif]>Relay 1 |
<![if ! IE]> <![endif]>Relay 2 |
<![if ! IE]> <![endif]>Relay 10 |
<![if ! IE]> <![endif]>Relay 11 |
<![if ! IE]> <![endif]>Relay 12 |
<![if ! IE]> <![endif]>e30ba600.12 |
|
1 |
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1 |
2 |
3 |
4 |
5 |
Illustration 11: Example 3
Danfoss A/S © 2020.08 |
AQ326832164524en-000101 / 130R0345 | 19 |