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:
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Applications for cascade control.
•
Installation.
•
Conguration of the system.
•
Parameters.
•
Conguration examples.
The Operating Guide is intended for use by qualied 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.
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The VLT® AQUA FC 202 Operating Guide provides detailed information for the installation and start-up of the drive.
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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:
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-ecient 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 congured in parallel.
The MCO 101 and MCO 102 enable control of multiple pumps congured 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-
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 Qualied Personnel
To allow trouble-free and safe operation of the unit, only qualied personnel with proven skills are allowed to transport, store, assemble, install, program, commission, maintain, and decommission this equipment.
Persons with proven skills:
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Are qualied electrical engineers, or persons who have received training from qualied 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.
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Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in
the Operating Guide.
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Have good knowledge of the generic and specialist standards applicable to the specic 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 qualied personnel can result in death or serious injury.
Only qualied 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.
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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.
When setting up the system, create a hardware conguration which communicates the number of connected pumps and drives to
the master. The necessary hardware is explained in the hardware conguration examples.
3.2.1 Hardware Conguration 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)
Illustration 2: Mains Circuit Alternating Lead Pump (4 Pumps)
Applications
The xed-speed pump conguration provides a cost-eective 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 conguration, 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 Conguration 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 conguration must be selected in parameter
27-10 Cascade Controller. For the conguration shown in Illustration 3, relay selections in parameter group 27-7* Connections are as
Pressure uctuations during staging/destaging transitions may occur and it may be less energy-ecient than the master/follower
congurations.
3.2.2 Hardware Conguration for Master/Follower Cascade Control
The master/follower cascade control mode oers 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 Conguration (Example)
In this conguration, 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.
Conguring 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 Conguration for Mixed Pumps
This conguration combines some of the benets of the master/follower conguration with some of the initial cost savings of the
xed-speedcongurations. It is a good choice when the extra capacity of the xed pumps is rarely needed.
The mixed-pump conguration 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 dierent size.
Illustration 5: Mixed-pump Conguration Example
For this conguration, set the relays as follows in parameter group 27-7* Connections:
The unequal-sized pumps conguration supports a limited mix of xed-speed pumps in dierent sizes. It provides for the largest
range of system output with the smallest number of pumps.
Illustration 6: Example of a Conguration with Unequal-sized Pumps
For this conguration, 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 conguration 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 dened 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 congurations than the ones shown in Table 3 are possible.
Illustration 8: Example of an Invalid Conguration
3.2.3.2 Mixed-pump Conguration with Alternation
In this conguration, 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 conguration, set the relay selection as follows in parameter group 27-7* Connections: