Danfoss VLT Soft Starter Installation guide

Installation Guide

Pumping Smart Card VLT® Soft Starter MCD 600

Installation Guide | Pumping Smart Card

Contents

1 Safety 5

1.1 Disclaimer 5

1.2 Warnings 5

2 Overview 6

2.1 Features of the Pumping Smart Card 6

2.1.1 Monitoring 6

2.1.2 Protection 6

2.1.3 Control 6

3 Setting up the Smart Card 7

3.1 Set-up Procedure 7

4 Installation 8

4.1 Installing the Expansion Card 8

4.2 Compatible Input Devices 8

4.3 Active and Passive 4–20 mA Input Devices 8

4.4 Minimizing Noise 9

4.5 Inputs 9

5 Operation 11

5.1 Monitoring 11

5.2 Protection and Monitoring 11

5.3 Protecting, Monitoring, and Controlling the Soft Starter 11

6 Configuration 12

6.1 Parameter Configuration 12

6.2 Off-line Configuration 12

6.3 Flow Protection 12

6.3.1 Operation 12

6.3.1.1 Using an Analog 4–20 mA Sensor 13

6.3.1.2 Using a Switch Sensor 13

6.3.1.3 Using a Pulse Sensor 13

6.3.2 Parameter Group 30-** Pump Input Configuration 14

6.3.3 Parameter Group 31-** Flow Protection 15

6.3.4 Parameter Group 36-** Pump Trip Action 15

6.4 Pressure Protection 16

6.4.1 Operation 17

6.4.1.1 Using an Analog 4–20 mA Sensor 17

6.4.1.2 Using a Switch Sensor 17

Installation Guide | Pumping Smart Card

6.4.1.3 Parameter Group 30-** Pump Input Configuration 18

6.4.1.4 Parameter Group 32-** Pressure Protection 18

6.4.1.5 Parameter Group 36-** Pump Trip Action 19

6.5 Pressure Control 20

6.5.1 Configuring Pressure Control 20

6.5.2 Operation 20

6.5.2.1 Level Control Operation 21

6.5.2.2 Pressure-based Operation 22

6.5.2.3 Parameter Group 30-** Pump Input Configuration 23

6.5.2.4 Parameter Group 33-** Pressure Control 23

6.5.2.5 Parameter Group 36-** Pump Trip Action 24

6.6 Depth Protection 24

6.6.1 Operation 25

6.6.1.1 Using an Analog 4–20 mA Sensor 25

6.6.1.2 Using a Switch Sensor 25

6.6.1.3 Parameter Group 30-** Pump Input Configuration 26

6.6.1.4 Parameter Group 34-** Depth Protection 26

6.6.1.5 Parameter Group 36-** Pump Trip Action 27

6.7 Thermal Protection 27

6.7.1 Parameter Group 35-** Thermal Protection 28

6.7.2 Parameter Group 36-** Pump Trip Action 28

Contents

7 Trip Messages 29

7.9 Pressure Sensor 31

8 Specifications 33

8.1 Connections 33

8.2 Certification 33

Installation Guide | Pumping Smart Card

Safety

1 Safety

1.1 Disclaimer

The examples and diagrams in this manual are included solely for illustrative purposes. The information contained in this manual is subject to change at any time and without prior notice. Responsibility or liability is never accepted for direct, indirect, or consequential damage resulting from the use or application of this equipment.

1.2 Warnings

WARN IN G

UNEXPECTED BEHAVIOR

When the soft starter is connected to mains voltage, the Pumping Smart Card can start or stop the motor without warning. Unexpected behavior can lead to personal injury.

To ensure personnel safety, isolate the soft starter from mains voltage before installing the smart card.

WA RN IN G

RISK OF PERSONAL INJURY AND EQUIPMENT DAMAGE

Inserting foreign objects or touching the inside of the soft starter while the expansion port cover is open may endanger personnel and can damage the soft starter.

Do not insert foreign objects in the soft starter with the port cover open.

Do not touch the inside of the soft starter with the port cover open.

NO TI CE

The hydraulic characteristics of pump systems vary considerably. The default parameter settings may not be suitable for every application and care should be taken to configure the soft starter appropriately.

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Installation Guide | Pumping Smart Card

Overview

2 Overview

2.1 Features of the Pumping Smart Card

The Pumping Smart Card provides dedicated inputs for pressure, depth, temperature, and flow sensors to allow protection, control, and monitoring integration in a range of pumping applications.

2.1.1 Monitoring

Data from analog or pulse sensors can be shown directly on the display of the soft starter.

A real-time graph is also available if the optional remote LCP is installed.

2.1.2 Protection

The smart card can trip the soft starter based on user-selected levels for high or low pressure, depth, temperature, or flow.

2.1.3 Control

The smart card can automatically start and stop the soft starter in response to rising or falling pressure, or rising or falling depth.

Smart card control can be used with the VLT® Soft Starter MCD 600 scheduling function to restrict starting or stopping to specified days and times.

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Installation Guide | Pumping Smart Card

Setting up the Smart Card

3 Setting up the Smart Card

3.1 Set-up Procedure

Context:

WA RN IN G

SHOCK HAZARD

Attaching or removing accessories while the soft starter is connected to mains voltage may cause personal injury.

Before attaching or removing accessories, isolate the soft starter from mains voltage.

Procedure

1. Insert the smart card into the soft starter.

2. Connect sensors to the inputs:

A Depth protection: B13, B14 or C13, C14

B Pressure protection: B23, B24 or C33, C34, C43, C44.

C Flow protection: B33, B34 or C23, C24.

D Motor temperature protection: R1, R2, R3.

E Pressure or depth-based control: B23, B24.

3. Configure the soft starter's auto-reset as required (parameter 6-1 Auto-Reset Count and parameter 6-2 Auto-Reset Delay).

4. Configure flow protection operation if required.

5. Configure pressure protection operation if required.

6. Configure pressure or depth-based control if required.

NO TI CE

Protection features still operate even if control is set to Off.

7. Configure depth protection if required.

8. Configure temperature protection if required.

9. Select the command source (parameter 1-1 Command Source).

• For protection and monitoring, use Digital input, Remote LCP, or Clock.

• For control, use Smart card or Smart card+Clock.

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1 2

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Installation Guide | Pumping Smart Card

Installation

4 Installation

4.1 Installing the Expansion Card

Procedure

1. Push a small flat-bladed screwdriver into the slot in the center of the expansion port cover and ease the cover away from the soft

starter.

2. Line up the card with the expansion port.

3. Gently push the card along the guide rails until it clicks into the soft starter.

Example:

Illustration 1: Installation of the Expansion Cards

4.2 Compatible Input Devices

The smart card supports the following types of input devices:

• Analog 4–20 mA active (self-powered) and passive (loop-powered)

• Pulse

• Digital switch

4.3 Active and Passive 4–20 mA Input Devices

The wiring connections for 4–20 mA sensors vary depending on how the sensor is powered. This manual describes the wiring connections for passive (loop-powered) sensors, but active (self-powered) sensors can also be used by changing the wiring connections.

• Passive (loop-powered) sensors are powered from the 4–20 mA terminals of the smart card. For these sensors, use B13-B14, B23B24, B33-B34.

• Active (self-powered) sensors have either an internal or external power supply. The sensor is not powered from the smart card terminals. For these sensors, connect the 0 V to terminal R1 and connect the active input to B13, B23, or B33 as required.

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USB

DIGITAL INPUTS 4/20mA INPUTSRTD

Keypad

C24

C33

C34

C43

C13

C14

C23

C44

B14

B13B23

B24

B33

B34R2R1

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Installation Guide | Pumping Smart Card

Active and passive sensors can be used in the same installation.

4.4 Minimizing Noise

To minimize noise when using the analog 4–20 mA inputs, use twisted pair wiring.

4.5 Inputs

Installation

Illustration 2: Location of Inputs

Table 1: Legend to Location of Inputs

Number Function Terminals Description

1 Reset input RESET, COM+ If the reset input is active, the soft starter does not operate. If a reset

switch is not required, fit a link across terminals RESET, COM+ on the soft starter. The reset input is normally closed by default.

2 Digital inputs (normally open) C13, C14 Depth protection

C23, C24 Flow protection and monitoring

C33, C34 Low-pressure protection

C43, C44 High-pressure protection

3 RTD/PT100 input R1, R2, R3 Motor temperature protection

4 4–20 mA inputs B13, B14 [+] Depth protection and monitoring

B23, B24 [+] Pressure protection and monitoring/pressure or depth-based control

B33, B34 [+] Flow protection and monitoring

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Installation Guide | Pumping Smart Card

NO TI CE

The reset input can be configured for normally open or normally closed operation. Use parameter 7-9 Reset/ Enable Logic to select the configuration.

NO TI CE

FLOW PROTECTION AND MONITORING

When used with a switch sensor, C23, C24 provide flow protection only. When used with a pulse sensor, C23, C24 provide flow protection and monitoring.

Installation

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Installation Guide | Pumping Smart Card

Operation

5 Operation

5.1 Monitoring

Data from analog or pulse sensors can be shown directly on the soft starter display.

A real-time graph is also available if the optional remote LCP is installed.

• To scroll to the graph screen, press [▵] and [▿].

• To change which data is shown on the graph, press [GRAPH] on the remote LCP.

5.2 Protection and Monitoring

The smart card can stop or trip the soft starter based on user-selected levels for high or low pressure, depth, temperature, or flow.

Smart card protection features are always active while the soft starter is operating. Protection levels are set via parameter groups 31 to

35.

5.3 Protecting, Monitoring, and Controlling the Soft Starter

Context:

The smart card can automatically start and stop the soft starter in response to rising or falling pressure, or rising and falling depth.

NO TI CE

Smart card protection features are always active while the soft starter is operating. Smart card protection is not affected by the command source.

NO TI CE

To use the smart card to control the soft starter, use sensors connected to B23, B24.

NO TI CE

If the reset input is active, the soft starter does not operate. If a reset switch is not required, fit a link across terminals RESET, COM+ on the soft starter.

Procedure

1. Set parameter 1-1 Command Source to Smart Card or Smart Card+Clock.

2. Set parameter 33-1 Pressure Control Mode as required.

3. Set parameter 4-1 Auto-Start/Stop Mode to Enable to use clock-based scheduling.

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