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Extended and Advanced Cascade Controller
Option
Contents
®
MI.38.C2.22 - VLT
is a registered Danfoss trademark
Contents
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Table of Contents
Related Manuals for Danfoss MCO 101
Summary of Contents for Danfoss MCO 101
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Page 1: Table Of Contents
Total lifetime hours Alternation of the Lead Pump Staging / De-staging in Mixed Pump Configurations Override Staging /De-staging Minimum Speed De-staging Fixed speed only operation 6 How to Program Extended Cascade Controller Parameters ® MI.38.C2.22 - VLT is a registered Danfoss trademark... - Page 2 Staging Speed, 27-3* Staging Settings, 27-4* Alternation Settings, 27-5* 6-10 Connections, 27-7* 6-11 Readouts, 27-9* 6-11 Cascade CTL Option 27-** 8 Annex A - Master/Follower Application Note Master/Follower Operation 9 Index ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 3: Safety And Precautions
1.1.1 High Voltage Warning The voltage of the adjustable frequency drive and the MCO 101 option card is dangerous whenever they are connected to line power. Incorrect installation of the motor or adjustable frequency drive may cause damage to the equipment, serious injury or death. Con- sequently, it is essential to comply with the instructions in this manual as well as local and national rules and safety regulations. - Page 4 This Instruction Manual can be used with all Extended Cascade Controller options with software version 1.24. NOTE! MCO 101 is software supported as of version 1.05 onwards and MCO 102 as of version 1.24. When reading through this instruction manual, you will come across various symbols that require special attention.
- Page 5 15–125 hp [11–90 kW] 525–690 V 60–550 hp [45–400 kW] 600–1600 hp [450–1200 kW] Be aware that there may be high voltage on the DC link even when the LEDs are turned off. ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
- Page 6 Extended and Advanced Cascade Controller 1 Safety and precautions Option ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 7: Introduction
When using group 27** Extended / Advanced Cascade Control, the systems with pump alternation can be set up with two relays per pump, which reduces the need for external equipment. With the MCO 101, a total of five relays can be used in cascade with the MCO 102. A total of eight pumps can be controlled. NOTE! If the MCO 102 is installed, the relay option MCB 105 can extend the number of relays to 13. -
Page 8: General Description
MCO 101 or 8 relays and 7 digital inputs on option card MCO 102. The difference between the MCO 101 and the MCO 102 is mainly the number of optional relays available to the adjustable frequency drive. When the MCO 102 is installed, the relays option card MCB 105 may be mounted in option slot B. - Page 9 Extended and Advanced Cascade Controller Option 2 Introduction 2.1.4 Extended Cascade Control MCO 101 The MCO 101 option includes three change-over contacts and can be inserted into option slot B. Electrical Data: Max terminal load (AC) 240 V AC 2A...
- Page 10 240 V AC 2A Max terminal load (DC) 24 V DC 1 A Min terminal load (DC) 5 V 10 mA Max switching rate at rated load/min load 6 min /20 sec ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
- Page 11 The power to the adjustable frequency drive must be disconnected. • The power to the live part connections on relay terminals must be disconnected. • Remove the LCP, the terminal cover and the cradle from the FC 202. ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
- Page 12 Figure 2.4: Enclosure A2, A3 (and B3) 1.57 in [40 mm] (only one C option). Wiring the Terminals: 8 relays 7 digital inputs Table 2.1: Advanced Cascade Controller MCO 102 terminal connections ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 13: Supported Configuration
VLT AQUA Drive, with the extended and advanced cascade controller option card installed. They support 1 to 8 additional pumps each connected to either a Danfoss VLT Drive with master/follower or to line power through a contactor or soft starter for a direct online system. - Page 14 Extended and Advanced Cascade Controller 3 Supported Configuration Option Figure 3.1: Control circuit alternating lead pump (4 pumps). Figure 3.2: Line power circuit alternating lead pump (4 pumps). ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 15: Fixed-Speed Pump Configuration
It will however produce wider pressure fluctuations during staging/ de-staging transitions and it may be less energy efficient than the Master-Follower configurations. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 16: Master-Follower Configuration
The speed will be the same in all running pumps with extended control. Up to 6 pumps can be controlled (with Advanced Control, up to 8 pumps). Master/Follower Operation Application for FC In master/follower mode, the MCO 101 supports up to 6 pumps - the MCO 102 up to 8 pumps. Please see (Annex A) for further details. Figure 3.4: Example For this configuration, relay selections in Group 27-7* “Connections”... -
Page 17: Mixed Pump Configuration
This configuration provides some of the benefits of the Master-Follower configuration with some of the initial cost savings of the Fixed Speed configuration. It is a good choice when the extra capacity of the fixed pumps is rarely needed. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 18: Unequal Size Pump Configuration
Invalid configurations will still run but will not stage on all of the pumps. This is done to allow for limited operation if a pump fails or is interlocked in this configuration. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 19: Mixed Pump Configuration With Alternation
27-71 RELAY 2 → [16] Pump 2 to Drive 1 27-72 RELAY 10 → [72] Pump 1 to Line Voltage 27-73 RELAY 11 → [73] Pump 2 to Line Voltage 27-74 RELAY 12→ [0] Standard Relay ® MI.38.C2.22 - VLT is a registered Danfoss trademark... - Page 20 For this configuration, relay selections in Group 27-7* “Connections” are as follows: 27-70 RELAY 1 → [8] Pump 1 to Drive 1 27-71 RELAY 2 → [16] Pump 2 to Drive 1 ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 21: Soft Starters
When using soft starters, a delay will be added from when the staging signal occurs until staging takes place. The delay is necessary due to the ramp time of the fixed speed pump because of the soft starter. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... - Page 22 Extended and Advanced Cascade Controller 3 Supported Configuration Option 3-10 ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 23: Configuring The System
The 3-41 Ramp-up Time and 3-42 Ramp-down Time must be the same for the master drive and for all of the follower drives in the system. These ramps should be set fast enough to enable the PID controller to maintain control of the system. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 24: Closed-Loop Control
P27-31 (27-32) and 27-33 (27-34) before enabling auto-tune. The goal is to find the stage on and off speeds where the system is most energy efficient. See the drawing below. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 25: Staging/De-Staging Of Fixed-Speed Pumps Based On Pressure Feedback
Over time, this feature will ensure the most energy-efficient operation, taking into account wear and tear on the pump system. Danfoss has made available the Multiple Unit Staging Efficiency Calculator (MUSEC), a free software program available on the Danfoss web site. By entering pump and system data, MUSEC provides the optimal settings for the Stage On and Stage Off speed parameters. - Page 26 Extended and Advanced Cascade Controller 4 Configuring the System Option ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 27: Cascade Controller Features
Offline-On - Turns the pump on and makes it unavailable for cascading. • Offline-Spin - Initiates a pump spin. If any of the “Offline” selections are chosen, the pump will no longer be available to the cascade controller until “Online” is selected. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 28: Runtime Balancing
The extended cascade controller will not compensate for the extra pressure generated during a pump spin. It is advisable to keep the spin time as short as possible to prevent damage caused by creating excess pressure in the output. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 29: Total Lifetime Hours
If the system pressure is still too high with only one drive running at minimum speed, it will begin to de-stage fixed-speed pumps. A fixed-speed pump will be de-staged when the pressure goes above the setpoint by the Normal Operating Range (27-20) percentage and stays there for the De-staging ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 30: Override Staging /De-Staging
If all of the variable speed pumps are unavailable and the system pressure goes above the Fixed Speed Only Operating Range (27-22) for the De-stage Delay (27-24) time, a fixed-speed pump will be turned off. This repeats until all of the pumps are off. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 31: How To Program
Selecting one of these will execute the command and then return to No Operation. Possible selections are: [0] * No Operation Does nothing. Online Makes the pump available to the cascade controller. Alternate On Forces the selected pump to become the lead pump. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 32: Configuration
Pump Capacity sets the capacity of each pump in the system, relative to the first pump. This is an indexed parameter with one entry per pump. The capacity of the first pump is always considered to be 100%. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... - Page 33 Option: Function: Reset Current Runtime Hours is used to reset all of the Current Runtime Hours to zero. This time is used for runtime balancing. [0] * Do not reset Reset ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 34: Bandwidth Settings
The override limit causes the drive to respond immediately. The value is entered as a % of Max Reference (P21-12). Override operation may be disabled by setting this parameter to 100%. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... - Page 35 Under these conditions, a pump may be turned off and the system will still be able to maintain control. The pumps that remain on will begin operating more efficiently. ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 36: Staging Speed
If the lead pump is operating above Stage On Speed for the time specified in Staging Delay (par. 27-23), and a variable speed pump is available, it will be turned on. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 37: Staging Settings
[0 s –120 s] Ramp-down Delay sets the delay between turning on a soft starter controlled pump and ramping down the drive-controlled pump. This is only used for soft starter-controlled pumps. ® MI.38.C2.22 - VLT is a registered Danfoss trademark... - Page 38 P27-40 is disabled. If P27-40 is disabled, the staging threshold in P27-43 can be changed manually, and the new value will then be used if P27-40 is enabled again. ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
- Page 39 Staging Speed is a readout parameter that shows the actual staging speed based on the staging threshold. 27-47 De-staging Speed (RPM) Option: Function: Units: RPM De-staging Speed is a readout parameter that shows the actual de-staging speed based on the de- staging threshold. ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 40: Alternation Settings
The value is entered as a % of the ca- pacity of pump 1. Alternate Capacity is < operation may be disabled by setting this parameter to 6-10 ® MI.38.C2.22 - VLT is a registered Danfoss trademark... -
Page 41: Connections
This is the speed at which the drive is operating or would be operating if it were on. It is scaled as a percentage of Motor Speed High Limit (P4-13[rpm] or P4-14[Hz]). Units: % 6-11 ® MI.38.C2.22 - VLT is a registered Danfoss trademark... - Page 42 A staging operation is in progress. De-staging A de-staging operation is in progress. Alternating An alternation operation is in progress. Lead Pump Not Set A lead pump has not been selected. 6-12 ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
- Page 43 Extended and Advanced Cascade Controller Option 7 Parameter Lists ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
- Page 44 Extended and Advanced Cascade Controller 7 Parameter Lists Option ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 45: Annex A - Master/Follower Application Note
Application Description ® The system used as example contains four equal-sized pumps in a water distribution system. They are each connected to a Danfoss VLT AQUA Drive. A pressure transmitter with an analog output format of 4–20 mA is used as feedback and connected to the drive named 'master drive'. The master ®... - Page 46 Display Line 1.1 Small 0-20 External Reference [1650] Display Line 3 Large 0-24 Frequency [1613] NOTE! Please note: the format of the analog input is set using switch S201 below the LCP. ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
- Page 47 27-16 in three levels. (Priority 1, Priority 2 and spare pump). Pumps with priority 2 will only be staged on when there is no priority 1 pump available. stage on/off It might be necessary to fine adjust the speed to optimize the energy consumption. ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
- Page 48 Extended and Advanced Cascade Controller 8 Annex A - Master/Follower Application Note Option ® MI.38.C2.22 - VLT is a registered Danfoss trademark...
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Page 49: Index
Display Settings - Follower Drives Display Settings - Master Drive Drive Configurations Easy Installation Electrical Wiring Energy Savings, Extended Cascade Controller, Mco 101, And Advanced Cascade Controller, Mco 102 Extension Of Basic Cascade Feedback Pressure 3-5, 5-3 Feedback Sensor Fixed Speed... - Page 50 Extended and Advanced Cascade Controller Index Option General Description Ground Leakage Current Introduction Introduction To The Mco 101 And Mco 102 Ip55 Or Even Ip66 Lead Pump 5-3, 5-4 Lead Pump Lifetime Hours Manual Pump Control Manual Pump Control, 27-02...
- Page 51 Staging/de-staging Of Fixed-speed Pumps Based On Pressure Feedback Supported Configuration Switch S201 Terminal 27 Terminal 29 Unequal Size Pump Configuration Variable Speed Pumps. Vlt® Extended Cascade Controller Option Mcb-101 Weak Pipe Systems ® MI.38.C2.22 - VLT is a registered Danfoss trademark...