Danfoss VLT AQUA Operating Instructions Manual
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Danfoss VLT AQUA Operating Instructions Manual

Cascade controller options mco 101/102
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Download this manual See also: Programming Manual, Instruction Manual
MAKING MODERN LIVING POSSIBLE
V V LT AQUA Drive
Cascade Controller Options MCO 101/102
Operating Instructions

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Summary of Contents for Danfoss VLT AQUA

  • Page 1 MAKING MODERN LIVING POSSIBLE V V LT AQUA Drive Cascade Controller Options MCO 101/102 Operating Instructions...
  • Page 2 11-90 kW 110-250 315-1000 525-600 0.75-7.5 11-90 kW 525-690 11-37 kW 45-400 450-1200 1400 kW High voltage may be present even when the warning LED display lights are off. Discharge Time ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 3 ® Safety AQUA Drive MCO 101/MCO 102 ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 4: Table Of Contents

    4.2.2 Manual Pump Control 4.2.3 Runtime Balancing 4.2.4 Pump Spin for Unused Pumps 4.2.5 Total Lifetime Hours 4.2.6 Alternation of the Lead Pump 4.2.7 Staging/De-staging in Mixed Pump Configurations 4.2.8 Override Staging/De-staging ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 5 5.1.11 Readouts, 27-9* 5.2 Parameter Lists 5.2.1 25-** Cascade Controller 5.2.2 27-** Cascade CTL Option 6 Configuration Examples 6.1 Master/Follower 6.1.1 Basic Settings 6.1.2 Master Drive Settings 6.1.3 Follower Drive Settings Index ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 6: Introduction

    MCO 101 (Extended Cascade Controller) The purpose of these operating instructions is to describe • MCO 102 (Advanced Cascade Controller) the Danfoss Cascade Controller Options MCO 101 and MCO 102. For further information, see 2 Application Types. The operating instructions contain information about: The Extended Cascade Controller can be used in two •...
  • Page 7 +Documentation.htm for listings. • Optional equipment may change some of the procedures described. Reference the instructions supplied with those options for specific requirements. Contact the local Danfoss supplier or visit the Danfoss website: www.danfoss.com/ BusinessAreas/DrivesSolutions/Documentations/ Technical+Documentation.htm, for downloads or additional information.

  • Page 8: Application Types

    Use of the extended cascade option MCO 101 as an extension of the built-in basic cascade in the frequency converter In applications already controlled by the built-in Cascade Controller in parameter group 25-**, the option card can ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 9 The variable speed pump provides the finer level of control needed between the stages. The direct online pumps are staged or de-staged depending on the feedback. Illustration 2.3 Fixed Speed Pump Configuration Example ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 10: Master-Follower Configuration

    Motor / Pump 1 Motor / Pump 2 Transmitter 0 - 10 V 0 - 20 mA or 4 - 20 mA 100% 100% 100% Illustration 2.4 Basic Wiring Principle (Example) ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 11: Mixed Pump Configuration

    All variable speed pumps and frequency converters must 27-70.0 RELAY 1 → [73] Pump 2 to Mains be the same size. Fixed speed pumps may be of different 27-70.1 RELAY 2 → [74] Pump 3 to Mains sizes. ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 12: Mixed Pump Configuration With Alternation

    Illustration 2.7 Valid Configuration Example NOTICE Invalid configurations, like in Illustration 2.8, will still run but will not stage on all pumps. This feature allows for limited operation if a pump fails or is interlocked. ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 13: Using Soft Starters For Fixed Speed Pumps

    27-70.9 RELAY 10 → [72] Pump 1 to Mains via parameter group 5-1* Digital Inputs). To use for example an electro-mechanical flow switch to detect a no 27-70.10 RELAY 11 → [73] Pump 2 to Mains ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 14: Basic Cascade Controller

    Stage 1 48.5 (i.e. parameter 2732.1) 30 (i.e. parameter 2734.1) Stage 2 48.5 (i.e. parameter 2732.2) 40 (i.e. parameter 2734.2) Stage 3 48.5 (i.e. parameter 2732.3) 42 (i.e. parameter 2734.3) Table 2.4 ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 15: Installation

    Fit the extended cradle and terminal cover. Remount the LCP. The MCO 101 option includes 3 pieces of change-over Connect power to the frequency converter. contacts and can be fitted into option slot B. ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 16 Illustration 3.3 Mounting of Cables WARNING Do not combine low voltage parts and PELV systems (see Illustration 3.4. Illustration 3.4 Incorrect and Correct Relay Wiring Live part PELV Table 3.4 Legend to Correct Relay Wiring ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 17: Advanced Cascade Controller

    Tools required Some items are needed for the installation of a C option mounting kit (depending on the enclosure): Illustration 3.5 Enclosure A2, A3 (and B3) 40 mm (only one C option) ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 18 Fit the extended cradle and terminal cover. Remount the LCP. Connect power to the frequency converter. Wiring the Terminals Illustration 3.7 Advanced Cascade Controller MCO 102 Terminal Connections, 8 Relays ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 19: Configuring The System

    1-00 Configuration Mode to [0] Open Loop and Define relays in parameter group 27-7* 3-15 Reference 1 Source to selection [7] Pulse input Connections 29 and 5-13 Terminal 29 Digital Input to [32] Pulse input. ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 20: Closed Loop Control

    Set the values The stage on and de-stage off speed can be auto tuned through: during automation or set manually. If Auto-tune is enabled ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 21: Operation

    If a pump is taken offline through 27-02 Manual Pump individual pumps. Select a specific pump to view the Control, the cascade Controller attempts to compensate for the offline pumps as follows: ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 22: Runtime Balancing

    Controller balances running hours by alternating the lead pump. Alternation of lead pumps can also be forced manually e.g. through 27-54 Alternation At Time of Day or through a digital input. Use alternation time parameters if the system ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 23: Staging/De-Staging In Mixed Pump Configurations

    27-24 Destaging Delay. If the system demand continues to drop the system will enter sleep mode. Operating Range for the Staging Delay time (27-23 Staging Delay), a fixed speed pump will be turned on. ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 24: Flow Compensation For Applications With Cascade Controller

    • Enable Flow Compensation in 22-80 Flow Compensation • Program the Pressure at No-Flow Speed in 22-87 Pressure at No-Flow Speed • Program the uncompensated setpoint (e.g. in 20-21 Setpoint 1) ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 25: Parameter Descriptions

    [30] Ext. Closed Loop 1 [31] Ext. Closed Loop 2 3-15 Reference 1 Source [32] Ext. Closed Loop 3 Option: Function: Select the reference input to be used for the first reference signal. ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 26 [166] Remote ref active Stand-by / no warning [167] Start command act. Running [168] Hand mode Running / no warning [169] Auto mode Run on ref/no warn [180] Clock Fault Alarm ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 27: Cascade Ctl Option, 27

    Value. Set terminal 29 to digital input (5-02 Terminal 29 Mode = [0] input 5.1.1 Cascade CTL Option, 27-** (default) and 5-13 Terminal 29 Digital Input = applicable value). Cascade Control Option parameter group. ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 28: Control & Status

    Offline - On The pump is not available for use by the operating hours for each connected Drive Cascade Controller, and the pump is pump. connected to mains and is running ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 29: Configuration

    % of Max Reference, see Spare Pump Turned on last, turned off ® 21-12 Ext. 1 Maximum Reference in the VLT first. AQUA Drive Programming Guide for further information. ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 30 Override operation may be disabled by setting this parameter to 100%. NOTICE Illustration 5.4 In master-follower applications the override limit is used as wake-up condition. See 6.1 Master/Follower for further information. ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 31: Staging Speed

    If the lead pump is operating above normal operating band before a pump will be Stage On Speed for the time specified turned off to save energy. Energy savings may be ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 32: Staging Settings

    27-34 Stage Off Speed [Hz] soft starter controlled pumps. Range: Function: Size [ 0.0 - If the lead pump is operating below related 50 Hz] Stage Off Speed for the time specified in ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 33: Alternation Settings

    If 27-40 Auto Tune Staging Settings is [1] Enabled will be kept up to date with new automatically calculated values. If 27-43 Staging Threshold and 27-44 Destaging ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 34: Digital Inputs

    This provides time for the contactors [65] Reset Counter B to switch while both pumps are stopped. [66] Sleep Mode [78] Reset Preventive Maintenance Word [80] PTC Card 1 [85] Latched Pump Derag ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 35 Reset Preventive Maintenance Word [80] PTC Card 1 [80] PTC Card 1 [85] Latched Pump Derag [85] Latched Pump Derag [120] Lead Pump Start [120] Lead Pump Start [121] Lead Pump Alternation ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 36 Latched Pump Derag [120] Lead Pump Start [120] Lead Pump Start [121] Lead Pump Alternation [121] Lead Pump Alternation [130] Pump 1 Interlock [130] Pump 1 Interlock [131] Pump 2 Interlock ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 37 Lead Pump Alternation [130] Pump 1 Interlock [130] Pump 1 Interlock [131] Pump 2 Interlock [131] Pump 2 Interlock [132] Pump 3 Interlock [132] Pump 3 Interlock [133] Pump 4 Interlock ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 38: Connections

    Pump 7 to Drive 7 [23] Pump 2 to Drive 8 [63] Pump 7 to Drive 8 [24] Pump 3 to Drive 1 [64] Pump 8 to Drive 1 [25] Pump 3 to Drive 2 ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 39: Readouts

    Current % of Total Capacity is a readout parameter that shows the system operating point as a % capacity of total system capacity. 100% means all pumps are on at full speed. Units: % Range: Function: [0 - 0 %] ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 40: Parameter Lists

    10 s TRUE Alternation Time set- Uint1 Destage At No- set- 25-52 Interval 24 h TRUE 25-26 Flow Disabled TRUE Uint8 Alternation Timer set- VisSt 25-53 Value 0 N/A TRUE r[7] ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 41: Cascade Ctl Option

    TRUE 27-04 Lifetime Hours TRUE 27-1* Configuration Reset Current [0] Do not set- Cascade 2 set- FALS 27-19 Runtime Hours reset TRUE Uint8 27-10 Controller null Uint8 27-2* Bandwidth Settings ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 42 0.1 s TRUE 27-41 Delay 10.0 s TRUE 27-6* Digital Inputs set- Uint1 27-42 Ramp Up Delay 2.0 s TRUE Terminal X66/1 [0] No set- 27-60 Digital Input operation TRUE Uint8 ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 43 Status 0 N/A TRUE r[25] Terminal X66/13 [0] No set- Advanced 27-66 Digital Input operation TRUE Uint8 Cascade Relay set- Uint1 27-7* Connections 27-95 Output [bin] 0 N/A TRUE Table 5.2 ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 44: Configuration Examples

    0 (s), Off Table 6.6 Master Drive Settings, 27-5* Alternate Settings An array parameter is used to configure the output of the master drive for the start signal of the follower drives. ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 45: Follower Drive Settings

    4-12 Motor Speed Low Limit [Hz] to enable sleep function (setting it to zero will disable the function). Set 27-21 Override Limit to wake up the application. After wake up the pump with the least running hours starts. ® MI38C402 - VLT is a registered Danfoss trademark...

  • Page 46: Index

    And De-staging Decisions............... 8 Settings, 27-4*................... 29 Speed, 27-3*..................28 Staging/de-staging................20 Input Power..................... iii Staging/De-staging Of Fixed Speed Pumps..............17 Of Variable Speed Pumps............. 17 Lead Pump................19, 20, 19 ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 47 ® Index AQUA Drive MCO 101/MCO 102 Supported Configurations..............5 Symbols..................... iii Unequal Size Pump Configuration..........8 Variable Speed Pumps................ 4 ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 48 ® Index AQUA Drive MCO 101/MCO 102 ® MI38C402 - VLT is a registered Danfoss trademark...
  • Page 49 130R0345 MI38C402 Rev. 2012-08-21 *MI38C402*...

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