Danfoss Cascade Operating Instructions Manual
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Danfoss Cascade Operating Instructions Manual

Danfoss Cascade Operating Instructions Manual

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Contents
MG.60.I3.02 - VLT is a registered Danfoss trademark
Safety regulations ...................................................................................................
Warning against unintended start ...........................................................................
............................................................................................
Cascade Control Operation ...................................................................................
Standard Cascade Control Mode ..........................................................................
Master/Slave Cascade Control Mode ....................................................................
Installing the cascade controller option card ..........................................................
Standard cascade control wiring diagram .............................................................. 17
Optional Hand/Off/Auto Switch .............................................................................. 18
Master drive in master/slave control wiring diagram .............................................. 19
Slave drive in master/slave control wiring diagram ................................................. 20
Introduction ............................................................................................................ 21
Changed systemstop functions .............................................................................. 22
Serial communications(parameter 500) .................................................................. 22
................................................................................................... 23
How to use the LCP for programming ................................................................... 23
Control keys for parameter setup .......................................................................... 23
Indicator lamps ...................................................................................................... 23
Drive Control .......................................................................................................... 23
Display modes ....................................................................................................... 24
Changing data ....................................................................................................... 25
Parameter setting procedure .................................................................................. 26
Example of how to change parameter data ........................................................... 26
Manual initialization ................................................................................................ 26
Introduction ............................................................................................................ 28
Quick Menu Summary ........................................................................................... 29
Language ............................................................................................................... 29
Motor nameplate data ............................................................................................ 30
Relay outputs ......................................................................................................... 32
Alternate programming ........................................................................................... 36
Introduction ............................................................................................................ 38
Initial Setup ............................................................................................................ 39
Alternate programming ........................................................................................... 45
Introduction ............................................................................................................ 46
Initial Setup ............................................................................................................ 46
Cascade Controller Option
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  • Page 1: Table Of Contents

    Standard Cascade Control Mode ................Master/Slave Cascade Control Mode ..............Installation and Wiring Instructions ............. Installing the cascade controller option card ............Standard cascade control wiring diagram .............. 17 Optional Hand/Off/Auto Switch ................18 Master drive in master/slave control wiring diagram ..........19 Slave drive in master/slave control wiring diagram ..........
  • Page 2 Two feedback signals and two setpoints: .............. 55 Programming example ................... 55 Parameter group 700, all parameters ........... 57 Parameter group 700 definitions ................57 Service parameters ..................58 Display information ....................58 Relay status ......................59 MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 3: Safety And Precautions

    The symbols used are the following: Indicates a general warning. NB!: Indicates something to be noted by the reader. Indicates a high-voltage warning. MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 4: Safety Regulations

    6. Do not remove the plugs for the motor and mains supply while the VLT frequency converter is connected to mains. Check that the mains supply has been disconnected and that the MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 5 200-240 and 380-480 V: wait at least 15 minutes 550-600 V: VLT 6002/8002 - 6027/8027: wait at least 15 minutes 550-600 V: VLT 6032/8032 - 6300/8300: wait at least 30 minutes MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 6: Operation Modes

    Cascade Controller Option Operation modes Cascade Control Operation With the cascade controller option card, the frequency In pumping applications, when a pressure feedback converter can automatically control up to five signal is not practical, the feedback signal may be motors. Staging motors on or off is done cyclically, taken near the pump by measuring flow.

  • Page 7: Standard Cascade Control Mode

    PID controller directs the cascade option off, as required, to maintain level control. card based upon the feedback signal. The cascade controller will continue operation of the constant speed motors to meet demand should the drive trip.

  • Page 8: Master/Slave Cascade Control Mode

    In some applications, it may Best efficiency is attained when a pressure transmitter be advisable for a second drive with a cascade is placed at the farthest significant load in the system. card to act as an auxiliary controller.

  • Page 9: Installation And Wiring Instructions

    Cascade Controller Option Installation and Wiring Instructions Installing the cascade controller option card This chapter provides instructions for installing the cascade controller option card into a VLT adjustable DANGER frequency drive. In Standard cascade control mode, VLT adjustable frequency drive...
  • Page 10 • Remove control wiring by unplugging connector terminals. • Remove wiring clamp by removing two screws. Save for reassembly. • Loosen two captive screws securing control board cassette to VLT chassis. MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 11 Disconnect two ribbon cables from VLT control board. 4. Remove LCP Keypad Cradle • Push tabs at side of LCP cradle to release clips. • Pull out to disengage and lift cradle free. MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 12 Align opposite side of card with mounting holes (B) provided. 6. Secure Option Card • Secure option card to control board cassette with 3 self-tapping screws and washers provided. Use a Torx T-10 screw driver. MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 13 Insert ribbon cable into corresponding socket (B) on VLT control board and push collar closed. Be sure not to crimp ribbon cables. • Repeat procedure for all ribbon cables. MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 14 Location of holes to mount grounding strips in VLT chassis can vary with drive configuration. • When applicable, remove mounting screws located in chassis using Torx T-20 screw driver and save for reassembly. Otherwise, grounding strips attach with screws provided. MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 15 Secure relay wiring with bottom right wiring clamp and fasten. Relay 6-9: A-B make, A-C break Max. 240 VAC, 2 A Max. cross-section: 1.5 mm (28-16 AWG) Torque: 0.22 - 0.25 Nm MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 16 • Attach terminal protective cover by positioning guide pins at bottom of cover into control card cassette and snaping into place. Transmitter wiring Please refer to chapter 10, Feedback Transmitter Wiring. MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 17: Standard Cascade Control Wiring Diagram

    Cascade Controller Option Standard cascade control wiring diagram The wiring diagram shows an example for a standard cascade control system with 4 fixed speed motors, a 4-20 mA pressure transmitter, and external safety interlock. Power terminal connections Control board terminal...

  • Page 18: Optional Hand/Off/Auto Switch

    Cascade Controller Option Optional Hand/Off/Auto Switch Optional Hand/Off/Auto Switch cascade controller will try to start it by triggering In standard cascade control mode, an optional its relay. Since no contribution will occur, the next Hand/Off/Auto switch on the constant speed motor pump will be switched on.

  • Page 19: Master Drive In Master/Slave Control Wiring Diagram

    The wiring diagram below shows an example of a slave drive speed reference is provided from terminal Master drive in Master/Slave cascade control. The 17 as a pulse signal. The relays on the option card are system demonstrates a 4-20 mA pressure transmitter, used for the Start/Stop command to the slave drives.

  • Page 20: Slave Drive In Master/Slave Control Wiring Diagram

    Start/Stop command and a pulse speed reference from the master drive. The speed reference and its common are typically looped from Slave-to-Slave. Power terminal connections Control board terminal connections Slave Drive MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 21: Changed Drive Functions

    New options are also available to stop pumps or fans controlled in cascade operation. A summary of VLT changed functionality is presented in this chapter. Changed Default Settings with the Cascade Controller Option Card Parameter Description Previous default...

  • Page 22: Changed Systemstop Functions

    Cascade Controller Option Changed systemstop functions Two stop functions are provided by the cascade Master/Slave cascade control mode controller option. One function quickly stops a Stop functions in Master/Slave cascade control system. The other stages off pumps in a sequence, are described in the table below.

  • Page 23: User Interface

    Hand Start - Off Stop - Auto Start - Reset parameter is not to be carried out. • Safety interlock [OK] is used for confirming a change to a • Coasting stop inverse selected parameter. • Reversing MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 24: Display Modes

    The active setup number and an arrow indicating the direction of motor rotation is shown on the right side of the large display. Clockwise indicates forward and counterclockwise indicates reverse. The arrow MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 25: Changing Data

    LOCAL indicates that the reference is determined the [CHANGE DATA] key gives access to changing via the [+] and [-] keys on the control panel. the selected parameter. Line 3 displays the parameter MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 26: Parameter Setting Procedure

    This applies to parameter 102, Motor power, parameter 103, Motor voltage, and parameter 104, Motor frequency. Parameter setting procedure Enter or change parameter data or settings as follows: 1. Press [Quick Menu] or [Extended Menu] key. MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 27 The following parameters are not reset when using manual initialization: 500, Protocol 600, Operating hours 601, Hours run 602, kWh counter 603, Number of power-ups 604, Number of overtemperatures 605, Number of overvoltages 724 - 737, Operating hours/counters MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 28: Vlt Drive And Cascade Controller Setup

    Cascade Controller Option VLT Drive and Cascade Controller Setup Introduction A new quick menu list is activated when a cascade selects the mode of operation for further setup. controller option card is installed in the VLT adjustable The Quick Menu Summary table on the next frequency drive.

  • Page 29: Quick Menu Summary

    Seconds 1-3600 Relay 1 Output Depending on choice See VLT 6000 HVAC Manual. Relay 2 Output Basic Set Up for Standard Cascade and Master/Slave. Closed loop units Selected according to your process. Minimum Feedback Maximum Feedback Warning low Feedback Units -999,999.999- FB High...

  • Page 30: Motor Nameplate Data

    500 HP (355.00 KW) [355.00] 600 HP (400.00 KW) [400.00] Depends on the unit Function: This sets the power value that corresponds to the nameplate power of the motor. The default setting MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 31 Value: 0.0 - Parameter 202 setting 0.0 HZ Function: This is where to select the minimum output frequency. The drive will be unable to run continuously below this value in any mode. MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 32: Relay Outputs

    39 (common for analogue/digital outputs. See chapter 10 for additional detail). If the output is used as a current output, the resulting impedence of the connected equipment should not exceed 500 W. MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 33 [25] Description of choice: lb/s [26] Set the value to be shown on the display when the lb/min [27] feedback signal is at its maximum value. lb/h [28] [29] [30] /min [31] MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 34 In Closed loop, the unit for the feedback is programmed Quick Menu 020 Par. 723 Mode Select in parameter 415 Units related to closed loop. (MODE SELECT) Value: Standard Control Master/Slave Master/Slave Control MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 35 Cascade Controller Option Function: Standard cascade control mode operation is a system consisting of one adjustable speed pump and up to four constant speed pumps. Master/Slave cascade control mode operation is for a system using variable speed pumps controlled by a Master drive.

  • Page 36: Alternate Programming

    Multi-Setup (MULTI SETUP) No copying (NO COPY) Upload all parameters Function: (UPLOAD ALL PARAMET.) This parameter defines the setup number that controls Download all parameters the drive. All parameters can be programmed in four MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 37 Settings in parameters 102, 103, 104, 105, 106, 215, 221, and 222 are not downloaded using this function. NB!: Copying is only possible when drive is stopped. MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 38: Standard Cascade Controller Setup

    Introduction In standard cascade control, a frequency converter Sensor placement: with the cascade option card controls a motor in Best efficiency is attained when the pressure response to system feedback signals while staging transmitter is placed at the farthest significant load additional constant speed motors on and off.

  • Page 39: Initial Setup

    The combinations of pumps and their rated capacities are selected in this parameter. The lead pump (or fan) with the cascade contol option must have a capacity of 100% and its speed is controlled by the VLT adjustable frequency drive. This enables the highest accuracy in regulation of the system.
  • Page 40 (STAGING BANDW%) Value: 1 - 100% Function: In cascade control systems, to avoid frequent switching of fixed speed pumps, the desired system pressure is typically kept within a bandwidth rather than at a constant level. The staging bandwidth (SBW) is programmed as a percentage of the setpoint (desired pressure).
  • Page 41 (TRANSITION FREQ %) Value: 0 - 120 % of F Function: The adjustable speed pump typically runs at maximum speed when staging on an additional fixed speed pump to match the system demand. MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 42 201 and 202. Setpoint 1 is a theoretical value that the cascade controller uses as an internal reference to calculate pressure loss in the system under minimum load.
  • Page 43 When pumps. The cascade controller uses the feedback to the programmed value of the timer expires, a fixed estimate the setpoint required at various rates of flow.
  • Page 44 Inverse is when the drive is to increase the output frequency as the feedback signal increases. Description of choice: Select the PID controller response option. MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 45: Alternate Programming

    In these cases, the cascade option can Quick Menu 028 Par. 418 Setpoint 1 use the drive’s PID controller to respond to system (SETPOINT 1) changes as programmed.

  • Page 46: Master/Slave Cascade Control Setup

    The The slave drives are programmed for open loop cascade controller uses the feedback to estimate the operation and receive a variable speed signal and setpoint required at various rates of flow. Setpoint 1 stop/start commands from the Master drive.
  • Page 47 Select the number of slave pumps or fans. adjustable frequency drive operating at full speed. Setpoint 1 is a theoretical value that the cascade controller uses as an internal reference to calculate pressure loss in the system under minimum load.
  • Page 48 (6, 7, 8 and 9) regardless of feedback signal is measured at the outlet of the the running hours. Destaging is in the reverse order. pumps. The cascade controller uses the feedback to estimate the setpoint required at various rates of flow. Description of choice: Setpoint 2 is the maximum pressure required when Choose whether to enable or disable the function.

  • Page 49: Step 2: Slave Drive Programming

    Best efficiency staging on frequency can be calculated plugged into another VLT drive where all parameter for the cascade controller based on pump and system values can be downloaded. If motor or drive sizes curves to meet feedback requirements. Use the...

  • Page 50: Alternate Programming

    (DOWNLOAD ALL PARAM.) significant load and measure actual pressure in the Download power-independent parameters system. In these cases, the cascade option can (DOWNLOAD SIZE INDEP.) use the drive’s PID controller to respond to system changes as programmed. Pumps or fans are staged Function: on and off in response to the system feedback signal.
  • Page 51 Quick Menu items 14 and 15 (parameter 413, Minimum Feedback, and parameter 414, Maximum Feedback). Setpoint 2, Quick Menu item 29, is not used in one feedback signal applications. MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 52: System Optimisation

    Final adjustments involves the following: a. Setting the best efficiency frequency in the cascade controller for staging and destaging pumps and fans b. Optimization of the process regulator Best efficiency frequency Quick Menu 036 Par.

  • Page 53: Optimization Of The Process Regulator

    Now increase the integration time from 15% to 50%. Starting and stopping the drive will produce the necessary error signal in the process to set the PID. MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 54: Feedback Transmitter Wiring

    VLT, both signals must be voltage signals. Both AI [V] 54 FUNCT. NO OPERATION transmitters must also have the same range. AI [mA] 60 FUNCT FEEDBACK AI 60 SCALE LOW 4 mA AI 60 SCALE HIGH 20 mA MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 55: Two 4 - 20 Ma Feedback Transmitters Connection

    AI [54] 54 FUNCT. FEEDBACK have the same output signal and range. AI 54 SCALE LOW AI 54 SCALE HIGH Programming example for 2 feedback and AI [mA] 60 FUNCT. NO OPERATION 2 setpoint controls: MG.60.I3.02 - VLT is a registered Danfoss trademark...
  • Page 56 In this example, load 1 requires a pressure of at least 30 Pa and load 2 at least 60 Pa. Parameter Parameter Parameter Number Description Value 2 FEEDBACK CALC. 2 ZONE MIN SETPOINT 1 SETPOINT 2 MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 57: Parameter Group 700, All Parameters

    Para 201 (1-4) Conversion Index Factors DataType Descriptions Conversion Index Conversion Factor Data type Description Integer 16 100.0 Integer 32 10.0 Unsigned 8 Unsigned 16 Unsigned 32 0.01 Text string 0.001 0.0001 MG.60.I3.02 - VLT is a registered Danfoss trademark...

  • Page 58: Service Parameters

    The relay timer accumulates the number (No.) of Parameter number Pump number times each relay has been switched on and is used Pump 2 by the cascade controller to determine the cycling Pump 3 pattern. This counter cannot be reset. Pump 4 Pump 5...

  • Page 59: Relay Status

    VLT. The second digit is Relay 02 which is located on the VLT control card. Digits 3 - 6 indicate the four relays of the cascade controller, relays 06, 07, 08 and 09 which are located on the option board.

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