Danfoss VLT Series Operating Instructions Manual
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- Programming manual (390 pages) ,
- Design manual (179 pages) ,
- Service manual (158 pages)
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Summary of Contents for Danfoss VLT Series
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Page 1: Table Of Contents
Pump Spin for unused pumps Total lifetime hours Alternation of the Lead Pump Staging / Destaging in Mixed Pump Configurations Override Staging /Destaging Minimum Speed Destaging Fixed speed only operation Cascade Controller Parameters ® MI.38.C3.02 - VLT is a registered Danfoss trademark... - Page 2 Operating Instructions Cascade CTL Option, 27-** Control & Status, 27-0* Configuration, 27-1* Bandwidth Settings, 27-2* Staging Speed, 27-3* Staging Settings, 27-4* Alternation Settings, 27-5* Connections, 27-7* Readouts, 27-9* Master/Follower Application Note Index ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
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Page 3: Extended And Advanced Cascade Controller Option
Extended Cascade Controller Option for VLT AQUA Drive FC 200 Operating Instructions Software version: 1.33 These Operating Instructions can be used with all Extended Cascade Controller options with software version 1.33. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 4: Symbols
Correct protective grounding of the equipment must be established. The user must be protected against supply voltage and the motor must be protected against overload in accordance with applicable national and local regulations. Ground currents are higher than 3 mA. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 5: Caution
When using group 27** Extended / Advanced Cascade Control, the systems with pump alternation can be set-up with 2 relays per pump, which reduces the need for external equipment. With MCO 101, a total of 5 relays can be used for cascade and with MCO 102, a total of 8 pumps can be controlled. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... - Page 6 Two (2) relays are standard in the FC and additional 3 relays are found on the option card MCO 101 or 8 relays and 7 digital inputs on option card MCO 102. ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
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Page 7: Extended Cascade Controller Mco 101
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. • Fit the MCO 101 option in slot B. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 8: Advanced Cascade Controller Mco 102
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.C3.02 - VLT is a registered Danfoss trademark... - Page 9 1 Extended and Advanced Cascade Controller ® Operating Instructions Option Illustration 1.3: Enclosure A2, A3 (and B3) 40 mm (only one C option). Illustration 1.4: Enclosures B (except B3) and C. ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
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Page 10: Supported Configurations
VLT AQUA Drive, with the Extended- and Advanced Cascade Controller option card installed. They support from 1 to 8 additional pumps each connected to either a Danfoss VLT Drive with Master / Follower or to mains through a contactor or soft starter for a direct online system. -
Page 11: Extension Of Basic Cascade - Parameter Group 25** Control Mode
Example: Electrical wiring diagram for the external equipment needed for systems with alternating lead pump of 4 pumps using Basic cascade and MCO 101 as relay extension. Illustration 1.5: Control circuit alternating lead pump (4 pumps). Illustration 1.6: Mains circuit alternating lead pump (4 pumps). ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 12: Fixed Speed Pump Configuration
It will however produce wider pressure fluctuations during staging/ destaging transitions and it may be less energy efficient than the Master-Follower configurations. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 13: Master-Follower Configuration
Furthermore it reduces wear and tear on pumps and motors. The relays set to [0] Std. Relay, can be used as general purpose relays, controlled by the parameters in group 5-4*. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 14: 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.C3.02 - VLT is a registered Danfoss trademark... -
Page 15: 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.C3.02 - VLT is a registered Danfoss trademark... - Page 16 Fixed Speed 100% 200% (no control between 100% and 200%) 100% 100% + 300% (no control between 200% and 300%) 100% 100% + 200% + 600% (no control between 400% and 600%) ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
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Page 17: Mixed Pump Configuration With Alternation
The first two pumps can be either variable speed or fixed speed with equal running hours between all three pumps as long as the system demand is typically greater than 1 pump. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 18: Soft Starters
Parameter groups 27-1* “Configuration” and 27-7* “Connections” are used to define the hardware configuration of the installation. Start the configuration of the cascade controller by selecting values for the parameters in the 27-1* “Configuration” group. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 19: Additional Configuration For Multiple Drives
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. Pin 27 Pin 27 Pin 29 Pin 29 Pin 29 Pin 29 ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 20: Closed Loop Control
This feature will over time ensure the most energy efficient way of operation taking into account wear and tear of the pump system. Danfoss has 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 Speed and Stage off Speed parameters. -
Page 21: Staging / De-Staging Of Fixed Speed Pumps Based On Pressure Feedback
Navigate to the 27-0* group on the LCP. Use right and left arrows on the LCP to select the pump. Use up and down arrows on the LCP to select the parameter. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 22: Manual Pump Control
Variable speed pumps are also staged off before fixed speed pumps. Parameter 27-19 is used to reset the Current Runtime Hours for all of the pumps and restart the balancing process. This parameter will not affect the Total Lifetime Hours (27-04) for each pump. Total Lifetime Hours is not used for runtime balancing. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 23: Pump Spin For Unused Pumps
Stage on Speed (27-31), and remains above that speed for the Staging Delay (27-23) time, the next variable speed pump is staged on. This repeats for all of the variable speed pumps. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 24: Override Staging /Destaging
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 Destage Delay (27-24) time, a fixed speed pump will be turned off. This repeats until all of the pumps are off. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 25: Cascade Controller Parameters
Offline-External Interlock the pump has been externally interlocked and is off. Spinning the cascade control is executing a spin cycle for the pump. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 26: Configuration
MCO 101: 1-6 MCO 102: 1-8 27-12 No. of Pumps Range: Function: [0 - No. of Drives] Number of Pumps to be controlled by the cascade controller. MCO 101: 0-6 MCO 102: 0-8 ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 27: Bandwidth Settings
(De-staging) before a cascade operation takes place. Normal refers to the system operating with at least one variable speed pump available. This value is entered as a % of Max Reference (See P21-12 in the VLT AQUA Drive Programming Guide for further information). ® MI.38.C3.02 - VLT is a registered Danfoss trademark... - Page 28 The value is entered as a % of Max Reference. When there are no operational variable speed pumps, the system will try to maintain control with the remaining fixed speed pumps. ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
- Page 29 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 then be operating more efficiently. ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
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Page 30: 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.C3.02 - VLT is a registered Danfoss trademark... -
Page 31: Staging Settings
[0 s – 12 s] Sets the delay between turning off a soft starter controlled pump and ramping up the drive controlled pump. This is only used for soft starter controlled pumps. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... - Page 32 When 27-40 is Enabled [1], 27-43, and 27-44 will be kept up to date with new automatically cal- culated values. If 27-43, and 27-44 are modified from the bus or LCP, then the new values will be used, but will continue to be automatically tuned. ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
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Page 33: Alternation Settings
27-53 Alternation Timer Value Option: Function: Units: min Alternation Timer Value is a readout parameter that shows the time remaining before an interval based alternation takes place. Parameter 27-52 sets the time interval ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 34: Connections
To setup the function of each relay, choose the specific relays and then choose the function. If the function option: Standard Relay is choosen, the relay can be used as general purpose relay and the wanted function can then be setup in parameter P5-4*. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... -
Page 35: Readouts
An alternation operation is in progress. Lead Pump Not Set A lead pump has not been selected. 27-94 Cascade System Status Cascade System Status is a readout parameter that shows the status of each individual pump. ® MI.38.C3.02 - VLT is a registered Danfoss trademark... - Page 36 1 Extended and Advanced Cascade Controller ® Option Operating Instructions ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
- Page 37 1 Extended and Advanced Cascade Controller ® Operating Instructions Option ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
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Page 38: Master/Follower Application Note
Application Description ® The system used as example contains 4 equal sized pumps in a water distribution system. They are each connected to a Danfoss VLT AQUA Drive. A pressure transmitter with an analogue output format of 4-20mA is used as feedback and connected to the drive named the 'master drive'. The master ®... - Page 39 Display Line 3 Large 0-24 Frequency [1613] Please note: the format of the analogue input is set using switch S201 below the LCP. Basic settings for both Master and Follower drives: ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
- Page 40 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 optimise the energy consumption, if not auto tuned. ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
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Page 41: Index
Fixed Speed Only Operating Range, 27-22 Fixed Speed Pump Fixed Speed Pump Configuration Fixed Speed Pump Configuration Follower Drive Follower Drives Free Software Introduction Introduction To Mco 101 And Mco 102 Ip55 Or Even Ip66 ® MI.38.C3.02 - VLT is a registered Danfoss trademark... - Page 42 Reset Current Runtime Hours, 27-19 Runtime Balancing 17, 19, 22 Runtime Balancing, 27-16 Settings For The Follower Drives Settings For The Master Drive Setting-up The Cascade Parameters Single Drive Soft Starters Software Version Software Version ® MI.38.C3.02 - VLT is a registered Danfoss trademark...
- Page 43 Staging Threshold, 27-43 Supported Configurations Switch S201 Terminal 27 Terminal 27 Mode 5-01 Terminal 29 Unequal Size Pump Configuration Variable Speed Pumps. Vlt® Extended Cascade Controller Option Mco-101 Weak Pipe System ® MI.38.C3.02 - VLT is a registered Danfoss trademark...