Danfoss VLT AQUA Drive FC 202 User guide

Operating Guide

VLT® Extended/Advanced Cascade Control-

lers MCO 101/MCO 102

VLT® AQUA Drive FC 202

drives.danfoss.com

1

1.1

1.2

1.3

1.4

1.5

1.5.1

2

2.1

2.2

2.3

3

3.1

3.2

3.2.1

3.2.2

3.2.3

3.2.3.1

3.2.3.2

3.2.4

3.3

3.3.1

3.3.2

3.3.3

4

4.1

4.2

4.2.1

4.2.2

4.3

4.3.1

4.3.2

5

5.1

Contents

Introduction 6

Purpose of the Operating Guide 6

Trademarks 6

Additional Resources 6

Document and Software Version 6

Product Overview 6

Intended Use 7

Safety 8

Safety Symbols 8

Qualied Personnel 8

Safety Precautions 8

Applications 11

Application Overview 11

Supported Congurations 12

Hardware Conguration for Expanding of Basic Cascade 12

Hardware Conguration for Master/Follower Cascade Control 14

Hardware Conguration for Mixed Pumps 15

Unequal-sized Pumps Conguration 16

Mixed-pump Conguration with Alternation 18

Using Soft Starters for Fixed-speed Pumps 20

Sleep Mode 20

Basic Cascade Controller 20

Master/Follower and Mixed-pump Congurations 20

Temporary Boost of the Setpoint Before Sleep Mode 21

Installation 22

Before Start 22

VLT® Extended Cascade Controller MCO 101 22

Installing the VLT® Extended Cascade Controller MCO 101 22

Electrical Data, VLT® Extended Cascade Control MCO 101 24

VLT® Advanced Cascade Controller MCO 102 24

Installing the VLT® Advanced Cascade Controller MCO 102 24

Electrical Data, VLT® Advanced Cascade Control MCO 102 26

Conguration of the System 27

Conguration of the Extended and Advanced Cascade Controllers 27

Contents

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

5.1.1

5.1.2

5.1.3

5.1.4

5.1.5

5.2

5.2.1

5.2.2

5.2.3

5.2.4

5.2.5

5.2.6

5.2.7

5.2.8

5.2.9

5.2.10

5.2.11

6

6.1

6.1.1

6.1.2

6.1.3

6.1.4

6.1.5

6.1.6

6.1.7

6.1.8

6.1.9

6.2

6.2.1

6.2.2

7

7.1

7.1.1

7.1.1.1

7.1.1.2

7.1.2

Basic Conguration of the Extended and Advanced Cascade Controllers 27

Conguring Multiple Drives 28

Conguring Closed-loop Control 28

Staging/Destaging of Variable-speed Pumps 28

Staging/Destaging of Fixed-Speed Pumps 29

Operation 30

Checking Pump Status and Controlling Pumps 30

Manual Pump Control 30

Run-time Balancing 30

Pump Spin for Unused Pumps 31

Total Lifetime Hours 31

Alternation of the Lead Pump 31

Staging/Destaging in Mixed-pump Congurations 31

Override Staging/Destaging 32

Minimum Speed Destaging 32

Fixed-speed-only Operation 32

Flow Compensation for Applications with Cascade Controller 32

Parameter Descriptions 34

Parameter Group 27-**, Cascade CTL Option 34

Parameter Group 27-0*, Control & Status 34

Parameter Group 27-1*, Conguration 35

Parameter Group 27-2*, Bandwidth Settings 37

Parameter Group 27-3*, Staging Speed 40

Parameter Group 27-4*, Staging Settings 41

Parameter Group 27-5*, Alternation Settings 44

Parameter Group 27-6*, Digital Inputs 45

Parameter Group 27-7*, Connections 47

Parameter Group 27-9*, Readouts 50

Parameter Lists 51

25-** Cascade Controller 51

27-** Cascade CTL Option 53

Conguration Example 56

Master/Follower 56

Basic Settings 56

Basic Settings, Master and Follower 56

Display Settings, Master and Follower 56

Master Drive Settings 57

Contents

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

7.1.2.1

7.1.2.2

7.1.2.3

7.1.2.4

7.1.2.5

7.1.3

7.1.3.1

7.1.3.2

7.1.4

Conguration Settings 57

Bandwidth Settings 57

Staging Speed Settings 57

Alternate Settings 58

Connection Settings 58

Follower Drive Settings 58

Open-loop Settings 58

Digital In/Out Settings 58

Conguring Sleep Mode 59

Contents

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

•

1 Introduction

1.1 Purpose of the Operating Guide

The purpose of this Operating Guide is to describe the VLT® Extended Cascade Controller MCO 101 and VLT® Advanced Cascade

Controller MCO 102. The Operating Guide contains information about:

Applications for cascade control.

Installation.

Conguration of the system.

Parameters.

Conguration examples.

The Operating Guide is intended for use by qualied personnel. To use the cascade controller options safely and professionally, read

this Operating Guide thoroughly and pay particular attention to the safety instructions and general warnings.

1.2 Trademarks

VLT

®

is a registered trademark for Danfoss A/S.

1.3 Additional Resources

Various resources are available to understand advanced drive operation, programming, and directives compliance.

The VLT® AQUA FC 202 Operating Guide provides detailed information for the installation and start-up of the drive.

The VLT® AQUA FC 202 Programming Guide provides greater detail on how to work with parameters. It also contains application

examples.

The VLT® AQUA FC 202 Design Guide provides detailed information about capabilities and functionality to design motor control

systems.

Supplemental publications, drawings, and manuals are available at www.danfoss.com.

Contact a Danfoss supplier or visit www.danfoss.com for more information.

1.4 Document and Software Version

This manual is regularly reviewed and updated. All suggestions for improvement are welcome.

The original language of this manual is English.

Table 1: Document and Software Version

Edition

Remarks

Software version

AQ326832164524, version 0101

Editorial update.

VLT® Extended Cascade Controller MCO 101: 2.6X

VLT® Advanced Cascade Controller MCO 102: 1.2X

N O T I C E

The Cascade Controller options for the VLT® AQUA Drive FC 202 are supported in the VLT® AQUA Drive software version 1.24 and

onwards.

1.5 Product Overview

The VLT® Extended Cascade Controller MCO 101 and VLT® Advanced Cascade Controller MCO 102 are add-on options extending the

supported number of pumps and the functionalities of the built-in Cascade Controller in the VLT® AQUA Drive FC 202.

The MCO 101 consists of an option board with 3 relays and is installed in slot B. Once the options are installed, the parameters

supporting the Cascade Controller functions are available via the LCP in parameter group 27-** Cascade CTL Option.

The following options for cascade control are available in the VLT® AQUA Drive FC 202:

Built-in Basic Cascade Controller (standard Cascade Controller)

VLT® Extended Cascade Controller MCO 101

VLT® Advanced Cascade Controller MCO 102

The MCO 101 and MCO 102 can be used in 2 dierent modes:

Introduction

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

•

With the extended features controlled by parameter group 27-** Cascade CTL Option.

Extending the number of available relays for the Basic Cascade Controller via parameter group 25-** Cascade Controller.

With MCO 101, a total of 5 relays can be used for cascade control. With MCO 102, a total of 8 pumps can be controlled. The options

are able to alternate the lead pump with 2 relays per pump.

N O T I C E

If the MCO 102 is installed, the VLT® Relay Card MCB 105 can extend the number of relays to 13.

1.5.1 Intended Use

Cascade control is a common control system used to control parallel pumps or fans in an energy-ecient way.

The VLT® Extended Cascade Controller MCO 101 and the VLT® Advanced Cascade Controller MCO 102 are designed for pump appli-

cations, however, it is also possible to use Cascade Controllers in any application requiring multiple motors congured in parallel.

The MCO 101 and MCO 102 enable control of multiple pumps congured in parallel by:

Automatically turning individual pumps on/o.

Controlling the speed of the pumps.

When using Cascade Controllers, the individual pumps are automatically turned on (staged) and turned o (destaged) as needed to

meet the required system output for ow or pressure. The speed of pumps connected to the VLT® AQUA Drive FC 202 is also control-

led to provide a continuous range of system output.

The Cascade Controller software runs from a single drive with a Cascade Controller option installed (master drive). It controls a set of

pumps, each controlled by a drive or connected to a contactor or a soft starter.

Other drives in the system (follower drives) do not need to have a Cascade Controller option card installed. They are operated in

open-loop mode and receive the speed reference from the master drive. Pumps connected to drives are referred to as variable-

speed pumps. Pumps connected to mains through a contactor or through a soft starter are referred to as xed-speed pumps.

Each pump, variable speed or xed speed, is controlled by a relay in the drive. The MCO 101 and MCO 102 can control a mix of

variable-speed and xed-speed pumps.

N O T I C E

VLT® Digital Cascade can be used instead of MCO 101 and MCO 102 for master/follower applications for full redundant system.

The VLT® Digital Cascade control is unlocked with a license code. Installation is easy using embedded Modbus RTU and multi-

master ability makes system redundant. Example: If the master breaks down, the back-up master takes its place until a replace-

ment takes place.

Introduction

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

•

-

2 Safety

2.1 Safety Symbols

The following symbols are used in this manual:

D A N G E R

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

W A R N I N G

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

C A U T I O N

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

N O T I C E

Indicates information considered important, but not hazard-related (for example, messages relating to property damage).

2.2 Qualied Personnel

To allow trouble-free and safe operation of the unit, only qualied personnel with proven skills are allowed to transport, store, as-

semble, install, program, commission, maintain, and decommission this equipment.

Persons with proven skills:

Are qualied electrical engineers, or persons who have received training from qualied electrical engineers and are suitably ex-

perienced to operate devices, systems, plant, and machinery in accordance with pertinent laws and regulations.

Are familiar with the basic regulations concerning health and safety/accident prevention.

Have read and understood the safety guidelines given in all manuals provided with the unit, especially the instructions given in

the Operating Guide.

Have good knowledge of the generic and specialist standards applicable to the specic application.

2.3 Safety Precautions

W A R N I N G

HIGH VOLTAGE

AC drives contain high voltage when connected to AC mains input, DC supply, or load sharing. Failure to perform installation,

start-up, and maintenance by qualied personnel can result in death or serious injury.

Only qualied personnel must perform installation, start-up, and maintenance.

W A R N I N G

UNINTENDED START

When the drive is connected to the AC mains, DC supply, or load sharing, the motor may start at any time, causing risk of death,

serious injury, and equipment or property damage. The motor may start by activation of an external switch, a eldbus command,

an input reference signal from the LCP or LOP, via remote operation using MCT 10 Set-up software, or after a cleared fault condi-

tion.

Press [O ] on the LCP before programming parameters.

Disconnect the drive from the mains whenever personal safety considerations make it necessary to avoid unintended motor

start.

Check that the drive, motor, and any driven equipment are in operational readiness.

Safety

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

-

W A R N I N G

DISCHARGE TIME

The drive contains DC-link capacitors, which can remain charged even when the drive is not powered. High voltage can be

present even when the warning indicator lights are o.

Failure to wait the specied time after power has been removed before performing service or repair work could result in death or

serious injury.

Stop the motor.

Disconnect AC mains, permanent magnet type motors, and remote DC-link supplies, including battery back-ups, UPS, and

DC-link connections to other drives.

Wait for the capacitors to discharge fully. The minimum waiting time is specied in the table Discharge time and is also visible

on the nameplate on top of the drive.

Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors

are fully discharged.

Table 2: Discharge Time

Voltage

[V]

Minimum waiting time (minutes)

4

7

15

20

30

40

200–240

0.25–3.7 kW (0.34–

5 hp)

–

5.5–45 kW (7.5–60

hp)

–

380–480

0.37–7.5 kW (0.5–

10 hp)

–

11–90 kW (15–125

hp)

110–250 kW

(150–335 hp)

–

315–1500 kW

(425–2000 hp)

525–600

0.75–7.5 kW (1.0–

10 hp)

–

11–90 kW (15–125

hp)

–

525–690

–

1.1–7.5 kW

(1.5–10 hp)

11–90 kW (15–125

hp)

45–400 kW (60–

540 kW)

450–1200 kW

(600–1600 hp)

1400 kW

(1875 hp)

W A R N I N G

LEAKAGE CURRENT HAZARD

Leakage currents exceed 3.5 mA. Failure to ground the drive properly can result in death or serious injury.

Ensure the correct grounding of the equipment by a certied electrical installer.

W A R N I N G

ROTATING SHAFTS

Contact with rotating shafts and electrical equipment can result in death or serious injury.

Ensure that only trained and qualied personnel perform installation, start-up, and maintenance.

Ensure that electrical work conforms to national and local electrical codes.

Follow the procedures in this guide.

W A R N I N G

UNINTENDED MOTOR ROTATION WINDMILLING

Unintended rotation of permanent magnet motors creates voltage and can charge the unit, resulting in death, serious injury, or

equipment damage.

Ensure that permanent magnet motors are blocked to prevent unintended rotation.

Safety

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

-

C A U T I O N

INTERNAL FAILURE HAZARD

An internal failure in the drive can result in serious injury when the drive is not properly closed.

Ensure that all safety covers are in place and securely fastened before applying power.

Safety

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

3 Applications

3.1 Application Overview

Built-in

MCO 101

MCO 102

100% 100% 100% 100%

e30ba594.12

Relay 1

Relay 2

Relay 10

1

1 2 3 4

1 VSP

(1)

+ 2

FSP

(2)

, pa-

rameter

group 25-**

Cascade

Controller

1 VSP + 5 FSP, parame-

ter group 25-** Cas-

cade Controller

1 VSP + 8 FSP, parame-

ter group 25-** Cas-

cade Controller

100% 100% 200% 200%

e30ba593.12

Relay 1

Relay 2

Relay 10

1

21

2 3 4

–

1–6 VSP + 1–5 FSP

(maximum 6 pumps),

parameter group 27-**

Cascade CTL Option

1–8 VSP + 1–7 FSP

(maximum 8 pumps),

parameter group 27-**

Cascade CTL Option

1

VSP=Variable-speed pump (directly connected to the drive).

2

FSP=Fixed-speed pump (the motor could be connected via contactor, soft starter, or star/delta starter).

Built-

in

MCO 101

MCO 102

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

Line supply

R1 R2

R10

e30ba595.12

1

2

3

4

1

2

3

4

100%

–

6 VSP, parame-

ter group 27-**

Cascade CTL

Option

8 VSP, parame-

ter group 27-**

Cascade CTL

Option

3.2 Supported Congurations

When setting up the system, create a hardware conguration which communicates the number of connected pumps and drives to

the master. The necessary hardware is explained in the hardware conguration examples.

3.2.1 Hardware Conguration for Expanding of Basic Cascade

In applications already controlled by the built-in Cascade Controller in parameter group 25-** Control Mode, the option cards can be

used to extend the number of relays for cascade control, for example, if a new pump is added to the system.

To enable the basic Cascade Controller in parameter 27-10 Cascade Controller, select [3] Basic Cascade Ctrl. Refer to VLT® AQUA Drive

FC 202 Programming Guide for further programming with settings from parameter group 25-** Control Mode.

Refer to

Illustration 1 and Illustration 2 for examples of external wiring required for systems with alternating lead pump of 4 pumps

using basic cascade and VLT® Extended Cascade Controller MCO 101 as relay extension.

R1

R2

Drive R10

R11

K3

K5

K7

K2

K1

K5

K7

K7 K4

K4

K3

K1

K3

K1

K3

K7

K6

K6K5

K5

K1

K3

K5

K8

K7

e30ba876.11

Illustration 1: Control Circuit Alternating Lead Pump (4 Pumps)

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

-

FC

K1

K2

K3

K4

K5

K6

K7

K8

M

e30ba875.11

Illustration 2: Mains Circuit Alternating Lead Pump (4 Pumps)

The xed-speed pump conguration provides a cost-eective method for controlling up to 9 pumps. It is able to control system

output by controlling the number of running pumps and the speed of the single variable-speed pump.

In this conguration, the VLT® AQUA Drive FC 202 with a VLT® Advanced Cascade Controller MCO 102 controls 1 variable-speed

pump and up to 8 xed-speed pumps. The xed-speed pumps are staged and destaged as needed through contactors direct online.

The variable-speed pump provides the ner level of control needed between the stages.

The direct online pumps are staged or destaged depending on their feedback.

e30ba592.13

Relay 1

Relay 2

Relay 10

1

2

3

4

100%

1

100% 100%

100%

Illustration 3: Fixed-speed Pump Conguration Example

N O T I C E

If the pumps are not equal in size or if 2 relays per pump are used, a mixed-pump conguration must be selected in parameter

27-10 Cascade Controller. For the conguration shown in Illustration 3, relay selections in parameter group 27-7* Connections are as

follows:

27-70.0 Relay 1 → [73] Pump 2 to mains

27-70.1 Relay 2 → [74] Pump 3 to mains

27-70.9 Relay 10 → [75] Pump 4 to mains

27-70.10 Relay 11 → [0] Standard relay

27-70.11 Relay 12 → [0] Standard relay

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

N O T I C E

Pressure uctuations during staging/destaging transitions may occur and it may be less energy-ecient than the master/follower

congurations.

3.2.2 Hardware Conguration for Master/Follower Cascade Control

The master/follower cascade control mode oers the best performance, the most precise control, and maximum energy savings. It

controls multiple equally sized pumps in parallel, running all pumps at the same speed, and stages the pumps on and o according

to system requirements. Compared to traditional cascade control, the number of running pumps is controlled by speed instead of

feedback. To obtain the highest energy saving, staging speed on and o must be set correctly according to the system. In this exam-

ple, terminal 27 of the master drive is used as pulse output for the reference, and terminals 29 of the follower drives are used as

pulse input for this reference. While the master drive is running in closed loop, the follower drives are running in open loop. All

follower drives are connected to mains and motor in the same way as the master drive.

Motor / Pump

1

Motor / Pump 2

Motor / Pump 3

DI 18

DI 18 DI

29

DI 29

DO

27

R 1

R 2

100%

P

U / I

T 54

T 55

T 20

2

Pressure

Transmitter

0 - 10 V

0 - 20 mA or

4 - 20 mA

T 12

DI18

2

Start

Master with

MCO 101/102

Follower 1

Follower 2

e30bd072.11

Illustration 4: Basic Wiring Principle for a Master/Follower Conguration (Example)

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

•

In this conguration, each pump is controlled by a drive. All pumps and drives must be of the same size. Staging and destaging

decisions are made based on the speed of the drive. The constant pressure is controlled by the master drive operating in closed

loop. The speed is the same in all running pumps.

In the master/follower mode, VLT® Extended Cascade Controller MCO 101 supports up to 6 pumps, while VLT® Advanced Cascade

Controller MCO 102 supports up to 8 pumps.

Conguring as in Illustration 4 requires the following settings in parameter group 27-7* Connections:

27-70.0 Relay 1 → [1] Drive 2 enable

27-70.1 Relay 2 → [2] Drive 3 enable

27-70.9 Relay 10 → [0] Standard relay

27-70.10 Relay 11 → [0] Standard relay

27-70.11 Relay 12 → [0] Standard relay

The system run-time balances all pumps automatically depending on the pump prioritization made in parameter 27-16 Runtime Bal-

ancing. The master/follower system provides a certain level of redundancy. If the master drive trips, it continues to control the fol-

lower drives.

N O T I C E

VLT® 24 V DC Supply MCB 107 can be added to increase the level of system redundancy.

Relays set to [0] Std. Relay can be used as general purpose relay controlled by parameter group 5-4* Relays.

3.2.3 Hardware Conguration for Mixed Pumps

This conguration combines some of the benets of the master/follower conguration with some of the initial cost savings of the

xed-speed congurations. It is a good choice when the extra capacity of the xed pumps is rarely needed.

The mixed-pump conguration supports a mix of variable-speed pumps connected to drives and also some xed-speed pumps.

First, the variable-speed pumps are staged and destaged based on the drive speed. The xed-speed pumps are staged and destag-

ed last based on the feedback pressure.

N O T I C E

The variable-speed pumps and the drives must be of the same size. Fixed-speed pumps may be of dierent size.

100% 100% 200% 200%

e30ba593.12

Relay 1

Relay 2

Relay 10

1

21

2 3 4

Illustration 5: Mixed-pump Conguration Example

For this conguration, set the relays as follows in parameter group 27-7* Connections:

27-70.0 Relay 1 → [1] Drive 2 enable

27-70.1 Relay 2 → [74] Pump 3 to mains

27-70.9 Relay 10 → [75] Pump 4 to mains

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

•

27-70.10 Relay 11 → [0] Standard relay

27-70.11 Relay 12 → [0] Standard relay

3.2.3.1 Unequal-sized Pumps Conguration

The unequal-sized pumps conguration supports a limited mix of xed-speed pumps in dierent sizes. It provides for the largest

range of system output with the smallest number of pumps.

100% 100% 200% 200%

e30bh880.10

Relay 1

Relay 2

Relay 10

1

1 2 3 4

Illustration 6: Example of a Conguration with Unequal-sized Pumps

For this conguration, set the relays as follows in parameter group 27-7* Connections:

27-70.0 Relay 1 → [73] Pump 2 to mains

27-70.1 Relay 2 → [74] Pump 3 to mains

27-70.9 Relay 10 → [75] Pump 4 to mains

27-70.10 Relay 11 → [0] Standard relay

27-70.11 Relay 12 → [0] Standard relay

For a conguration to be valid, it must be possible to stage pumps in increments of 100% of the size of the variable-speed pump of

the master drive. The variable-speed pump must control the output between the xed-speed stages, see Illustration 7.

100% is dened as the maximum ow produced by the pump connected to the master drive. The xed-speed pumps must be mul-

tiples of this size.

N O T I C E

Other valid congurations than the ones shown in Table 3 are possible.

Table 3: Valid Congurations

Variable speed

Fixed speed

100%

100% + 200% (see Illustration 7)

100%

100% + 200% + 200%

100%

100% + 100% + 300%

100%

100% + 100% + 300% + 300%

100%

100% + 200% + 400%

100% + 100%

200%

100% + 100%

200% + 200%

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

100 %

200 % 200 %

C

1

100 %

200 %

300 %

400 %

2

3

4

e30bd073.11

Illustration 7: Example of a Valid Conguration

N O T I C E

Invalid congurations, as in Illustration 8, will still run, but will have a poor control performance. This allows only limited operation

if a pump fails or is interlocked.

Table 4: Invalid Congurations

Variable speed

Fixed speed

100%

200%

No control between 100% and 200%

100%

100% + 300%

No control between 200% and 300%, see Illustration 8

100%

100% + 200% + 600%

No control between 400% and 600 %

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

e30bd074.11

100 %

300 %

100 %

300 %

C

1

100 %

200 %

300 %

400 %

2 3 4

Illustration 8: Example of an Invalid Conguration

3.2.3.2 Mixed-pump Conguration with Alternation

In this conguration, the drive alternates between 2 pumps and controls the other as extra xed-speed pumps. The Cascade Con-

troller attempts to balance the running hours of the pumps.

e30ba602.12

Relay 10

Relay 1

Relay 2

Relay 12

1

2

Illustration 9: Example 1

In Illustration 9, the 2 pumps are operated either as variable-speed pumps or as xed-speed pumps.

For this conguration, set the relay selection as follows in parameter group 27-7* Connections:

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

•

27-70.0 Relay 1 → [8] Pump 1 to drive 1

27-70.1 Relay 2 → [16] Pump 2 to drive 1

27-70.9 Relay 10 → [72] Pump 1 to mains

27-70.10 Relay 11 → [73] Pumps 2 to mains

27-70.11 Relay 12 → [0] Standard relay

e30ba601.12

Relay 10

Relay 1

Relay 2

Relay 11

Relay 12

1

2

3

Illustration 10: Example 2

In Illustration 10, 2 pumps are operated either as variable-speed pumps or as xed-speed pumps. The 3

rd

pump is an extra xed-

speed pump.

For this conguration, set the relays as follows in parameter group 27-7* Connections:

27-70.0 Relay 1 → [8] Pump1 to drive 1

27-70.1 Relay 2 → [16] Pump2 to drive 1

27-70.9 Relay 10 → [72] Pump 1 to mains

27-70.10 Relay 11 → [73] Pump 2 to mains

27-70.11 Relay 12 → [74] Pump 3 to mains

e30ba600.12

Relay 1

Relay 2

Relay 10

Relay 11

Relay 12

1

2

3

4

5

Illustration 11: Example 3

Applications

VLT® Extended/Advanced Cascade Controllers MCO 101/MCO 102

Operating Guide

•

In Illustration 11, either pump 1 or pump 2 is connected to the drive. The pump for the connection to the drive can be selected

either automatically for balancing the running hours or forced by the congured alternation event. The xed-speed pumps 3, 4, and

5 are turned on and o as required.

For this conguration, set the relay as follows in parameter group 27-7* Connections:

27-70.0 Relay 1 → [8] Pump 1 to drive 1

27-70.1 Relay 2 → [16] Pump 2 to drive 1

27-70.9 Relay 10 → [74] Pump 3 to mains

27-70.10 Relay 11 → [75] Pump 4 to mains

27-70.11 Relay 12 → [76] Pump 5 to mains

3.2.4 Using Soft Starters for Fixed-speed Pumps

Soft starters can be used instead of contactors for any conguration using xed-speed pumps.

N O T I C E

Mixing soft starters and contactors prevents control of output pressure during staging and destaging transitions. The use of soft

starters delays the staging due to the ramp time of the xed-speed pump.

3.3 Sleep Mode

If the load on the multi-pump system allows it, it can be stopped by activating the sleep mode function. When in sleep mode, cer-

tain congurable conditions are monitored to nd out when load has been applied again and the system has to be restarted.

Depending on the system, sleep mode can be activated either from the low-power detection/low-speed detection or via an external

signal applied to 1 of the digital inputs (must be programmed via parameter group 5-1* Digital Inputs). Using, for example, an electro-

mechanical ow switch to detect a no-ow condition, activates sleep mode at the raising edge of the external signal applied.

Implementation and conguration of sleep mode depend on the hardware conguration and the requirements.

3.3.1 Basic Cascade Controller

For Basic Cascade Controller applications, sleep mode can be used and congured exactly as it is described for single-pump applica-

tions in the parameter groups 22-2* to 22-4* in the VLT® AQUA Drive FC 202 Programming Guide.

Low-speed detection and low-power detection combined with the timers for minimum run-time, minimum sleep time, and the

boost feature are supported. The feedback from the pressure transducer is monitored and when this pressure has dropped with a

set percentage below the normal setpoint for pressure (parameter 22-44 Wake-up Ref./FB Dierence), the motor ramps up again, and

pressure is controlled for reaching the set value.

3.3.2 Master/Follower and Mixed-pump Congurations

In multiple-drive applications, sleep mode can be used in 2 dierent ways:

Low-speed detection for applications with multiple drives can be enabled by a selection in parameter 22-22 Low Speed Detection.

Using the Stage O-speeds in parameter group 27-3* Staging Speed.

In the following example, sleep mode is entered at 30 Hz in a master/follower application.

Stage ON [Hz]

Stage OFF [Hz]

Stage 1

48.5 (parameter 2732.1)

30 (parameter 2734.1)

Stage 2

48.5 (parameter 2732.2)

40 (parameter 2734.2)

Stage 3

48.5 (parameter 2732.3)

42 (parameter 2734.3)

This mode is activated by programming the corresponding speed in parameter 27-33 Stage O Speed [RPM] or parameter 27-34 Stage

O Speed [Hz].

The value for this speed has to be higher than the minimum speed in parameter 4-11 Motor Speed Low Limit [RPM] or parameter 4-12

Motor Speed Low Limit [Hz].

The value for the override limit in parameter 27-21 Override Limit causes the drive to wake up again. The value is entered as a % of

the maximum reference as programmed in parameter 3-03 Maximum Reference.

Danfoss VLT AQUA Drive FC 202 User guide

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