Danfoss MCO 101 User manual

Contents
1 Safety and precautions
1-1
Safety Instructions 1-1
Avoid unintended Start. 1-1
2 Introduction 2-1
General Description 2-2
3 Supported Configuration 3-1
Introduction 3-1
Fixed-speed Pump Configuration 3-3
Master-Follower Configuration 3-4
Mixed Pump Configuration 3-5
Unequal Size Pump Configuration 3-6
Mixed Pump Configuration with Alternation 3-7
Soft Starters 3-9
4 Configuring the System 4-1
Introduction 4-1
Setting up the cascade parameters 4-1
Additional Configuration for Multiple Drives 4-1
Closed-loop Control 4-2
Staging /De-staging of Variable Speed Pumps Based on Drive Speed 4-2
Staging/De-staging of Fixed-speed Pumps Based on Pressure Feedback 4-3
5 Cascade Controller Features 5-1
Pump Status and Control 5-1
Manual Pump Control 5-1
Runtime Balancing 5-2
Pump Spin for unused pumps 5-2
Total lifetime hours 5-3
Alternation of the Lead Pump 5-3
Staging / De-staging in Mixed Pump Configurations 5-3
Override Staging /De-staging 5-4
Minimum Speed De-staging 5-4
Fixed speed only operation 5-4
6 How to Program 6-1
Extended Cascade Controller Parameters 6-1
Extended and Advanced Cascade Controller
Option Contents
MI.38.C2.22 - VLT®is a registered Danfoss trademark

Cascade CTL Option 27-** 6-1
Control & Status, 27-0* 6-1
Configuration, 27-1* 6-2
Bandwidth Settings, 27-2* 6-4
Staging Speed, 27-3* 6-6
Staging Settings, 27-4* 6-7
Alternation Settings, 27-5* 6-10
Connections, 27-7* 6-11
Readouts, 27-9* 6-11
Cascade CTL Option 27-** 7-1
8 Annex A - Master/Follower Application Note 8-1
Master/Follower Operation 8-1
9 Index 9-1
Contents Extended and Advanced Cascade Controller
Option
MI.38.C2.22 - VLT®is a registered Danfoss trademark

1 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.
1.1.2 Safety Instructions
Prior to using functions that directly or indirectly influence personal safety (e.g., Safe Stop or other functions either forcing the motor
to stop or attempting to keep it functioning), a thorough risk analysis and system test must be carried out. The system tests
must include testing failure modes regarding the control signaling (analog and digital signals and serial communication.
• Make sure the adjustable frequency drive is properly grounded.
• Do not remove AC line input connections, motor connections or other power connections while the adjustable frequency drive is connected to
line power.
• Protect users against supply voltage.
• Protect the motor against overloading in accordance with national and local regulations.
• The ground leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the adjustable frequency drive from line power.
1.1.3 Avoid unintended Start.
While the adjustable frequency drive is connected to line power, the motor can be started/stopped using digital commands, bus commands, references
or via the Local Control Panel.
• Disconnect the adjustable frequency drive and the MCO 101 option card from line power whenever personal safety considerations make it
necessary to avoid the unintended start of a motor.
• To avoid an unintended starts, always activate the [OFF] key before changing parameters.
Extended and Advanced Cascade Controller
Option 1 Safety and precautions
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1.1.4 Software Version
Extended Cascade Controller Option for
VLT AQUA Drive FC 200
Instruction Manual
Software version: 1.24
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.
The symbols used are the following:
Indicates a general warning.
NOTE!
Indicates something to be noted by the reader.
Indicates a high-voltage warning.
1 Safety and precautions Extended and Advanced Cascade Controller
Option
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1.1.5 Caution
The adjustable frequency drive DC link capacitors remain charged after power has been disconnected. To avoid the risk of electrical
shock, disconnect the adjustable frequency drive from the line power before performing maintenance procedures. Wait at least as long
as follows before servicing the adjustable frequency drive:
Voltage Min. Waiting Time
4 min. 15 min. 20 min. 30 min.
200–240 V 0.34–5 hp [0.25–3.7 kW] 7.5–60 hp [5.5–45 kW]
380–480 V 0.5–10 hp [0.37–7.5 kW] 15–125 hp [11–90 kW] 150–160 hp [110–250 kW] 450–1350 hp [315–1000 kW]
525–600 V 1–10 hp [0.75 kW–7.5 kW] 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.
Extended and Advanced Cascade Controller
Option 1 Safety and precautions
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1 Safety and precautions Extended and Advanced Cascade Controller
Option
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2Introduction
2.1.1 Introduction to the MCO 101 and MCO 102
The MCO 101 and 102 are add-on options which extend the supported number of pumps and the functionalities of the built-in cascade controller in the
VLT®AQUA Drive.
The extended cascade controller can be used in two different modes.
It can either be used with the extended features controlled by parameter group 27** or it can be used to extend the number of available relays for the
basic cascade controlled by parameter group 25**.
When one of the cascade options is installed, only group 27 will appear. If the option needs to extend the relays in the built-in cascade controller group
25, the basic cascade can be enabled in parameter 27-10, after which group 25 will be visible again in the main menu. If 27-10 is set to Basic Cascade,
only the basic cascade functionality will be available, but three relays will be added to make a total of five relays.
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.
2.1.2 Extended Cascade Controller, MCO 101, and Advanced Cascade Controller, MCO 102
Cascade control is a common control system used to control parallel pumps or fans in an energy-efficient way.
The Cascade Controller option provides the capability to control multiple pumps configured in parallel in a way that makes them appear as a single larger
pump.
When using cascade controllers, the individual pumps are automatically turned on (staged) and turned off (de-staged) as needed in order to satisfy the
required system output for flow or pressure. The speed of the pumps connected to VLT AQUA Drives is also controlled to provide a continuous range of
system output.
Extended and Advanced Cascade Controller
Option 2 Introduction
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Figure 2.1: Cascade control of multiple pumps
Cascade controllers are optional hardware and software components that can be added to the VLT AQUA Drive. It consists of an option board containing
three relays that are installed in option slot B on the drive. Once options are installed, the parameters needed to support the cascade controller functions
will be available through the control panel in the 27-** parameter group. The Extended Cascade Controller offers more functionality than the Basic
Cascade Controller. It can be used to extend the basic cascade with three relays and even up to eight relays with the Advanced Cascade Control card
installed.
While the cascade controller is designed for pumping applications and this document describes the cascade controller for this application, it is also possible
to use cascade controllers for any application requiring multiple motors configured in parallel.
2.1.3 General Description
The cascade controller software runs from a single VLT AQUA Drive with the Cascade Controller option card installed. This adjustable frequency drive is
referred to as the master drive. It controls a set of pumps each controlled by an adjustable frequency drive or connected directly to line power through
a contactor or through a soft starter.
Each additional adjustable frequency drive in the system is referred to as a Follower Drive. These adjustable frequency drives do not need the cascade
controller option card installed. They are operated in open-loop mode and receive their speed reference from the master drive. The pumps connected to
these adjustable frequency drives are referred to as Variable Speed Pumps.
Each additional pump connected to line power through a contactor or through a soft starter is referred to as a Fixed Speed Pump.
Each pump, variable speed or fixed-speed, is controlled by a relay in the master drive. The adjustable frequency drive with the cascade controller option
card installed has five relays available for controlling pumps. Two (2) relays are standard in the adjustable frequency drive and additional three relays
are found on the option card 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.
The cascade controller is capable of controlling a mix of variable speed and fixed-speed pumps. Possible configurations are described in more detail in
the next section. For simplicity of description within this manual, pressure and flow will be used to describe the variable output of the set of pumps
controlled by the cascade controller.
2 Introduction Extended and Advanced Cascade Controller
Option
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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
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-1/20 sec-1
Figure 2.2: Mounting B-options
Warning Dual supply
NOTE!
The label MUST be placed on the LCP frame as shown (UL-approved).
How to add the MCO 101 option:
• 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.
• Fit the MCO 101 option in slot B.
Extended and Advanced Cascade Controller
Option 2 Introduction
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• Connect the control cables and fasten the cables by the enclosed cable strips.
• Different systems must not be mixed.
• Fit the extended cradle and terminal cover.
•ReplacetheLCP.
• Connect power to the adjustable frequency drive.
Wiring the Terminals
Do not combine low voltage parts and PELV systems.
2.1.5 Advanced Cascade Control MCO 102
The MCO 102 option supports a maximum of eight pumps and is able to alternate the lead pump with two adjustable frequency drive relays per pump.
This reduces the need for external auxiliary switches as well as the cost of installation.
When the MCO 102 (C-option) is used, the number of relays can be increased to a total of 13 by adding the MCB 105 (B option).
Electrical Data:
Max terminal load (AC) 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-1/20 sec-1
2 Introduction Extended and Advanced Cascade Controller
Option
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