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Danfoss Cascade, Operating Instructions Manual, Page: 5 / 59

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Cascade Controller Option

Safety and precautions

175ZA678.1

1

 

Warning:

Touching the electrical parts may be fatal - even after the equipment has
been disconnected from mains.
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

5

Summary of Contents for Cascade

Page 1: ...21 Introduction 21 Changed systemstop functions 22 Serial communications parameter 500 22 User Interface 23 How to use the LCP for programming 23 Control keys for parameter setup 23 Indicator lamps 23...

Page 2: ...back Transmitter Wiring 54 Connecting feedback transmitters 54 Single 0 10 V feedback transmitter connection 54 Two 0 10 V feedback transmitter connections 54 Two 4 20 mA feedback transmitters connect...

Page 3: ...AQUA Operating Instructions When reading through this Operating Instructions you will come across various symbols that require special attention The symbols used are the following Indicates a general...

Page 4: ...against motor overload is included in the factory setting Parameter 117 Motor thermal protection default value is ETR trip 1 For the North American market The ETR functions ensure overload protection...

Page 5: ...parts may be fatal even after the equipment has been disconnected from mains 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 603...

Page 6: ...n response to actual system demand The VLTs PID controller accommodates two feedback signals and two setpoints which allows regulating a system with different setpoint zones In pumping applications wh...

Page 7: ...d control when the drive runs continuously at minimum speed with one or more constant speed motors running Since a variable speed pump at minimum speed adds no or very limited flow to the system it is...

Page 8: ...at the same speed the possibility of running a pump continuously into a closed check valve is all but eliminated This reduces pump maintenance by minimizing the wear on pump seals and bearings Danfos...

Page 9: ...ed in this chapter to 7 1 in lbs 0 8 Nm unless specified otherwise Optional transmitter connections VLT drive terminals12 and 13 provide a 24 VDC 200 mA power supply This supply can be used to power r...

Page 10: ...s Drive configurations vary 2 Disconnect VLT Drive Control Wiring Touching electrical parts may be fatal even after equipment has been disconnected from AC line To be sure that capacitors have fully d...

Page 11: ...es Lift control board cassette from bottom Disconnect two ribbon cables from VLT control board Unhinge cassette at top to remove 4 Remove LCP Keypad Cradle Push tabs at side of LCP cradle to release c...

Page 12: ...ller option card through slot at side of VLT control board cassette Option card mounts with component side down Feed plastic option card insulation pad through terminal opening in control board casset...

Page 13: ...ollar A of control board ribbon cable socket DO NOT remove blue insulation on end of option card ribbon cable Insert ribbon cable into corresponding socket B on VLT control board and push collar close...

Page 14: ...ounding 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 strip...

Page 15: ...cables to control board in corresonding connectors as removed in step 3 Hinge VLT cassette at top of VLT chassis and reposition into place Use Torx T 20 screwdriver to fasten two captive screws Ensure...

Page 16: ...d insert into slot in side of control card cassette Attach insulation pad to top most clamp position with one screw from removed wiring clamp Route VLT control terminal wiring through bottom left wiri...

Page 17: ...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 t...

Page 18: ...or The HAND position allows manual operation of the motor The motor can be disabled by setting the switch to OFF For a motor in the OFF position the cascade controller will try to start it by triggeri...

Page 19: ...emonstrates a 4 20 mA pressure transmitter an external safety interlock and four slave drives The slave drive speed reference is provided from terminal 17 as a pulse signal The relays on the option ca...

Page 20: ...in the same way receiving the 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 connectio...

Page 21: ...e and Cascade Controller Card Setup 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 Def...

Page 22: ...a stop STOP via Terminal 27 Coast Inverse parameter 304 Constant speed motors stop immediately Controller coasts its motor to a stop STOP via Terminal 27 Safety Interlock parameter 304 Constant speed...

Page 23: ...xtend Menu or the Quick Menu mode CANCEL is used if a change to a selected parameter is not to be carried out OK is used for confirming a change to a selected parameter are used to scroll through para...

Page 24: ...Parameters 008 009 and 010 select the data displayed on the top line Parameter 007 Large Display Readout selects the data displayed on line 2 The list on the next page defines the operating data that...

Page 25: ...tus line indicates the reference element that is active REMOTE means that reference from the control terminals is active while LOCAL indicates that the reference is determined via the and keys on the...

Page 26: ...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 2 Use and keys to find parameter yo...

Page 27: ...t 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 Operat...

Page 28: ...ller efficiency after system start up Items 2 6 are motor characteristics In Standard cascade control mode only the motor data from the variable speed motor run by the cascade controller are entered I...

Page 29: ...Ref max 0 019 205 Ref max Units Ref min Max feedback 0 020 723 Operational Mode select Standard M S Standard Cascade 021 712 Pump combination 1 8 1 022 713 Staging BandW 1 0 100 0 10 0 023 714 Destag...

Page 30: ...250 00 400 HP 300 00 KW 300 00 450 HP 315 00 KW 315 00 500 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 o...

Page 31: ...will be unable to run continuously below this value in any mode Description of choice Set a value from 0 0 Hz to the Output frequency high limit set in Quick Menu item 008 parameter 202 Quick Menu 00...

Page 32: ...ut 0 10 V a pull down resistor of 500 should be fitted to terminal 39 common for analogue digital outputs See chapter 10 for additional detail If the output is used as a current output the resulting i...

Page 33: ...n the Display mode and as a unit for Minimum Maximum Feedback Minimum Maximum Reference Warning Feedback High Low and for the H1 H0 and the calculated Hmx parameter settings readings Description of ch...

Page 34: ...and via the relay outputs In Closed loop the unit for the feedback is programmed in parameter 415 Units related to closed loop Description of choice Set the desired value within the feedback range be...

Page 35: ...ystem using variable speed pumps controlled by a Master drive NB Set the correct control option Improper setting may result in system damage operational errors or wasted energy Description of choice S...

Page 36: ...be selected in parameter 004 to omit downloading motor and current dependent data Extended Menu Par 002 Active Setup ACTIVE SETUP Value Factory Setup FACTORY SETUP 0 Setup 1 SETUP 1 1 Setup 2 SETUP 2...

Page 37: ...load all parameters to copy all parameter values from the drive to the LCP Select Download all parameters to copy all parameter values from the LCP to the drive on which the keypad is mounted Select D...

Page 38: ...e the 39 parameters are programmed in sequence Procedures for programming are in the following order Initial Setup Quick Menu items 1 20 Step 1 Standard control mode programming Step 2 Optimization of...

Page 39: ...n Standard cascade control mode additional pumps can be either 100 200 or 300 relative to the VLT driven pump Description of choice Select the pump combination and capacities from the choices offered...

Page 40: ...ime DESTAGING DELAY Value 0 3000 sec 30 sec Function Immediate destaging of a fixed speed pump is not desirable when a momentary pressure increase in the system that exceeds the staging bandwidth SBW...

Page 41: ...be optimized with increased familiarity with the system See parameter 717 Override Bandwidth Timer Commissioning the Cascade Controller To avoid unintended staging during the commissioning phase and f...

Page 42: ...tion frequency might cause the check valve at the discharge of a variable speed pump to close during the transition which could add pressure in the system Ensure that the transition frequency setting...

Page 43: ...edback signal originates at the far end of the system the drive does not need to compensate for system pressure changes due to flow For this system configuration or for two setpoint PID control or for...

Page 44: ...ed off Not operating a pump over long time periods can create corrosion concerns If cycling is disabled the controller follows the fixed pattern of relay activation 6 7 8 and 9 regardless of the runni...

Page 45: ...Menu is accessed by pressing the EXTEND MENU key on the drive control panel Parameter 418 may be accessed through either the Extended Menu or as item 28 in the Quick Menu EXTENDED MENU Par 417 Feedba...

Page 46: ...e program available on the Danfoss website By entering pump and system data MUSEC provides the programmer with Master drive on and off staging frequencies for each pump at optimal efficiency For a fre...

Page 47: ...Function Staging delay time is used to prevent the fast cycling on of the slave pumps or fans Increase the time if frequent switching is encountered Description of choice Set staging on delay time In...

Page 48: ...its Quick Menu 031 Par 722 Pump cycling PUMP CYCLING Value Enabled Disabled Enabled Function To achieve equal hours of operation use of pumps or fans can be cycled Timers on the relay outputs relays 6...

Page 49: ...uency for each pump After pressing the CHANGE DATA key in parameter 740 use the and keys to scroll through all four slave settings If the pump or system data is unknown refer to the section Alternativ...

Page 50: ...uency low limit Alternate Feedback Programming In water supply systems it is often impractical to place a pressure sensor at the far end of the system In HVAC and other applications however it is ofte...

Page 51: ...t reference for one setpoint PID control or for the setpoint for zone 1 in two setpoint PID control Description of choice Set the required value the system is to maintain during normal operation The v...

Page 52: ...efore PID control is activated The drive will follow the acceleration ramp when a start signal is received as if in open loop When the programmed start frequency is reached it will change to closed lo...

Page 53: ...ct and become unstable See Optimization of the Process Regulator for information on proper adjustment Procedure for Optimization of the Process Regulator The process regulator is set by Quick Menu ite...

Page 54: ...CK Transmitter high limit 308 AI V 53 FUNCT NO OPERATION 311 AI V 54 FUNCT NO OPERATION 314 AI mA 60 FUNCT FEEDBACK 315 AI 60 SCALE LOW 4 mA 316 AI 60 SCALE HIGH 20 mA Single 0 10 V feedback transmitt...

Page 55: ...T NO OPERATION Two feedback signals and two setpoints Similar to two feedback signals and one setpoint the need for two feedback signals with two setpoints is frequently encountered Whenever two criti...

Page 56: ...I mA 60 FUNCT NO OPERATION The reference range is generally set to equal the range of the transmitter In this way the setpoint reference can be set to any value that the transmitter can produce If req...

Page 57: ...ur meter for pump 2 Hrs 0 130000 0 0 Yes 7 1 725 PUMP 3 ON TIME Hour meter for pump 3 Hrs 0 130000 0 0 Yes 7 1 726 PUMP 4 ON TIME Hour meter for pump 4 Hrs 0 130000 0 0 Yes 7 1 727 PUMP 5 ON TIME Hour...

Page 58: ...o of times each relay pump is switched on The cycle counter can be reset to zero when a pump is replaced Par 736 Relay on time RELAY ON TIME Value h 0 130000 Function The relay timer accumulates the h...

Page 59: ...ch 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 Digits 7 8 are reserved for future use...

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