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Danfoss MCO 101, Manual

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Danfoss MCO 101 Manual Download Page 24

DO

DI

DI

DO

DI

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Pin 27

Pin 29

Pin 29

 

4.1.4 Closed-loop Control

The master drive is the primary controller for the system. It monitors the output pressure, adjusts the speed of the adjustable frequency drives and
decides when to add or remove stages. To perform this function the master drive must be set up in closed-loop mode with a feedback sensor connected
to an analog input of the drive.

The PID controller of the master drive must be set up to match the needs of the installation. Setting up the PID parameters is described in the 

VLT AQUA

Drive Programming Guide

 and will not be covered in this manual. Please also refer to the application note Master/Follower Operation included in this

manual.

 

4.1.5 Staging /De-staging of Variable Speed Pumps Based on Drive Speed

In master/follower configurations and mixed-pump configurations, the variable speed pumps are staged and de-staged based on the speed of the drives.

Staging occurs when the speed of the drives has reached the value in parameter 27-31 (27-32) Stage on Speed. At this speed the system pressure is still
maintained, but the pumps begin to operate outside of their peak efficiency points. Staging on an additional pump will lower the speed of all of the running
pumps and provide a more energy efficient operation.

De-staging occurs when the speed of the drives drops below the value in parameter 27-33 (27-34) Stage Off Speed. At this speed the system pressure
is still maintained, but the pumps begin to operate below their peak efficiency points. De-staging a pump will cause the speed of the drives to increase
to a more energy-efficient range.

Parameters 27-31 (27-32) Stage on Speed and 27-33 (27-34) Stage Off Speed are installation dependent. These parameters are indexed parameters
with one set of entries for each pump stage.

The stage on and de-stage off speed can be auto-tuned during automation or set manually. If auto-tune is enabled, the system will start operation using
default settings or the pre-settings set by the user in P27-31 (27-32) and 27-33 (27-34) before enabling auto-tune.

The goal is to find the stage on and off speeds where the system is most energy efficient. See the drawing below.

4 Configuring the System

Extended and Advanced Cascade Controller

Option

4-2

MI.38.C2.22 - VLT

®

 is a registered Danfoss trademark

4  

Summary of Contents for MCO 101

Page 1: ...ultiple 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...

Page 2: ... 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 ...

Page 3: ...table 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 doe...

Page 4: ...e 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 Opti...

Page 5: ...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 of...

Page 6: ...1 Safety and precautions Extended and Advanced Cascade Controller Option 1 4 MI 38 C2 22 VLT is a registered Danfoss trademark 1 ...

Page 7: ...dvanced 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 10...

Page 8: ...em 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...

Page 9: ...igure 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 an...

Page 10: ...d 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 D...

Page 11: ...drive during operation How to add the MCO 102 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 Extended and Advanced Cascade Controller Option 2 Introduction MI 38 C2 22 VLT is a registered Danfoss trademark 2 5 2 ...

Page 12: ...VLT Advanced Cascade Control Card MCO 102 option is exclusively intended for use in option slot C1 The mounting position of C1 options is shown in the drawing below Figure 2 4 Enclosure A2 A3 and B3 1 57 in 40 mm only one C option Wiring the Terminals 8 relays 7 digital inputs Table 2 1 Advanced Cascade Controller MCO 102 terminal connections 2 Introduction Extended and Advanced Cascade Controller...

Page 13: ...ended cascade in parameter group 27 3 1 2 Extension of Basic Cascade Use of the extended cascade option MCO 101 as an extension of the basic cascade built into drive 3 1 2 In applications already controlled by the built in cascade controller in group 25 the option card can be used to extend the numbers of relays for cascade control For instance if a new pump is added to the system It can also be u...

Page 14: ...cuit alternating lead pump 4 pumps Figure 3 2 Line power circuit alternating lead pump 4 pumps 3 Supported Configuration Extended and Advanced Cascade Controller Option 3 2 MI 38 C2 22 VLT is a registered Danfoss trademark 3 ...

Page 15: ...27 70 RELAY 1 73 Pump 2 to Line Power 27 71 RELAY 2 74 Pump 3 to Line Power 27 72 RELAY 10 75 Pump 4 to Line Power 27 73 RELAY 11 0 Standard Relay 27 74 RELAY 12 0 Standard Relay The fixed speed pump configuration provides a cost effective method for controlling up to 6 pumps It is able to control system output by controlling the number of running pumps as well as the speed of the single variable ...

Page 16: ...2 Enable 27 71 RELAY 2 2 Drive 3 Enable 27 72 RELAY 10 3 Drive 4 Enable 27 73 RELAY 11 0 Standard Relay 27 74 RELAY 12 0 Standard Relay The master follower configuration provides the gentlest transition from one stage to the next and the most energy efficient operation For most instal lations the energy savings make this the most cost effective configuration The system will automatically balance a...

Page 17: ...edback pressure Figure 3 5 Example For this configuration relay selections in Group 27 7 Connections are as follows 27 70 RELAY 1 1 Drive 2 Enable 27 71 RELAY 2 74 Pump 3 to Line Voltage 27 72 RELAY 10 75 Pump 4 to Line Voltage 27 73 RELAY 11 0 Standard Relay 27 74 RELAY 12 0 Standard Relay This configuration provides some of the benefits of the Master Follower configuration with some of the initi...

Page 18: ...ts of 100 of the size of the master drive s variable speed pump This is necessary since the variable speed pump must be able to control the output between the fixed speed stages Valid Configurations 100 is defined as the maximum flow produced by the pump connected to the master drive The fixed speed pumps must be multiples of this size Variable Speed Fixed Speed 100 100 200 100 100 200 200 100 100...

Page 19: ...e running hours between all of the pumps as specified by the Runtime Balancing parameter Figure 3 7 Example 1 The two pumps can be ether variable speed or fixed speed with equal running hours For this configuration relay selections in Group 27 7 Connections are as follows 27 70 RELAY 1 8 Pump 1 to Drive 1 27 71 RELAY 2 16 Pump 2 to Drive 1 27 72 RELAY 10 72 Pump 1 to Line Voltage 27 73 RELAY 11 73...

Page 20: ...0 72 Pump 1 to Line Voltage 27 73 RELAY 11 73 Pump 2 to Line Voltage 27 74 RELAY 12 74 Pump 3 to Line Voltage Figure 3 9 Example 3 The first two pumps alternate each with 50 of the running hours The fixed speed pumps turned on and off as needed with equal running time between them For this configuration relay selections in Group 27 7 Connections are as follows 27 70 RELAY 1 8 Pump 1 to Drive 1 27 ...

Page 21: ...LL fixed speed pumps Mixing soft starters and contactors will result in an inability to control the output pressure during staging and de staging transitions When using soft starters a delay will be added from when the staging signal occurs until staging takes place The delay is necessary due to the ramp time of the fixed speed pump because of the soft starter Extended and Advanced Cascade Control...

Page 22: ...3 Supported Configuration Extended and Advanced Cascade Controller Option 3 10 MI 38 C2 22 VLT is a registered Danfoss trademark 3 ...

Page 23: ... need to be defined Parameter group 27 7 Connections provides a list of all of the available relays Each follower drive in the system needs to have one relay assigned to enable disable the drive as needed Each fixed speed pump needs to have one relay assigned to control the contactor or enable the soft starter to turn the pump on off If it is necessary to have a single drive alternate between two ...

Page 24: ...ystem pressure is still maintained but the pumps begin to operate outside of their peak efficiency points Staging on an additional pump will lower the speed of all of the running pumps and provide a more energy efficient operation De staging occurs when the speed of the drives drops below the value in parameter 27 33 27 34 Stage Off Speed At this speed the system pressure is still maintained but t...

Page 25: ...aging occurs These values are set through parameters 27 20 Normal Operating Range 27 23 Staging Delay and 27 24 De staging Delay These parameters are installation dependent and should be set to meet the requirements of the system Automatic stage de stage threshold The speed of the variable speed pump at the point of staging or de staging is defined by a stage threshold or a de stage threshold Thes...

Page 26: ...4 Configuring the System Extended and Advanced Cascade Controller Option 4 4 MI 38 C2 22 VLT is a registered Danfoss trademark 4 ...

Page 27: ... an individual pump can be manually controlled for maintenance purposes The parameter group is organized as follows Pump 1 Pump 2 Pump 3 Pump 27 01 Status On Drive Ready Offline off 27 02 Control No Operation No Operation No Operation 27 03 Current Hrs 650 667 400 27 04 Lifetime Hrs 52673 29345 30102 Navigate to the 27 0 group on the LCP Use the right and left arrows on the LCP to select the pump ...

Page 28: ...mps At each priority level the pump with the greatest number of current runtime hours will be de staged first An exception to this occurs in Mixed Pump configurations with more than one drive All variable speed pumps are staged on before fixed speed pumps 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 pump...

Page 29: ...ed of the drives The second is the feedback pressure going outside of the normal operating range In a Mixed Pump configuration with more than one drive both methods are used In the following example feedback is referred to as pressure Staging When the master drive receives a start command a variable speed pump is selected and started using one of the available drives If the system pressure drops t...

Page 30: ...ontroller will de stage another pump This will repeat until only the lead pump is left on or until the pressure stabilizes The Override Limit parameter 27 21 is set as a of the maximum reference It defines a point above and below the system setpoint where override staging and de staging will occur 5 2 9 Minimum Speed De staging To reduce emergency usage the cascade controller will de stage a pump ...

Page 31: ... controller and is connected to line power and running 5 Offline On Drive The pump is not available for use by the cascade controller and is connected to line power and running 6 Offline Fault The pump is not available for use by the cascade controller and is connected to line power and running 7 Offline Hand The pump is not available for use by the cascade controller and is connected to line powe...

Page 32: ...roller option Master Follower Operates using only variable speed pumps connected to drives This selection simplifies the set up Mixed Pumps Operates using both variable and fixed speed pumps Basic Cascade Ctrl Turns off the cascade option and reverts to basic cascade operation See parameter group 25 in the VLT AQUA Drive Programming Guide for further information The additional relays on the option...

Page 33: ...fixed speed pumps All of the fixed speed pumps must be configured the same Possible choices are None contactors Soft starters Star delta starters 27 18 Spin Time for Unused Pumps Range Function 1 0 s 0 0 s 99 0 s Spin Time for Unused Pumps sets the length of time to spin unused pumps If a fixed speed pump has not been run in the last 72 hours it will be turned on for this time This is to prevent d...

Page 34: ...he VLT AQUA Drive Programming Guide for further information 27 21 Override Limit Range Function 100 Dis abled P27 20 100 Override Limit is the allowed offset from the setpoint before a pump will immediately be added or removed for instance if a fire tab is switched on Normal Operating Range includes a delay that limits the system response to transients This makes the system respond too slowly to l...

Page 35: ...least one variable speed pump available the Normal Operating Range P27 20 is used If there are no variable speed pumps available the Fixed Speed Only Operating Range P27 22 is used 27 25 Override Hold Time Range Function 10 s 0 300 s Override Hold Time is the minimum time that must elapse after a stage or de stage before a stage or de stage may take place due to the system exceeding the override l...

Page 36: ...e optimized in order to ensure high performance and low energy consumption If disabled the speeds can be set manually 0 Disabled 1 Enabled 27 31 Stage On Speed RPM Range Function P4 13 par 4 11 par 4 13 To be used if RPM is chosen 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 6 How to...

Page 37: ...27 24 and more than one variable speed pump is on a variable speed pump will be turned off 6 1 7 Staging Settings 27 4 Parameters for configuring staging transitions 6 1 8 Auto tune Staging Settings 27 40 27 40 Auto tune Staging Settings Option Function When enabled the staging threshold will be auto tuned during operation The settings are optimized in order to prevent overpressure and underpressu...

Page 38: ...d in the staging ramp at which the fixed speed pump should be turned on Set as a percentage of maximum pump speed If Auto tune Staging Settings is enabled in P27 40 P27 43 will be hidden The actual value can be read if P27 40 is disabled If P27 40 is disabled the staging threshold in P27 43 can be changed manually and the new value will then be used if P27 40 is enabled again 6 How to Program Exte...

Page 39: ...When 27 40 is Enabled 1 27 41 27 42 27 43 and 27 44 will be kept up to date with new au tomatically calculated values If 27 41 27 42 27 43 and 27 44 are modified from the bus the new values will be used but will also continue to be automatically tuned modified Values will be recalculated and the parameters updated when staging occurs 27 45 Staging Speed RPM Option Function Units RPM Staging Speed ...

Page 40: ...te at Time of Day allows the user to select a specific time of day for alternating pumps The time is set in parameter 27 55 Alternation at Time of Day requires the real time clock to be set 0 Disabled 1 Time of Day 27 55 Alternation Predefined Time Range Function 1 00 00 00 23 59 Alternation Predefined Time is the time of day for pump alternation This parameter is only available if parameter 27 54...

Page 41: ...e specific relays and then choose the function If the function option Standard Relay is chosen the relay can be used as general purpose relay and the desired function can then be set up in parameter P5 4 0 Drive X Enable Enable follower drive X Pump K to Drive N Connect pump K to drive N Pump K to Line Power Connect pump K to line power NOTE If the MCO 102 is installed the relay option MCB 105 may...

Page 42: ...unning in fixed speed mode No variable speed pumps are available Jogging The system is running at the jog speed set in P3 11 In Open loop The system is set to open loop Frozen The system is frozen in the current state No changes will take place Emergency The system has stopped due to Coast Safety Interlock Trip Lock or Safe Stop Alarm The system is operating with an alarm condition Staging A stagi...

Page 43: ... Tune Staging Speeds 1 Enabled All set ups TRUE Uint8 27 31 Stage On Speed RPM ExpressionLimit All set ups TRUE 67 Uint16 27 32 Stage On Speed Hz ExpressionLimit All set ups TRUE 1 Uint16 27 33 Stage Off Speed RPM ExpressionLimit All set ups TRUE 67 Uint16 27 34 Stage Off Speed Hz ExpressionLimit All set ups TRUE 1 Uint16 27 4 Staging Settings 27 40 Auto Tune Staging Settings 0 Disabled All set up...

Page 44: ... X66 9 Digital Input 0 No operation All set ups TRUE Uint8 27 65 Terminal X66 11 Digital Input 0 No operation All set ups TRUE Uint8 27 66 Terminal X66 13 Digital Input 0 No operation All set ups TRUE Uint8 27 7 Connections 27 70 Relay 0 Standard Relay 2 set ups FALSE Uint8 27 9 Readouts 27 91 Cascade Reference 0 0 All set ups TRUE 1 Int16 27 92 Of Total Capacity 0 All set ups TRUE 0 Uint16 27 93 ...

Page 45: ...re Very easy installation no need for external equipment The drives can be delivered in IP55 or even IP66 which means no need for panels except for fuses Issues to keep in mind Compared to traditional cascade control the number of running pumps is controlled by speed instead of feedback To obtain the highest energy sav ings the stage on and off speed must be set correctly according to the system T...

Page 46: ...0 bar Parameter settings Display settings Master drive Display Line 1 1 Small 0 20 Reference 1601 Display Line 1 2 Small 0 21 Feedback 1652 Display Line 1 3 Small 0 22 Motor current 1614 Display Line 2 Large 0 23 Frequency 1613 Display Line 3 Large 0 24 Cascade reference 2791 Display settings Follower drives Display Line 1 1 Small 0 20 External Reference 1650 Display Line 3 Large 0 24 Frequency 16...

Page 47: ...Drive 4 Enable Minimum Reference 3 02 0 bar Maximum Reference 3 03 10 bar Terminal 27 Mode 5 01 Output 1 Terminal 27 Digital Output 5 30 Pulse output 55 Terminal 27 Pulse Output Variable 5 60 Cascade Reference 116 Pulse Output Maximum Frequency 27 5 62 5000 Hz Settings for the follower drives only Set Reference 1 Source 3 15 Pulse input 29 7 Set Terminal 29 Digital Input 5 13 Pulse input 32 Set Te...

Page 48: ...8 Annex A Master Follower Application Note Extended and Advanced Cascade Controller Option 8 4 MI 38 C2 22 VLT is a registered Danfoss trademark 8 ...

Page 49: ...Critical Systems 5 4 Current Runtime Hours 27 03 6 2 D De staging 4 2 5 4 De staging Delay 27 24 6 5 De staging Speed rpm 27 47 6 9 De staging Threshold 27 44 6 9 Display Settings Follower Drives 8 2 Display Settings Master Drive 8 2 Drive Configurations 3 1 E Easy Installation 8 1 Electrical Wiring 8 2 Energy Savings 8 1 Extended Cascade Controller Mco 101 And Advanced Cascade Controller Mco 102 ...

Page 50: ...es 5 3 Multiple Unit Staging Efficiency Calculator 4 3 Musec 4 3 8 1 N Normal Operating Range 27 20 6 4 Number Of Drives 4 1 Number Of Drives 27 11 6 2 Number Of Pumps 27 12 6 2 O Open loop Mode 2 2 Optimize The Energy Consumption 8 3 Override Hold Time 27 25 6 5 Override Limit 5 4 Override Limit 27 21 6 4 Override Staging de staging 5 4 P Parameter Settings 8 2 Pid Controller 4 2 Pressure Fluctua...

Page 51: ...age On Speed hz 27 32 6 6 Stage On Speed rpm 27 31 6 6 Stage On Speed Hz 8 1 Staging 4 2 5 4 Staging De staging 5 3 Staging de staging Of Variable Speed Pumps Based On Drive Speed 4 2 Staging And De staging Decisions 3 4 Staging Delay 27 23 6 5 Staging Settings 27 4 6 7 Staging Speed hz 27 46 6 9 Staging Speed rpm 27 45 6 9 Staging Speed 27 3 6 6 Staging Threshold 27 43 6 8 Staging de staging Of F...

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