Megacontrol

Summary

Product identification

The product is a control unit in the Megacontrol series, manufactured by DP-Pumps. This documentation is valid from Megacontrol version V1.7.1.

Operating limits

Megacontrol Unit:

• Maximum ambient temperature: 50 °C
• Relative atmospheric humidity: 20 - 90 % (no condensation)
• Voltage: 1 x 230 V AC ± 5%
• Frequency: 50/60 Hz
• Intended Use: Controlling a Hydro-Unit consisting of 1, 2, 3, 4, 5 or 6 pumps within the indicated working range.
• Application Areas: Building possible in Hydro-Unit®, Break-Unit, and Fire-Unit installations, each with 1 - 6 pumps.

WSD-Sensor (option):

• Maximum ambient temperature: 30 °C
• Medium temperature: 5 - 30 °C
• Switching flow: ± 14 l/min
• Applications: Installations with a maximum of 3 membrane switch vessels.

Electrical

• Power Supply: The control unit requires 1 x 230 V AC ± 5% at 50/60 Hz.
• RS485-termination:
  • For 1-6 DANFOSS Micro-Drives: Megacontrol T+/T- clamps open, Microdrives bus termination switch to ON on each drive.
  • For 1-2 DANFOSS AQUA Drives: Megacontrol T+/T- clamps open, AQUA Drive bus termination switch to ON on each drive.
  • For 3-6 DANFOSS AQUA Drives: Megacontrol T+/T- clamps open, AQUA Drive bus termination set only on the last drive, external active bus termination (e.g., 6ES7 972-0DA00-0AA0 or FBCon DP M12 Term 24V) placed near the Megacontrol.
• Contactor Use: When using contactors and/or auxiliary relays, always place a suitable RC filter or varistor across the coil (e.g., Siemens 3RT29-16-1CD00).

Control Unit Functionality

The Megacontrol is an intelligent control unit for pressurization systems with up to 6 pumps. It senses system pressure on the outlet side and switches pumps on or off to maintain a set point. Key features include:

• Energy Saving: Minimum run time is constantly optimized.
• Programming: Programmable via the Human Machine Interface (HMI) operating panel or a service port (requires special service port cable Art. nr. 6147117698). Access is password protected.
• Pump Management: Determines pump activation/deactivation based on operating hours to ensure equal wear.
• Test Run: Automatic test run procedure prevents pumps from prolonged standstill.
• WSD-Sensor (option): Can generate failure messages for insufficient membrane switch vessel refreshment, defective membrane, lack of air, or incorrect installation.
• Temperature-sensor (option): Can generate temperature-dependent failure messages.

The control panel features a back-lit display, function keys (Operation, Diagnosis, Settings, Information), navigation keys (Up/Down, Escape, OK, Help), and LEDs:

• Red LED: Alert / urgent alarm active.
• Amber LED: Warning / non-urgent alarm active.
• Green LED: O.K. / trouble-free operation.

Access levels include Standard, User (default password 7353), Service, and Factory. The system automatically returns to the default access level after ten minutes of inactivity.

Hydro-Unit Configurations

The Megacontrol supports various Hydro-Unit configurations, each with specific parameter settings:

Hydro-Unit MC

• Number of pumps: 1, 2, 3, 4, 5, 6
• Inlet: Switch, Pressure, Level / valve ON-OFF, Level / valve prop.
• Discharge: Fixed Speed
• Bandwidth: 30
• Low pressure alarm: 100
• Opt. pump starts/h: 10
• Min. run time: Default 180 s (DOL ≤ 2.2 kW 90 s)
• Min. run time corr.: 10 s
• Run-dry delay: Default 30 s (Float/level control 1 s)

Hydro-Unit MC ++

• Number of pumps: 1, 2, 3, 4, 5, 6
• Inlet: Switch, Pressure, Level / valve ON-OFF, Level / valve prop.
• Discharge: Fixed Speed
• Bandwidth: 50
• Low pressure alarm: 100 kPa
• Opt. pump starts/h: 30
• Min. run time: 1 s
• Min. run time cor.: 1 s
• Run-dry delay: Default 30 s (Float/level control 1 s)

Hydro-Unit MCJ (with jockey pump)

• Number of pumps: 1, 2, 3, 4, 5, 6
• Inlet: Switch, Pressure, Level / valve ON-OFF, Level / valve prop.
• Discharge: One Jockey
• Bandwidth: 30
• Low pressure alarm: 100 kPa
• Opt. pump starts/h: 30
• Min. run time: Default 180 s (DOL ≤ 2.2 kW 90 s)
• Min. run time corr.: 10 s
• Run-dry delay: Default 30 s (Float/level control 1 s)

Hydro-Unit MCF (one variable frequency drive)

• Number of pumps: 1, 2, 3, 4, 5, 6
• Inlet: Switch, Pressure, Level / valve ON-OFF, Level / valve prop.
• Discharge: VFD change-over
• Communication: Analog 0-20 mA / 4-20 mA
• Proportional const.: 3
• Integral const.: 0.9
• Bandwidth: 10
• Accumulation press.: 30 kPa
• Low pressure alarm: 100 kPa
• Opt. pump starts/h: 30
• Min. run time: 1 s
• Min. run time corr.: 0 s
• Run-dry delay: Default 30 s (Float/level control 1 s)

Hydro-Unit MCMF (multiple variable frequency drives)

• Number of pumps: 1, 2, 3, 4, 5, 6
• Inlet: Switch, Pressure, Level / valve ON-OFF, Level / valve prop.
• Discharge: VFD fixed all
• Communication: Danfoss VLT 2800, Danfoss MicroDrive, Danfoss AquaDrive
• Proportional const.: 3
• Integral time.: 0.9
• Differential time.: 0
• No flow bandwidth: 0-1000 kPa (6), 0-2500 kPa (16)
• No flow step: 1
• VFD Ramp-Up: 3
• VFD Ramp-Down: 3
• VFD min. frequency: 30
• VFD max. frequency: 160
• P nominal of VFD: 1500 (See VFD)
• U nominal of VFD: 400 (See VFD)
• F nominal of VFD: 50/60
• I nominal of VFD: 4 (See VFD)
• RPM nominal of VFD: 2880 (See motor name plate)
• Bandwidth: 10
• Accumulation press.: 30 kPa
• Low pressure alarm: 100 kPa
• Opt. pump starts/h: 30
• Min. run time: 1 s
• Min. run time corr.: 0 s
• Run-dry delay: Default 30 s (Float/level control 1 s)

Hydro-Unit PumpDrive 2 Eco

• Number of pumps: 1, 2
• Inlet: Switch
• Discharge: VFD fixed all
• Pumps ON sensor fail: 1
• Max power: Limitation of the maximum power / maximum system load (1 pump is 100%)
• Communication: PumpDrive 2
• Proportional const.: 3
• Integral time.: 0.9
• Differential time.: 0
• No flow bandwidth: 0-1000 kPa (6), 0-2500 kPa (16)
• No flow time: 16
• No flow step: 3
• No flow max. power: 100
• VFD min. frequency: 30 Hz
• VFD max. frequency: 50/60 Hz
• U nominal of VFD: 400 V
• F nominal of VFD: 50/60 Hz
• Set point: 400
• Bandwidth: With pressure vessel 10 kPa / Without pressure vessel 20 kPa
• Accumulation press.: 30 kPa
• Low pressure alarm: 100 kPa
• Opt. pump starts/h: 30
• Min. run time: 10
• Min. run time corr.: 0
• RDP delay: Default 30 s (Float-level control 1 s)
• Nominal Cos Phi Value: 0.00...1.00
• PTC Analysis: OFF, ON
• Motor Direction of Rotation: 0=Clockwise, 1=Anti-clockwise
• Motor Control Method: Asynchronous Motor Vector Control
• Start Automatic Motor Adaptation: Standard AMA - Motor at Standstill
• Type of Control: 1=Discharge Pressure
• Role in Multiple Pump System: 1=Auxiliary Control
• Flow Rate Estimation: 0=OFF
• Device ID: 1 - 6
• Other VFD parameters: VFD Ramp-Up, VFD Ramp-Down, P nominal of VFD, I nominal of VFD, RPM nominal of VFD, Nominal Motor Power, Nominal Motor Voltage, Nominal Motor Frequency, Nominal Motor Current, Nominal Motor Speed, Minimum Motor Speed, Maximum Motor Speed, Thermal Motor Protection Behaviour, Fixed Speed 1, Digital Input 1 Function, Digital Input 2 Function, Digital Input 3 Function, Upper Limit (warning) are configurable.

Hydro-Unit Level control

This configuration provides parameters for supply valve ON/OFF, supply valve proportional control, general settings, and threshold settings. Threshold 1/2 contacts are only available with the MCIII 6 pumps version when using a maximum of 4 pumps. See the official PDF for exact tabulated values.

Special Input/Output

• External off (27-29 NC): Switches the unit off.
• Fire Alarm (28-29 NC): Switches all pumps on (has higher priority).
• Function TH.FAIL. P1-P6: Digital inputs for thermal failure signals of pumps 1-6.
• Input1 (WSD1 6-7), Input2 (WSD2 8-9), Input3 (WSD3 10-11): These pulse contacts can be configured for various functions if not used for WSD, including Check run, Alternate set point, Leakage, Remote Acknowledge, By-pass valve, or External power operation.
• Function RDP (Run-Dry Protection): Digital input for run-dry protection via a digital contact (e.g., Floater switch).
• Function TFR (Thermal Failure): Digital input for thermal failure.

---

Disclaimer: This summary is based on extracted text and may not include all figures, footnotes, or the complete context of the original OEM PDF datasheet. For contractual data and full product specifications, the official OEM PDF revision used on the project must be consulted.

Official datasheet (PDF)

Lenntech datasheet mirror