Orca

 

  • An industry proven dedicated pump control system designed to operate as a constant pressure, variable flow control system.
  • Complete control package.
    • Connect power, wire in the pumps and attach the pressure tube.
  • Supplied equipment.
    • ORCA controller
    • Danfoss Variable Frequency Drive (Other brands available)
    • Moeller switchgear
    • IP54 Enclosure
    • Mains Isolator
    • Circuit breakers
    • Fan forced ventilation
    • MEN power connections
    • 25Bar pressure transducer 4-20mA
  • Constant Level or Constant Flow also available
  • Multiple control voltages.
  • Capable of operating up to 6 pumps.
  • Real English Menus with a 2 Line 16 characters LCD Display.
  • Pump enabled and run indicators.
  • Easy navigation menu system with password access control.
  • For clarity Menus disappear when an option or function is not selected or required.
  • Whilst tuning the actual pressure is displayed along side the value of the adjustment to facilitate rapid evaluation of any change. 
  • Simple push button actions to enable/disable or manually operate each pump.
  • Inbuilt settable time clock.
  • Remote Control capability via digital input or telemetry.
  • SCADA Compatible Modbus/RS485 for remote data acquisition, download or control.
  • Capable of up to 7 separate input or time activated set pressures for changing duties.
  • User selectable timed activated outputs that can be associated to a time activated pressure settings. 
  • Data protection or user entry via access code.
  • Multiple (12 + 8) programmable inputs for user selectable functions with adjustable delay.
  • Multiple (4 +4) programmable voltage free outputs for BMS interfacing or user selectable output functions.
  • Selectable Duty /Standby and Backup pump operating mode options.
  • Temporary mute of the buzzer on key press actions for silent operation.
  • Automatic spin up mode for backup pumps. (Adjustable Interval & time).
  • Friction Loss Compensation.
    • Linear, exponential or none.
  • User selectable DOL backup mode in the event of a VFD failure.
  • Continuous display of the pressure and setpoint.
  • Optional Rotary Auto/Off/Manual switches.
    • Manual can be configured to one of two modes.
      • Indirect- The ORCA will operate the pump at full speed.
      • Direct- The pump switchgear is operated directly from the AOM switch. Provides further redundancy.
  • User selectable decimal placement for pressure and flow readings. Allows the user to have setting such as PSI with greater resolution. EG 20.3 PSI
  • Simple scaling and zeroing for all types of sensors or transducers.
  • Optional backup pressure transducer with auto change over on detection of a faulty transducer.
  • Data logs for local or remote viewing.
    • Total system flow. (Calculated or Actual)
    • Current average flow rate (Calculated or Actual)
    • Average pressure since last start.
    • Highest pressure recorded
    • Resettable Hours runs and pump starts for each pump
    • Status of all inputs or outputs.
    • Local temperature of controller.
    • Communications status.
  • Fault logging.
  • User adjustable Low Pressure Setting with adjustable delay which performs a Low Pressure Shutdown.
  • User adjustable Cut In (Restart) Pressure setting.
  • User adjustable High Pressure setting with adjustable delay which performs a High Pressure Shutdown.
  •  High pressure shutdown displays the pressure that exceeded the limit until the system is reset.
  • Continuously displays the current flow rate.
    • If a flow meter is attached it will be actual flow.
    • If there is no flow meter it will be based on calculated flow.
  • Individual pump fault protection option with adjustable delay.
  • Individual pump protection option with auto-resetting and adjustable delay.
  • User adjustable next pump In (ON) delay timer
  • User adjustable next pump Out (OFF) delay timer
  • System Restart Delay Timer.
  • System No Flow Input with adjustable timer.
    • Two possible uses for system No Flow Input
      • System loss of prime.
      • Detection of possible standby or sleep condition.
  • Various Pump Modes – Duty/Standby or Backup
    • Duty/Standby- A pump set as Duty/Standby will automatically be available when the system is running. The maximum number of duty pumps running at any one time is limited by the “Duty Pumps” setting, when the number of duty pumps running is reached the balance automatically become standby pumps. If Auto rotation is enabled then the Duty & Standby pumps are re-allocated for each restart.
    • Backup- Pumps configured as Backup take over when a fault has been detected with one of duty/standby pumps.
  • Backup pump options.
    • Backup Spin Settings
      • Spin Interval- Adjustable to occur every x days/hours
      • Spin time- Adjustable for a specified duration
  • Pump Rotation Options:
    • At a specified time each day pump rotation will be initiated.
    • Normal Full Autorotation will occur during any system restart.
    • Fixed Pump Start. The same pumps starts on every restart.
    • Pump with the lowest hours to start next.
  • Configuration Backup and Restore.
    • A complete backup of settings and system configuration including sensor scaling can be implemented at any time and then restored if unconfirmed or doubtful changes have been made.
  • Eight individual set points activated by time or external signal.
    • Each of the extra setpoints can be activated by the activation of an input.
    • Each of the extra setpoints can be activated by a start and stop time from the internal clock.
    • Each one of the timed Set Points can also have one of the Programmable Outputs operating at the same time. Typically used to operate valves for different systems.
  • Specialised Control algorithms that are ultra responsive to minimise overpressure occurrences for critical applications.
    • Pipe Fill Mode- Elimination of water hammer at start-up. 
    • Operator adjustable settings to determine at what point pipe fill should be initiated during a restart.
    • Operator adjustable time for pipe filling which automatically stages all pumps to coincide with the overall time.
    • Automatic resumption of pressure control if pipe was only partially empty.
    • Settings to prevent cavitation during the initial stages of pipe fill or when using turbines or bore pumps it facilitates the movement of water past the motor or bearings.
      • Jump duration- This sets how long it takes for the first pump to get to the jump speed before commencing the actual pipe fill sequence.
      • Jump Final Speed- This specifies the final speed of the first pump after the jump duration time. 
  • Flow Meter Support.
    • Digital output meters
    • Analogue output meters.
      • A digital output pulsed flow meter or Analogue output meter can be connected to log/monitor flow and also used to determine any no flow condition for normal standby mode or faults such as loss of prime.
  • Optional Knob style Set Point adjustment available for ease of use.
  • Programmable Start and Stop times for system operation.
  • Options for zero pump displacement detection-  Fixed Frequency or Pump Shut Off Head.
    • The entry of a Shutoff head allows the minimum pump speed to be automatically calculated from the current set point and is essential for multiset point control when the set points vary dramatically.
    • Fixed minimum pump speed is sometimes desirable to enforce a greater overlap between pumps or preset the change over point between pumps.
    • Accurate zero displacement or minimum frequency is also required to determine when the system should be placed on standby or sleep mode.
  • Relative or fixed pressure settings.
    • Low pressure shut down. This setting can be a fixed or relative a value.
      • Relative mode. The Low pressure will be a percentage of the current set point. As the set point changes the Low Pressure will then change.
      • Fixed mode. Low pressure will remain constant regardless of the current set point.
    • Cut In Pressure, High pressure limit and High pressure shutdown. (Relative settings)
      • These settings are all set as a percentage of the current set point.  The actual value calculated by from the % of set point is also shown to make it easy to use.
  • Optional independent Jockey pump.
    • A full set of independent settings available for Jockey pump operation.
    • Types available.
      • DOL with fixed cut in & cut out
      • Independent Variable Speed
      • Utilising the main VFD.
    • Settings.
      • Restart pressure
      • Cut Out (DOL Only)
      • Independent Set pressure or global using main pump setting
      • Independent Jockey Pump calculated flow rate.
      • Independent Tuning Parameters
      • Change over delay when JP runs from main VFD
      • Optional mode to allow system to fallback to JP from main pumps at a prescribed minimum flow rate or flow switch input.
  • Soft Pause Input.
    • Used to ramp the system down slowly. Typically used in conjunction with an irrigation controller to turn off the system at the end of a cycle. Pause is displayed when Pause is activated.
    • Two options available.
      • Pause all pumps including the Jockey pump.
      • Pause the main pumps and allow the Jockey pump to run.
  • Low Level Input option.
    • Used with floats or similar. Displays "Paused - Low-Level".
  • Optional Access Code Features
    • Selectable Access code functions.
      • Three different Levels-
      • Menu adjustments only.
      • Pumps only.
      • All.
  • Multiple Sensor interface
    • Sensor signals.
      • 0-20mA
      • 4-20mA
      • 0-10VDC
      • 0-5VDC
  • Telemetry
    • The ORCA is capable of communicating with an external telemetry system based on digital Inputs and/or Outputs from other devices.
    • A serial communications port is provided for direct connection to SCADA or BMS system for access to the ORCA operating parameters. This is via RS485 MODBUS RTU protocol. A full list of registers addresses can be provided.
    • Option interfaces can be provided such as.
      • Ethernet.
      • Multi Mode Fibre
      • Single Mode Fibre
  • Digital Outputs
    • The ORCA has 4 programmable outputs that can be selected for a variety of functions. They are rated to 5 amps 240VAC with change over contacts.  The number of outputs can be expanded to 8 if required.
  • Digital Inputs
    • All inputs can be configured to operate as contact closure = ON or Contact Open = ON (Inverted).
    • The ORCA has 12 programmable voltage free inputs that can be selected for a variety of functions. The number of inputs can be expanded to 20 if required. 

Downloads

Category Name File
VFD Manuals Danfoss FC 202 Operation Manual
VFD Manuals Danfoss FC100 HVAC Basic manual
VFD Manuals Danfoss FC102 Operation Manual
VFD Manuals Danfoss FC102 Programming Manual
VFD Manuals Danfoss FC51 Programming Guide
VFD Manuals Danfoss FC51 Quick guide
Help Files, Technical Bulletin Fitting a new transducer to an ORCA
Technical Bulletin MPCSV to ORCA conversion drawing
VFD Configuration Settings Orca ABB ACS 400 Settings
VFD Configuration Settings Orca ABB ACS 550 Settings
Data Sheet ORCA Colour Brochure
VFD Configuration Settings Orca Danfoss FC101 Settings
VFD Configuration Settings Orca Danfoss FC102 & FC202 Settings
VFD Configuration Settings Orca Danfoss FC51 Settings
VFD Configuration Settings ORCA Danfoss VLT6000 Settings
Data Sheet Orca Data Sheet
VFD Configuration Settings Orca Eaton MMX Settings
Help Files Orca Fault Messages
Data Sheet ORCA Features
Techsys Manuals ORCA Flow Manual
Techsys Manuals ORCA Level Manual
Techsys Manuals ORCA Manual Ver 4310
Help Files ORCA Menu structure
VFD Configuration Settings ORCA PDL-UD3 Settings 28-11-12
Presentations Orca sales presentaion
VFD Configuration Settings Orca Schneider ATV21 Settings
VFD Configuration Settings Orca Siemens MM440 Settings
Techsys Manuals Site Record
 
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