Installation Instructions: VLT® HVAC Basic Drive FC 101 Control Card

Safety Instructions

Only Danfoss-authorised, qualified personnel are permitted to repair this equipment. Personnel must be familiar with the instructions and safety measures described in the VLT® HVAC Basic Drive FC 101 Service Manual.

[Warning] DISCHARGE TIME

The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not powered. Failure to wait the specified time after power has been removed before performing service or repair work, can result in death or serious injury.

• Stop motor.
• Disconnect AC mains and remote DC-link power supplies, including battery back-ups, UPS, and DC-link connections to other frequency converters.
• Disconnect or lock PM motor.
• Wait for the capacitors to discharge fully, before performing any service or repair work. The duration of waiting time is specified in Table 1.1.

High voltage can be present even when the warning LED indicator lights are off.

Table 1.1 Discharge Time

Additional Items Required

• FC 101 frequency converter
• MCT 10 Set-up Software. The software must be activated to support the Drive Software Upgrader feature. For information about activating the software, contact the Danfoss sales office.
• USB to RS-232 Converter
• The OSE file containing the appropriate control card software.

Obtaining the OSE File

Download the appropriate OSE file from the Danfoss Intranet site or get it from a Danfoss sales office. When contacting the Danfoss sales office, provide the frequency converter order number, listed as "P/N" on the frequency converter nameplate.

To download the OSE file from the Danfoss Intranet site:

1. On the Danfoss Intranet home page, select Danfoss Power Electronics > Marketing & Segments > Product Management > VLT® HVAC Basic Drive FC 101.
2. In the Software updates section, select the appropriate file:
   • P618 platform: Select the ZIP file with the following name: FC-101_vX_XX_OSE_P618. X_XX stands for the latest software version number. In the ZIP file, select the OSE file that matches the order number of the frequency converter, listed as "P/N" on the frequency converter nameplate.
   • P619 platform: Select the FC-101_P619_vX_XX_OSE.ose file.

Replacing the Control Card

Follow the instructions in the VLT® HVAC Basic Drive FC 101 Service Manual to disassemble the frequency converter and replace the control card.

Item Supplied

The following item is supplied:

• Control Card

Upload the Software

To upload the new software to the control card:

1. Connect the frequency converter to the computer where the MCT 10 Set-up Software is installed. For wiring instructions, see MCT 10 Set-up Software Operating Instructions, chapter Set-up of Communication.
2. Power up the frequency converter with the new control card installed. The LCP may show the alarm AL 038 Internal Fault. This is normal operation.
3. Start MCT 10 Set-up Software.
4. Configure the bus: In the Network group, right-click 'Serial' and select 'Configure Bus'. The 'Serial fieldbus configuration' dialog box opens, showing fields for Port, Baud rate, Parity, Stop bits, and Fieldbus scanning settings (Start scanning from address, Stop scanning at address).
5. Scan the bus for active drives: In the Network group, right-click 'Serial' and select 'Scan Bus for Active Drives'. The MCT 10 Set-up Software displays a 'Scanning for Drives' dialog box.
6. When the scanning is complete, the frequency converter appears under the 'Serial' item.
7. Right-click 'Serial' and select 'Drive Software Upgrader'.
8. In the 'Drive Software Upgrader' dialog box, click 'Browse'. In the prompt dialog box, select the appropriate OSE file and click 'OK'.
9. When an OSE file is selected in the 'Firmware file' field, the 'Start upgrade' button becomes active. Click 'Start upgrade'.
10. The 'Drive Software Upgrader' dialog box shows the 'Upgrading Software' step. [Important] Do NOT interrupt the process by closing this program or disconnecting the drive. Upgrading can take several minutes. A progress indicator shows data being sent (e.g., "Sending firmware X of Y").
11. When the software upgrade process is finished, the following message appears: "Your drive's software has been successfully upgraded".
12. To confirm successful software upgrade, open parameter 15-43 'Software Version' and check that the software version in the frequency converter is the same as the version in the OSE file. The control card now contains the appropriate software, and the frequency converter is ready for operation.