DOKUMENTIN NIMI / DOCUMENT NAME

Vacon-Configuration-Loader-System-User-Guide-
Vacon Oyj V06.docx
TALLENNETTU/SAVED PAINOS / REVISION TEKI / PREPARED
2014-06-27 1.1 Jere Syvnne
Timo Kujansuu

M-Platform Software

Vacon Configuration Loader System

User Guide

COMPANY CONFIDENTIAL
This document contains Vacon proprietary information.
This is an unpublished work subject to trade secret and copyright protection.

This document contains information which is maintained in confidence by

Vacon as a trade secret. In addition, the information may be the subject
of patent applications in the Finland and foreign countries.

THE DISCLOSURE OF THIS INFORMATION OUTSIDE THE COMPANY

WITHOUT AN APPROPRIATE SIGNED CONFIDENTIALITY AGREEMENT
MAY FORFEIT THE COMPANYS TRADE SECRET AND PATENT RIGHTS.
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REVISION
HISTORY:
REV DATE/ NOTES & CHANGES
PREPARED
A 2013-11-11 / First version
Arvi Lehesvuo
0.1 2013-11-14 Combined VCS, VCL and MES user guides prepared by Arvi
/Jere Syvnne Lehesvuo, Henri Juntunen and Sami Rikala
0.2 2013-12-09 Fixed formatting
/Jere Syvnne
0.5 2013-12-09 Fixed formatting
Timo Kujansuu
1.0 2013-03-27 Document updated based on the piloting feedback
Timo Kujansuu
1.1 2014-06-06 Document updated based on general feedback
Timo Kujansuu

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Table of content:
1 INTRODUCTION ................................................................................................................ 4
1.1 PURPOSE AND SCOPE ........................................................................................................ 4
1.2 DEFINITIONS, ACRONYMS AND ABBREVIATIONS................................................................ 4
1.3 WHAT IS VACON CONFIGURATION LOADER SYSTEM?........................................................ 4
1.4 VCS AND VCL TOOL SUPPORT BY VACON FACTORIES ..................................................... 5
2 PREPARATIONS ................................................................................................................ 6
2.1 SERVICE POLICY............................................................................................................... 6
2.2 ORDERING CORRECT SPARE PARTS FROM VS TOOL ............................................................ 6
2.3 SALES CODE FOR "NOT PROGRAMMED" VACON 100 CARDS .............................................. 7
2.4 SALES CODE FOR TAXATION PURPOSES .............................................................................. 7
2.5 INSTALLATION OF VACON CONFIGURATION LOADER ......................................................... 7
2.6 ACCESS TO VCS AND MES SYSTEMS ................................................................................ 7
3 PROCESS ............................................................................................................................. 8
4 VACON MANUFACTURING EXECUTION SYSTEM (MES) QUICK GUIDE ............ 9
4.1 LOGGING INTO MES SYSTEM ............................................................................................ 9
4.2 HOW TO IDENTIFY WHEN IS NEEDED TO USE THE MES SYSTEM ......................................... 10
4.3 UNACHIEVED ACTION TO RELEASE THE SERIAL NUMBER INFORMATION ............................ 11
4.4 FINDING POWER MODULE SERIAL NUMBER WITH THE DRIVE SERIAL NUMBER .................... 11
5 VACON CONFIGURATION SERVER (VCS) QUICK GUIDE..................................... 13
5.1 LOGIN TO VACON SALES TOOL ....................................................................................... 13
5.2 OPEN VACON CONFIGURATION SERVER .......................................................................... 13
5.3 LOAD CONFIGURATION ................................................................................................... 14
6 VACON CONFIGURATION LOADER (VCL) QUICK GUIDE ................................... 16
6.1 STARTING VACON CONFIGURATION LOADER .................................................................. 16
6.2 OPEN CONFIGURATION PACKAGE..................................................................................... 16
6.3 UPDATING THE CONFIGURATION ..................................................................................... 16
6.4 ERROR SITUATIONS IN VACON CONFIGURATION LOADER ................................................ 18
6.5 DEBUGGING ................................................................................................................... 18
7 VERIFYING THE DRIVE CONFIGURATION.............................................................. 19
7.1 PREPARATION................................................................................................................. 19
7.2 VERIFYING THE DRIVE TYPE CODE .................................................................................. 19
8 GENERAL TEST INSTRUCTIONS ................................................................................ 20
8.1 DC BUS TESTING WITHOUT MOTOR .................................................................................. 20
8.2 DRIVE TESTING WITH AC SUPPLY .................................................................................... 20

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1 Introduction
1.1 Purpose and Scope

This document describes the Vacon Configuration Loader System and gives instructions
for using the Vacon Configuration Loader (VCL), Vacon Configuration Server (VCS) and
Manufacturing Execution System (MES) to configure programmable VACON 100 spare
parts. The document does not take into consideration the content of the data loaded with
VCL application.

1.2 Definitions, Acronyms and Abbreviations

VCL Vacon Configuration Loader

VCS Vacon Configuration Server
SFC Shop Floor Control (equals to serial number of the drive or power module)
MES Manufacturing Execution System
Black Mamba CAB-USB/RS422 adapter cable
Shop Order ID Identifies each shop order in MES (for each sales order position)

1.3 What is Vacon Configuration Loader System?

Vacon Configuration Loader System is a set of tools for updating drive configuration after
replacement of a power board or measurement board. The system is intended for Vacon
internal use only.

The system consist of the following components:

Vacon Configuration Loader (VCL) Windows application
Vacon Configuration Server (VCS) application in Vacon Sales Tool
Manufacturing Execution System (MES)

In addition the following tools are needed:

A basic repair tool set
Adapter cable CAB-USB/RS422
A Laptop
An external 0,5-1,0kV power supply

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NOTE!
VCS and VCL tools are not compatible with VACON 100 first generation drives which
have been manufactured before,

- Vacon 100 MR4-6 06/2012

- Vacon 100 MR7-9 07/2012

If power module P.ID ends to -MFP1B then drives are VACON 100 HVAC first
generation drives.

1.4 VCS and VCL tool support by VACON factories

VCS and VCL tool support function in different VACON factories:

Factory VCS VCL PRODUCT NOTE!

Vacon Suzhou - - Vacon100 Release day by end of 2014
Vacon Chambersburg - - Vacon100 Release day by end of 2014
Vacon Italy - - Vacon100X Release day by end of 2014
Vacon Finland x x Vacon100

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2 Preparations
2.1 Service Policy

Service Policy for VACON 100 is available on extra.vacon.com page (Vacon Service -->
Warranty --> Title: Vacon100 Products

2.2 Ordering correct spare parts from VS tool

VACON 100 product family uses the same range of spare parts. Vacon Configuration
Loader system can be used to configure spare parts, which have not been programmed
earlier. These spare parts are available for ordering in Vacon Sales Tool and they can be
identified with the suffix -EMPTY and description -not programmed.

The spare parts are available in the Options and Spares NEW product menu in Vacon
Sales Tools configurator. Make the following basic selections:
Product Range: Vacon0100 Parts
Category: SPR- Spare Parts
Frame: All Frame

To find the type -EMPTY parts in the Part Selections tab start typing cmb0 to filter
the options in the Part Customization drop-down menu. See picture below.

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2.3 Sales code for "not programmed" VACON 100 cards

SPR-CMB01790-EMPTY; Description: Gen2 240/500V MR07-MR09 Measurement board

SPR-CMB04704-EMPTY; Description: 12A 500V Gen2 MR04 Power board

SPR-CMB04706-EMPTY; Description: 5,6A 500V Gen2 MR04 Power board
SPR-CMB04707-EMPTY; Description: 12A 240V Gen2 MR04 Power Board
SPR-CMB04708-EMPTY; Description: 4A 240V Gen2 MR04 Power Board

SPR-CMB04709-EMPTY; Description: 31A 500V Gen2 MR05 Power board

SPR-CMB04710-EMPTY; Description: 31A 240V Gen2 MR05 Power board

SPR-CMB04711-EMPTY; Description: 61A 500V Gen2 MR06 Power Board

SPR-CMB04712-EMPTY; Description: 62A 240V Gen2 MR06 Power Board

NOTE! These spare part cards are only compatible with VACON 100 second generation
drives

2.4 Sales code for taxation purposes

The taxation price must be added to ALL orders when you are invoicing the end
customer. This is defined by the law.

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WSC-CONF-FLOW-FIX; Description: VACON 100 FLOW power board configuration

WSC-CONF-HVAC-FIX; Description: VACON 100 HVAC power board configuration
WSC-CONF-V100-FIX; Description: VACON 100 power board configuration

2.5 Installation of Vacon Configuration Loader

Run Vacon Configuration Loader install.exe. This tool can be found from Vacon.com
page. This installer will also install Microsoft .NET 3.5 Framework SP1, Moxa UPort USB
to Serial drivers & Silicon Laboratories USB to Serial drivers if needed.

Application can be uninstalled by running uninstall.exe from application installation folder

or by removing it through Windows Control Panel\All Control Panel Items\Programs and
Features.

2.6 Access to VCS and MES systems

Contact to vbas.support@vacon.com and request access to Vacon Configuration Loader

System. Mention that access to Vacon Configuration Server in Vacon Sales and
Manufacturing Execution System are required.

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3 Process

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4 Vacon Manufacturing Execution System (MES) Quick Guide

To be able to retrieve drive and power module related data from MES there are certain
procedures to complete before and after the operation. This instruction walks through the
required steps for successfully preparing the target drive and power module information
in MES.

Good to know:
Steps must to be repeated for both, the drive and the power module serial
numbers (=SFCs in MES)
Archiving is done every night so if the loading is not completed the same day as
SFC was unarchived, it must be unarchived again the next day.
Unarchiving must be done using the Shop Order number instead of SFC

4.1 Logging into MES System

Open MES URL in browser

Address: http://visiprise:7101/manufacturing/login?SITE=VAASA

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4.2 How to identify when is needed to use the MES system

1. Do you have drives serial number available?

- Location: Top of the drives (near by the fastening points)

2. Do you have power unit serial number available?

- Location: Top of the power unit cover (behind the control unit)

NOTE!
- If you answered "NO" to step number 1 and/or 2 then you must use MES system
or else you cannot proceed to forward.

- If you answered "YES" to step number 1 and 2 then you dont need to use MES
system in any phase, skip to chapter 5.

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4.3 Unachieved action to release the serial number information

All drives which have older (from manufactured day) than 3 month must be do
"unarchive" action

1. Open from MES: Production Advanced Archive

2. Change Activity to Unarchive
3. Insert SFC number and click OK button

4.4 Finding power module serial number with the drive serial number

1. Open As Built Summary

2. Insert SFC number and click Search button
3. Click SFC number on the search result and a popup will open

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4. Browse the list until you find the power module item row and expand it until you
get to the Actual component level. Serial number of the power module is shown
as on the example (SFC Number).

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5 Vacon Configuration Server (VCS) Quick Guide

5.1 Login to Vacon Sales Tool

1. Go to http://www.intra.vacon.com/ and click Vacon Sales on the Quick links:

2. Click link VaconSales and login with your username and password

5.2 Open Vacon Configuration Server

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5.3 Load configuration

1. Enter drive serial number,

2. Enter power module serial number
3. Enter spare part board serial number from new EMPTY spare part board (last 5
digits from the card data matrix).

Example from MR6 power board data matrix label

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4. Click Load Package button in the bottom right corner.

5. Save Package to your computer.

6. Vacon Configuration Server informs when download is completed.

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6 Vacon Configuration Loader (VCL) Quick Guide

Vacon Configuration Loader (VCL) application is a tool for programming VACON 100
power boards and measurement boards to configure the drive back to its as-delivered
state.

6.1 Starting Vacon Configuration Loader

1. Open the Vacon Configuration Loader tool from the the Start menu or from the
desktop icon.

6.2 Open configuration package

Select *.vcl file and open it with one of the following methods.
1. Double click the file
2. Drag & drop the file to VCL window
3. Click folder icon on VCL window and browse for the file

After selecting a functioning *.vcl file the folder icon has a green check-mark on top of it.
The complete file path appears as a tooltip when a mouse pointer is held over the file
name.

6.3 Updating the configuration

1. Start the update by clicking the Update button.

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2. During update, progress bar will show status of the process.

Note that the communication protocol used by the VCL has a long communication
timeout. To ensure that the protocol layer communication is closed properly,
please wait patiently until the process finishes. Apply the same patience even if
e.g. wrong serial port was selected in the first place.

3. Status view will indicate whether the update process was successful or failed.

In case the update failed identify the cause of failure (see chapter below) and try
again. The status view can be closed by clicking the OK button. To close the
application click Cancel button.

NOTE!

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Unsuccessful programming may damage the card and this causing that re-
programming is not possible to do anymore

6.4 Error Situations in Vacon Configuration Loader

Following table describes the possible error situations and corresponding messages.
Error message
Protocol layer error occurred: <error text>
Working route not found!
File invalid!
File version not supported!
Failed to init connection to device
Communication errors occurred while
updating spare part
Selected file is incompatible with the spare
part.
Description
Protocol layer error usually initiates from
physical serial port connection failure.
Check the cabling and communication to
the drive.
VCL could not detect device part which is
compatible with the selected .vcl file.
Make sure correct *.vcl file is used.
File is not compatible with VCL application.
VCL doesnt support the selected .vcl-file
version. Update VCL application.
Serial port cable is not connected to the
device, wrong serial port is selected or
there is some problems with the physical
serial port connection. Check the cabling
and communication to the drive.
Some of the .vcl-file batches failed to
complete. Make sure that the
communication to the drive is working and
try again. If the problem persists send the
debugging log to vbas.support@vacon.com
Drive or spare part serial number doesnt
match. Make sure that
1. Correct file matching the drive and
the spare part board is used.
2. The file was created with the correct
drive and spare part serial number.

6.5 Debugging

In case of VCL faces some unexpected error situations a debug log can be exported for
VCL developers by clicking Export log file from bottom left corner of the window. Log is

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encrypted for security purposes, so it cannot be opened by VCL users. Send the file to
vbas.support@vacon.com for further investigations.

7 Verifying the Drive Configuration

7.1 Preparation

1. After completing the power unit programming exit the programming tool, start
Vacon Live and connect to the programmed drive

2. Backup original parameters as necessary

3. Reset the drive to factory default values by using the parameter Restore Factory
Defaults

7.2 Verifying the Drive Type code

1. Vacon Live : Select Information from the Drive pull-down menu

2. Verify that the Frequency Converter Label data matches the drives Type code
Stickers

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8 General test instructions

8.1 DC bus testing without motor
1. Check the testing instructions from drives service manual

8.2 Drive testing with AC supply

1. Use a current clamp meter suitable for frequency converter output current
measurement
2. Connect the main cables, motor cables and earth connections
3. Switch on the AC supply
4. Set the correct parameters from the motor name plate, e.g. motor name plate
values, current limit, minimum frequency, maximum frequency, acceleration time,
deceleration time
5. Run the motor without load between minimum and maximum frequency and
measure the output current with current clamp meter. Compare the value on the
current clamp meter to the unit's monitoring value of the drive. The current clamp
meter may not be accurate at low frequencies
6. Load the motor to the nominal value, if it is possible, and compare the value on
the current clamp meter to the monitoring value of the drive
7. Check that the fan operates properly. Follow the unit temperature from the
monitoring page

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