Danfoss VLT 2800 Replacement: VLT Midi Drive FC 280 – Adapter Plates, Terminal Differences, PROFIBUS and Variants with No Successor (DeviceNet, Single-Phase with Brake Chopper)
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The Danfoss VLT 2800 has been discontinued, and according to the manufacturer its successor is the VLT Midi Drive FC 280. See what carries over unchanged (plug-in terminals, RS485, adapter plates) and what does not: DeviceNet, single-phase versions with a brake chopper and the FC profile in PROFIBUS.
Danfoss VLT 2800 replacement: VLT Midi Drive FC 280 - adapter plates, terminal differences, PROFIBUS and variants with no successor (DeviceNet, single-phase with brake chopper)
When a drive that has quietly run a conveyor, pump or fan for years fails in the cabinet and there is no spare, the search for a replacement begins. A frequency converter supplies an induction motor with voltage of adjustable frequency, which lets it change the motor speed, soften starts and match the speed to the needs of the process. It is used on conveyors, in pumping stations and ventilation systems and on packaging machines, and it is controlled by a PLC through I/O signals or over a fieldbus.
The Danfoss VLT 2800 has been discontinued, so maintenance teams have two options: buy a successor drive or get a used or refurbished VLT 2800 that has been tested before installation. In both cases the downtime depends on what fits unchanged after the swap, that is the mounting holes, the control wiring and the communication with the controller. If the system includes an industrial network or braking, the replacement is no longer a simple one-to-one swap and has to be planned before the order is placed.
According to the manufacturer, the VLT Midi Drive FC 280 is the successor to the VLT 2800, and the manufacturer gives the older model's non-compliance with EU RoHS 2.0 as the main reason for ending its production. The FC 280 is said to be compatible with the VLT 2800 in terms of interfaces, cable lengths and parameterization software, which makes it easier to fit into existing cabinets. The power range is 0.37-22 kW at 3x380-480 V, 0.37-3.7 kW at 3x200-240 V and 0.37-2.2 kW at 1x200-240 V, so the new drive comes in both three-phase and single-phase versions. The supply version therefore has to be selected to match the nameplate of the old drive.
Mounting in the existing enclosure - adapter plates and dimensions
An adapter plate lets you mount the FC 280 in place of the VLT 2800 without drilling new holes, which saves a lot of work in a densely packed cabinet. Its order code depends on the enclosure size of the old drive, so the size has to be determined before ordering.
VLT 2800 → FC 280 adapter plates
| Adapter plate | Application |
|---|---|
| 132B0363 | adapter plate for VLT 2800 enclosure size A |
| 132B0364 | adapter plate for VLT 2800 enclosure size B |
| 132B0365 | adapter plate for VLT 2800 enclosure size C |
| 132B0366 | adapter plate for VLT 2800 enclosure size D |
The plate solves the hole problem, but the dimensions of the two drives are not identical, so before ordering it is worth comparing the FC 280 dimensions from the manufacturer's manual with the space in the cabinet, especially above and below the drive where the cable ducts run. The FC 280 has a degree of protection of IP20, and the IP21/NEMA1 version is obtained with an external option kit.
Control terminals and RS485
The FC 280 control terminals are plug-in, which reduces the risk of wiring errors during replacement because the wires can be prepared and labelled before the terminal block is plugged in. The RS485 interface stays on the same terminal numbers: in the FC 280 these are terminals 68 (P, TX+, RX+) and 69 (N, TX-, RX-), and the manufacturer marks them as fully compatible with the VLT 2800, so the serial bus wires are moved over unchanged. Two terminals change their number: terminal 20 of the VLT 2800 is replaced in the FC 280 by terminal 55, and terminal 60 by terminal 54, so before disconnecting the old drive the wires need to be labelled so that they end up in their new places after the replacement. Terminals 67 and 70 do not exist in the FC 280, and the manufacturer notes that they are not needed with PROFIBUS in the FC 280.
PROFIBUS and the MCM 103 memory module
A PROFIBUS network is where the replacement stops at the controller configuration, because after replacing a VLT 2800 with PROFIBUS by an FC 280 the configuration parameters (GSD file) have to be changed in the bus masters, that is in the PLCs. The MCM 103 memory module (code 132B0466) emulates the PROFIBUS of the VLT 2800 drive and makes it possible to avoid changes to the GSD configuration, and in addition it allows a full backup of the drive (software and parameters). The MCM 102 module (code 132B0359) contains parameters and firmware, but without VLT 2800 PROFIBUS compatibility, so it is not suitable for this purpose.
The emulator is activated in several steps. After connecting the module to the drive, in parameter 14-70 Compatibility Selections you select option [12] VLT 2800 3M or [14] VLT 2800 12M, and then switch the power off and on so that the drive starts up as a VLT 2800 PROFIBUS 3M or 12M. Parameter 31-40 Memory Module Function must not be set to [0] Disabled, because the module will then not work as a PROFIBUS converter.
What to watch for during replacement
The differences below concern items that do not carry over unchanged or have to be ordered separately, so it is worth checking each of them before the old drive is removed.
- DeviceNet in the VLT 2800 - the FC 280 has no DeviceNet communication option, so according to the manufacturer a VLT 2800 with a DeviceNet option cannot be replaced by it. For such an installation the solution has to be worked out separately, before removal.
- Single-phase VLT 2800 with brake chopper - there is no equivalent among the FC 280. The single-phase FC 280 has no brake chopper, whereas in all three-phase versions it is built in. Check whether the drive brakes with a resistor, because in the single-phase version such an arrangement will not carry over.
- Adapter plate - it is ordered as a separate accessory for the existing VLT 2800 holes. Without the plate you have to drill new holes or modify the mounting plate.
- LCP panel - in the VLT 2800 the panel is built in, and in the FC 280 it is not. The numeric LCP 21 (132B0254) is not supplied with the drive, and the graphical LCP 102 (130B1107) requires the 132B0281 adapter. The panel is ordered together with the drive so that parameters and alarms can be read on site after installation.
- VLT 2800 accessories and power options - VLT 2800 accessories are not compatible with the FC 280, and VLT 2800 power options are not always compatible. Do not assume, therefore, that the equipment of the old drive will be reused.
- FC profile in PROFIBUS - it is not compatible between the VLT 2800 and the FC 280. A controller that communicates using the FC profile needs to be checked and possibly reprogrammed.
- MCM 103 - it is ordered separately and is not part of the FC 280 delivery, and it needs FC 280 firmware version 1.50 or higher to work. Before installation you therefore have to check the software version of the new drive.
- PROFIBUS connector position - in the FC 280 it is at the top of the drive, whereas in the VLT 2800 PROFIBUS is brought out on terminals 68/69 at the bottom. The bus cable has to be routed differently and its length checked.
- Parameter conversion - the converter transfers only the current values, not the default values or parameter attributes. After conversion the most important parameters, especially those changed in the old drive, therefore have to be checked manually.
In addition there are practical checks: compare the nameplates and markings of the old and new drive, visually inspect the connectors and terminals, and for used units request documentation of origin. It is also worth testing the drive before installation rather than only in the cabinet.
How the VLT 2800 to FC 280 replacement proceeds
A suitable order of actions reduces the risk of finding a missing item after removal. The manufacturer recommends checking the order codes in the configurator, because not every VLT 2800 code has a direct equivalent among the FC 280 codes (special configurations). Danfoss provides a tool that converts a VLT 2800 code into an FC 280 code, and the result has to be verified in the Configurator Drive in the Danfoss shop.
- Write down the VLT 2800 code from the nameplate and back up the parameters and settings, including the position of the termination switches.
- Check the installed communication option: DeviceNet means there is no equivalent, and PROFIBUS means a decision about the MCM 103 module.
- Convert the code to an FC 280 code and verify it in the configurator.
- Select the supply version and accessories: the LCP panel, the adapter plate, the MCM 103 and the IP21/NEMA1 kit, if needed.
- Mount on the adapter plate and connect the wires, moving terminal 20 to 55 and 60 to 54.
- First start-up, loading the parameters and setting the communication option.
- Test the inputs and outputs and the communication with the controller, and finally complete the documentation.
Before ordering, three things therefore need to be checked: whether the old drive has DeviceNet or is a single-phase version with a brake chopper, what the enclosure size is, because the adapter plate code depends on it, and whether the PROFIBUS network is to remain unchanged in the controller. The order then includes the adapter plate, the LCP panel and, if needed, the MCM 103, and what remains to be planned is moving the wires to terminals 55 and 54 and the space in the cabinet.
Enetiv works in industrial automation from two sides: we supply parts and we repair them. We carry PLC controllers, inverters, HMI panels and external devices as new, used and refurbished, including brands such as Allen-Bradley (Rockwell Automation), Siemens, Schneider Electric, Bosch Rexroth and ABB. We also specialize in end-of-life (EOL) parts and service, including older-generation and unusual components. We diagnose and repair inverters, servo drives, I/O modules and controllers, and we also service motors and servomotors. Contact us at enetiv.com/kontakt.