Danfoss FC-302P55KT5E20H2BGXXXXSXXXXAXBXCXXXXDX Frequency Converter

VLT AutomationDrive FC-302 High-Performance General-Purpose Convertitore di frequenza

Ordine n.: 131F7151

Model Segment-by-Segment Decoding

FC-302 P55K T5 E20 H2 B G XXXX SXXXX AXBXCXXXXDX

Specifiche elettriche principali

Potenza nominale: 55 kW

Ingresso: 3-phase 380-500 V AC

Corrente di uscita continua: 106 UN

Sovraccarico: 160 % for 1 min (high-overload mode)

Chassis frame size: C4

On-board components: DC link reactor, brake chopper, Class C3 RFI filter

Standard protocol: Modbus-RTU; no additional communication cards fitted

Funzione di sicurezza: Safe-Stop hardware terminal

Temperatura ambiente: Full-rating at 40 °C; derate above up to max. 50 °C

Key Configuration Summary

✅ 55 kW, 380-500 V, IP20 open-frame

✅ Built-in brake chopper, compatible with brake resistor

✅ Equipped with LCP-102 graphical operator panel

✅ Class C3 industrial EMC filter, integrated DC-link reactor

❌ No Profinet / EtherNet-IP or other fieldbus cards; can be retrofitted via A/B slots

❌ No MCO motion-control card

Applicazioni tipiche

Tifosi, pompe, estrusori, trasportatori, miscelatori, mandrini di macchine utensili. Supports closed-loop vector, open-loop and servo modes; suitable for applications with regenerative braking energy.

Spare-part & Replacement Hints

1. If brake chopper is not required: change B to X; order number will differ.
2. For Profinet: fit option AL (MCA120); for EtherNet-IP: fit option AN (MCA121).
3. Same power rating without panel: replace G with X, model becomes FC-302P55KT5E20H2BXXXXSXXXXAXBXCXXXXDX

FC-302P55KT5E20H2BGXXXXSXXXXAXBXCXXXXDX

55 kW / 380-500 V IP20, chopper di frenatura integrato, Class C3 EMC filter, LCP102 graphical Chinese panel; no communication card, no MCO motion-control card.

1. Essential Wiring Notes (power OFF; allow DC-bus minimum 20 min discharge time)

Main-Power Circuit

Cable sizing suggestion for 55 kW: power-supply cable ≥16 mm²; motor cable ≥16 mm²; brake-resistor cable ≥10 mm².

Control-circuit mandatory connections (fault or drive-inhibited if ignored)

1. STO Safe-Torque-Off: short terminal 12 A 37. Without short-circuit, inverter output is inhibited. For external safety circuits, wire safety contacts in series.
2. Coast-to-stop terminal 27 is factory-active: if coast-to-stop is not needed: set parameter 5-12 = 0 (nessuna funzione). To retain coast-to-stop: corto 12-27.
3. Terminali 12/13: internal +24 V output (max. 200 mA); terminal 20 = digital-input common ground.
4. Analogue inputs: 53 (0-10 V voltage); 54 (4-20 mA). Hardware dip-switches select voltage / modalità corrente.
5. Terminali 68/69: RS485 Modbus-RTU; 68 = A, 69 = B.

Example terminal-based start-stop logic

18 (DI): Inizio (parameter 5-10 = Start)

19 (DI): Inversione (parameter 5-11 = Reverse)

54: 4-20 mA frequency reference

Relè 01-02-03: configurable for Run / Fault signalling.

Practical advice: power-up without motor first and check I/O status. For commissioning, decouple motor coupling and test at low speed.

2. Factory-reset procedures

Method 1: Recommended Initialisation (retains run-hours and communication settings)

1. Main Menu → 14-Special Functions → 14-22 Modalità operativa
2. Selezionare 2 Initialisation → press OK
3. Disconnect main supply; wait until panel fully dark; re-apply power
4. A80 “Drive initialised” informational message appears (not a fault); press Reset.

Method 2: Full Hard Initialisation (all parameters cleared)

1. Spegnimento; wait for panel to extinguish.
2. Hold Status + Main Menu + OK keys together, then switch-on main supply.
3. Keep holding for 5 s then release. Full factory reset completes on power-on.

Parameter backup tip: 0-50 LCP Copy → select 1 Copy all parameters to LCP. The panel can store parameters for download to identical units. Do NOT copy parameters across different power ratings.

3. Key Commissioning Parameters (unit fitted with built-in brake chopper)

Brake-chopper warning: short-circuited or under-rated low-ohm resistors will destroy the brake chopper. Always populate 2-11 & 2-12 for thermal protection.

4. Incoming-inspection checklist for second-hand FC-302-55 kW (C4 frame)

Ispezione visiva

1. PCBs: check for water ingress, corrosion or burn marks. Examine cooling air-path and fan for heavy dust. Manually spin fan for free rotation, nessun attaccamento.
2. Terminali di potenza: check for arcing / burn damage. Verify nameplate model string: FC-302P55KT5E20H2B G……, order No. 131F7151.
3. Test all keys on LCP102 graphical panel.

Power-off static multimeter tests (full DC-bus discharge mandatory)

1. Rectifier stage: measure forward / reverse diode drop L1/L2/L3 against +DC /-DC.
2. IGBT stage: measure U/V-W versus +DC, -DC. Three-phase readings must be well-matched; large deviation indicates module failure.
3. Brake circuit: test BR+ / BRchopper transistor for short-circuit breakdown.
4. Confirm no control-terminal-to-earth short-circuits.

No-load power-on test (motor disconnected)

1. Accensione, verify no active faults. Read run-hours 15-00; inspect fault-history log 15-30.
2. Perform factory reset then AMA auto-tune. Run 0-50 Hz no-load; check three-phase output-voltage balance. Unbalance points to IGBT / drive-board damage.
3. Brake-chopper functional test: set short deceleration time to induce regeneration; observe DC-bus voltage rise and brake activation.
4. STO test: aprire 12-37 link → STO fault appears; re-short to clear.
5. Full point-by-point test for all digital inputs and relay outputs.

Motor-coupled test

Disconnect mechanical load. Run motor, verify balanced 3-phase current, no vibration or abnormal noise. High-overload 160 % / 1 min test: exercise with caution.

Common failure items: fan wear, current-sensor drift, brake-chopper damage, STO safety-circuit faults, aged electrolytic capacitors. Typical alarms: AL13 Over-current, AL16 Over-voltage, AL29 Heatsink Over-temp, AL-8 STO fault.

5. Domestic Chinese-manufactured alternative selection (55 kW high-performance vector, 380-500 V)

FC-302 features: flux-vector control, asynchronous & PMSM support, built-in DC-link reactor, chopper di frenatura integrato, expandable fieldbus cards, STO Safe-Torque-Off. Verify feature-match before substitution.

Substitution caveats:

1. Original FC-302 has integrated DC-link reactor. Many domestic alternatives omit this; add external DC-reactor for sites with high-harmonic-grid conditions.
2. Original unit includes built-in B-option brake chopper. Confirm alternative unit has on-board brake chopper or plan for external brake unit.
3. STO Safe-Torque-Off may be an option card for some domestic drives; do not overlook for safety-related machinery.
4. Comunicazioni: base unit has no fieldbus card (MCA120 Profinet retrofittable). Confirm bus-interface requirements for replacement drive.
5. Quick fault-troubleshooting guide
6. Drive will not run; alarm AL-8: inspect STO loop (12-37 cortocircuito / safety-contact continuity).
7. Coast-to-stop-related alarm: either short 12-27 or set parameter 5-12 to no-function.
8. Deceleration over-voltage AL16: ① extend deceleration ramp time; ② confirm brake chopper enabled; ③ validate brake-resistor value & potenza nominale.
9. AL29 Heatsink Over-temperature: clean dust build-up, inspect fan, reduce carrier-frequency, limit sustained ambient temperature ≤40 °C.

Danfoss FC-302P55KT5E20H2BGXXXXSXXXXAXBXCXXXXDX Full Detailed Specifications

Serie: VLT® AutomationDrive FC-302; Ordine n.: 131F7152 (B = built-in brake chopper, G = LCP102 graphical Chinese panel)

Dimensioni del telaio: C4; IP20 cabinet-mount open-frame; 3-phase 380-500 V; 55 kW / 75 HP; integrated DC-link reactor, Class C3(A2) RFI filter, chopper di frenatura integrato; no A/B/C/D option-cards; standard uncoated PCB.

1. Main Supply Input Ratings

2. Uscita motore: Energia, Attuale & Sovraccarico (C4 frame, 55 kW)

Application guidance: High-overload for extruders, miscelatori, montacarichi. Normal-overload for fan-pump quadratic-torque loads.

3. Brake-circuit Specifications (B-option built-in brake chopper)

4. Safety-related Functions
5. STO Safe-Torque-Off (hard-wired terminals 12-37), PL d / SIL 2 rating. Hardware-level IGBT gating inhibition; cannot be overridden by software.
6. Coast-to-stop via digital-input terminal 27.
7. Motor thermal-protection: ETR electronic thermal relay; PTC / KTY84 temperature-sensor inputs.
8. I/O Interface Specifications (Control Board)

Ingressi digitali DI (6 channels total)

Logic level 24 V, PNP / NPN compatible. Input impedance ~ 2 kΩ. On-board 24 V supply max. 200 mA.

Terminali: 18, 19, 27, 29, 32, 33; common reference terminal 20.

Uscite digitali DO (2 open-collector channels)

24 V, maximum 40 mA sink-current.

Uscite relè (3 relè)

01-02-03: AC 250 V, 2 UN; 04-05-06; 07-08-09. Configurable for Run, Colpa, Alarm signalling.

Analogue Inputs AI

AI53: 0-10 V voltage input.

AI54: hardware-dip-switch selectable 0-10 V / 4-20 mA. Impedenza di ingresso: voltage-mode 10 kΩ; current-mode 200 Ω.

Analogue Output AO

AO42: 0-10 V, max. 1 mA. Can output frequency, motor-current, torque etc.

Communications Interfaces

Standard hardware: RS485 Modbus-RTU (terminals 68 A, 69 B).

Slots A/B/C/D empty as-delivered. Retrofit-capable options: MCA120 (Profinet), MCA121 (EtherNet-IP), MCA111 (DeviceNet), MCO305 motion-control card.

6. Dimensioni meccaniche, Peso & Valutazioni ambientali (C4 frame IP20)

Condizioni operative ambientali

Operating ambient: -10 °C ~ +40 °C full power. Derate output > 40 °C; absolute maximum operating temperature 50 °C (derated).

Magazzinaggio & temperatura di trasporto: -25 °C ~ +65 °C.

Altitudine: full rating ≤ 1000 m above sea-level; derate 1 % output power per additional 100 m elevation.

Rivestimento PCB: XXXX = standard uncoated PCB. Specify coated-PCB variant for corrosive-gas environments.

7. Perdita di potenza & Efficienza

Total power loss at nominal load: approx. 1020 W.

Efficienza: 98 % at rated operating point.

8. Pannello operatore & Software

LCP102 graphical multi-language Chinese-capable keypad-display (G-option). Parameter copy-backup feature; panel-extension-cable support for remote mounting.

Firmware identifier SXXXX = latest factory production firmware.

Commissioning software MCT-10: PC-connected upload / download parameters, fault-log recording.

9. Hardware Protection & Alarm Events

Sovracorrente, over-voltage, sottotensione, earth-fault, output short-circuit, heatsink over-temperature, sovraccarico del motore, STO Safe-Stop, brake-resistor over-temperature, fan-fault, communication-fault.

10. Full Model-code Re-check

FC-302 P55K T5 E20 H2 B G XXXX SXXXX A X B X C XXXX D X

FC-302: product family

P55K: 55 kW power

T5: 3-phase 380-500 V supply

E20: IP20 open-frame construction

H2: Class C3 RFI filter

B: Chopper di frenatura integrato (key feature of this unit)

G: LCP-102 graphical operator panel

XXXX: uncoated standard PCB, no auxiliary-power options

SXXXX: factory-standard firmware

ASCIA / BX / CX / DX: slots A/B/C/D empty, no fieldbus or motion-control cards fitted.

Nota importante: Part-number 131F7151 corresponds to variant without brake-chopper and without operator-panel (B=X, G=X). The present full-feature unit uses order-number 131F7152 (B+G options).