DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX 22kW IP55 Three Phase 500V Automation VFD

The DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX 22kW IP55 Three Phase 500V Automation VFD is a high-performance variable frequency drive designed for demanding industrial applications. This robust unit excels in providing precise motor control, energy efficiency, and enhanced operational reliability. Key advantages include its advanced control algorithms for optimal performance across various loads, a rugged IP55 enclosure for harsh environments, and a wide operating voltage range of 500V. The drive’s core features encompass integrated safety functions, extensive communication options, and a user-friendly interface for streamlined setup and monitoring.

Product Specifications

| Parameter              | Value                                      |

| :--------------------- | :----------------------------------------- |

| Model Number           | FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX     |

| Power Rating           | 22 kW                                      |

| Enclosure Protection   | IP55                                       |

| Phase                  | Three Phase                                |

| Voltage                | 500V                                       |

| Series                 | VLT® AutomationDrive FC 302                |

| Maximum Output Current | 45 A                                       |

| Efficiency             | Up to 98%                                  |

| Harmonic Distortion    | <5% with optional filters                  |

| Ambient Temperature    | -25°C to +50°C (derating above 40°C)        |

| Mounting               | Wall or floor mount                        |

| Braking Options        | Integrated brake chopper, optional resistors |

Core Features & Market Positioning

The DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX stands out in the competitive VFD market due to its focus on energy savings and intelligent automation. Its advanced VLT® Motion control platform ensures superior motor performance, reducing wear and tear and extending equipment lifespan. The drive’s flexible configuration options and compatibility with various motor types, including asynchronous and permanent magnet motors, position it as a versatile solution for diverse industrial needs. Danfoss's reputation for reliability and robust build quality further enhances its market appeal for critical applications where downtime is not an option.

Key Application Scenarios

This 22kW VFD is engineered for a broad spectrum of industrial automation tasks, including pump and fan control in HVAC systems, conveyor belt systems in material handling, and process control in manufacturing. Its IP55 rating makes it ideal for dusty or wet environments, such as food and beverage processing or outdoor installations. The 500V rating is particularly relevant for heavy-duty machinery and large industrial complexes requiring substantial power. Its precise speed regulation capabilities are crucial for applications demanding consistent torque and output, such as extruders or mixers.

Practical System Integration Guidance

Integrating the DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX involves careful consideration of power supply, motor connection, and control wiring. Ensure the input power supply (500V, three-phase) is within the drive's tolerance. Connect the motor using appropriately sized shielded cables to minimize electromagnetic interference (EMI). For control signals, use shielded cables as well, and ensure proper grounding according to Danfoss guidelines to prevent electrical noise and ensure safe operation.

Parameter programming is typically performed via the drive's local control panel or through PC-based software like Danfoss VLT® EnergyBox or MCT 10. Essential parameters to configure include motor data (nominal voltage, current, frequency, speed), application type (e.g., pump, fan, general purpose), and any specific control modes desired. For network communication, ensure the correct fieldbus adapter is installed and configured with the appropriate network address and settings.

Braking control, if required, can be managed internally via the brake chopper or externally with a braking resistor. Ensure the braking resistor is correctly sized for the expected braking duty to prevent overheating. Safety functions, such as Safe Torque Off (STO), require dedicated wiring to the relevant safety control system, adhering to EN ISO 13849-1 standards for functional safety.

Operation and Risk Mitigation

Safe operation of the DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX necessitates adherence to local electrical codes and Danfoss installation manuals. Before powering up, verify all connections are secure and correct. During operation, monitor for any unusual noises, vibrations, or error codes displayed on the control panel. Common fault codes, such as F001 (Overcurrent) or F002 (Overvoltage), typically indicate issues with motor load, power supply, or drive parameters.

Troubleshooting often involves checking motor winding insulation, verifying cable connections, and confirming that the drive's parameters are correctly set for the connected motor and application. Overheating issues might point to inadequate ventilation, an undersized braking resistor, or operating the drive beyond its rated capacity. Always ensure the drive is properly grounded to mitigate electrical hazards and prevent damage from transient voltages.

The integrated safety features, like Safe Torque Off (STO), are critical for risk mitigation during maintenance or emergency stops. STO functionality ensures that the motor cannot be inadvertently started, providing a high level of personnel protection. Regularly inspect the drive and its environment for signs of wear, damage, or contamination to proactively address potential issues and maintain safe, reliable performance.

Scalability & Long-Term Value

The DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX offers significant scalability and long-term value through its modular design and compatibility with broader automation ecosystems. Its support for various fieldbus protocols, including PROFIBUS, PROFINET, and EtherNet/IP, allows seamless integration into existing SCADA and DCS systems, enabling centralized monitoring and control. This facilitates data collection for performance analysis and predictive maintenance.

The drive’s ability to control a wide range of motor types, coupled with its energy-saving features, contributes to reduced operational costs and a favorable return on investment. For future expansions or upgrades, Danfoss provides a clear technology roadmap, ensuring that the FC 302 series can be part of evolving automation strategies, including the adoption of Industry 4.0 principles and IIoT initiatives.

Furthermore, Danfoss's commitment to product longevity and availability of spare parts ensures that the FC 302 remains a viable and supported solution for many years. This reduces the need for costly system-wide replacements and supports sustainable industrial practices.

FAQs

What is the maximum output current for the DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX?

The DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX has a maximum output current of 45 Amperes. This rating is critical for selecting appropriate motor and cabling.

This current capacity allows the drive to effectively manage motors up to its 22kW power rating. It ensures the drive can deliver sufficient power for demanding applications.

Understanding this parameter is vital for system design, ensuring the drive is correctly sized to prevent overload and ensure optimal performance.

How do I connect a braking resistor to the DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX?

Connect the braking resistor to the dedicated terminals marked "B1" and "B2" on the drive. Ensure the resistor's power and resistance values are compatible with the drive's specifications.

Refer to the drive's manual for precise wiring diagrams and recommended resistor types. Incorrect resistor sizing can lead to overheating or drive faults.

Proper installation of the braking resistor is crucial for effective energy dissipation during deceleration, preventing overvoltage and protecting the drive.

What are the primary application areas for this VFD?

This VFD is ideal for pumps, fans, conveyors, and general industrial machinery. Its robust design suits various manufacturing and processing environments.

The 22kW power and IP55 rating make it suitable for heavy-duty and exposed applications. It offers precise speed and torque control.

Key sectors include water treatment, material handling, food processing, and general automation where variable speed is beneficial.

How can I perform a parameter backup for the FC-302 drive?

Use the Danfoss MCT 10 software via a compatible interface to read and save the parameter settings. This allows for quick restoration if needed.

Alternatively, some models allow parameter copying between drives using the control panel or an optional parameter copy stick.

Regularly backing up parameters is a best practice for efficient troubleshooting and minimizing downtime during equipment replacement.

What is the meaning of the IP55 rating on this Danfoss VFD?

IP55 signifies the drive is protected against dust ingress and low-pressure water jets from any direction. This ensures durability in challenging industrial settings.

This rating makes the drive suitable for environments with significant dust or occasional moisture exposure. It enhances reliability in non-cleanroom applications.

The enclosure protects internal components from common environmental contaminants, reducing the risk of operational failure.

How does the Safe Torque Off (STO) feature work on this drive?

STO ensures the motor cannot generate torque by disabling the drive's output stage. It is a safety function for stopping motors safely.

This feature is activated via a dedicated safety input, typically linked to an emergency stop button or safety gate switch. It requires specific wiring.

STO prevents unexpected starts, safeguarding personnel during maintenance or in emergency situations, and meets safety standards.

What types of motors can be controlled by the DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX?

The drive supports asynchronous (induction) motors and permanent magnet motors. Its advanced control algorithms optimize performance for both.

Accurate motor data entry during commissioning is essential for maximizing efficiency and ensuring proper operation with any motor type.

This versatility allows users to select the most suitable motor for their application while leveraging the VFD's advanced control capabilities.

Can this VFD be integrated into a PROFIBUS network?

Yes, the DANFOSS FC-302P22KT5E55H2XGCXXXSXXXXAXBXCXXXXDX can be integrated into a PROFIBUS network with an optional communication adapter. This enables seamless data exchange and remote control.

The appropriate PROFIBUS adapter must be selected and correctly configured within the drive's parameter settings and the master system.

Integration with PROFIBUS allows for centralized monitoring, diagnostics, and control within an industrial automation network.

What is the typical energy saving potential with this VFD?

Energy savings of up to 50% or more are achievable, particularly in pump and fan applications. This is due to precise speed control matching motor output to demand.

By reducing motor speed, the drive significantly lowers energy consumption compared to traditional fixed-speed operation with mechanical throttling.

The VFD's high efficiency and intelligent control algorithms contribute to a reduced carbon footprint and lower operational electricity costs.

How is commissioning performed for this VFD?

Commissioning involves initial setup of power, motor, and control wiring, followed by parameter configuration using the keypad or software. Essential parameters include motor data and application type.

A thorough site acceptance test should verify functionality, safety features, and performance under actual operating conditions.

Proper commissioning ensures the drive operates safely, efficiently, and reliably, maximizing its benefits for the application.