ESP32-Based Error Handling Prototype for Danfoss FC302 VFD

Farras Ammar Majid; Bustanul Arifin

doi:10.69693/jesa.v3i2.108

Authors

Farras Ammar Majid Universitas Islam Sultan Agung
Bustanul Arifin Universitas Islam Sultan Agung

DOI:

https://doi.org/10.69693/jesa.v3i2.108

Keywords:

Danfoss FC302, ESP32-S3, Modbus RTU, Thingsboard, IoT

Abstract

The used of Variable Frequency Drives (VFDs) in the mineral processing industry often encounters operational issues in the form of minor faults, such as torque limit (A12), overcurrent (A59), and frequency limit (A62) trips. The main challenge lies in the time required for manual troubleshooting, which requires technicians to visit the Motor Control Center (MCC) room, as well as restrictions on user access rights within the Distributed Control System (DCS). This study aims to design a prototype for remote monitoring and handling of minor faults in the Danfoss VLT AutomationDrive FC 302 using an ESP32-S3 microcontroller. The development method employed in this study is Research and Development (R&D), following the ADDIE model (Analyze, Design, Develop, Implement, and Evaluate). The system was developed using the ESP32-S3 as a Modbus master to retrieve operational parameters, including current, voltage, frequency, rotational speed, and alarm codes and descriptions, from the FC 302 VFD through the Modbus RTU protocol over an RS485 interface. The acquired data were subsequently transmitted to the ThingsBoard IoT platform via MQTT for real-time visualization using numerical values and trend graphs. In addition to monitoring, a remote reset feature was implemented using a Remote Procedure Call (RPC) mechanism over MQTT, allowing technicians to issue reset commands remotely through the ThingsBoard dashboard. The test results showed that the prototype displayed operational parameters, including voltage, current, frequency, and rotational speed (RPM), with a measurement error of 1% compared with the values shown on the Local Control Panel (LCP). The system also enabled real-time monitoring of fault status. The results indicated that the developed system had the potential to reduce the time required to handle minor faults, improve operational efficiency, and support decision-making for subsequent troubleshooting actions.

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