Vacon 100 FLOW Application

The motor cable current exceeds the hardware or software limits (>4*I H). This can be caused by a sudden heavy load increase, a short circuit in the motor cables, an incorrectly matched motor type, or improper parameter settings. If left unresolved, it can damage the motor or drive components.

A malfunction in the supply voltage or issues with input fuses/cables are detected. The supervision for this fault requires a minimum load of 10-20% to function correctly. This fault indicates a problem with the incoming power supply to the drive, which can cause motor and drive instability.

The feedback value for PID controller 1 is outside the configured supervision limits (P3.13.6.2 and P3.13.6.3) for a specified delay (P3.13.6.4). This indicates a deviation from the expected process variable feedback, suggesting an issue with the process or the sensor. It can lead to incorrect control actions and process instability.

The feedback value for the external PID controller is outside its configured supervision limits (P3.14.4.2 and P3.14.4.3) for a specified delay (P3.14.4.4). This indicates a problem with the external process feedback, potentially leading to unstable control or incorrect process regulation. It signifies a deviation in the external process variable.

The input pressure supervision signal (P3.13.9.2) has dropped below either the alarm limit (ID 1109) or the fault limit (ID 1409), indicating an issue with the system's input pressure. This could affect pump or process operation, potentially leading to cavitation, poor performance, or system shutdown.

This fault indicates that the drive's current measurement system has detected zero current in one of the motor phases. This typically points to a disconnection or malfunction in the motor or its cabling, or an issue with an associated du/dt or sinus filter. Continued operation with a missing phase can lead to motor damage or reduced performance.

One or more temperature input signals (configured in P3.9.6.1) have exceeded the alarm limit (P3.9.6.2) or the fault limit (P3.9.6.3). This indicates an overtemperature condition in a monitored area or a problem with the temperature sensing circuit. Unresolved overtemperature can lead to equipment damage.

One or more temperature input signals (configured in P3.9.6.5) have exceeded the alarm limit (P3.9.6.6) or the fault limit (P3.9.6.7). This signifies an overtemperature condition in a second monitored area or an issue with the second set of temperature sensing inputs. Ignoring this can lead to critical component failure.

In a Multipump system, one or more pump running time counters have exceeded a user-specified alarm or fault limit. This indicates that a pump has reached its programmed maintenance interval or has been operating for an excessively long period without intervention. Timely maintenance prevents wear and premature failure.

The internal temperature of the AC drive's heatsink or power board has fallen below the specified minimum operating temperature. This is usually caused by an excessively low ambient temperature surrounding the drive. Operating the drive outside its specified temperature range can lead to unstable operation or premature component failure.

Maintenance counter 1 has exceeded its programmed fault limit, which is typically higher than the alarm limit. This indicates that a critical maintenance interval has been significantly surpassed, potentially impacting equipment reliability or safety. This fault requires immediate attention to prevent operational issues.

Maintenance counter 2 has exceeded its programmed alarm limit, serving as an advisory to schedule or perform maintenance for the component it monitors. This is a pre-warning before a potential fault condition. Proactive maintenance is crucial to maintain optimal equipment performance and prevent unexpected downtime.

Maintenance counter 2 has exceeded its programmed fault limit, indicating that the maintenance interval for the monitored component has been critically overdue. This fault state demands immediate action as continued operation without maintenance could compromise equipment integrity or lead to system failures.

The temperature of the power unit's heatsink has reached an elevated level, triggering an alarm, indicating it is approaching the fault limit. This could be due to inadequate cooling, dusty heatsink, high ambient temperature, excessive switching frequency, or a failing cooling fan. While not yet a fault, sustained high temperatures will reduce component lifespan and may lead to a fault trip.

The drive is unable to convert one or more values for Fieldbus Process Data Out because the data type is not correctly specified or incompatible. This prevents the drive from accurately transmitting process data over the fieldbus. Incorrect data types can lead to misinterpretation by the fieldbus master and potential control anomalies.

An overflow has occurred during the mapping and conversion of values for Fieldbus Process Data Out (specifically 16-bit values). This means that a value being transmitted is too large to be represented accurately within a 16-bit data format, leading to truncation or incorrect data. This can result in inaccurate control or monitoring feedback.

The temperature on the AC drive's power board has exceeded its safe operating limit, indicating a critical overheating condition. This fault is typically caused by insufficient cooling air, high ambient temperatures, or internal component issues. Sustained high temperatures on the board can lead to permanent damage to sensitive electronic components.

The temperature on the AC drive's power board has reached an elevated level, triggering an alarm before reaching a critical fault condition. This indicates that the board's temperature is approaching its fault limit, likely due to insufficient cooling or high ambient temperatures. Although not yet a fault, continuous operation under these conditions can lead to component degradation and eventual fault tripping.

The temperature of the power unit's heatsink has exceeded its permissible limit, triggering a fault. This can be due to insufficient cooling air flow, accumulation of dust on the heatsink, high ambient temperature, excessive switching frequency, or a malfunctioning cooling fan. Prolonged operation at high temperatures significantly reduces the lifespan of power electronic components.

This fault occurs when the motor's rotor has stopped rotating despite receiving power, typically due to excessive load, mechanical binding, or an issue within the motor itself. A stalled motor can draw dangerously high currents, leading to winding overheating and potential motor or drive damage if not addressed quickly.

The motor has exceeded its safe operating temperature, often indicating that the load applied to the motor is too heavy for its current capabilities. If the load is not excessive, the motor's thermal protection parameters in the drive may be incorrectly configured. Sustained motor overtemperature can degrade winding insulation, leading to premature motor failure.

The motor is operating with insufficient load, meaning the actual load is below the expected or minimum threshold. This can occur if the mechanical load is unexpectedly disconnected or too light, or if drive parameters related to load monitoring are incorrectly set. While less critical than overload, persistent underload can indicate a process issue or inefficiency.

The drive has experienced a sustained power demand that continuously exceeds its rated capacity over an extended period. This condition signifies that the drive is consistently undersized for the application's demands, leading to thermal stress on its power components. Persistent long-time overloads will severely shorten the drive's operational life and lead to component failure.

The drive has detected an excessive power demand that is too high for its specified rating over a short duration. This suggests that the drive itself may be undersized for the connected motor and load, or the current load is momentarily exceeding its capabilities. Repeated short-time overloads can lead to drive component stress and eventual failure.

The DC-link voltage has exceeded its defined limits, detected by either hardware or software. This often occurs when the deceleration time is too short, or high overvoltage spikes are present in the supply. Excessive DC bus voltage can stress and potentially damage drive components.

This fault, specific to customer-specific applications, indicates a malfunction during the start angle identification process. Possible causes include rotor movement during identification or a mismatch between the new and old angle values. This prevents accurate motor control and startup.

The drive cannot perform a startup because a new software (firmware or application), parameter setting, or other file affecting operation was loaded while a Run request was ON. The drive prevents startup to ensure configuration integrity and prevent improper operation.

The ATEX thermistor has detected an overtemperature condition, indicating that the motor or an ATEX-rated component is exceeding its safe operating temperature. This is a critical safety fault that requires immediate attention to prevent damage or hazardous conditions.

The sum of the motor phase currents is not zero, indicating a current leakage to earth, detected by either hardware or software. This is typically caused by insulation malfunction in the motor or its cables, or a malfunction in associated filters (e.g., du/dt, sinus filters). An earth fault poses a safety risk and can cause equipment damage.

This fault encompasses diverse issues related to the drive's safety functions. It can be triggered by an active Safe Off signal preventing drive readiness, incorrect safety configuration (e.g., wrong safety switch installation, incorrect STO board placement or count, incompatibility), safety diagnostics failures (e.g., STO input status mismatch, ATEX thermistor connection issues or short circuits), or the activation of the Safe Torque Off (STO) function itself (e.g., via emergency stop). These faults indicate a compromise in the drive's ability to maintain a safe operating state and require careful investigation.

This fault indicates an issue with the cooling fan, either its speed does not accurately match the reference (for MR7 and larger drives) or its estimated lifetime (50,000 h) has expired. Inadequate cooling can lead to drive overheating, reduced performance, and eventual damage.

The drive's Fire mode is currently enabled, which intentionally disables certain drive protections to ensure continuous operation in emergency situations. This is an informational alarm indicating a specific operational state, and it resets automatically when Fire mode is disabled.

A power unit or option board (in slot B, C, D, or E) has been replaced with a new one of the *same type and size* as previously used. The device is ready for use, and its original parameter settings are available. This is an informational fault indicating a successful, compatible hardware replacement.

An option board configured for slot C has been physically removed from the drive. This indicates that the functionalities provided by this option board are now unavailable. The drive will register this as an error until the issue is addressed.

An option board previously installed in slot D has been detected as removed from the drive. The functionalities associated with this specific option board are no longer accessible. This fault requires attention to either acknowledge the removal or reinstall the board.

An option board that was configured for slot E has been physically removed from the drive. This means any features or connections provided by this option board are currently inactive. This fault will remain until appropriate action is taken.

An option board previously configured for slot A or B has been physically removed from the drive. This means the functionality provided by that specific option board is no longer available. This condition will persist until acknowledged or corrected.

The drive has detected an unknown device connected to one of its slots, such as an unrecognized power unit or option board. The drive cannot identify or utilize this device, rendering its functionality unavailable. This can lead to system instability or prevent expected operations.

The calculated temperature of the drive's Insulated Gate Bipolar Transistors (IGBTs) has exceeded its safe operating limit. This critical condition can be caused by excessive motor load, high ambient temperatures, insufficient cooling air flow, a dusty heatsink, high switching frequency, or internal hardware malfunction. Overheated IGBTs are prone to rapid degradation and catastrophic failure.

A power unit or option board (in slot C, D, or E) has been replaced with a new one of a *different type* than previously used in that position. This means saved parameters for the old device are not compatible or available for the new hardware, requiring reconfiguration. Improper configuration can lead to operational errors.

A new power unit or option board (in slot C, D, or E) of a *different type* has been added or detected in the drive. Similar to 'Device changed (different type),' this means parameters for the new device are not saved or compatible, requiring initial configuration. Without proper setup, the added device will not function correctly.

The voltage of the Real Time Clock (RTC) battery is low, indicating it needs replacement. A low RTC battery can lead to loss of time and date settings upon power cycle, affecting data logging and time-dependent functions.

The drive's software (full package or an application) has been successfully updated. This is an informational message and not an error or fault requiring troubleshooting. It confirms the successful completion of a software upgrade.

The internal charging switch is commanded to close, but its feedback indicates it is still open, suggesting an operational malfunction or a defective component. This prevents the DC link from being properly charged, inhibiting drive startup or operation. If ignored, the drive will not function.

One or more analog input signals are below 50% of their minimum signal range. This suggests a defective or loose control cable, or a malfunction in the signal source itself. This can lead to incorrect control inputs and affect drive operation.

A user-specified digital input signal (configured with parameter P3.5.1.11 or P3.5.1.12) was activated, triggering an external fault. This indicates an issue with an external device or its signaling to the drive, which is configured to stop the drive upon activation.

The connection between the control panel (keypad) and the drive is defective, preventing proper communication. This could be due to a faulty cable, improper seating of the keypad, or a damaged control panel itself. Loss of communication means the drive cannot be controlled or monitored via the keypad.

The data connection between the fieldbus master and the fieldbus board in the drive is defective. This prevents the drive from receiving or sending data via the fieldbus network, disrupting remote control and monitoring. Prolonged communication loss can lead to process control issues.

A defective option board or slot has been detected in one of the drive's expansion slots (A, B, C, D, or E). This indicates a hardware issue with an installed option board or its physical slot on the control unit. Such faults can disable functionality provided by the option board or prevent drive operation.

The motor identification run failed to complete successfully. This can occur if the motor is not properly connected, if there's mechanical load on the shaft during the run, or if the start command is prematurely removed. An incomplete identification run means the drive may not have optimal motor parameters.

The Quick Stop function has been activated, causing the drive to stop rapidly. This fault indicates an intentional or unintentional triggering of the quick stop safety feature, designed to bring the motor to a halt quickly. Understanding its activation source is crucial to prevent unintended stops.

The data connection between the PC and the drive is defective, preventing communication with PC tools (e.g., commissioning software). This can be caused by faulty cabling, incorrect terminal connections, or installation issues. Without this connection, advanced configuration and diagnostics are not possible.

The motor temperature has increased beyond limits, as detected by a thermistor input, or there is an issue with the thermistor circuit itself. This could be due to inadequate motor cooling, excessive mechanical load on the motor, or a faulty thermistor connection. Overtemperature can lead to motor damage and reduced lifespan.

Maintenance counter 1 has exceeded its programmed alarm limit, indicating that scheduled maintenance is due or overdue for the component it monitors. This is an advisory alarm to prompt proactive maintenance activities. Ignoring this alarm could lead to component wear, reduced performance, or unexpected faults.

This fault indicates an issue with fieldbus communication, specifically that an invalid ID number is being used for mapping values to Fieldbus Process Data Out. This prevents correct data exchange between the drive and the fieldbus master, leading to control issues or loss of monitoring.

This fault indicates a serious hardware failure such as a defective IGBT, a de-saturation short circuit within an IGBT, or a short circuit/overload in the brake resistor. This fault suggests significant damage to the power stage and continuing operation can cause further severe damage or injury.

The drive's start command has been blocked, primarily to prevent accidental motor rotation, especially during the initial power-up sequence. This is a safety feature to ensure the system is in a known, safe state before operation. The drive will not operate until this prevention is cleared.

The drive has detected more than 5 active fieldbus or PC tool connections simultaneously. The system limits concurrent connections to a maximum of 5. Exceeding this limit can cause communication instability or prevent new connections.

This broad fault indicates various internal drive malfunctions, including lack of communication between control and power boards, defective components (e.g., control board), low auxiliary power voltage, output phase voltage disagreement with reference, software incompatibility between units, unreadable software versions, resource overload, or CPU overload. These issues compromise the drive's operational integrity and can lead to unpredictable behavior.

The DC link voltage has fallen below acceptable limits while the drive is in the Run state. This can be caused by a low supply voltage, a defective internal component, a blown input fuse, or an external charge switch not being closed. A persistent undervoltage can prevent drive operation and indicate a power supply issue.