Vacon NXS NXP Drive

The drive has detected an excessively high current (>4*IH) flowing in the motor cable, which can be caused by a sudden heavy load increase, a short circuit in the motor cables, or an incorrectly sized motor. This condition can lead to severe damage to the motor, cables, or the drive's internal power components if not promptly addressed.

The drive has detected a missing phase in the incoming AC supply voltage. This typically indicates a power supply issue, such as a blown input fuse, a tripped circuit breaker, or a disconnected supply cable. Operating the drive with a missing input phase can lead to internal damage, particularly to the input rectifier bridge.

The drive's current measurement system indicates no current flowing in one of the motor phases. This suggests a problem with the motor cable connection, a break in the cable, or an issue within the motor itself, such as an open winding. Operating the drive with a missing output phase can severely damage both the motor and the drive's inverter section.

The brake chopper supervision has detected an issue, indicating either a missing or broken brake resistor, or a defective brake chopper unit. This fault prevents the drive from effectively dissipating regenerative energy, which can lead to overvoltage faults (Fault 2) during deceleration or when braking heavily.

The heatsink temperature of the power unit or power board has fallen below its safe operating limit, typically below -10 °C (14 °F). This cold condition can affect the performance and reliability of the drive's internal components, potentially causing damage or preventing proper operation if started at extremely low temperatures.

The drive's heatsink temperature has exceeded its maximum safe operating limit (e.g., 90 °C or 77 °C for specific models). This is commonly caused by inadequate cooling airflow, accumulation of dust on heatsinks, high ambient temperatures, or an excessive switching frequency relative to the motor load. Sustained overtemperature will severely degrade and damage the drive's power components.

The motor has stalled, meaning it is not rotating despite receiving a run command. This is typically due to an excessive mechanical load or an obstruction preventing rotation. A stalled motor will draw very high current, leading to rapid overheating of the motor windings and potentially the drive's output stage.

The drive's internal motor temperature model or an external sensor indicates that the motor is operating at an excessively high temperature, primarily due to an overly heavy load. Prolonged motor overtemperature will degrade the motor winding insulation, leading to premature motor failure and increased energy consumption.

The motor underload protection has tripped, indicating that the motor is operating with insufficient mechanical load or no load at all. This can be caused by a broken belt, pump cavitation, an uncoupled shaft, or a process anomaly. Operating in an underload condition can sometimes lead to drive instability or signify a mechanical issue that requires attention.

An unbalance has been detected between power modules within paralleled power units. This signifies a discrepancy in current sharing or performance among the modules, which can lead to uneven wear and a reduced lifespan of the power components. If persistent, this fault indicates an internal issue within the paralleled power system.

The DC-link voltage within the drive has exceeded its predefined safe operating limits. Common causes include overly short deceleration times, high overvoltage spikes from the incoming AC supply, or a very rapid Start/Stop sequence. Sustained overvoltage can lead to critical damage to the drive's DC-link capacitors and IGBTs.

An error occurred during the saving of parameters to the EEPROM, or the checksum of the stored parameters is incorrect. This indicates a potential operational malfunction or a defective memory component within the drive. This fault can lead to the loss of drive parameters, causing the drive to operate with default or incorrect settings.

The drive's internal counters are displaying incorrect values, which suggests a potential data corruption or an internal processing error. While not immediately critical to motor operation, inaccurate counter data can lead to incorrect system logging or misdiagnosis. This fault usually points to an internal software or hardware issue with the control unit.

The drive's internal microprocessor watchdog has triggered, indicating that the control software or hardware has become unresponsive or entered an unexpected state. This can be due to an operational malfunction or a defective internal component. A persistent watchdog fault prevents proper drive control and operation.

The drive's start-up sequence has been inhibited, typically because a run request signal was active while a new application program was being downloaded or after a configuration change. This is a safety feature designed to prevent unintended motor starts. The drive will not initiate operation until this preventative condition is safely resolved.

The thermistor input on an option board has detected an increase in motor temperature beyond safe limits, or the input itself is not properly terminated if unused. This indicates potential motor overload or inadequate motor cooling. Overheating can severely damage the motor windings, reduce motor lifespan, and lead to efficiency losses.

The drive's current measurement system has detected that the sum of the motor phase currents is not zero, indicating a leakage current to earth. This is typically a result of insulation malfunction within the motor windings or the motor cables. An unresolved earth fault poses a significant electrical safety hazard and can cause severe damage to both the motor and the drive.

The 'Safe Disable' input on an OPTAF board has opened, activating a safety interlock that prevents drive operation. This feature is typically used to safely shut down or inhibit the start-up of the drive for maintenance or emergency situations. The drive will remain disabled until this safety condition is cleared.

The hardware-level overtemperature protection for the IGBT inverter bridge has activated, indicating an excessively high short-term overload current. This can be caused by heavy motor loading or an incorrectly sized motor. Persistent high temperatures can permanently damage the IGBTs, leading to catastrophic drive failure.

The cooling fan of the AC drive failed to start when a run command was issued. This indicates a potential fan motor failure, wiring issue, or a problem with the drive's internal fan control circuit. Without proper cooling, the drive will quickly overheat and trip, potentially leading to damage to internal power components.

A message sent over the CAN bus was not acknowledged by another device on the network. This typically points to a communication issue, such as an incorrectly configured device, a disconnected bus, or a fault in the CAN network's physical layer. Loss of communication can prevent proper control and monitoring of the drive.

A problem has been detected within the drive's application software. This could be due to a programming error, corrupted application file, or an unexpected runtime condition. An application fault will prevent the drive from executing its programmed functions correctly or at all, disrupting machine operation.

There is an incompatibility or communication failure between the NXS Control Unit and the NXP Power Unit (or vice versa). This prevents the control unit from properly commanding the power unit, effectively rendering the drive inoperable. This is often caused by mismatched hardware components or internal communication bus issues.

An option board has been replaced with another board of the exact same type that was previously used in the same slot. The drive has recognized the replacement and still has the old parameter settings available. This is primarily an informational alarm, indicating the hardware change and that the drive is ready to use the previously stored settings.

An option board of the same type, which was previously used in the same slot, has been added to the drive. The drive recognizes the board and has its parameters available. This is primarily an informational alarm, indicating the drive is ready to use the previously stored settings for this specific board.

An option board has been removed from its slot, making the device unavailable to the drive. This indicates a configuration change where a previously installed board is no longer present. The drive needs to acknowledge this change to clear the fault status.

An unknown or unrecognized power unit or option board has been connected to the drive. This indicates an incompatible hardware component that the drive cannot identify or operate with. The drive will be unable to start or function properly until a compatible device is installed.

The IGBT Inverter Bridge overtemperature protection has activated, detecting excessively high short-term overload current. This can be caused by heavy motor loading or an incorrectly sized motor. Persistent high temperatures can permanently damage the IGBTs, leading to catastrophic drive failure.

The brake resistor overtemperature protection has activated, indicating that the brake resistor is dissipating too much energy, likely due to overly heavy or frequent braking cycles. This condition can lead to premature resistor failure or a fire hazard if not addressed.

A problem has been detected with the encoder signals, such as missing channels (A or B), reversed direction, or a missing encoder board. This prevents accurate motor speed and position feedback, leading to unstable or incorrect motor control in closed-loop applications.

An option board or power unit has been replaced with a device of a different type or power rating. The drive detects this incompatibility and requires a complete reconfiguration. If parameters are not correctly reset and adjusted, the drive may operate incorrectly, become unstable, or fail to start.

A new option board of a different type has been added to the drive. The drive recognizes the new hardware but requires specific configuration to integrate it properly. Without correct parameter setup, the newly added option board may not function, or it could cause system instability.

A division by zero error has occurred within the custom application program running on the drive. This indicates a mathematical error in the program logic, which can cause the drive to halt or behave unpredictably. If left unaddressed, the drive cannot execute the affected part of the application, disrupting operations.

The internal charging switch, which is responsible for pre-charging the DC-link capacitors, remains open when a START command is given. This indicates either an operational malfunction or a defective internal component within the drive. If this fault persists, the drive will be unable to start and operate, signaling a serious internal hardware issue.

The analogue input configured for a 4-20 mA current loop is receiving a current signal below 4mA. This typically indicates a break or loose connection in the control cable, or a failure of the signal source device. Loss of the analogue signal means the drive cannot receive its intended reference or feedback, leading to incorrect control.

A digital input configured as an external fault has been triggered, indicating a fault condition in an external device connected to the drive. This causes the drive to trip, preventing further operation until the external fault is cleared. The specific external device must be identified and resolved.

Communication between the control panel (or NCDrive software) and the drive has failed. This is usually due to a defective physical connection or cable. Loss of keypad communication means the drive cannot be monitored or controlled locally via the control panel.

The data connection between the fieldbus master and the drive's fieldbus option board is defective, leading to a loss of communication. This prevents the drive from being controlled or monitored via the fieldbus network, disrupting integrated system operations. An incorrect installation or a faulty fieldbus master are common causes.

A defective option board or a faulty slot within the drive has been detected. This indicates a hardware failure preventing the option board from functioning correctly or being recognized by the drive. This fault will impact any functionality associated with the affected option board.

An internal temperature sensor has registered a temperature exceeding its predefined limit, or the sensor itself is disconnected or short-circuited. This indicates inadequate cooling, excessive load, or a sensor malfunction. Overheating can lead to premature component failure and severe damage to the drive.

The motor identification run, which is crucial for tuning the drive to the motor's specific electrical characteristics, has failed. This can occur if the run command was removed prematurely, the motor is not correctly connected to the AC drive, or an external load is present on the motor shaft during the process. An unsuccessful identification run can lead to suboptimal motor control and performance.

The actual status feedback from the mechanical brake (e.g., open/closed) does not match the drive's control signal for the brake. This indicates a malfunction in the brake mechanism, its feedback sensor, or the associated wiring. A malfunctioning brake poses a safety risk and can prevent proper machine operation or holding.

Communication has been lost between the Master and Follower drives via the SystemBus or CAN communication link. This could be due to incorrect option board parameters or a damaged/disconnected communication cable (optical fibre or CAN). Loss of communication prevents synchronized operation in a master-follower system, leading to operational halts.

An emergency stop signal has been received from an option board, causing the drive to immediately halt operation. This is a critical safety interlock feature. The drive will remain stopped and will not accept new run commands until the emergency stop condition is cleared and the integrity of the safety circuit is verified.

The coolant circulation system for a liquid-cooled drive has failed. This means the drive is not receiving adequate cooling, which will rapidly lead to overtemperature conditions and potential severe damage to internal components. This requires immediate attention to the external cooling system.

The motor's actual speed deviates significantly from its commanded speed reference. This can be caused by a faulty encoder connection (if an encoder is used), or for Permanent Magnet Synchronous (PMS) motors, exceeding the pull-out torque. An uncorrected speed error leads to inaccurate motor control, poor process performance, and potential instability.

The 'Run Enable' signal, which is required for the drive to operate, is currently low or inactive. This is a safety interlock designed to prevent the drive from starting. The drive will remain disabled until the run enable condition is met and the corresponding signal is active.

An emergency stop command has been received by the drive from either a digital input or via the fieldbus, resulting in an immediate halt of operation. This is a critical safety function that stops the machinery in an emergency. The drive will not accept a new run command until the fault is reset and the emergency stop condition is completely cleared.

The main input power switch for the drive is detected as open, preventing power from reaching the drive and making it inoperable. This could refer to a physical disconnect switch, a tripped circuit breaker, or an internal contactor. The drive cannot function without incoming power.

An internal temperature sensor has registered a temperature exceeding its predefined limit, or the sensor itself is disconnected or short-circuited. This indicates inadequate cooling, excessive load, or a sensor malfunction. Overheating can lead to premature component failure and severe damage to the drive.

This fault indicates a severe internal component defect, potentially related to a short-circuited or overloaded brake resistor. It's a critical fault that prevents normal drive operation and requires immediate, specialized attention. Attempting to restart the drive or reconnect power without addressing the root cause risks further catastrophic damage to the unit.

In a Master-Follower configuration, this fault code is generated when one or more of the follower drives trip into a fault state. This indicates an underlying issue with a specific follower drive, which then propagates to the master. The master cannot resume normal operation until the root fault on the follower drive(s) is identified and resolved.

This is a general system fault, indicating either an internal operational malfunction or a defective component within the drive. If the fault persists after a reset, it points to a more fundamental hardware or software issue requiring expert diagnosis. The drive cannot operate normally while this fault is active.

The DC-link voltage has fallen below its acceptable operating limits. This can be caused by a low incoming supply voltage, a defective input fuse, an external charge switch failing to close, or an internal AC drive fault. Prolonged undervoltage can cause erratic drive behavior, prevent proper starting, and potentially stress internal components.