Danfoss VLT HVAC-FC 102 Frequency Converter

The control card voltage from terminal 50 has dropped below 10 V. This is typically caused by an overloaded 10 V supply (exceeding 15 mA or below 590 Ω minimum resistance) or a short circuit in a connected potentiometer or its wiring. If left unresolved, this can lead to unstable control card operation or system shutdown.

According to the electronic thermal protection (ETR), the motor is too hot. This fault occurs when the motor runs with more than 100% overload for an extended period. Unresolved motor overheating risks severe motor damage or premature failure.

The motor thermistor indicates an over-temperature condition, or the thermistor itself may be disconnected or improperly wired. This suggests the motor is overheating, which can lead to severe damage if left unaddressed. Select whether the frequency converter issues a warning or an alarm in 1-90 Motor Thermal Protection.

The motor torque has exceeded the programmed limits in parameter 4-16 (Motor Mode) or 4-17 (Generator Mode). This can be caused by excessive load, rapid acceleration/deceleration, or incorrect limit settings. Persistent torque limiting can hinder application performance or cause unexpected stops.

The inverter peak current limit (approximately 200% of the rated current) has been exceeded, causing the frequency converter to trip after about 1.5 seconds. This is often caused by shock loading, rapid acceleration with high inertia loads, or can occur after kinetic back-up. Repeated overcurrent can lead to damage to the inverter's power stage.

There is an undesirable current path from one or more output phases to earth, either in the cable connecting the frequency converter to the motor or within the motor itself. This fault indicates a serious insulation breakdown, posing a safety risk and potential for severe equipment damage if power is not immediately removed.

A fitted option card or module is not compatible or operational with the current control board hardware or software version in the frequency converter. This prevents the unit from functioning correctly and requires contacting support for resolution. Incorrect component pairings can lead to system instability.

A direct short circuit exists in the motor windings or the motor wiring connected to the frequency converter's output terminals. This is a critical fault that can cause immediate and severe damage to the frequency converter's output stage if power is not removed quickly. Continued operation is highly dangerous.

This warning or alarm appears if programmed in 6-01 Live Zero Timeout Function. It indicates that the signal on one of the analog inputs is less than 50% of the minimum value programmed for that input. Common causes include broken wiring or a faulty device sending the signal, which can lead to incorrect process control.

Too many power-ups have occurred within a short time period, leading to excessive inrush current events. This frequent power cycling prevents the unit from dissipating heat and can stress internal components, potentially shortening the drive's lifespan.

The fieldbus communication option card is not functioning or communicating correctly. This prevents the drive from receiving commands or sending status information to the connected control system, leading to loss of remote control and monitoring capabilities. Unresolved, this fault will halt automated operation.

The frequency converter has detected a loss of incoming supply voltage, and the 'Mains Failure' parameter (14-10) is configured to generate an alarm. This indicates a power supply interruption to the drive, which will cause the motor to stop. Until mains power is restored, the drive cannot operate.

A general internal fault has been detected within the frequency converter, preventing normal operation. A specific sub-code, referenced in Table 7.6, provides more detailed diagnostic information about the nature of the internal issue. This fault indicates a critical hardware or software problem requiring specific troubleshooting based on the sub-code.

The internal serial communication port failed to initialize upon power-up or during operation. This can prevent communication with the LCP or external serial devices, indicating a possible internal hardware or firmware issue with the control board.

A general internal system error has occurred within a specific range, indicating a deeper hardware or firmware issue not covered by more specific sub-codes. This type of fault typically points to a critical internal component failure that prevents normal drive operation.

The software version on the option card installed in slot A is detected as being outdated or incompatible with the frequency converter's current firmware. This mismatch can lead to communication errors, incorrect functionality, or complete failure of the option card.

The software version on the option card installed in slot B is detected as being outdated or incompatible with the frequency converter's current firmware. This mismatch can lead to communication errors, incorrect functionality, or complete failure of the option card.

The software on the option card installed in slot A is not recognized or supported by the frequency converter's firmware. This indicates a fundamental incompatibility, preventing the option card from integrating correctly with the drive's control system.

The software on the option card installed in slot B is not recognized or supported by the frequency converter's firmware. This indicates a fundamental incompatibility, preventing the option card from integrating correctly with the drive's control system.

A general internal system error has occurred within a specific range, indicating a deeper hardware or firmware issue not covered by more specific sub-codes. This type of fault typically points to a critical internal component failure that prevents normal drive operation.

The Electrically Erasable Programmable Read-Only Memory (EEPROM) on the power card, which stores crucial operational data, is either corrupted or obsolete. This hardware fault on the power card prevents the drive from properly initializing or operating.

The frequency converter's control card has been detected as faulty and is no longer able to perform its critical functions. This component is essential for all drive operations, and its failure will completely disable the drive.

An internal memory stack overflow has occurred within the Local Control Panel (LCP) processor. This typically indicates a transient software issue or excessive processing demand within the LCP firmware, potentially leading to unresponsive controls or system crashes.

The internal serial communication buffer has overflowed, meaning data is being received faster than the drive can process it. This leads to data loss and unreliable serial communication, affecting remote control and monitoring via the serial port.

The internal USB communication buffer has overflowed, indicating that data is being received faster than the drive can process it. This leads to data loss and unreliable USB communication, affecting diagnostics or parameter transfers.

An internal parameter's stored value has fallen outside its predefined minimum or maximum allowable range within a specific memory region. This can be caused by data corruption, an incorrect parameter write, or a software anomaly, leading to unexpected drive behavior or shutdown.

A general internal system error has occurred within a specific range, indicating a deeper hardware or firmware issue not covered by more specific sub-codes. This type of fault typically points to a critical internal component failure that prevents normal drive operation.

The hardware of the option card installed in slot A is fundamentally incompatible with the drive's control board hardware. This hardware mismatch prevents the option card from functioning correctly and may lead to system instability or other operational faults.

The hardware of the option card installed in slot B is fundamentally incompatible with the drive's control board hardware. This hardware mismatch prevents the option card from functioning correctly and may lead to system instability or other operational faults.

A general internal system error has occurred within a specific range, indicating a deeper hardware or firmware issue not covered by more specific sub-codes. This type of fault typically points to a critical internal component failure that prevents normal drive operation.

An internal parameter's stored value has fallen outside its predefined minimum or maximum allowable range. This can be caused by data corruption, an incorrect parameter write, or a software anomaly, leading to unexpected drive behavior or shutdown.

The frequency converter is not receiving a temperature signal from the heatsink sensor, specifically the IGBT thermal sensor on the power card. This loss of feedback means the drive cannot monitor critical internal temperatures, posing a significant risk of overheating and damage to the power semiconductors if not resolved.

A phase is missing on the supply side, or the mains voltage imbalance is excessively high. This message can also indicate a fault within the input rectifier on the frequency converter. Unresolved mains phase loss can lead to severe damage to the frequency converter or connected motor.

The 1.8 V DC internal power supply on the control card, crucial for its operation, is outside its allowable limits. This indicates a potential issue with the control card itself or an overvoltage condition if an option card is present. This can lead to erratic behavior or complete failure of the control card.

The motor speed is not within the specified range set in parameters 4-11 (Motor Speed Low Limit) and 4-13 (Motor Speed High Limit), generating a warning. If the speed drops below the limit set in 1-86 (Trip Speed Low) (except during start/stop), the frequency converter will trip. This indicates an operational deviation that could affect process control or product quality.

The intermediate circuit voltage (DC) has risen above the high-voltage warning limit, which is dependent on the frequency converter's voltage rating. The unit is still active, but operating at an elevated voltage could stress internal components or lead to a trip if limits are exceeded.

The Automatic Motor Adaptation (AMA) calibration process has failed. This means the drive could not successfully characterize the connected motor, which is critical for optimal performance and protection. Without successful AMA, motor control may be suboptimal or protection features less effective, impacting efficiency.

The settings for motor voltage, motor current, or motor power are incorrect, preventing successful Automatic Motor Adaptation (AMA). Incorrect motor data can lead to poor motor control, reduced efficiency, and inadequate motor protection. This also impacts the drive's ability to properly characterize the motor.

The motor current is detected as too low for the Automatic Motor Adaptation (AMA) process to properly function. This may indicate an incorrect motor data entry or an undersized motor for the drive's capabilities. Incorrect current settings hinder accurate motor characterization and optimal drive performance.

The connected motor is too large for the Automatic Motor Adaptation (AMA) function to operate successfully with this frequency converter. This suggests an incompatibility or misapplication, preventing proper motor characterization and potentially leading to suboptimal or unsafe operation. The drive may not be able to accurately control or protect such a large motor.

The connected motor is too small for the Automatic Motor Adaptation (AMA) function to operate successfully. This indicates an incompatibility or misapplication, preventing proper motor characterization and potentially leading to suboptimal performance or inadequate motor protection. The drive may struggle to accurately control or protect such a small motor.

During the Automatic Motor Adaptation (AMA) process, one or more motor parameter values were found to be outside the acceptable range for the frequency converter. This prevents AMA from completing and can result from incorrect motor data entry or unusual motor characteristics. The drive cannot perform optimal motor control without successful AMA.

The Automatic Motor Adaptation (AMA) process was intentionally stopped by the user. If this was unintentional, it means AMA did not complete its motor characterization. This will prevent the drive from optimizing motor control and protection based on the motor's actual electrical properties.

An internal fault occurred during the Automatic Motor Adaptation (AMA) process. This indicates a problem within the drive's control logic or measurement system during motor characterization. Repeated attempts could overheat the motor, and the underlying fault needs to be addressed.

An internal fault occurred during the Automatic Motor Adaptation (AMA) process that requires expert intervention. This indicates a more complex problem within the drive's control logic or measurement system during motor characterization. It cannot be resolved by simple restart and requires deeper diagnosis.

The output current has exceeded the value set in parameter 4-18 (Current Limit). This indicates that the motor is drawing more current than configured, possibly due to overload, incorrect motor data, or an inappropriately set current limit. Persistent current limiting can restrict motor performance and lead to unexpected shutdowns.

The intermediate circuit voltage (DC) has dropped below the low-voltage warning limit, which is dependent on the frequency converter's voltage rating. The unit is still active, but operating with insufficient voltage could affect performance or lead to a trip.

A digital input signal has indicated an external fault condition, causing the frequency converter to trip. This means an external safety or control system has commanded the drive to stop due to a detected issue. The external fault must be cleared before normal operation can resume.

The output frequency has reached the maximum value set in parameter 4-19 (Max Output Frequency). This indicates the drive is attempting to run the motor faster than its configured limit, potentially due to incorrect parameter settings or application requirements exceeding the drive's setup. The warning will clear when the output frequency drops below the maximum limit.

The control card temperature has reached its cut-out limit of 80 °C, indicating excessive heat within the control section of the frequency converter. This can lead to erratic behavior, reduced lifespan, or permanent damage to the control card if not addressed. Proper cooling is essential for its reliability.

The frequency converter's heatsink temperature, measured by a sensor in the IGBT module, is too low for safe operation. This indicates the unit is too cold to operate efficiently or without condensation risk. Operation at extremely low temperatures can affect component reliability and performance.

One or more option modules (e.g., fieldbus cards, I/O extensions) have either been added or removed since the last power-down cycle. The drive detects a change in its hardware configuration and requires user confirmation. This alarm serves as a notification and requires a reset to ensure the change was intentional before proceeding.

The Safe Stop function has been activated, bringing the motor to a controlled stop and preventing unintended restart. This is a critical safety feature typically triggered by an external safety input. The drive will remain in this state until the safety input is cleared and a reset commanded.

The temperature sensor on the power card indicates that it is either too hot or too cold, exceeding safe operating limits. Extreme temperatures can severely affect the power components (IGBTs, capacitors), leading to reduced lifespan, performance issues, or immediate failure of the drive if not corrected.

If the intermediate circuit voltage exceeds its critical limit, the frequency converter will trip after a time delay. This fault often occurs due to regenerative braking, sudden load changes, or issues with the mains supply. Repeated overvoltage trips can damage the drive's power components.

The installed control card and power card within the frequency converter are incompatible with each other. This indicates an incorrect pairing of components, potentially due to wrong spare parts or an assembly error. The drive cannot operate with this configuration and requires corrective action.

If the intermediate circuit voltage (DC link) drops below the under-voltage limit, the frequency converter checks for a 24 V DC back-up supply. If no back-up is connected, the unit trips after a fixed delay. This condition can lead to unexpected shutdowns and loss of motor control.

The frequency converter's parameter settings have been reset to their factory default values, typically after a manual reset action. This alarm serves as a notification that custom configuration has been lost. The drive will operate with default parameters until reconfigured, potentially affecting application performance and safety.

The frequency converter is operating with an excessively high current for too long, nearing its thermal protection limit. The electronic thermal inverter protection counter issues a warning at 98% and an alarm trip at 100%. The unit cannot be reset until the counter drops below 90%, indicating a significant risk of damage to the inverter if prolonged.

A no-flow condition has been detected in the system, and parameter 22-23 (No-Flow Function) is set to trigger an alarm. This indicates a critical deviation in the process, such as a pump running dry or a blocked pipe. Continued operation in a no-flow state can damage pumps or other system components.