When an industrial process comes to a halt, it’s often the drive system that engineers look at first. And when that drive is a Vacon, known for its reliability and precision, issues aren’t always obvious but when they occur, they need fast, expert intervention. Whether you’re managing production lines, HVAC systems, pumps or automation processes, drive reliability directly impacts uptime. This guide walks through common Vacon drive problems, how to spot early warning signs and what to do next.

Why Vacon Drives Sometimes Fail

Vacon drives are engineered to meet the high demands of industrial environments. However, like any technical equipment, they can develop faults over time due to:

  • Environmental stress (heat, dust, moisture)
  • Incorrect installation or wiring
  • Outdated firmware
  • Mechanical wear on connected motors
  • Power supply fluctuations or harmonics

The good news? Most issues can be repaired or resolved with targeted diagnostics and expert servicing no need to replace the entire system.

Signs Your Vacon Drive Needs Attention

Not every problem will trigger a full shutdown. Here are typical indicators something’s wrong:

  • Frequent tripping or nuisance faults
  • Unusual motor behaviour (slow response, overheating)
  • Display showing error codes
  • Loss of communication with PLC or control system
  • Fan noise or no cooling
  • Drive not starting after power cycle

Addressing these early could save hours of production downtime.

Common Vacon Drive Issues (and How to Troubleshoot Them)

1. Overcurrent Faults

Symptoms: Drive trips when the motor starts or under heavy load.

Causes:

  • Motor size mismatch
  • Short circuits
  • Incorrect motor parameters
  • Loose cabling

Fix: Double-check motor nameplate values, drive configuration and load conditions. Replace damaged motor cables if insulation resistance is low.

2. Undervoltage / Overvoltage Faults

Symptoms: Drive fails to start or trips during operation.

Causes:

  • Incoming mains voltage too low or too high
  • Power supply instability
  • Incorrect supply configuration

Fix: Measure actual supply voltage, inspect power input terminals and ensure correct phase setup. Surge protection may also be necessary.

3. Drive Not Responding to Control Signals

Symptoms: Motor doesn’t start despite correct setup.

Causes:

  • Control wiring fault
  • Incorrect digital input settings
  • Programming error in PLC or HMI

Fix: Use Vacon’s keypad or PC tool to check digital input status and I/O mapping. Ensure logic levels are aligned with input type (NPN or PNP).

4. Motor Not Reaching Desired Speed

Symptoms: Drive appears functional but motor is underperforming.

Causes:

  • Speed reference not scaled correctly
  • PID settings misconfigured
  • Mechanical load too high

Fix: Check analogue input scaling, verify PID parameters and inspect the mechanical system for issues. Recalibrate the drive’s reference values if necessary.

5. Cooling Fan Failure

Symptoms: Drive overheats or gives thermal warnings.

Causes:

  • Fan clogged or worn out
  • Ambient temperature exceeds spec
  • Internal thermal sensor fault

Fix: Clean or replace the fan, ensure airflow is unobstructed and check cabinet cooling. In some cases, fan kits are available as spare parts for specific Vacon models.

6. Drive Won’t Power Up

Symptoms: Blank display, no indicator LEDs.

Causes:

  • Blown fuses
  • Faulty power supply board
  • Internal short

Fix: Check fuses and main input supply first. If all external factors are sound, internal repair by a certified technician is usually required.

Repair vs Replacement: When Can a Vacon Drive Be Fixed?

In many cases, Vacon repair is more cost-effective than a full replacement especially for legacy systems or panel-mounted units.

Drives that can usually be repaired:

  • Showing intermittent faults or warning codes
  • With damaged components (e.g. IGBTs, caps, fans)
  • Failing due to age-related issues (dry solder joints, degraded boards)

Replacement may be necessary when:

  • The control board is irreparably damaged
  • The drive’s firmware is obsolete and no longer supported
  • The drive is not economically viable to repair

A professional diagnostics report can guide this decision.

Why You Need Industrial Drive Repair Experts

DIY fixes might work for low-risk applications but in industrial setups, you need professionals who understand:

  • Vacon’s internal architecture
  • Correct diagnostic tools (like VACON Live and diagnostic charts)
  • Safe disassembly and reassembly
  • Compatibility of spare parts and firmware versions

Digicon engineers, for example, offer full repair services with quick turnaround, proper testing and warranty-backed repairs often extending the lifespan of your equipment by several years.

Preventative Maintenance: Avoiding Future Problems

If your business relies heavily on drive-controlled processes, don’t wait for faults to appear. Here’s what you can do:

  • Schedule regular thermal and electrical testing
  • Keep firmware updated
  • Clean air filters and inspect fans
  • Log and monitor drive alarms over time
  • Use surge protection on mains supplies

Most importantly, maintain a record of drive configurations and backups especially if your plant operates 24/7.

Don’t Let Minor Vacon Drive Issues Escalate

A tripping drive doesn’t always mean failure — it means you need to pay attention. Many Vacon issues are preventable or repairable with the right support.

By understanding what’s typical, recognising the early warning signs and calling in help when needed, you can extend the life of your drives and avoid costly downtime.

Need Expert Help with Vacon Repair?

Digicon Solutions provides professional industrial drive troubleshooting, on-site diagnostics and in-house repair for Vacon drives across the UK.

We’ll help you get back up and running quickly and make sure it stays that way.