Nordac frequency converter: Safety upgrade for drives

Functional Safety Integrated Protection in the Drive

2026-06-03 Updated on 2026-06-03 Source: Nord Drivesystems | Translated by AI 6 min Reading Time

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With consistent safety and communication structures in its decentralized frequency converters, Nord Drivesystems enables safe and flexible system concepts. Users benefit without compromising performance.

Nord has equipped, among others, the decentralized frequency converters of the Nordac-On family with new features in the area of functional safety.(Image: Nord Drivesystems) — Nord has equipped, among others, the decentralized frequency converters of the Nordac-On family with new features in the area of functional safety.
(Image: Nord Drivesystems)

In automated production, drive electronics with integrated safety functions enable the secure operation of almost all motion sequences. Functional safety protects people, machines, and the environment from the consequences of technical malfunctions. It ensures that systems respond reliably and in a controlled manner, even in the event of a failure. In many industries and industrial applications, implementing functional safety is also legally mandated. As a result, this topic is gaining increasing importance in Nord's drive systems and is being continuously expanded. The latest variants of the decentralized frequency inverter families Nordac on and Nordac Link from the manufacturer are now receiving a comprehensive safety upgrade to meet the demands of advanced safety applications.

In many industries and applications, the implementation of functional safety is legally required.

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Nord Drivesystems offers a modular system with decentralized drive electronics and complete consistency(Image: Nord Drivesystems)

The Nordac Link for wall mounting is also available with an integrated Ethernet interface and enhanced functional safety(Image: Nord Drivesystems)

Nordac Fusion – compact drive solution with the decentralized frequency converter Nordac On(Image: Nord Drivesystems)

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Motion Monitoring Made Easy

In addition to STO and SS1, motion monitoring functions such as SLS, SMS, or SSM are now integrated for safety-oriented control of rotational movement. This means the decentralized frequency converters not only feature safe stop functions but also enable the safe control of speeds in a drive solution (see info box).

"By using secure Ethernet-based protocols, data exchange takes place error-free and protected against manipulation in real-time," emphasizes Jörg Niermann, Head of Marketing at Nord Drivesystems. "The latest variants of our decentralized frequency inverters can be fully integrated into safety-oriented applications within an existing industrial Ethernet network via Profisafe or FSoE—the desired industrial Ethernet dialect is simply configured during commissioning." Stand-alone use is also possible.

The safe digital inputs and outputs of the decentralized frequency inverters can be used for integrating safety-related peripheral components or functions. This allows, among other things, direct connection of emergency stop buttons, safety door switches, or light barriers. Two safe single-channel digital inputs can be combined into one safe dual-channel digital input, and two safe outputs can be combined into one safe dual-channel output.

Users also benefit from a scalable system architecture with clear hierarchies, simplified wiring, and reduced installation effort thanks to integrated communication via standard safety protocols. Additional installations, such as safe encoders, can thus be omitted. Nord frequency inverters with drive-based functional safety offer safety functions with SIL2 or SIL3 as well as Performance Level "d" or "e." The reliability of the systems is certified in accordance with the international standards IEC 61508 (SIL) and EN ISO 13849-1 (PL). This provides the company with solutions for applications with the highest safety requirements.

Overview of safety functions

STO (Safe Torque Off)—Immediate interruption of the power supply. The motor no longer generates torque and coasts to a stop uncontrollably. STO is often combined with SS1 or used as a safe restart lock.
SS1-r and SS1-t (Safe Stop 1)—Are two variants of Safe Stop 1. In both cases, the motor is first decelerated in a controlled manner, and then STO is automatically activated. SS1-r operates with monitored deceleration, while SS1-t is time-controlled.
SLS (Safe Limited Speed)—Monitors a safely limited speed, for example, during setup mode. If the limit value is exceeded, the drive is safely shut down, usually via SS1 followed by a power shutdown.
SSM (Safe Speed Monitor)—Provides a safe signal indicating whether the motor speed is below a defined limit.
SMS (Safe Maximum Speed)—Safe monitoring of the speed, which must not exceed a maximum value. Stops the drive if it exceeds the maximum speed.

Decentralized Drive Electronics in Demand

Particularly in expansive intralogistics, space-saving, decentralized drive solutions are often required. However, if frequency converters for wall mounting and motor installation have different safety and communication features, this restricts system planning.

"Our customers can flexibly choose between frequency converters for motor installation or wall mounting."

Jörg Niermann, Head of Marketing at NORD DRIVESYSTEMS

"The decentralized frequency converters Nordac On and Nordac Link are part of our comprehensive system modular kit and offer the same communication and safety features," said Niermann. "This means that our customers can flexibly choose between frequency converters for motor installation or wall mounting when planning their systems, thanks to this consistency."

Another advantage: While Nordac on covers a power range from 0.37 kW to 3.7 kW, Nordac Link covers a power range from 0.37 kW to 7.5 kW. Both frequency inverters feature an integrated Ethernet interface and full plug-in capability. Thanks to their plug-and-play functionality, they significantly reduce wiring effort and provide a maintenance-friendly solution for modern production environments. Combined with the manufacturer's efficient IE3 and IE5+ motors, they create powerful, efficient, and future-proof drive systems that can be seamlessly integrated into existing networks.

Dynamic Applications Without Encoders

Particularly efficient: Both the Nordac on and Nordac Link enable encoderless control of the manufacturer's highly efficient IE5+ synchronous motors (PMSM). Using the CFC open-loop injection method, the rotor position and motor speed can be detected without the additional installation of an encoder. The CFC open-loop injection method allows for a start with 150% overload and achieves more dynamic accelerations through short ramp times. This ensures high energy efficiency, especially in partial load operation. Since no encoder is required, the CFC open-loop injection control reduces material and installation costs. This makes Nord's solution a robust and economical drive system suitable even for dynamic applications.

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The IE5+ permanent magnet synchronous motors (PMSM) from Nord are characterized by a consistently high efficiency of up to 95% across a wide torque range. This ensures optimal energy consumption performance even in partial load and partial speed ranges, enabling a reduction in variants for streamlined production, logistics, storage, and service processes.

High-performance Unit in a Compact Space

For those seeking maximum drive performance in the smallest space, Nord offers the Nordac Fusion: a powerful drive system that merges motor and inverter into a compact unit. The Nordac Fusion combines asynchronous motors (IE3) and permanent magnet synchronous motors (IE5+) in both ventilated and unventilated versions with a decentralized frequency inverter from the Nordac on family. The optimal electrical and mechanical coordination of both components achieves high power density while keeping the installation space as small as possible. Users benefit from a reliable and efficient system that is ready for use quickly. Complex parameterization or time-consuming component selection is no longer necessary.

The optimized motor-inverter combinations Nordac Fusion cover a power range from 0.31 to 3.7 kW. They feature consistent safety and communication capabilities, are suitable for worldwide use, and can be complemented with a gearbox from the manufacturer's modular product system. The level of functional safety can also be individually defined with the Nordac Fusion.

Ideal for Demanding Environments

The Nordac Fusion drive solution can be used at temperatures as low as -30 °C (-22°F). The combination of IE5+ synchronous motors and Nordac on pure with the NXD tupH® surface treatment is suitable for wash-down applications in the food industry. Additional features such as Ethernet on board, hybrid cable, and daisy-chain technology enable efficient and hygiene-friendly topologies that are slimmer and easier to clean than traditional decentralized cabling.

High Flexibility for System Planners

Overall, Nord is taking the topic of functional safety to a new level with the enhanced safety functions of the Nordac on and Nordac Link in the field of decentralized drive electronics—integrating the protection of people and machinery directly into the drive. Additional components can be omitted. The decentralized frequency inverters are now equipped with consistent communication and safety structures, allowing plant designers to flexibly choose between wall and motor mounting, thereby benefiting from greater design freedom in plant design and an extended performance range.

High-performance systems like the Nordac Fusion further reduce engineering efforts and commissioning time in large-scale projects with a high degree of automation, ensuring consistently high drive quality. "Our customers trust that we continuously develop our products with practical relevance," emphasizes Jörg Niermann in conclusion. "With our modularly expandable product portfolio, we offer customized drive systems that can be precisely tailored to the requirements of each specific industry or application."