Overcurrent (OC) is one of the most common issues that inverter systems face. This alarm often appears when there's an unexpected surge in current, which can be caused by a variety of factors. For example, if the system trips immediately upon starting, it might indicate a short circuit in the load or a problem with the motor’s torque. In some cases, the inverter module itself could be damaged, leading to this kind of failure. Another scenario is when the inverter trips during acceleration, which may suggest that the acceleration time is set too short or the current limit is too low. These problems are often linked to improper parameter settings or mechanical issues.
Overvoltage (OU) typically occurs when the inverter is stopped, especially if the deceleration time is too short or if the braking resistor is not functioning properly. In such cases, the energy from the motor being slowed down gets fed back into the DC bus, increasing its voltage. A typical solution is to check the braking resistor and the brake unit for faults. If the resistor is damaged, replacing it usually resolves the issue.
Undervoltage (Uu) is another frequent problem, often related to the main circuit voltage being too low. This can happen due to a faulty rectifier bridge, a malfunctioning thyristor, or issues with the contactor in the charging circuit. For instance, if the inverter fails to start and displays an undervoltage error, it might be due to a damaged voltage regulator or a faulty power supply. Careful inspection of these components is essential to identify and fix the root cause.
Overheating (OH) is commonly caused by environmental factors like high ambient temperature, blocked fans, or poor performance of the temperature sensor. In one case, an ABB ACS500 inverter started showing overheating alarms after running for a while. Upon inspection, it was found that the fan was not working properly due to dust buildup, and cleaning the fan resolved the issue.
Output imbalance is usually indicated by motor jitter or unstable speed. This can be due to a faulty IGBT module, a defective drive circuit, or issues with the reactor. When an output voltage difference is observed, checking the IGBT module and the drive circuit is crucial. Replacing a damaged module or fixing the drive circuit often restores normal operation.
Overload is a common fault that can occur either in the motor or the inverter itself. If the motor is overloaded, it may trigger the inverter’s overload protection. However, if the inverter itself is at fault, it could be due to its limited overload capacity. Monitoring the output voltage and adjusting the parameters accordingly can help prevent this issue.
Switching power supply damage is one of the most frequent causes of inverter failures. Issues like short circuits in the load or faulty components in the power supply can lead to no display, no control voltage, or non-functional fans. Checking the switching power supply and replacing any damaged parts is often the first step in troubleshooting.
SC (Short Circuit) faults are common in Yaskawa inverters. These can be caused by damaged IGBT modules or faulty drive circuits. The design of the drive circuit plays a key role here, as the upper and lower bridges use different optocouplers for driving and monitoring. If the IGBT module is damaged, it can lead to an SC alarm, requiring replacement of the module and further checks on the drive circuit.
Ground Fault (GF) is another common issue, often triggered by a faulty Hall sensor or motor grounding. Environmental factors like humidity and temperature can affect the sensor’s performance, causing drift and triggering the GF alarm. Regular maintenance and checking of the sensor can help prevent this type of fault.
Current Limiting Operation occurs when the inverter detects that the current is approaching its maximum allowable value. In such cases, the system automatically reduces the voltage or frequency to bring the current back within safe limits. Danfoss inverters use internal slope control to manage this, ensuring smooth motor operation and providing feedback to the user. It’s important to check the load and motor for any potential issues when this happens.
These are just a few of the common faults that can occur in inverter systems. Understanding the root causes and following proper diagnostic procedures is essential for effective troubleshooting and repair. Whether it's an overcurrent, overvoltage, or ground fault, each issue requires a systematic approach to ensure the system runs smoothly and efficiently.
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