An inverter is an electronic device or circuit designed to convert electrical energy. Its primary function is to transform direct current (DC) or alternating current (AC) into an AC output with adjustable frequency and phase to meet different operational requirements.
What is an inverter?
An inverter is an electrical device engineered to modify the frequency of AC power, allowing the frequency to be adjusted according to usage needs.
Its operating principle involves converting AC power into DC through a rectifier circuit. The converted DC is then inverted back into AC with a variable frequency, thanks to semiconductor components.
What are the key functions of an inverter?
Nowadays, inverters are equipped with advanced features to meet the increasing demands of motor control and protection.
1. Motor speed control
An inverter functions as a motor speed controller, enabling precise adjustment of speed from zero to the maximum rated level. This allows for flexible and accurate speed regulation based on operational needs.
2. Applications of inverters in speed control
- Energy savings: By adjusting power consumption according to specific application requirements, inverters help significantly reduce electricity costs.
- Improved operational efficiency: Speed regulation via inverters optimizes performance, extends equipment lifespan, and minimizes the risk of mechanical failures.
- Ensuring Product Quality: Precise speed control plays a crucial role in maintaining consistent product quality throughout the production process.
- Enhanced Work Environment: Using inverters reduces motor noise and vibration, creating a safer and more comfortable workspace.
3. Torque control
Inverters provide torque control, ensuring smooth motor startup and reducing electrical load during startup, which significantly minimizes vibration.
Advantages of using an inverter for torque control:
Reduced electrical system stress: Lowering starting current prevents voltage drops and protects the electrical system from overload conditions..
Extended motor lifespan: Smooth startup reduces mechanical damage and increases motor durability.
Enhanced operational efficiency: Smoother motor performance contributes to improved system productivity.
4. Rotation direction changing
An inverter enables quick and efficient reversal of motor rotation.
This function is particularly useful in applications requiring frequent directional changes, such as conveyor systems, fans, and industrial machinery.
5. Motor protection
Inverters help protect motors from conditions such as overload, overcurrent, overvoltage, and overheating.
This feature extends motor lifespan while reducing maintenance and repair costs.
6. Additional auxiliary functions
Currently, inverters are integrated with various advanced auxiliary functions, including:
Communication support: Inverters can connect to other devices via communication protocols such as RS-485, Modbus, and Ethernet.
Built-in PLC Programming: Allows users to implement simple control programs directly on the inverter.
Monitoring and display of technical parameters: Provides real-time data on speed, torque, and current.
Common inverter errors?
1. Inverter indicator error
Check Power Supply Voltage: Ensure the supplied voltage matches the inverter's requirements. Any discrepancies should be corrected immediately.
Inspect the Rectifier Bridge (Diode Bridge): If the rectifier bridge is malfunctioning, contact the supplier for technical support.
CHARGE Indicator Status: If the indicator does not light up, the issue may be caused by a faulty rectifier bridge or capacitor. If the indicator is lit but the inverter still does not function properly, the problem may lie in the internal power supply.
2. Inverter fuse failure
Check Wiring: Ensure that electrical cables are intact and not exposed or shorted to the ground.
Rectifier Bridge Inspection: If the rectifier bridge is defective, contact the supplier for replacement assistance.
3. Motor malfunction
Verify Output Phase Balance: Check if the output terminals (U, V, W) are balanced. If the output is balanced but the motor is not functioning correctly, the issue likely lies with the motor itself. If the output is unbalanced, the problem may be due to a faulty inverter control board.
4. Inverter operates normally, but the fuse blows during operation
Check for short circuits: Ensure there are no short circuits at the inverter output terminals.
Ground Fault Inspection: If a ground fault is detected, it must be resolved before resuming operation.
5. Reasons why an inverter may explode
Inverter cleaning: Keep the inverter free from dust and metallic debris.
Installation check: Ensure proper wiring and secure connections for both input and output terminals.
Component Failure Risks: Critical components such as IGBT modules or the rectifier bridge (diode bridge) may become damaged, increasing the risk of fire or explosion.
Surge Protection: Implement appropriate protection measures to shield the inverter from lightning strikes.
Parameter Configuration: Verify that all settings on the inverter are correctly configured.
Power source stability: Measures are needed to protect the inverter from power source instability.
6. Overcurrent fault (OC)
This is a common issue that occurs when the current through the inverter exceeds the allowable limit..
Possible causes:
- Motor overload
- Rectifier fuse failure
- IGBT malfunction
Troubleshooting solutions:
- Reduce the motor load
- Inspect and repair the rectifier fuse
- Replace the IGBT module if damaged
Overvoltage fault (OV)
This occurs when the input voltage of the inverter exceeds the permissible level.
Possible causes:
- Sudden spikes in power supply voltage
- DC capacitor failure
Troubleshooting solutions:
- Check and regulate the power supply voltage
- Replace the DC capacitor if faulty
Overtemperature fault (OT)
The Overtemperature (OT) fault occurs when the internal temperature of the inverter exceeds the safe threshold. Possible causes include a malfunctioning cooling fan, an excessively high ambient temperature, or blocked ventilation paths. To fix this, check and repair the cooling fan if necessary, cool the environment around the device, and clean the ventilation to ensure air can circulate freely.
Phase loss fault (UVP)
This fault occurs when one or more phases of the power supply do not provide sufficient voltage or are disconnected. Common causes include power supply instability or loss, as well as loose wiring connections. Troubleshooting measures include checking and improving the power supply condition and inspecting and tightening wiring connections to ensure effective operation.
Motor protection fault (OL)
This issue arises when the motor experiences an overload or damage, which can trigger an overload fault. To resolve this, reduce the motor load and conduct inspections or repairs as necessary.
Communication fault (COM)
This fault typically occurs due to issues in the connection between the inverter and other devices. Causes may include loose or damaged communication cables or incorrect communication settings. Troubleshooting involves checking and securing the connection cables and verifying and adjusting the communication settings accordingly.
Inverter errors and troubleshooting methods
How to fix Hitachi inverter errors
Error codes and their meanings:
E41: ModBus connection error - Communication issue detected.
E38: Overload at low speed – The system is overloaded when running at low speed.
E37: Emergency stop error – The machine stops abruptly due to safety reasons.
E36: Braking error – Malfunction in the deceleration system.
E35: Thermal sensor fault – The machine temperature exceeds the permissible limit.
E30: IGBT fault – A component in the electronic circuit is damaged.
E25: Main control board error – A critical issue in the primary control board.
E24: Input phase loss – Unstable power supply or missing phase.
E23: Communication gate array fault – Communication port connection issue..
E21: Overheating error – The system requires cooling.
E20: Cooling fan running slow - Making the machine hot.
E16: Temporary power loss – An interruption in power supply.
E15: Input overvoltage - The input voltage exceeds the allowable range.
E14: Ground fault – Electrical leakage detected.
E13: USP error – Issue with the backup power supply (UPS).
E11: CPU error – Malfunction in the central processing unit.
E10: Abnormal current detection – Warning of irregular current.
E08: Low voltage error – Input voltage drops below the allowable limit.
E07: Overvoltage or EEPROM fault – Excessive input voltage or data storage issue.
E06: Brake resistor overload – Overheating in the braking system.
E05: Overload warning – The system is operating beyond its capacity.
E04: Overcurrent under other conditions – Unexpected high current in special scenarios.
E03: Overcurrent during acceleration - Excessive current when the machine accelerates.
E02: Overcurrent during deceleration - Excessive current when the machine decelerates.
E01: Overcurrent at steady speed – Excessive current when the system runs at a stable speed.
Inverter errors troubleshooting method
Below is a guide to handling common errors in Hitachi inverters, presented in a clear and understandable manner:
When an inverter signals an overcurrent fault, follow these steps:
- If the motor speed remains unchanged, check the output wiring to ensure there is no insulation fault and verify whether the motor is overloaded.
- If the motor speed decreases, inspect the wiring for insulation issues and extend the deceleration time.
- If the motor speed increases, check the insulation of the wiring and increase the acceleration time to ensure system safety.
For other errors
Below are troubleshooting instructions for some common inverter errors:
If an overcurrent fault occurs in a special situation, contact a professional repair team to ensure safety and efficiency. If an overload fault occurs, check whether the motor is operating beyond its rated capacity. For brake resistor overload, inspect any sudden changes in load conditions.
Regarding overvoltage or undervoltage errors, ensure that the input voltage remains within the inverter's permissible range. In the event of a ground fault, check whether the wiring between the inverter and the motor has any issues, such as short circuits. If an overvoltage at the input is detected, verify the power supply voltage.
For temporary power loss issues, adjust the power supply or inspect circuit boards. If the cooling fan operates at low speed or the motor overheats, inspect and repair as necessary. For communication faults or input phase loss, check the control wiring and three-phase power connections. Lastly, if there is a malfunction in the main control board or IGBT module, inspect and determine whether they need to be replaced or repaired.
Error codes and solutions for Schneider inverters
F010 - Overcurrent: Check motor settings, use chokes if necessary, and inspect wiring connections.
F018 and F019 - Overcurrent: Check motor settings, use chokes if necessary, and inspect wiring connections.
F020 - IGBT Short Circuit: Contact Schneider Vietnam for technical support.
F025 - Overspeed: Inspect the motor and feedback device; a braking resistor may be required to reduce speed.
F033 - AI Input Signal Loss: Check input signal settings and wiring connections.
F014 and F015 - Loss of One or Three Output Phases: Inspect motor connections.
F017 - Input Phase Loss: Check the power supply and fuses, and disable phase loss detection if necessary.
F022 - Communication Error: Inspect the communication system settings and connections.
F030 - Undervoltage: Ensure power supply quality and adjust settings accordingly.
F027 - IGBT Overtemperature: Reduce motor power and switching frequency; allow time for IGBT cooling.
F012 - Overload Handling: Restart the inverter to reset the fault.
If you encounter software issues with the inverter, check and reset the parameters. In cases where the inverter is unstable or frequently experiences faults, it is advisable to contact a certified repair center. For low voltage fault (LVT) displayed on the control panel, check the input power supply.
If the inverter has a burnt circuit board or a damaged IGBT, replacing the IGBT is necessary. In case of lightning strike damage, contact the warranty center for support. If there are difficulties in controlling the inverter, inspect the wiring and control system.
When the inverter indicates an overload fault (OLT), you may need to reduce the motor load or adjust the braking time. If the LCD screen is faulty and not displaying information, contact a repair center for replacement. For output phase loss, indicated as POT fault, check the output power supply.
A fault in the MMIO board or a ground fault (GFT) requires inspection of wiring connections. If the LS inverter is not functioning, replacement may be necessary. For overload faults (IOL) or overcurrent faults (OCE, OC2), reducing the motor load is a viable solution. Finally, for communication errors (ERR), check the wiring connections and resolve any communication issues.
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Step 1: Identify the error code
Vicruns inverters use an LED display to show error codes, helping users accurately identify issues. This allows for effective troubleshooting and the application of appropriate corrective actions.
Step 2: Troubleshoot the error
Below are guidelines for resolving some common issues with Vicruns inverters.
Overcurrent fault (OC)
Causes: Motor overload, damaged rectifier fuse, faulty IGBT module
Solutions:
- Reduce motor load
- Inspect and repair the rectifier fuse
- Replace the IGBT module if faulty
Overvoltage fault (OV)
Causes: Abnormally high input voltage or faulty DC capacitor
Solutions:
- Check and adjust the power voltage
- Replace the DC capacitor if defective
Overtemperature fault (OT)
Causes: Broken cooling fan, excessively high ambient temperature or blocked ventilation slots
Solutions:
- Check and Repair the Cooling Fan
- Lower the ambient temperature
- Clean the ventilation slots to improve airflow
Phase loss fault (UVP)
Causes: Power failure or unstable power supply, loose wiring connections
Solutions:
- Inspect and resolve power supply issues
- Check and tighten wiring connections
Motor protection fault (OL)
Causes: Motor overload or motor failure
Solutions:
- Reduce the motor load
- Inspect and repair the motor if necessary
Communication fault (COM)
Causes: Loose or damaged connection cable, incorrect communication configuration
Solutions:
- Check and secure the connection cable
- Verify and adjust the communication settings
How to fix Emerson inverter errors
HF04: The inverter reports an error due to the voltage being lower than the normal operating range.
HF05: The inverter fails to start because the DSP does not generate a signal.
HF06: The inverter suddenly stops operating while running.
HF07: Issues with scan time lead to operational errors.
HF08: The inverter is not operating stably, which can be manifested by jerking or not maintaining a constant speed.
HF11: The inverter cannot connect to the EEPROM, and all operations related to EEPROM communication are rejected.
HF20: There is a problem with the power supply to the inverter.
HF21: The input voltage does not match the expected value, potentially causing power-related errors.
HF23 and HF24: Software-related issues require inspection, updates, or repairs.
HF32: The inverter's thermal feedback system is not functioning, which may lead to overheating issues.
HF25: A communication failure between the main processor and the auxiliary processor results in a lost connection.
HF26: Startup failure or an IGBT short circuit, typically indicating severe PCB issues.
HF27: The inverter temperature exceeds the allowable limit.
HF28: A software error occurs in the DSP on the printed circuit board (PCB).
HF29: The cooling fan is not functioning, requiring inspection or replacement.
HF30: A problem with the DCCT cable requires checking and repairs.
HF31: The module’s fan is not operating, affecting cooling efficiency.
How to fix Panasonic inverter errors
If the inverter runs for a while and then suddenly stops, you need to check whether the inverter is still in RUN mode. Below is a simple guide for each situation:
Case 1: RUN mode is not active
Issue: The automatic run command signal is interrupted, causing the inverter to display an error, and the "TRIP" indicator light turns on.
Solutions:
- Check and tighten the control wiring.
- Ensure all control terminals are securely connected.
Case 2: RUN mode is active
Issue: The inverter gradually slows down until it comes to a complete stop. Possible causes include a jammed motor, unstable voltage, a faulty rectifier bridge, or a capacitor charging resistor failure.
Solutions:
- Use a multimeter to check and adjust the supply voltage if necessary.
- Check whether the motor is overheating when operating with the inverter.
Other causes and solutions:
Causes:
- Incorrect parameter settings on the inverter.
- Improper motor wiring connections.
- Operating frequency is too low.
Solutions:
- Refer to the user manual and adjust the inverter parameters accordingly.
- Check and ensure the motor wiring is connected correctly.
How to fix Siemens inverter errors
Overcurrent error (F001):
Causes: Mismatched motor power, excessively long cables leading to short circuits or ground faults.
Solutions: Check the motor power rating, ensure the cable length is appropriate and free from short circuits, adjust the stator impedance as needed, inspect the motor to ensure it is not jammed or overloaded.
Overvoltage error (F002):
Causes: DC link voltage is too high, possibly due to excessive input voltage or regenerative energy feedback from the motor.
Solutions: Verify and ensure the input voltage is within the allowable range, adjust deceleration time to match the system’s inertia, manage braking energy to prevent exceeding the limit.
Undervoltage error (F003):
Causes: Power supply failure or excessive load impact.
Solutions: Ensure the supply voltage is within the acceptable range, maintain a stable and continuous power source.
How to fix ABB inverter errors
Overcurrent fault (A001):
Causes: Short circuit at the inverter output, motor malfunction, internal circuit failure in the inverter.
Solutions: Check the motor load, inspect motor cables, review startup time and surrounding environmental conditions.
DC overvoltage error (A002):
Causes: High-inertia load, improper braking resistor value
Solutions: Check the control system settings, ensure the braking resistor has an appropriate value, reset the inverter parameters.
IGBT overtemperature fault (A003):
Causes: IGBT temperature exceeds the limit, typically 135°C
Solutions: Check environmental conditions, ensure the cooling fan operates efficiently, inspect motor voltage.
Short circuit fault (A004):
Causes: Short circuit in the inverter or motor.
Solutions: Check the motor, cables, and inverter for any signs of burning or short circuits.
Parameter setting error (A005):
Solutions: Adjust device parameters or reset to default settings if necessary
Conclusion on Common Inverter Errors
We hope that the information provided above will assist you in troubleshooting inverter issues and improving the efficiency of your equipment's operation and maintenance. Let’s move forward together with Han My Viet on the path of progress!
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