During the use of the inverter, we sometimes feel at a loss for the occurrence of inverter faults and do not know where to start.
This article is mainly about the handling of A1000 fault OL1 of Yaskawa frequency converter and the handling of frequency converter failure.
Solutions to A1000 Fault OL1 of Yaskawa Inverter
OL1 motor overload
Reasons: 1. The load is large, the acceleration and deceleration time, and the cycle is too short.
The voltage of the V/f-characteristic is high.
3. The setting value of E2-01 (motor rated current) is inappropriate
Countermeasures: 1. Adjust the size of the load, acceleration and deceleration time, cycle
2. Adjust the V/f characteristics
3. Confirm the setting of E2-01 (motor rated current)
Summary of common faults of frequency converterWith the help of the digital multimeter, the technician can simply judge whether the main circuit device is damaged or not according to the above figure. (Mainly rectifier bridge, IGBT, IPM) For personal safety, it is necessary to ensure that the machine is powered off, and the input power lines R, S, T and output lines U, V, W are removed and then put into operation!
First, set the multimeter to the "secondary tube" file, and then use the red and black test leads of the multimeter to test according to the following steps:
1. The black test pen touches the negative pole P (+) of the DC bus, the red test pen touches R, S, T in turn, and the displayed value on the multimeter is recorded; then the red test pen touches N (-), and the black test pen touches R, S, and R in turn. T, record the displayed value of the multimeter; if the displayed value of the six times is basically balanced, it indicates that there is no problem with the inverter diode rectification or soft-start resistance. On the contrary, the rectifier module or soft-start resistance in the corresponding position is damaged. Phenomenon: no display.
2. The red test pen touches the negative pole P (+) of the DC bus, the black test pen touches U, V, W in sequence, and the displayed value on the multimeter is recorded; then the black test pen touches N (-), and the red test pen touches U, V, and U, V, and W in sequence. W, record the displayed value of the multimeter; if the displayed value of the six times is basically balanced, it indicates that there is no problem with the inverter IGBT inverter module. On the contrary, the IGBT inverter module at the corresponding position is damaged. Phenomenon: no output or failure.
As a well-known brand in Japan, Yaskawa inverters also occupy an important position in the inverter market in China. Yaskawa has a complete range of inverters. General-purpose inverters have won the market with their good quality from the early 616G3, to the later 616G5, and now the 616G7. In addition, Yaskawa inverters have a broader market in the promotion industry. From the original 676VG3 to the current 676GL5, Yaskawa inverters have established a good reputation in the promotion industry with their superior torque characteristics and established a leading advantage. The control method of Yaskawa inverters has also been improved from the voltage vector control method commonly used by the original inverter manufacturers to the current vector control method with better torque dynamic characteristics, making it more and more closer to DC speed regulation.
We will still encounter various faults in the use of Yaskawa inverters. The following will discuss common faults of Yaskawa inverters with the majority of users.
1. The switching power supply is damaged
Switching power supply damage is the most common failure of many inverters. It is usually caused by a short circuit in the load of the switching power supply. In the switching power supply circuit design of many inverters, Yaskawa inverters should be said to be relatively successful. 616G3 uses a two-stage switching power supply, which is similar to Fuji G5. First, the first-stage switching power supply converts the DC voltage of more than 500 volts on the DC bus side into a DC voltage of more than 300 volts. Then through the secondary coil of the high-frequency pulse transformer, lower voltages such as 5V, 12V, 24V, etc. are output for the control board of the inverter, the drive circuit, the detection circuit, etc. as power supply. In the design of the second-level switching power supply, the Yaskawa inverter uses a controllable voltage-stabilizing device called TL431 to adjust the duty cycle of the switching tube, so as to achieve the purpose of stabilizing the output voltage. The LG inverter we talked about in the previous issues also uses a similar control method. QM5HL-24 and TL431 used as switch tubes are relatively easily damaged devices. In addition, if we hear harsh screams in use, which are emitted by the pulse transformer, it is very likely that there will be a short circuit on the output side of the switching power supply. We can find the fault from the output side. In addition, when there is no display, no voltage at the control terminal, DC12V, 24V fan does not work, etc., we should first consider whether the switching power supply is damaged.
2. SC failure
SC failure is a common failure of Yaskawa inverters. The IGBT module is damaged, which is one of the reasons for the SC fault alarm. In addition, damage to the drive circuit can easily lead to SC fault alarms. In the design of the drive circuit, Yaskawa uses a drive optocoupler PC923, which is an optocoupler with an amplifier circuit dedicated to driving IGBT modules, and Yaskawa’s lower bridge drive circuit uses an optocoupler PC929. It is an optocoupler with an amplifier circuit and a detection circuit inside. In addition, motor jitter, three-phase current, unbalanced voltage, frequency display but no voltage output, these phenomena may be IGBT module damage. There are many reasons for the damage of the IGBT module. The first is the damage of the IGBT module caused by the failure of the external load, such as the short-circuit of the load and the blocked rotor. Secondly, the aging of the driving circuit may also cause the distortion of the driving waveform, or the driving voltage fluctuates too much, which may cause the damage of the IGBT, which may cause the SC fault alarm.
3. OH—overheating
Overheating is a fault that is usually encountered. When encountering this situation, the first thing to think of is whether the cooling fan is running. Observing the outside of the machine, you will see whether the fan is running. In addition, for 30kW
The above machines also have a cooling fan inside the machine. The damage of this fan will also cause an OH alarm.
4. UV-undervoltage fault
When an undervoltage fault occurs, first check whether the input power supply is lacking phase. If there is no problem with the input power supply, then we must check whether there is a problem with the rectifier circuit. If there is no problem, then it depends on whether there is a problem with the DC detection circuit. For a 200V class machine, when the DC bus voltage is lower than 190VDC, a UV alarm will appear; for a 400V class machine, when the DC voltage is lower than 380VDC, a fault alarm will appear. It mainly detects whether a voltage drop resistor is open.
5. GF—ground fault
Ground faults are also common faults. In addition to troubleshooting the grounding problems of the motor, the most likely part of the fault is the Hall sensor. The Hall sensor is affected by environmental factors such as temperature and humidity, and the operating point is very easy. Drift occurs, causing GF to alarm.
Yaskawa inverter reports Uv1 fault name:
Main circuit undervoltage
When the run command is not input (the inverter is stopping), the following conditions will occur.
· The DC voltage of the main circuit is lower than the set value of L2-05 (Detection value of undervoltage (UV) of the main circuit) · 200V class: about 190V (160V for single phase)
· 400V class: about 380V (when the setting of E1-01 (input voltage setting) is less than 400, it is 350V.) Yaskawa inverter reports Uv1 failure reason 1: input power phase loss occurs. Countermeasures: confirm whether the main circuit power supply is connected A wire break or wiring error has occurred. Wire correctly.
Reason: The wiring terminals of the input power supply are loose. Countermeasures: Check whether the terminals are loose.
Please tighten the terminals according to the tightening torque in this manual. Yaskawa inverter reports Uv1 failure reason 2: power supply voltage failure Countermeasure: confirm the voltage.
Adjust the voltage to within the power supply specification range of the inverter. Reason: Power failure occurred. Countermeasure: Improve power supply.
Yaskawa inverter reports Uv1 failure cause 3: the internal circuit of the inverter is aging. Countermeasures: use U4-05 (capacitor maintenance) to confirm the maintenance period of the capacitor. If U4-05 exceeds 90%, replace the inverter.
Reason: Due to the insufficient capacity of the power transformer, the inrush current of the inverter reduces the power supply voltage
Countermeasures: Check whether an alarm occurs when the wiring circuit breaker, leakage circuit breaker (with overcurrent protection function) or electromagnetic contactor is opened.
Modify the capacity of the power transformer.
Reason: The internal temperature of the inverter is abnormal. Countermeasure: Confirm the ambient temperature of the inverter. Reason: The charging indicator is defective (the indicator is disconnected). Countermeasure: Replace the inverter.
Yaskawa inverter ov fault name:
Main circuit overvoltage
The DC voltage of the main circuit exceeds the overvoltage detection value 200 V class: about 410 V
400 V class: about 820 V (E1-01
The deceleration time is too short, and the regenerative energy of the motor flowing to the inverter is too large. Countermeasures: Increase the value of C1-02, 04, 06, 08 (deceleration time). Connect the braking resistor or braking resistor unit to the inverter.
Set L3-04 (selection of stall prevention function during deceleration) to 1 (valid). (Factory setting: 1) Yaskawa inverter ov failure reason 2: acceleration time is too short
Countermeasure: Check whether an overvoltage alarm occurs when the sudden acceleration ends. When an alarm occurs, increase the acceleration time. Use S-shaped acceleration and deceleration.
Yaskawa inverter ov failure reason 3: brake load is large
Countermeasures: Connect a braking resistor or braking resistor unit to the inverter. Reason: Surge voltage is mixed in the input power. Countermeasure: Install a DC reactor.
(Note) In the same power system, if the phase capacitors or SCR converters are switched on or off, it may cause the input voltage to rise rapidly (surge) for a short time. Yaskawa inverter ov fault reason 4: grounding short circuit occurred in the motor
Countermeasures: (The grounding short-circuit current charges the main circuit capacitor in the inverter through the power supply). Check the power cables, relay terminals, and motor terminal boxes of the motor. Remove the part where the ground short-circuit occurred, and turn on the power again.
Yaskawa Inverter ov fault cause 5: Improper setting of speed search related parameters Countermeasures: (including the situation that occurs when the instantaneous power failure is restored and the fault retry) Modify the setting of the speed search related parameters.
Set the speed search retry function to be effective. (Set b3-19 ≥ 1 to 10.) Adjust b3-02 (speed search operation current) and b3-03 (speed search deceleration time). After performing self-learning of motor resistance between wires, use b3-24=1 (speed estimation form search function). Yaskawa inverter ov failure reason 6: The regenerative energy when overshooting after the end of acceleration is too large
Countermeasure: Set L3-11 (overvoltage suppression function selection) to 1 (valid). Yaskawa inverter ov failure reason 7: The power supply voltage is too high. Countermeasures: Check the voltage.
Reduce the voltage to within the power supply specification range of the inverter. Yaskawa inverter ov failure reason 8: the brake transistor is damaged. Countermeasures: replace the inverter.
Reason: The wiring of the brake resistor or the brake resistor unit is incorrect
Countermeasures: Check whether there is an error in the wiring with the brake resistor or the brake resistor unit. Wire correctly. Cause: Misoperation occurred due to interference. Countermeasure: Check the status of anti-interference countermeasures.
Check the wiring of the control circuit, the wiring of the main circuit, and the grounding wiring, and take adequate anti-interference measures. If the electromagnetic contactor is the source of interference, connect a surge suppressor to the coil of the electromagnetic contactor. Set L5-01 (fault retry times) to a value other than 0. Yaskawa Inverter ov failure reason 9: The motor is out of adjustment Countermeasures: adjust the parameters of the control out of adjustment. Adjust N1-02 (to prevent offset gain).
Adjust the N2-02 and N2-03 (without PG vector) speed feedback detection control (AFR) time parameters. Adjust N8-45 (PM speed feedback detection control gain), N8-47 (draw current compensation time parameter). Yaskawa inverter ov failure reason 10: the load moment of inertia is set incorrectly
Countermeasures: Confirm the setting of load inertia when using functions such as KEB, overvoltage suppression, and stall prevention during deceleration (optimal adjustment). Adjust L3-25 (load inertia ratio) according to the applicable machinery.
Reason: The short-circuit braking function is used in the PM-free vector control mode without PG. Countermeasure: Connect the braking resistor.
Yaskawa inverter CoF fault name:
Current bias fault
Current detection circuit is bad, or PM motor starts in free running. Yaskawa inverter CoF fault 1:
Reason: In the automatic adjustment of the current bias, the adjustment value exceeds the allowable range (when using a PM motor, it needs to be started in free running)
Countermeasure: Set b3-01 (speed search selection at startup) to 1 (valid).
Please use the external search command 1 or 2 (H1-port = 61 or 62) from the external terminal for speed search. (Note) In PM motor control, the actions of external search command 1 and external search command 2 are the same. Yaskawa inverter CoF failure 2: Reason: hardware failure
Countermeasures: Seek help from the inverter repair service provider or directly replace the inverter.
Yaskawa inverter oC fault name:
Overcurrent
The detected output current of the inverter exceeds the overcurrent detection value. Yaskawa inverter oC fault 1: Cause: The motor is burned or the insulation is aging. Countermeasures: Confirm the insulation resistance of the motor. If it is on, replace the motor. Yaskawa inverter oC fault two:
Reason: Contact and grounding short-circuit occurred due to cable damage. Countermeasure: Check the power cable of the motor.
Remove the part where the ground short-circuit occurred, and turn on the power again. Check the resistance value between the cable and the terminal. If there is continuity, replace the cable. Yaskawa inverter oC fault three: Cause: excessive load
Countermeasure: Measure the current value flowing through the motor.
If the current exceeds the rated current of the inverter, replace the inverter with a larger capacity. I confirm whether the current value is changing rapidly.
When the current changes rapidly, the load change will decrease, or the capacity of the converter will increase. it
The OC failure of the transmission inverter four: the reason is: the acceleration and deceleration time is set too short.
Countermeasure: Calculate the torque required for acceleration through the load moment of inertia and acceleration time. When the torque is abnormal, take the following measures.
Increase C1-01, 03, 05, 07 (acceleration time). Increase the setting value of C2-01 (04 s) character. Increase the capacity of the transducer. Hon Chuan Chuan inverter OC failure five:
The reason is: Use a special motor or the motor with the most suitable capacity. Countermeasure: Confirm the motor capacity. it
Please recombine the motor and the inverter so that the rated current of the motor nameplate is less than the rated current of the inverter. Hon Chuan Chuan inverter OC failure six:
Reason: The electromagnetic contactor is opened and closed on the output side (both sides) of the inverter.
Countermeasure: Please connect the sequence controller so that the electromagnetic contactor does not open or close during the inverter output current period. Hon Chuan Chuan inverter OC failure 7: Reason: V/F setting is abnormal.
Countermeasure: Study the relationship between the frequency and voltage set by V/F, and adjust E1-04 to E1-10. (Second motor: adjust E3-04 to E3-10). When the voltage is higher than the frequency, please lower the voltage. Hon Chuan Chuan frequency converter OC failure eight: Reason: the countermeasure of the torque lifting capacity is larger: confirm the torque lifting amount. it
Reduce the torque compensation (torque boost) gain until the current decreases and the motor does not stop. Yaskawa inverter OC failure 9: Reason: due to interference and misoperation. Countermeasures: determine the state of anti-interference measures.
Check the wiring of the control circuit, the wiring of the main circuit and the grounding wire, and take adequate measures to prevent interference.
If the electromagnetic contactor is the source of interference, the coil of the surge contactor is connected to a surge suppressor. L5-01 (fault retry time) is set to a value exceeding 0. Hon Chuan Chuan inverter OC failure ten: Reason: overexcitation operation gain is too large.
Countermeasures: Check whether the overexcitation operation is faulty. it
Please consider the magnetic saturation of the motor and reduce the setting of N3-13 (overexcitation deceleration gain). Yaskawa inverter OC failure 11: Reason: The motor is running freely and the starting countermeasure: Please take any of the following countermeasures.
B3-01 (start speed search selection) is set to 1 (valid). Search the input speed from the input terminal of the multi-function touch point. it
H1 port is set to 61 or 62 (external search command).
OC twelve failed:
Reason: The motor code is not set correctly (PM PG, no vector control mode).
Countermeasure: According to the permanent magnet motor or IPM motor used, set E5-01 (motor code selection (PM use)) correctly. Hon Chuan Chuan inverter OC failure thirteen:
Reason: The combination of control mode and motor is incorrect.
Countermeasure: Confirm the setting of A1-02 (control mode selection). When using IM motor, A1-02=0 or 2.
When using PM/IPM motor, A1-02=5
ConclusionThis is the end of the introduction about the fault of Yaskawa Inverter A1000, I hope this article can be helpful to you. If there are any deficiencies, please correct me.
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