Drives Troubleshooting 301

© 2012 Eaton Corporation. All rights reserved.

Agenda

• Drive will not start

• Drive will not get to speed
• 10 Common Fault codes
1. Overcurrent
2. Current limit controller
3. Ground fault
4. Output phase fault
5. Overvoltage Fault
6. Overvoltage controller
7. Undervoltage fault
8. Unit over temperature
9. Motor over temperature
10.Input phase fault
© 2014 Eaton. All Rights Reserved.. 2
 Drive does not start
Causes No Start
• Drive not ready
• Drive not receiving a Run Signal
Drive No Active
Ready? Fault?

Yes Yes

Check
Start No DC Bus
source OK?
settings

Not Ready Causes Yes Yes

• Active fault Check No Run

Control Correct Settings
• DC bus too high or low Place
Enable?

• Run enable input not present Yes

Yes

Run Signal not present Check No Ensure start

• Control place not correct Start
Signal
command is active,
check wiring
Example trying to start from I/O
Yes
when active control place is
keypad. Restart Drive

© 2014 Eaton. All Rights Reserved.. 3

 Drive does not get to speed
Not getting to speed Causes
• Missing reference
• Preset speed or jog speed active
Current Yes Check
or DC Motor
bus Limit Current

No OK?

No
Analog DC Bus
Input Check wiring OK?
reading?

Yes Yes
Missing Reference
Check
Reference
No
Correct Settings
• Check analog input monitor
source
settings • Check that the drive is
Yes programmed to follow the correct
Preset Yes input
Remove fixed speed
speed
active?
command • Ensure the drive is not hitting any
other limits
No
• Check frequency reference
Check Speed compared to output frequency

© 2014 Eaton. All Rights Reserved.. 4

 10 Common Fault Codes - Overcurrent
Causes Over Current
• Incorrect motor parameters
• Mechanical fault
• Electrical fault Check No
Correct Settings
Motor
• Current measurement error Settings

Yes

Disconnect Motor
Leads, Restart drive

• Check wiring and motor for

insulation failures and proper Over
No
Check Motor, Load,
Current and drive size
connections
• Check for mechanical overload, Yes
Locked rotor Current
measurement fault in
• Check for proper drive size Drive

Restart Drive

© 2014 Eaton. All Rights Reserved.. 5

 10 Common Fault Codes – Current Limit
Current Limit
Causes
• Incorrect motor parameters
Check • Mechanical fault
No
current
limit
Correct Settings • Electrical fault
Settings
• Current measurement error
Yes

Check Motor, Load,

and drive size

No
• Not all models have an indication
Current
Limit
when the current limit is reached
• Current limit will reduce output
Yes
frequency to reduce output current
Perform motor to at or below the current limit
identification
setting

Restart Drive

© 2014 Eaton. All Rights Reserved.. 6

 10 Common Fault Codes – Ground Fault
Ground Fault
Causes
• Faulty motor
• Electrical fault
Check No
• Current measurement error Motor
leads
Correct cabling

Yes

Disconnect Motor
Leads, Restart drive

• Check for loose or high resistance No Check Motor, and

Ground
connections to the motor Fault
test drive with known
good motor
• Test motor for electrical failure
Yes
• Disconnect motor leads or apply
Current
known good motor to verify current measurement fault in
Drive
measurements

Restart Drive

© 2014 Eaton. All Rights Reserved.. 7

10 Common Fault Codes – Output Phase
Causes
• Loose Motor Connections
Output Phase
• Faulty Motor
• Current measurement error
Disconnect Motor
Leads

Output No Check Motor and

Phase connections
Fault
• Caused by current imbalance on
Yes
the output of the VFD
Faulty Current
Measurement
• Look for loose connections or fault
in motor windings

Restart Drive

© 2014 Eaton. All Rights Reserved.. 8

 10 Common Fault Codes - Overvoltage
Causes Over Voltage
• High Line Voltage
• Regenerated voltage from load
Line
• Excessive line side harmonics Voltage
No
Correct input voltage
OK?

Yes Yes

Fault occurs during Increase

deceleration or when deceleration time or
motor is over run add brake chopper

No
• If Fault occurs during deceleration
or stop command then increase Monitor = Yes
Check line side
Measured
Harmonics
deceleration time or brake chopper value

may be needed. No
• Cyclic loads may need regen unit measurement fault
or brake chopper. in drive

• Excess harmonics may be

overcharging DC link capacitors.
Restart Drive

© 2014 Eaton. All Rights Reserved.. 9

 10 Common Fault Codes – Overvoltage
Controller
Over Voltage
Causes
• High Line Voltage
• Regenerated voltage from load
Line
Voltage
No
Correct input voltage
• Excessive line side harmonics
OK?

Yes Yes

Fault occurs during Increase

deceleration or when deceleration time or
motor is over run add brake chopper

No
• Trouble shooting is the same as for
Monitor = Yes
Check line side the overvoltage fault, the
Measured
value Harmonics overvoltage controller will increase
No
the reference in an attempt to
bleed off excess voltage
measurement fault
in drive • Not all series of VFD’s have an
indication of when this controller is
active.
Restart Drive

© 2014 Eaton. All Rights Reserved.. 10

 10 Common Fault Codes – Undervoltage
Under Voltage
Causes
• Low Line Voltage
• Improperly sized drive Line No
Voltage Correct input voltage
OK?

Yes

No
Static
Replace faulty
Checks
OK? components

Yes

• Check for low line voltage or drops Monitor = Yes Check power quality
Measured and proper drive
in line voltage under load. value sizing
• Check for damaged input rectifiers No
with static checks
measurement fault
• Check for even current draw on in drive

input when drive is running

Restart Drive

© 2014 Eaton. All Rights Reserved.. 11

10 Common Fault Codes – Unit Over temp
Unit Over Causes
Temperature
• High Ambient temperature
• Insufficient airflow
Cooling No Repair Cooling • Plugged heat sink
fan on? Fan(s)
• Failed cooling fan
Yes

No
Heat sink
clear
Clean heat sink

Yes
• Check Main cooling fan for rotation
Yes Check ambient
Monitor =
Measured temperature of inlet • Ensure unobstructed heat sink and
value air airflow
No • Check ambient temperature is
measurement fault below the drives ratings
in drive

Restart Drive

© 2014 Eaton. All Rights Reserved.. 12

 10 Common Fault Codes – Motor Over
temp
Causes Motor Over
Temperature
• Overloaded Motor
• Operating Motor at high load at low
speeds Motor No
Parameter Correct Parameters
• Undersized Motor s OK?

• Incorrect Motor Parameters Yes

No Check Motor thermal

Motor overload parameters after
Overload ensuring no overload
condition exists

• Check Motor Parameters Yes

• Observe current and speed Reduce Motor Load

• Current should be nearly

proportional to speed, if running
half speed at FLA drive will protect
motor from increased thermal
stress from reduced cooling

Restart Drive

© 2014 Eaton. All Rights Reserved.. 13

10 Common Fault Codes – Input Phase
Input phase fault
Causes
• Missing Input phase
Line No • Damaged Drive
Voltage Correct input voltage
OK?

Yes

No
Static
Replace faulty
Checks
OK? components

Yes

No • Check for Line Voltage imbalance

Input
phase fault
• Check for loose connections or
blown fuses
Yes
• Check for damaged input rectifiers
measurement fault
in drive with static checks
• Single phase input drives need to
have this protection disabled
Restart Drive • Check for even current draw on
input when drive is running
© 2014 Eaton. All Rights Reserved.. 14
© 2016
2012 Eaton.
Eaton Corporation.
All Rights Reserved..
All rights reserved. 15