Inverter overload

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The electronic thermal protection for the inverter indicates that the drive is close to disconnecting due to prolonged high output current. The internal counter gives a warning at 98% and trips at 100%. The drive cannot be reset until the counter drops below 90%.

• Mechanical overload on the motor and driven equipment (e.g., jammed conveyor, worn bearings), causing sustained high current draw.
• Incorrect motor parameters (P1-20 to P1-25) entered into the drive, leading to inaccurate thermal modeling.
• Drive is undersized for the application, consistently operating above its nominal rated current.
• High ambient temperature around the drive, reducing its cooling efficiency and thermal capacity.
• Output filter or reactor issues causing excessive current ripple or impedance.

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1. 1

   1. Measure the motor's actual operating current (A01-04) and compare it to the drive's rated output current and the motor nameplate FLA.

2. 2

   2. Inspect the mechanical system (bearings, gears, alignment) for binding, excessive friction, or jams that increase motor load.

3. 3

   3. Verify all motor nameplate data (kW, V, A, Hz, RPM) is accurately entered into drive parameters P1-20 to P1-25.

4. 4

   4. Ensure adequate airflow and ambient temperature (within specified limits) around the drive's heatsink and cooling fans; clear any dust or obstructions.

5. 5

   5. If the application has high starting torque or transient loads, consider increasing the drive's current limit parameter (P2-21) temporarily for testing, if within safe operating limits.

6. 6

   6. Perform a motor no-load test to determine if the drive's output current (A01-04) is reasonable without mechanical load.