— A Focus on “END” Faults and TRIP Light Illumination
Table of Contents
- Introduction
- Fundamentals of Inverters 2.1 How Inverters Work 2.2 Technical Specifications of Anruiji E6 Series Inverters 2.3 Core Functions and Applications
- Basic Fault Diagnosis Process 3.1 Classification of Fault Phenomena 3.2 Steps for Fault Diagnosis
- In-Depth Analysis of “END” Faults and TRIP Light Illumination 4.1 Definition and Manifestation of Faults 4.2 Possible Causes of Faults 4.3 Viewing and Interpreting Fault Codes
- Common Fault Types and Solutions 5.1 Overcurrent Faults (OC1/OC2/OC3) 5.2 Overload Faults (OL1/OL2) 5.3 Phase Loss Faults (SP1/SP0) 5.4 Overvoltage/Undervoltage Faults (OV1/OV2/UV) 5.5 Motor Parameter Autotuning Faults (TE) 5.6 External Faults (EF)
- Principles and Troubleshooting of Motor Parameter Autotuning 6.1 Purpose and Process of Autotuning 6.2 Causes and Solutions for Autotuning Failures
- Maintenance and Upkeep of Inverters 7.1 Daily Maintenance Checklist 7.2 Periodic Maintenance Procedures 7.3 Replacement of Wear-Prone Components
- Advanced Fault Diagnosis Techniques 8.1 Using Oscilloscopes for Signal Analysis 8.2 Diagnosing Issues via Analog Inputs and Outputs 8.3 Remote Monitoring through Communication Functions
- Case Studies 9.1 Case Study 1: “END” Fault Due to Failed Motor Parameter Autotuning 9.2 Case Study 2: TRIP Light Illumination Caused by Overcurrent 9.3 Case Study 3: Inverter Shutdown Due to Input Phase Loss
- Preventive Measures and Best Practices 10.1 Avoiding Common Faults 10.2 Best Practices for Parameter Settings 10.3 Environmental Factors Affecting Inverters
- Conclusion
1. Introduction
Inverters are pivotal components in modern industrial automation systems, widely used for motor control, energy conservation, and precise speed regulation. The Anruiji E6 series inverters are renowned for their high performance, reliability, and extensive functionality. However, inverters can encounter various faults during operation, such as the “END” fault and TRIP light illumination, which can disrupt production and potentially damage equipment.
This article focuses on the Anruiji E6 series inverters, providing an in-depth analysis of the causes, diagnostic methods, and solutions for “END” faults and TRIP light illumination. Combined with practical case studies, this guide offers a systematic approach to troubleshooting and maintenance, helping engineers and technicians quickly identify and resolve issues to restore production efficiency.
2. Fundamentals of Inverters
2.1 How Inverters Work
Inverters adjust the frequency and voltage of the input power supply to achieve precise control of AC motors. Key components include:
- Rectifier Unit: Converts AC power to DC power.
- Filter Unit: Smooths the DC voltage.
- Inverter Unit: Converts DC power back to adjustable frequency and voltage AC power.
- Control Unit: Adjusts output frequency and voltage based on set parameters and feedback signals.
2.2 Technical Specifications of Anruiji E6 Series Inverters
The Anruiji E6 series inverters feature:
- Input/Output Characteristics:
- Input Voltage Range: 380V/220V ±15%
- Output Frequency Range: 0~600Hz
- Overload Capacity: 150% rated current for 60s, 180% rated current for 10s
- Control Modes:
- Sensorless Vector Control (SVC)
- V/F Control
- Torque Control
- Functional Features:
- PID Control, Multi-Speed Control, Swing Frequency Control
- Instantaneous Power Loss Ride-Through, Speed Tracking Restart
- 25 types of fault protection functions
2.3 Core Functions and Applications
Inverters are widely used in:
- Fans and Pumps: Achieving energy savings through speed regulation.
- Machine Tools and Injection Molding Machines: Precise control of speed and torque.
- Cranes and Elevators: Smooth start/stop operations to reduce mechanical stress.
- Textile and Fiber Industries: Swing frequency control for uniform winding.
3. Basic Fault Diagnosis Process
3.1 Classification of Fault Phenomena
Inverter faults can be categorized as:
- Hardware Faults: Such as IGBT damage, capacitor aging, and loose connections.
- Parameter Faults: Incorrect parameter settings or failed autotuning.
- Environmental Faults: Overheating, high humidity, and electromagnetic interference.
- Load Faults: Motor stalling, excessive load, or mechanical jamming.
3.2 Steps for Fault Diagnosis
- Observe Fault Phenomena: Note display messages and indicator light statuses.
- Check Fault Codes: Retrieve specific fault codes via the panel or communication software.
- Analyze Possible Causes: Refer to the manual to list potential causes based on fault codes.
- Systematic Troubleshooting: Start with simple checks and progress to more complex issues.
- Verification and Repair: After fixing the fault, restart the inverter to verify the solution.
4. In-Depth Analysis of “END” Faults and TRIP Light Illumination
4.1 Definition and Manifestation of Faults
- “END” Display: Typically appears after motor parameter autotuning or parameter setting completion. If accompanied by the TRIP light, it indicates a fault during autotuning or operation.
- TRIP Light Illumination: Indicates that the inverter has triggered a fault protection and stopped output.
4.2 Possible Causes of Faults
- Failed Motor Parameter Autotuning:
- Motor not disconnected from the load (autotuning requires no load).
- Incorrect motor nameplate parameters (F2.01~F2.05).
- Inappropriate acceleration/deceleration times (F0.09, F0.10) causing overcurrent.
- Overcurrent Faults:
- Motor stalling or excessive load.
- Unstable input voltage (undervoltage or overvoltage).
- Mismatch between inverter power and motor power.
- Overload Faults:
- Motor operating under high load for extended periods.
- Overload protection parameter (Fb.01) set too low.
- Input/Output Phase Loss:
- Loose connections in input (R, S, T) or output (U, V, W).
- Overvoltage/Undervoltage:
- Significant input voltage fluctuations.
- Short deceleration time causing energy feedback and bus overvoltage.
4.3 Viewing and Interpreting Fault Codes
- Press PRG/ESC or DATA/ENT to view specific fault codes (e.g., OC1, OL1, TE).
- Refer to the “Fault Information and Troubleshooting” section in the manual to find solutions based on fault codes.
5. Common Fault Types and Solutions
5.1 Overcurrent Faults (OC1/OC2/OC3)
Causes:
- Acceleration time too short (F0.09).
- Motor stalling or excessive load.
- Low input voltage.
Solutions:
- Increase acceleration time (F0.09).
- Check motor and load for mechanical jamming.
- Verify input voltage stability.
5.2 Overload Faults (OL1/OL2)
Causes:
- Motor operating under high load for extended periods.
- Overload protection parameter (Fb.01) set too low.
Solutions:
- Adjust overload protection current (Fb.01).
- Check motor cooling and load conditions.
5.3 Phase Loss Faults (SP1/SP0)
Causes:
- Loose input or output connections.
- Incorrect wiring of power source or motor.
Solutions:
- Check input (R, S, T) and output (U, V, W) connections.
- Ensure no short circuits or open circuits in power source or motor wiring.
5.4 Overvoltage/Undervoltage Faults (OV1/OV2/UV)
Causes:
- Significant input voltage fluctuations.
- Short deceleration time causing energy feedback and bus overvoltage.
Solutions:
- Increase deceleration time (F0.10).
- Install braking resistors or units.
- Check input voltage stability.
5.5 Motor Parameter Autotuning Faults (TE)
Causes:
- Incorrect motor parameters.
- Motor not disconnected from the load.
- Autotuning timeout.
Solutions:
- Re-enter motor nameplate parameters (F2.01~F2.05).
- Ensure motor is unloaded.
- Set appropriate acceleration/deceleration times (F0.09, F0.10).
5.6 External Faults (EF)
Causes:
- External fault input terminal activation.
- Communication faults (CE).
Solutions:
- Check external fault input signals.
- Verify communication lines and baud rate settings.
6. Principles and Troubleshooting of Motor Parameter Autotuning
6.1 Purpose and Process of Autotuning
Motor parameter autotuning aims to obtain precise motor parameters (e.g., stator resistance, rotor resistance, inductance) to enhance control accuracy. The process includes:
- Set F0.13=1 (Full Autotuning).
- Press RUN to start autotuning.
- The inverter drives the motor and calculates parameters.
- Upon completion, parameters are automatically updated to F2.06~F2.10.
6.2 Causes and Solutions for Autotuning Failures
| Cause | Solution |
|---|---|
| Motor not unloaded | Ensure motor is disconnected from load |
| Incorrect parameters | Re-enter motor nameplate parameters (F2.01~F2.05) |
| Short acceleration/deceleration times | Increase F0.09, F0.10 |
| Incorrect motor wiring | Check U, V, W connections |
| Unstable power supply | Verify input voltage |
7. Maintenance and Upkeep of Inverters
7.1 Daily Maintenance Checklist
- Check environmental temperature and humidity.
- Ensure fan operates normally.
- Verify input voltage and frequency stability.
7.2 Periodic Maintenance Procedures
| Check Item | Check Content | Action |
|---|---|---|
| External Terminals | Loose screws | Tighten |
| PCB Board | Dust, debris | Clean with dry compressed air |
| Fan | Abnormal noise, vibration | Clean or replace |
| Electrolytic Capacitors | Discoloration, odor | Replace |
7.3 Replacement of Wear-Prone Components
- Fans: Replace after 20,000 hours of use.
- Electrolytic Capacitors: Replace after 30,000 to 40,000 hours of use.
8. Advanced Fault Diagnosis Techniques
8.1 Using Oscilloscopes for Signal Analysis
- Check input/output voltage waveforms for distortions or phase loss.
- Analyze analog input/output signals for interference.
8.2 Diagnosing Issues via Analog Inputs and Outputs
- Verify A11, A12 inputs are normal.
- Check AO1, AO2 outputs match settings.
8.3 Remote Monitoring through Communication Functions
- Use Modbus communication to read real-time inverter data.
- Remotely adjust parameters to avoid on-site operation risks.
9. Case Studies
9.1 Case Study 1: “END” Fault Due to Failed Motor Parameter Autotuning
Phenomenon: Inverter displays “END”, TRIP light illuminated. Cause: Motor not disconnected from load, autotuning timeout. Solution:
- Disconnect motor from load.
- Re-enter motor parameters (F2.01~F2.05).
- Restart autotuning (F0.13=1).
9.2 Case Study 2: TRIP Light Illumination Caused by Overcurrent
Phenomenon: Inverter shuts down during operation, displays OC1. Cause: Acceleration time too short, motor stalling. Solution:
- Increase acceleration time (F0.09=20s).
- Check motor load for jamming.
9.3 Case Study 3: Inverter Shutdown Due to Input Phase Loss
Phenomenon: Inverter fails to start, displays SP1. Cause: Input power source R phase loss. Solution:
- Check input connections, ensure R, S, T are connected.
- Restart inverter, fault cleared.
10. Preventive Measures and Best Practices
10.1 Avoiding Common Faults
- Regularly check connections and environment.
- Set reasonable acceleration/deceleration times and overload protection parameters.
- Avoid frequent starts/stops to reduce mechanical stress.
10.2 Best Practices for Parameter Settings
- Accurately set motor parameters (F2.01~F2.05) based on nameplate.
- Optimize carrier frequency (F0.12) to balance noise and efficiency.
- Enable AVR function (F0.15) to improve voltage stability.
10.3 Environmental Factors Affecting Inverters
- Avoid high temperature, humidity, and dusty environments.
- Ensure good ventilation to prevent overheating.
11. Conclusion
The “END” fault and TRIP light illumination in Anruiji E6 series inverters are typically caused by failed motor parameter autotuning, overcurrent, overload, phase loss, and other issues. Through a systematic fault diagnosis process, combined with fault codes and practical case studies, issues can be quickly identified and resolved. Regular maintenance and proper parameter settings are crucial for ensuring the long-term stable operation of inverters. Engineers should be familiar with the working principles and fault characteristics of inverters to enhance the efficiency and accuracy of troubleshooting.