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Many end users fail to post a schematic in the panel or near the frequency inverter. When problems occur, the personnel who respond may not have documentation for the system. Most frequency inverter inputs are now programmable, and their purpose is not easily deduced without proper documentation. That's why the control mode and other control-specific information should be prominently displayed, along with I/O connections. Time lost while troubleshooting due to poor or non-existent documentation is non-productive and unnecessary.End users should maintain an offline backup of all frequency inverter parameters and settings. This can be helpful when a damaged inverter must be replaced, or when checking to see if any parameters have been changed. The ability to quickly revert to a known, good set of frequency inverter parameters can be critical to reducing downtime and increasing productivity.
Designers are constantly challenged with minimizing frequency inverter size to lower cost and reduce space requirements. This can make the frequency inverter less effective for the installer. In many cases, terminations on terminal blocks for signal inputs are so close in proximity that wire shorting is inevitable. Other times, mounting tabs are located too close to the frequency inverter's enclosure, making installation difficult. Wiring compartments have also diminished in size, complicating the wiring procedure.
In short, designers shouldn't neglect the installation process; they should design frequency inverters that are easier to install, thereby enhancing cost effectiveness of the installation process.
Some of the most common problems can be avoided by closely following the manufacturer's guidelines for installing and wiring the frequency inverter, such as following proper grounding techniques, using shielded cable where recommended, and routing wiring correctly. Failure to install line-conditioning apparatus (such as line reactors or chokes) where less than perfect plant power is available and running overly long motor leads without adding output impedance correction are factors of which end users should be mindful.
Mounting the frequency inverter in an area that is too hot, cold, or moist, or failure to provide sufficient space around the frequency inverter for proper cooling can also be problematic. Again, following the frequency inverter manufacturers recommendations - and selecting a frequency inverter that provides the right amount of protection demanded by its environment - are key to reducing lost production caused by failure.
Not all motors offer the same value to the end user. End users should not simply look at the initial cost of the motor system; rather, they need to consider the effort and costs associated with servicing motors in the final equipment. If you take brushed-type dc motors as an example, they are almost always lower in initial costs compared to a similar brushless dc motor system. At a later time, however, the end user must be able to access the brushed-type dc motor, which sometimes is buried inside the machine and hard to get to, in order to change out brushes. In such cases, this is not simply an inconvenience, but also leads to lower productivity.
Using cables that are too long (or that have poor shielding) is a common mistake made by end users with frequency inverters. The resulting noise destroys motor insulation and causes eventual winding shorts. Having to replace an unnecessarily damaged motor is a sure way to lower productivity.
An even more prevalent mistake is contamination of the frequency inverter. A frequency inverter is often protected by a simple yet effective air filter. If the filter gets clogged, the frequency inverter heats up unnecessarily, causing it to age more quickly.