Choosing and using an inverter seems simple until that one moment when the overload alarm starts beeping nonstop. I’ve been asked this question by homeowners, shop owners, and even large buyers who source products from a solar inverter manufacturer or tubular battery manufacturer: “Why does my inverter show overload even when I’m not using much electricity?”

If you’ve faced this issue, don’t worry. In this blog, I’ll explain—in a clear, practical, and friendly way—what causes inverter overload problems, how to fix them, and how to prevent them in the future.

Whether you’re an end customer or a business owner working with a solar products manufacturer, exporter, or supplier, this guide will help you understand your inverter better and keep your power system running smoothly.

Common Reasons Why Inverters Show Overload

I’ve seen these issues regularly while helping customers troubleshoot their systems:

1. You’re Running More Appliances Than the Inverter Supports

Every inverter comes with a load rating—for example, 700VA, 900VA, 1500VA, 2kVA, etc.
If your total appliance wattage exceeds this rating, overload is natural.

Typical high-wattage items include:

• Iron

• Room heater

• Grinder

• Water pump

• Microwave

• Hair dryer

Even a single high-power appliance can trigger overload.

2. Faulty or Weak Battery

If the battery (150Ah, 200Ah, or lithium-ion) cannot deliver sufficient current, the inverter struggles and shows overload.
This is common in:

• Old tubular batteries

• Poor-quality batteries

• Undercharged batteries

Solar batteries and tubular batteries need proper charging to handle peak loads.

3. Loose or Damaged Wiring

Loose terminals, burnt wiring, or thin wires increase resistance.
This forces the inverter to draw more current to compensate—leading to overload warnings.

4. Short Circuit in Load

Even a small internal short circuit in an appliance can instantly trigger overload protection.

5. Inverter Internal Fault

If the inverter’s internal components—like MOSFETs, transformer, or control board—are damaged, the system may mistakenly show an overload error.

6. Low Input Voltage (for Hybrid or Solar Inverters)

For users connected to solar panels or EV charging systems, low input voltage can cause the inverter to overcompensate and overload.

How to Solve an Inverter Overload Problem (Step-by-Step)

Now let’s fix the problem with a practical and easy-to-follow approach.

1. Reduce the Load Immediately

The very first step is simple:

• Switch OFF heavy appliances

• Reduce the number of devices connected

• Restart the inverter

If the overload clears, you’ve identified the reason.

2. Check the Total Load Capacity

Calculate the combined wattage of the devices connected to your inverter.

Example:
LED TV (100W) + Fan (75W) + Light (20W) + WiFi router (10W) = 205W
Such a load is perfect for a 700VA or 900VA inverter.

If your total load exceeds the inverter’s rating, upgrade your inverter to a higher capacity.

3. Inspect the Battery Condition

If you’re using a 150Ah tubular battery or lithium-ion battery:

• Check water levels (for tubular batteries)

• Check battery terminals for corrosion

• Ensure the battery is fully charged

• Test voltage using a multimeter

Weak batteries are one of the most underestimated reasons for overload.

4. Check and Tighten All Connections

Loose connections can increase current draw.

Inspect:

• Battery terminals

• Plug points

• Input and output wires

• Fuse points

Clean corrosion, tighten terminals, and replace burnt wires.

5. Reset the Inverter

Most modern inverters (especially from solar inverter manufacturers or online UPS manufacturers) have a reset button.

Steps:

1. Turn OFF the inverter

2. Disconnect all loads

3. Press the reset button (usually 3–5 seconds)

4. Reconnect the battery

5. Restart the inverter

Resetting clears minor internal faults.

6. Check for Faulty Appliances

One faulty device can cause overload—even if it’s small.

To test:

• Disconnect all appliances

• Turn ON inverter

• Connect devices one by one

The moment overload appears again, you’ve found the faulty device.

7. Inspect Input Voltage (For Solar or Hybrid Systems)

If your inverter is connected to:

• Solar panels

• EV charger systems

• Wind inputs

Check whether the input voltage is stable.
Low solar voltage during cloudy weather can trigger overload if the inverter tries to draw more current.

8. Get the Inverter Serviced

If none of the above steps solve the issue, contact a professional technician or your inverter supplier.

Common internal problems include:

• Burnt MOSFET

• Faulty transformer

• Damaged control board

• Relay failure

• Overheating issues

These require expert attention.

Important Tips to Prevent Overload in the Future

Here are practical tips I share with anyone using an inverter system:

Use Only Compatible Appliances

Match your inverter’s VA rating with the total load you want to run.

Invest in a Good Battery

A high-quality tubular battery or lithium-ion battery ensures stable performance.

Choose a Reliable Inverter Brand

Prefer manufacturers who are also:

• solar products manufacturers

• exporters

• suppliers

• online UPS manufacturers

• EV charger manufacturers

• tubular battery manufacturers

• lithium ion battery manufacturers

These companies generally follow higher quality standards.

Service Your Inverter Once a Year

A simple maintenance schedule can prevent overload, overheating, and long-term damage.

When Should You Upgrade Your Inverter?

You should consider upgrading if:

• Your power needs have increased

• Your inverter frequently shows overload

• You want to add heavy appliances

• You are shifting to a solar system

• Your current inverter is older than 7–10 years

Upgrading ensures smoother backup, better battery life, and higher efficiency.

Final Thoughts

An inverter overload problem is usually easy to fix once you understand the cause. Most issues come from excessive load, weak batteries, loose wiring, or faulty appliances. By following the step-by-step solutions I shared above, you can troubleshoot your system confidently—whether you’re a home user or someone who buys from a solar inverter manufacturer, tubular battery manufacturer, or solar products exporter.

And if you want long-lasting performance, always choose high-quality products from experienced manufacturers and suppliers.