Fault analysis
The panel information of the Lenze 8215E inverter is normal, but there is no output. The panel display is normal, indicating that the on-board Switching Power Supply and the CPU on the main board are working properly. The main reasons why the inverter has no output are:
1 The input voltage is lower than the allowable value, and the output is in the disabled state;
2 set the output frequency to 0;
3 The internal components fail, causing the output to be blocked. Dealing with such faults should be combined with various factors and follow the principle of overhaul and difficulty.
2. Troubleshooting
The three-phase AC power supply voltage is about 385V, and the power supply is normal. The panel does not display LU (the main power supply voltage of the inverter is too low), and it can be confirmed that the DC bus voltage in the machine meets the requirements, thereby judging that the power frequency rectifier bridge and the filter capacitor are working normally. When there is no power, use the multimeter to test the inverter output terminals U, V, W. There is no diode effect between +UG (DC bus end) and -UG (DC ground), indicating that the main circuit of the inverter module is good.
Focus on the driver board gate drive circuit, including the inverter module (drive board core) 6-way bridge arm power supply voltage and drive signals from the motherboard. Open the inverter housing, remove the filter board and the motherboard, and leave the driver board. The normal output voltage of each bridge arm power supply of the inverter module is a necessary condition for the operation of the inverter module, and the +12V generated by the switching power supply of the inverter supplies power to the gate power supply of each bridge arm of the inverter module, which should be separately confirmed.
The principle of switching power supply in the machine, the three-phase AC voltage is rectified, and the DC bus voltage generated after filtering is input by X3N and X5N terminals, and the V100 is excited by HYB001 to generate oscillation. The DC voltage of each specification required by the inverter is obtained through different windings of T100 (such as +12V). The characteristic of the power supply of the inverter module of the Lenze 8215E inverter is obtained by different DC conversion circuits (Fig. 2), which can effectively prevent electromagnetic coupling between multiple coils, reduce mutual interference and improve the reliability of the whole machine. The V107's 5,6-pin indirect RC components generate self-oscillation and generate a 1MHz square wave signal for the DC conversion circuit. V108, V109 can significantly improve the current drive capability of the rear stage circuit. V102, V103 are connected to push-pull circuit, drive T101, T103 and T104, V200, V219 drive T102. Since the inverter module is very sensitive to static electricity, the inverter module should be welded from the drive board during maintenance. Reconnect the cable between the driver board and the motherboard. The external power supply (including the isolation transformer, three-phase autotransformer, rectifier, filter circuit, etc.) is input to the driver board through the X3N and X5N terminals. For safety reasons, adjusting the output voltage of the autotransformer applies a low to high DC voltage to the drive board. If the red indicator light on the main board starts to flash, it indicates that the internal switching power supply has been started, all DC voltages are output, the main board has been working, and the collector voltage of V102 and V200 is measured by a multimeter, both of which are +12V. The power is normal. Then, the 6-channel gate power supply voltage is measured, and it is found that the three-way gate power supply voltage of the upper arm is about 8V, which is normal, and the three-way gate power supply voltage of the lower arm is 0V, which is abnormal. Figure 2 shows that the upper and lower arm gate power circuits have similarities. According to the signal flow direction, the signal waveform is checked point by point with an oscilloscope. It is found that the signal waveforms of the input terminals of V108 and V109 are basically the same, but the output is very different. There is a significant inverse relationship between the output of V108 and the input signal. The output voltage of V109 is almost constant, which is basically 0V. Possible causes:
1V109 short circuit.
2V200, V219 short circuit to ground.
Use a heat gun to remove the V109 from the board and test its output one by one. It is found that the output pin 6 is shorted to ground. V109 is connected in parallel in each circuit of the circuit. Although the current drive capability can be improved, if any one of the circuits is short-circuited to ground, the output of the entire circuit can be affected. No abnormalities were observed in V200 and V219.
Replace the V109 chip, re-test, the output voltage of the three-way gate power supply of the lower arm is normal, re-install all components, the inverter is connected to three-phase AC, test the functions of the whole machine, and the machine returns to normal.
The panel information of the Lenze 8215E inverter is normal, but there is no output. The panel display is normal, indicating that the on-board Switching Power Supply and the CPU on the main board are working properly. The main reasons why the inverter has no output are:
1 The input voltage is lower than the allowable value, and the output is in the disabled state;
2 set the output frequency to 0;
3 The internal components fail, causing the output to be blocked. Dealing with such faults should be combined with various factors and follow the principle of overhaul and difficulty.
2. Troubleshooting
The three-phase AC power supply voltage is about 385V, and the power supply is normal. The panel does not display LU (the main power supply voltage of the inverter is too low), and it can be confirmed that the DC bus voltage in the machine meets the requirements, thereby judging that the power frequency rectifier bridge and the filter capacitor are working normally. When there is no power, use the multimeter to test the inverter output terminals U, V, W. There is no diode effect between +UG (DC bus end) and -UG (DC ground), indicating that the main circuit of the inverter module is good.
Focus on the driver board gate drive circuit, including the inverter module (drive board core) 6-way bridge arm power supply voltage and drive signals from the motherboard. Open the inverter housing, remove the filter board and the motherboard, and leave the driver board. The normal output voltage of each bridge arm power supply of the inverter module is a necessary condition for the operation of the inverter module, and the +12V generated by the switching power supply of the inverter supplies power to the gate power supply of each bridge arm of the inverter module, which should be separately confirmed.
The principle of switching power supply in the machine, the three-phase AC voltage is rectified, and the DC bus voltage generated after filtering is input by X3N and X5N terminals, and the V100 is excited by HYB001 to generate oscillation. The DC voltage of each specification required by the inverter is obtained through different windings of T100 (such as +12V). The characteristic of the power supply of the inverter module of the Lenze 8215E inverter is obtained by different DC conversion circuits (Fig. 2), which can effectively prevent electromagnetic coupling between multiple coils, reduce mutual interference and improve the reliability of the whole machine. The V107's 5,6-pin indirect RC components generate self-oscillation and generate a 1MHz square wave signal for the DC conversion circuit. V108, V109 can significantly improve the current drive capability of the rear stage circuit. V102, V103 are connected to push-pull circuit, drive T101, T103 and T104, V200, V219 drive T102. Since the inverter module is very sensitive to static electricity, the inverter module should be welded from the drive board during maintenance. Reconnect the cable between the driver board and the motherboard. The external power supply (including the isolation transformer, three-phase autotransformer, rectifier, filter circuit, etc.) is input to the driver board through the X3N and X5N terminals. For safety reasons, adjusting the output voltage of the autotransformer applies a low to high DC voltage to the drive board. If the red indicator light on the main board starts to flash, it indicates that the internal switching power supply has been started, all DC voltages are output, the main board has been working, and the collector voltage of V102 and V200 is measured by a multimeter, both of which are +12V. The power is normal. Then, the 6-channel gate power supply voltage is measured, and it is found that the three-way gate power supply voltage of the upper arm is about 8V, which is normal, and the three-way gate power supply voltage of the lower arm is 0V, which is abnormal. Figure 2 shows that the upper and lower arm gate power circuits have similarities. According to the signal flow direction, the signal waveform is checked point by point with an oscilloscope. It is found that the signal waveforms of the input terminals of V108 and V109 are basically the same, but the output is very different. There is a significant inverse relationship between the output of V108 and the input signal. The output voltage of V109 is almost constant, which is basically 0V. Possible causes:
1V109 short circuit.
2V200, V219 short circuit to ground.
Use a heat gun to remove the V109 from the board and test its output one by one. It is found that the output pin 6 is shorted to ground. V109 is connected in parallel in each circuit of the circuit. Although the current drive capability can be improved, if any one of the circuits is short-circuited to ground, the output of the entire circuit can be affected. No abnormalities were observed in V200 and V219.
Replace the V109 chip, re-test, the output voltage of the three-way gate power supply of the lower arm is normal, re-install all components, the inverter is connected to three-phase AC, test the functions of the whole machine, and the machine returns to normal.
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