Fault Analysis:
The control panel of the Lenze 8215E inverter appears normal, yet there is no output. The panel functioning correctly suggests that the onboard switching power supply and the CPU on the mainboard are operational. However, several issues could lead to the inverter failing to produce an output:
1. Insufficient input voltage, causing the output to be disabled.
2. Output frequency set to zero.
3. Internal component failure obstructing the output. Addressing these faults requires a comprehensive assessment and prioritization based on complexity and repair feasibility.
Troubleshooting:
The three-phase AC supply voltage measures around 385V, confirming a stable power source. The panel does not display LU (indicating low main power voltage), verifying that the DC bus voltage meets the necessary requirements. Thus, the power frequency rectifier bridge and filter capacitor are functioning properly. Testing the inverter output terminals U, V, and W with a multimeter confirms no diode effect between +UG (DC bus end) and -UG (DC ground), indicating the main circuit of the inverter module is intact.
Focus now shifts to the driver board's gate drive circuit, particularly the inverter module’s six-bridge-arm power supply voltage and drive signals from the motherboard. Removing the filter board and motherboard while leaving only the driver board allows for individual confirmation of the essential +12V power supply for each bridge arm.
The switching power supply within the inverter operates by rectifying the three-phase AC voltage, then filtering it into a DC bus voltage supplied via X3N and X5N terminals. V100, activated by HYB001, generates oscillation. Different windings of T100 produce various DC voltages required by the inverter (e.g., +12V). This design prevents electromagnetic coupling between coils, minimizing interference and enhancing reliability. The RC components at V107's 5,6-pin generate self-oscillation, creating a 1 MHz square wave signal for the DC conversion circuit. V108 and V109 enhance the current drive capability of subsequent stages, while V102 and V103 form a push-pull circuit driving T101, T103, and T104, and V200 and V219 drive T102.
Given the inverter module's sensitivity to static electricity, maintenance involves soldering directly from the driver board. After reconnecting cables between the driver board and motherboard, the external power supply (isolation transformer, autotransformer, rectifier, filter circuit, etc.) is connected via X3N and X5N terminals. Adjusting the autotransformer's output voltage provides a safe, low-to-high DC voltage to the driver board. When the mainboard's red indicator light flashes, it signifies the internal switching power supply has started, delivering all necessary DC voltages. A multimeter measures +12V collector voltages for V102 and V200, confirming proper power supply. Measuring the six-channel gate power supply reveals normal 8V readings for the upper arm but 0V for the lower arm, which is abnormal.
Using an oscilloscope to trace signal waveforms reveals similar input signals for V108 and V109, yet vastly different outputs. V108’s output exhibits a strong inverse relationship to its input, while V109's output remains nearly constant at 0V. Possible causes include:
1. V109 short circuit.
2. V200 or V219 shorting to ground.
After removing V109 with a heat gun and testing its output, it becomes evident that pin 6 is shorted to ground. As V109 is part of multiple circuits, a single ground short can impact the entire circuit. V200 and V219 show no anomalies.
Replacing V109 and retesting confirm normal three-way gate power supply voltages for the lower arm. Reinstalling all components, connecting the inverter to three-phase AC, and performing a full system check restore the machine to normal operation.
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