February 22, 2025

Inverter maintenance and aging inspection techniques

Inverter component damage, such as power module burst, short circuit or open circuit, capacitor discharge, drum top, IC circuit breakdown damage, open circuit resistance components, etc., not only with a multimeter from the resistance value of components or on-line voltage Values ​​can be easily detected and some of them are damaged. It is only by visually observing the shape and deformation of their appearance that a clear judgment can be made. The deterioration of the performance of components and components is not a state of “obvious damage” due to a short circuit or open circuit. Not only is there no obvious abnormality in the appearance of the device, but sometimes even multimeters and other measuring devices are ineffective. . Such damage, such as the large lead electrolytic resistance of the electrolytic capacitor, the dielectric loss of the small-capacity capacitor increases, the high-frequency characteristics deteriorate, and the transistor amplification ability deteriorates, the rectifier characteristics of the diode deteriorates, etc. We use a multimeter and a capacitor. Table tests are all good, but the faulty component “does not perform well” in the actual work of the circuit. It seems that a person works hard with negative emotions. Therefore, the work is bound to be full of loopholes, and it is difficult to complete the tasks successfully. The deterioration of the performance of the components is not a qualitative change but a quantitative change. After many years of use of the machine, the electrolytic solution such as the capacitor dried up, the amplification ability of the triode reduced, and the oxidation of the component pins gradually changed with the passage of time. Therefore, to overhaul the "old machine", it is necessary to pay attention to this aspect. The problem.

The definition of damage to such components is more suitable for aging, inefficiency, failure, and performance degradation, and breakdowns, disconnections, and the like are not appropriate. The deterioration of the performance of components and components, the degree of deterioration is often very different, the phenomenon of failure and detection difficulties are also ever-changing, difficult to grasp, but often manifested as difficult problems, or called "soft failure", people scratching their heads - Can not find the bad parts, but the circuit is obviously not normal! Overhaul such failures, need to repair the basic skills of the electronic circuit solid, many years of accumulated experience, and even the maintenance of psychological quality, but also a test.

Fortunately, such failures are after all a minority, and generally the components are "hard". If repairers are willing to accept this challenge, the maintenance of such soft faults will also be transformed into a pleasure. The process of repair can even become a process of enjoyment. (Ordinary faults will change parts, and those who have fun will have fun. What?) It makes people feel very fulfilled. In the long-term maintenance work, we will always encounter such failures, we can simply not repair such machines, we can also accept it, enjoy one, what is not good?

For some components, the manufacturer has given the useful life, such as cooling fan and electrolytic capacitor in the inverter, and the replacement period given by the manufacturer is 8-10 years. Fan is a rotating part, rotating parts such as bearings, always wear long-term use; In order to increase the capacity, the electrolytic capacitor is filled with electrolyte, so there is a negative leakage current production, installation and use should pay attention to its polarity. At the same time, as the service life increases, the electrolyte will gradually dry out, causing the capacity to drop. After reaching the useful life, even if the inverter is not damaged, in principle, fans and electrolytic capacitors should also be replaced to prevent problems.

The fan is damaged and relatively intuitive. Let's talk about the damage of the DC circuit's energy storage capacitor by the fault example.

First, the phenomenon of failure of the large-capacity electrolytic capacitor aging and repair ideas:

[Fault Example 1] A Fujitsu 5000G9 90kW inverter, running under voltage fault. The frequency converter has been working continuously for nearly 10 years. After taking over, it first uses a capacitance meter to measure the capacity of the DC circuit energy storage capacitor. There are 6 energy storage capacitors, each with a capacity of 8200 uF and a capacity of 8000-8300 uF. Feeling capacitance is no problem. From the regulator into the adjustable three-phase power supply, check the voltage detection circuit and monitor the panel display DC voltage value, indicating that there is no problem with the DC voltage detection circuit. DC loop voltage is measured. When the input voltage is 380V, the DC voltage is about 540V (light load), and the problem can not be checked.

The inverter is driven by a 37kW motor, full load operation, and no circuit undervoltage fault. Still feel uneasy, and later found a factory, using a frequency converter to drive 75kW motor, full load operation, jump under voltage fault shutdown, running detection DC circuit voltage, has dropped to 430V. There is a fault in the inverter!

Under load conditions, the DC link voltage is low, and there are only two components that can be suspected: One is a three-phase rectifier circuit. This unit consists of six 100A rectifier modules to form a three-phase rectifier circuit, and each two are used in parallel. With the diode file of the digital multimeter, measure the forward voltage drop of the rectifier bridge, around 430 (0.43V), use an analog multimeter to measure the forward and reverse resistance, and there is no problem. The inverter has a characteristic that the use of the rectifier module and the inverter module has a considerable margin in power, and the stability of the rectifier module is also superior to the electrolytic capacitor. So still can not rule out the suspect of the capacitor. If you want to replace the test, you don't have so many rectifier modules and capacitor spare parts on hand. Only by determining whether the bridge is a bridge or a capacitor, verify the fault after purchasing the part.

Obviously, the damage of the capacitor is not due to the decrease in capacity caused by the long service life. The test capacity with a capacitance meter is also satisfactory. However, the performance of the local fault does indeed appear to be a decrease in the capacity of the storage capacitor, which does not achieve the proper energy storage function, and the voltage of the DC loop is reduced, causing the voltage detection circuit to report an undervoltage fault.

The capacity of the capacitor is reduced. Lighter ones have poor load capacity. When the load increases, they often jump to the DC circuit undervoltage fault, further damage the capacitor, and may cause the DC loop voltage to fluctuate, forming a fatal blow to the inverter module. Such failures are often more subtle, unlike component short-circuiting, which is easy to attract attention, and sometimes it is difficult to check them up, especially for capacitors in high-power inverters. After many years of operation, the lead-out electrodes withstand hundreds of Hertz for many years. High-current charge and discharge shock, there are different degrees of oxidation, measured with a capacitance meter, normal capacity; measured with a multimeter, there is a clear charge and discharge phenomenon, reverse leakage resistance is within the allowable range, but connected to the circuit In the case of an increase in the internal resistance of charge and discharge, it is equivalent to a resistance and a discharge circuit connected in series with a resistance of a certain resistance! The transient charge and discharge current values ​​of the capacitor are greatly reduced, and the capacity of the capacitor is substantially reduced. Equivalent to a serious reduction in capacity. Due to the decrease of the power storage capacity, the DC link voltage is dropped, the inverter cannot work normally, and the maintenance personnel may make a misjudgment! If the non-load state, at the same time, the voltage value of the DC loop is monitored, it is difficult under the light load condition of the maintenance department. The problem of energy storage capacitance is determined and analyzed.

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