1. Discrimination
The inverter power module mainly includes IGBT, IPM, etc., check whether the appearance has exploded, and whether there are ablation marks between the terminal and the connected printed board. Use a multimeter to check whether C-E, G-C, G-E have been turned on, or use a multimeter to measure whether there is any inconsistency between the resistance of P to U, V, W and N to U, V, W, W, and whether there is any inconsistency between the resistance of the control pole of each driving power device to U, V, W, P, N, so as to determine which power equipment is damaged.
2. Find out the cause of the damage
(1) The quality of the equipment itself is not good.
(2) The external load has serious overcurrent and unbalance, a certain phase of the motor is short-circuited to the ground, there is a phase winding resistance internal short circuit, the load is mechanically stuck, the phase breakdown, and the output wire is short-circuited or short-circuited to the ground.
(3) The load is connected to the capacitor, or the capacitance to the ground is too large due to improper wiring, so that the power tube has an impulse current.
(4) The user's power grid voltage is too high, or there is a strong instantaneous overvoltage, resulting in overvoltage damage.
(5) The overvoltage absorption circuit of the power switch in the machine is damaged, resulting in the IGBT being damaged due to the inability to effectively absorb the overvoltage, as shown in Figure 1.
(6) Due to the aging of the filter capacitor, the capacity is reduced or the internal inductance becomes larger, and the overvoltage absorption capacity of the bus is reduced, resulting in the overvoltage on the bus being too high and damaging the IGBT. The overvoltage on the bus during normal operation is transformed by the inductive energy storage of the bus circuit when the inverter switch equipment is pulsed off.
(7) The pre-stage optical resistance barrier equipment of IGBT or IPM power equipment also breaks down due to breakdown, or ignition breakdown is formed by dust and moisture in the printed board barrier equipment, resulting in damage to IGBT and IPM.
(8) Improper operation, or defects in the product design software, cause the upper and lower power switch equipment to be turned on at the same time in the unstable conditions such as disturbance, start-up, and shutdown.
(9) Accidents such as lightning strikes, water leakage intrusion of houses, entry of foreign objects, and accidental collision by inspection personnel.
(10) The filter capacitor is replaced by repair, because the quality of the capacitor is not good, or the wire connected to the capacitor is longer than the original, so that the inductance is added, and the overvoltage fluctuation of the bus bar is significantly increased.
(11) The pre-rectifier bridge is damaged, because the pre-amp of the main power supply enters the alternating current, resulting in IGBT and IPM damage.
(12) Repair and replace the power module, because there is no electrostatic protection method, the IGBT is damaged during the welding operation. or due to poor treatment of heat dissipation, fastening, insulation, etc. in the repair, resulting in short-term use and damage.
(13) IGBT is used in parallel, and the consistency of type and batch number is not considered when replacement, resulting in uneven current and damage to each parallel component.
(14) A component of the internal maintenance circuit (over-voltage, over-current maintenance) of the inverter is damaged and the maintenance function is lost.
(15) A certain group of power supplies inside the inverter, especially the IGBT drive stage + and - power supply is damaged, the output value is changed or the insulation between the two groups of power supplies is broken down.
3. Replacement
As long as the root cause of the damage is found and the possibility of re-damage is eliminated, the inverter module can be replaced, otherwise the new module will be damaged again.
(1) IGBT is the same as insulated gate FET, and it is necessary to avoid electrostatic damage. The fundamental way to avoid damage in installation and welding is to connect the machine, IGBT module, electric soldering iron, person, and operating table backing plate with wires to be repaired, so that the operation can be carried out at the same electric field potential, and it is better if the common points connected can be grounded. In particular, the soldering iron tip should not have a high potential of the mains power, and the oscilloscope power supply should be blocked by a transformer with excellent barrier. Before the IGBT module is used, it is necessary to insist on the connection between the control pole G and the emitter E, and the anti-static maintenance G-E connection method of the equipment before leaving the factory shall not be removed at will.
(2) Thermal grease is applied between the power module and the heat sink to ensure that the coating thickness is 0.1 and 0.25 mm, the contact surface is more than 80%, and the tightening torque is applied according to the size of the fastening screw (M4 13 kg · cm, M5 17 kg · cm, M6 22 kg · cm) to ensure that the module has excellent heat dissipation.
(3) When the machine is disassembled, take notes on the disassembled parts, threads, and parts. When reinstalling, deal with all kinds of technical methods on the original installation, and shall not simplify or omit them. For example, the input twisted pair, the resistance value of each electrode connection, the insulator, the absorber plate or the absorber capacitor should be left as is; It is necessary to clean the drive printed board that has been repaired and welded to avoid creepage painting, and ensure reliable insulation, not to mention less and wrong parts.
(4) The type and number of parallel modules are required to be consistent, and when the numbers cannot be consistent, it is necessary to ensure that the performance of all modules connected in parallel is the same.
(5) For the defects of copper parts formed by the frying machine, the burrs should be rounded and sanded to avoid damage again due to overvoltage tip discharge.
4. Power-on after replacing the module
Often, after the module is replaced, it burns out again as soon as the power is on. In order to avoid such incidents, a resistor is generally inserted into the DC main circuit of the inverter, with a resistance value of 1 Yao 2 K and a power of more than 50 W. The current flowing through the resistor at no load is small, and the voltage drop is also small, so it can be viewed at no load.
Generally, as long as the no-load operation is normal, most of the resistance will be normal.
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