High-voltage inverters are equipped with advanced computing capabilities and a comprehensive fault detection system. This allows for accurate identification of various faults and provides clear guidance on the main control interface. In real-world applications, common issues often include problems in the control channel, IGBT overcurrents, and overvoltage faults. Below are detailed explanations of these typical faults along with their causes and solutions.
1. Control Channel Abnormal Fault
A control channel issue is typically caused by faulty fiber-optic communication between the PWM board and the power unit board. Common causes include:
- Poor contact or disconnection of the fiber optic connector;
- Dust accumulation inside the fiber transmitter/receiver;
- Fiber breakage;
- Damage to the optical fiber communication control board.
When a fiber issue occurs, it's essential to determine whether the problem lies with the power unit or the controller. You can test this by swapping the fiber corresponding to one power unit in the same phase with a faulty one. If the fault remains in the original location on the monitoring interface, it indicates a faulty fiber board. Otherwise, if the fault moves, the power unit may be at fault. In such cases, replacement or repair of the affected unit is recommended.
2. IGBT Overcurrent Fault – Causes and Solutions
The IGBT (Insulated Gate Bipolar Transistor) is a critical component in high-voltage inverters. It is susceptible to damage from overcurrent conditions. Common causes of IGBT overcurrent faults include:
- Short circuit in the inverter output;
- Failure of the IGBT in the power unit;
- Damage to the drive detection circuit;
- Electrical interference in the detection circuit.
To diagnose the issue, locate the corresponding module using the fault indication on the monitoring interface and inspect the IGBT for damage. Use a multimeter to check the internal DC bus of the power unit. Connect the black probe to V+ and the red probe to U and V respectively. The diode reading should be approximately 0.4V. If the reverse reading shows infinity, the IGBT is likely damaged and needs to be replaced.
3. Overvoltage Fault – Causes and Solutions
Overvoltage faults are usually caused by excessive input voltage. Under normal conditions, grid voltage fluctuations remain within ±10% of the rated voltage. However, in certain situations, the DC bus voltage may rise beyond safe limits, triggering overvoltage protection. To prevent this, you can adjust the transformer tap or add an absorption device on the input side to reduce voltage spikes. These measures help maintain stable operation and avoid unnecessary shutdowns.
By understanding and addressing these common issues, users can ensure the reliable and efficient operation of high-voltage inverters in various industrial applications.
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