Vesper DIY repair

In detail: do-it-yourself vesper repair from a real master for the site my.housecope.com.

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Posts: 1180

I will describe in more detail.
I inherited a burned-out 7011 at work. One IGBT scattered, changed all three. I immediately found a burnt out high-speed fuse (80A), changed it .. One channel still did not work, found a punctured transistor in one of the IGBT controls, found still faulty opto-assemblies in this channel, after which the frequency converter began to start. Then I was delighted and installed it in its regular place (pump control), but it worked for only 8 minutes and stopped with the error “short circuit at the output”. I had to shoot (

Can anyone have any ideas? And I would like to understand how he defines his KZ, what criteria does he use?

Warnings: 1
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Posts: 4116

Dmitry65

    The repair of such a product is very problematic. Specifically, I did not pick yours, but everything is exotic from the executive keys to the firmware of the controllers. I'll see today what kind of base it was, and there seem to be a bunch of details, if I haven't disposed of it. If the keys die, or something from the power unit, you can save, but if the microcontroller, then the khan, only the plant. Do not count the firmware even if there is a serviceable one.

ROCK

    Dmitry65 I will be grateful! Image - DIY Vesper Repair

mvlab

    Yes, there probably are IGBT keys in the assembly, or separately. They die most often.

Dmitry65

    Eats
    Super electricians put 24 volts on the terminals of the potentiometer. The owner refused to repair it and bought a new one, so I have it and stayed for a small shop. Even a burnt resistor can be seen on the board, there is an instruction document. Is it for sale? I don't need it, suggest something if you need it. The case is available, so a complete set.
Video (click to play).

tohasadist

    weak only. kilowatt 10 maximum

tohasadist

    strange, we mainly have S200 / 30 FCs, and even then, they seem more, although they are so bad.

Hellephant

    And I have some kind of Danphos lying around, zero in a box with a controller, no one needs it?

    ROCK , There is a Talmud for Vesper E2-8300, as much as 100 pages, if anything helps, I can scan it, send it.

    A frequency converter is a special-purpose device that allows you to control the rotation speed of electric motors. Their ease of use and design have helped frequency converters become the most common devices in various industrial and urban sectors.

    As elsewhere, in addition to the advantages, frequency converters also have some disadvantages, mainly associated with all sorts of breakdowns and malfunctions. Users of these devices should be aware of what kind of breakdowns and malfunctions of frequency converters can occur.

  1. Lack of response from the converter to the control panel. Most often, this can happen as a result of incorrect settings, and, as a rule, after setting the correct parameters, this problem will be resolved.
  2. The engine does not rotate. This situation is surprisingly common. One of the most probable reasons is too low or, conversely, high voltage at the input or output of the frequency converter. To prevent such failures, the engine load must be constantly adjusted.
  3. Rotation of the motor at the same constant speed. Any expert will say that this happens as a result of determining the wrong frequency parameters of the device. Again, the load on the device should be kept within the optimum range.
  4. Overheating of the engine. Of course, the reason lies in the climatic conditions of the operation of the frequency converter. If the fan does not cope with its work, it stops cooling the equipment, as a result, the device breaks down.

Frequency converters, the price of which depends on their individual characteristics, are in great demand at the moment among buyers.This is quite understandable, because frequency converters allow you to extend the life of the equipment.

Having discovered faults or breakdowns of frequency converters, users are immediately faced with a choice: to repair the frequency converter with their own hands or to contact a specialist? Of course, many people decide to repair themselves. However, then it becomes clear that this is a very long time, painful and, moreover, is fraught with the final disabling of an expensive unit.

Fortunately, our online store of electrical equipment ENERGOPUSK can help you with the repair of frequency converters. Experts will provide you with consulting services on equipment and carry out high-quality repairs at affordable prices.

Many buyers believe that specialists should be contacted for the reason that they provide a guarantee, while “do-it-yourself” repairs do not guarantee this. In addition, it is not uncommon for users, by interfering with the device, to worsen its condition and lead to its final breakdown.

Today in the industry, the basis of a controlled drive is made up of AC motors working in conjunction with frequency converters. The number of such systems only increases every year, respectively, there is a certain flow of failures of such equipment. Considering that the price of even the simplest models starts at around 10 thousand rubles, the need for repair of frequency converters is constantly growing.

The components of the power circuit become the nodes most susceptible to failures in frequency converters. Typically, these include a mains rectifier and a transistor inverter. The reasons for refusals can be very different. For instance:

  • short circuit in case of ingress of foreign objects or liquids;
  • overheating of circuits, due to pollution;
  • interference from the supply network;
  • accidents related to engine problems;
  • other.

In most cases, they lead to the failure of one of the power modules, or several at once.

Fixing a power circuit malfunction is quite simple. A malfunction of the input rectifier when the supply voltage is applied to the converter, leads to the operation of the input circuit breaker, or the display does not show any signs of life. If the rectifier is working properly, the control system functions normally, while attempts to start the engine, even with reduced parameters, lead to an error such as overload, open circuit or short circuit in the engine.

Read also:  Renault Rapid DIY repair

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As an example, the repair of a China-made Prostar 6000 4S2G series frequency inverter is shown. Upon inspection, you can immediately diagnose a power circuit malfunction, since when power is applied, the input circuit breaker is triggered. Opening the transmitter housing of this model is not particularly difficult, since the top cover is held on by latches, and all internal mechanical elements are connected with screws.

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After opening, the input rectifier was dialed with a multimeter, which confirmed the fact of the failure of the latter. All variants of the position of the probes showed a short circuit of the internal circuits. In this case, the varistor at the input turned out to be intact. A similar situation made us doubt the serviceability of the transistor module. Unfortunately, in this model of the transducer, only its lower part can be visually inspected. For further action, both elements have been removed. Even a cursory examination of the upper side of the transistor module left no doubt about its failure.

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Further, to check the serviceability of the internal circuits, instead of the standard rectifier of the KBJ1510 series, a similar serviceable one was soldered and it was switched on again without a power module.To our great joy, the control circuit started up normally, the numbers on the display lit up, the converter began to respond to pressing the buttons.

Further repair of the Prostar frequency converter with our own hands consisted in replacing the transistor module, since in this case it is made in the form of a single PS219A5 microcircuit. It was not possible to find one in Russia, so I had to wait a month for it to arrive from China. After replacing the module, the inverter started up again and the connected motor began to rotate.

The assembly was carried out in the reverse order, while the thermal grease on the radiators was additionally updated and the boards and internal parts were cleaned from contamination. The stress test also gave positive results. Unfortunately, the shown do-it-yourself repair of the frequency converter is one of the simplest and it does not always end with only the replacement of two modules.

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The picture is like this. turning on the emergency after parking, it normally works for 6-7 minutes, then stop and the error “short circuit at the exit”. If you reset the error and start again, then the error is issued almost immediately at startup, although sometimes it happens that it accelerates and works for a short time, then again the error. If you do not disconnect from the network, but keep in stop mode, then after the start, the time before the error occurs is also small. As if some element heats up when turned on and provokes an error. If you turn off the power supply and let it stand for a few minutes, and then turn on and start the motor, then the time before the error is again 6-7 minutes.

Checked on three engines - the picture is about the same. Moreover, other chastotniks with these motors work normally. Now a test one is connected on the table in idle mode. I tried it before without an engine, but not for a long time, by the way, I must try. Without a motor, the error did not occur, although it did not last long.

And how to make a full reset, by the way? there was such an idea ..

I found a question on one of the forums with the same problem as mine for Vespers of the year 2011, but there the second answer was that another had the same problem, but there was no advice. So I think, maybe this is the subtlety of the Vespers?

I did not find a schematic diagram, but according to the wiring there are no low-resistance resistances, the rectified input voltage through a capacitive filter is immediately fed to the IGBT modules, and from them immediately to the output. There are, of course, current transformers at the outputs, but they, apparently, do not participate in the diagnosis of short-circuit. I tried to start without them - the engine starts, only the vibration increases noticeably. The error “short circuit at the output” also appears as with them. Turning off the fans - immediately the error "Overheating" (or something like). He lubricated the fans themselves, cleaned the radiator from dust. Disconnected the temperature sensor, error “short circuit. ”Arises in the same way. None of the elements get too hot to the touch. Well, or I did not check everything, only which it was not dumb to touch)

On one of the varieties of the EI-7011, there is really a "DC sensor", but on mine this one is not even divorced.

So it’s interesting, what criteria does the processor use to decide that it has a short circuit at the output?

I double-checked the constants - I did not find anything criminal.

I don't know where to dig yet. Can you tell me?
If you don't sleep with the problem, the solution will not be born.

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