It is commonly reported that many technicians who repair inverters have encountered situations where inverter modules frequently burn out. In most cases, the standard approach is to replace the faulty module with a new one, without thoroughly investigating whether the failure might be related to the drive circuit. However, during maintenance, it's crucial to pay close attention to aging components within the drive system. This article outlines some of the key parts in an inverter that are prone to degradation over time.
**Resistors**
Resistance refers to a material’s ability to oppose the flow of electric current. Materials with low resistance are known as conductors, while those with high resistance are called insulators. When measuring the resistance of a capacitor, the multimeter’s pointer will swing, and the larger the capacitance, the more pronounced the movement. It’s important to discharge the capacitor before performing a second measurement to avoid inaccurate readings or potential damage.
**Insulating Paint**
Insulating paint is a specialized type of coating made from high-molecular polymers that can form an insulating film when cured under certain conditions. For example, radiator aluminum sheets must be kept clean, and if the cooling fan is broken or making unusual noises, it should be replaced. Additionally, if a filter capacitor has lost 20% of its capacity, it should be replaced, especially if it’s older than eight years. All main circuit connection screws should also be checked and tightened. When disassembling integrated circuits, it’s common for high-temperature soldering irons to cause damage or performance degradation. To prevent this, placing a small piece of paper on top of the IC before desoldering can help dissipate heat effectively.
**Voltage Regulator (Zener Diode)**
A Zener diode is a type of semiconductor diode that operates by utilizing the stable voltage characteristic of the breakdown region in a PN junction. These diodes are widely used in power supply circuits and other applications requiring voltage regulation. Unlike regular diodes used for rectification or detection, Zener diodes are specifically designed for their voltage-stabilizing function. They can be challenging for ordinary electricians to test, so it's often best to replace them entirely when suspected of failure.
During inverter repairs, overall maintenance is essential. The circuit board should be cleaned with a spray, dried thoroughly, and then coated with insulating paint to protect against moisture and dust.
**Optocoupler**
An optocoupler, also known as an optical isolator, is a device that transfers electrical signals between two isolated circuits using light. It provides excellent isolation between input and output, making it a popular choice in various electronic systems. Today, optocouplers are among the most versatile optoelectronic components available.
In circuits driven by an optocoupler, a feedback detection system is often present. This system compares the output signals of the three phases (Eu, Ev, Ew) with the drive signal. If an abnormality is detected in the inverter’s output, a high-level signal is sent to the motherboard via the optocoupler, which immediately cuts off the drive signal and displays an over-current or IGBT short-circuit fault. This protection mechanism is very fast and effective. Inverters equipped with such circuits are less likely to damage their modules, but issues like unstable drive components or aging parts can still affect the overall performance and reliability of the system.
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