当电源模块发生IFBK故障时,通常的原因是电流板反馈到电源模块的电流信号不对,我们可以将电源模块切换到开环模式来查看电流板上检测到的电流和电源模块显示的电流是否一致。如果不一致则可能是电流板连接到电源模块的同轴电缆接触不良,大部分情况下重新连接即可,或者更换电流板。
但是在开环模式下,开高压仍然无辉光,则需要对电源模块进行深层次的排查。
When the power module has an IFBK fault, the common reason is that the current signal fed back by the current board to the power module is incorrect. We can switch the power module to the open-loop mode to check whether the current detected on the current board is consistent with the current displayed by the power module. If it is inconsistent, it may be that the coaxial cable connecting the current board to the power module has poor contact. In most cases, it can be reconnected or the current board can be replaced.
However, in the open loop mode, there is still no glow at the open high voltage, so it is necessary to carry out in-depth troubleshooting on the power module.
现在的故障可能有四个原因,我们逐级排查:1、电源模块三相380V供电。如果电源模块有报IFBK故障,则通过去掉CPU板上的J3跳线帽将电源模块切换到开环模式避免IFBK故障,从而进行测量。
There may be four reasons for the current fault. We can check it step by step: 1. The three-phase 380V power supply of the power module. If the power module reports an IFBK fault, switch the power module to the open loop mode by removing the J3 jumper on the CPU board to avoid the IFBK fault, and then measure.
在开高压的情况下,电源模块顶端的18,19,20号端子上应该有三相交流380V电压,
When the HV is turned on, there should be three-phase AC 380V voltage on terminals 18, 19 and 20 on the top of the power module,
如果没有,则检查如下线路是否将380VAC送到电源模块
If not, check whether the following lines send 380VAC to the power module
如果以上没问题,则检查电源模块内的滤波电容上有没有530V左右的直流电压
If there is no problem above, check whether there is about 530V DC voltage on the filter capacitor in the power module
如果没有,则可能是整流桥损坏,如果530VDC无问题,则可进行下一项检查。
If not, the rectifier bridge may be damaged. If 530VDC is OK, the next inspection can be carried out.
2、CPU和接口板发送到驱动板的信号有问题
2. Is there a problem with the signal sent by the CPU and interface board to the driver board?
首先检查接口板连接到该位置的电缆是否牢固
First, check whether the cable connecting the interface board to this position is secure
如果电缆连接没有问题,则进行下面的测试,去掉CPU板上的J3跳线帽将电源模块切换到开环模式,否则会报电源模块故障。
If there is no problem with the cable connection, carry out the following test, remove the J3 jumper on the CPU board and switch the power module to the open-loop mode, otherwise the power module fault will be reported.
断开PLC控制板上的CB3空开,禁止380VAC送到电源模块,防止强制给电源模块测试信号的时候发生放电
Disconnect the CB3 air switch on the PLC control board and prohibit 380VAC from being sent to the power module to prevent discharge when the power module is forced to test the signal
将PLC上Q1.7输出点上的40号线摘下,接到该控制板上的任一24V上,强制给电源模块启动信号
Remove the 40 # line on the Q1.7 output point on the PLC, connect it to any 24V on the PLC control board, and force the power module to start the signal
如果在以下的检测过程中由于误触导致电源模块故障,则需要激光器断电后再重新上电清除电源模块故障。
If the power module fails due to wrong touch during the following detection process, the laser needs to be powered off and then powered on again to clear the power module failure.
之后在驱动板上检测以下三个15V电压正常
After that, the following three 15V voltages are normal on the drive board
如下图,用示波器监测驱动板上R13,R14,R15,R16电阻的两端的信号,在未放电时是0V,在放电时是一个17kHz 15V的脉冲信号。由于前面我们已经强制给电源模块一个启动信号,因此现在应该可以检测到脉冲信号,如果可以检测到这4路脉冲信号,则证明CPU板和接口板发过来的信号没问题。
As shown in the following figure, use an oscilloscope to monitor the signals at both ends of R13, R14, R15, and R16 resistors on the drive board, which are 0V when not discharging and a 17kHz 15V pulse signal when discharging. Since we have forced a start signal to the power module, we should be able to detect the pulse signal now. If we can detect these four pulse signals, it will prove that the signal from the CPU board and the interface board is OK.
如果没有示波器,也可以用万用表的直流档来检测,没放电时是0V,放电时是一个低于15V的直流电压,电压大小随功率设置信号的大小而改变。由于前面我们已经强制给电源模块一个启动信号,如果CPU板和接口板发过来的信号没问题,则可以检测到一个低于15V的电压。
If there is no oscilloscope, you can also use the DC range of the multimeter to detect. When there is no discharge, it is 0V. When it is discharged, it is a DC voltage lower than 15V. The voltage changes with the value of the power setting signal. Since we have forced a start signal to the power module, if the signal from the CPU board and interface board is OK, we can detect a voltage lower than 15V.
如果检测到信号有问题,则证明接口板和CPU板有问题。
If a problem is detected with the signal, it is proved that there is a problem with the interface board and CPU board.
否则进行以下驱动板的检测。
Otherwise, carry out the following drive board detection.
3、驱动板检测:如下图四处的信号在电源正常工作时是有高压存在,因此,检测时切记CB3空开断开,否则可能总成人员伤害及仪器损坏。
3. Drive board detection: as shown in the figure below, the signals at four places have high voltage when the power supply works normally. Therefore, remember to disconnect the CB3 air switch during detection, otherwise the assembly may be injured and the instrument may be damaged.
以下四处在未放电时是10V左右直流,在放电时是一个17kHz 10V左右的脉冲信号。由于前面我们已经强制给电源模块一个启动信号,因此现在应该可以检测到脉冲信号,如果可以检测到这4路脉冲信号,则证明驱动板没有问题。
The following four parts are about 10V DC when they are not discharged, and a pulse signal of about 17kHz 10V when they are discharged. Since we have forced a start signal to the power module, we should be able to detect the pulse signal now. If we can detect these four pulse signals, it will prove that there is no problem with the drive board.
如果没有示波器,也可以用万用表的直流档来检测,没放电时是10V左右直流电压,放电时是一个低于10V的直流电压,电压大小随功率设置信号的大小而改变。由于前面我们已经强制给电源模块一个启动信号,如果CPU板和接口板发过来的信号没问题,则可以检测到一个低于10V的电压。
If there is no oscilloscope, you can also use the DC range of the multimeter to detect. When there is no discharge, it is about 10V DC voltage. When there is discharge, it is a DC voltage lower than 10V. The voltage changes with the value of the power setting signal. Since we have forced a start signal to the power module, if the signal from the CPU board and interface board is OK, a voltage lower than 10V can be detected.
如果检测到信号有问题,则大概率是对应的U1,U3,U6,U7光耦损坏,也不排除IPM损坏。
If a problem is detected in the signal, the high probability is that the corresponding U1, U3, U6, U7 optocoupler is damaged, and the IPM is also damaged.
4、如果以上的检测都正常,则在断电的情况下,恢复PLC上Q1.7输出点上的40号线和CB3空开,启动激光器,开高压。
4. If the above tests are normal, turn off the power of the laser, restore the line 40 on the Q1.7 output point on the PLC, start the laser and turn on HV.
采用带有隔离电压高于1000V探头的示波器监测电源模块顶部端子上的1(TR1),2(TR2)这两个点,可以检测到幅值600V左右,频率17kHz的电压。
Using an oscilloscope with a probe with isolation voltage higher than 1000V to monitor the two points 1 (TR1) and 2 (TR2) on the top terminal of the power module, the voltage with amplitude of about 600V and frequency of 17kHz can be detected.
如果没有带有隔离电压高于1000V探头的示波器,也可以用万用表的交流档来做个大致的判断,如果正常则会有几百伏的电压,如果不正常,则没有电压。通常采用指针式的模拟万用表可以检测到电压,采用数字式的万用表有些可以检测到电压,有些则显示乱码。
If there is no oscilloscope with a probe with isolation voltage higher than 1000V, you can also use the AC range of the multimeter to make a rough judgment. If it is normal, there will be hundreds of volts of voltage. If it is abnormal, there will be no voltage. Generally, analog multimeter with pointer type can detect voltage, while digital multimeter can detect voltage and display garbled code.
如果这个信号可以检测到,则证明电源模块没有问题,大概率是高压油箱内谐振电容坏了。如果检测不到这个信号,则表明IPM损坏。
If this signal can be detected, it proves that there is no problem with the power supply module. It may be that the resonant capacitor in the high voltage oil tank is damaged. If this signal is not detected, the IPM is damaged.