(1) LENZE Inverter Pulse Transformer Damage
For early 8100 and 8300 series inverters, one common fault is damage to the switching power supply, often caused by a faulty pulse transformer. The symptoms usually include no response when powered on and no voltage at the control terminals. Due to the difficulty in disassembling the pulse transformer's core, this can be a challenging repair. Since each brand uses different parameters for their pulse transformers, winding them without access to original parts is difficult. Given the limited market for these older models, we don’t go into too much detail here.
(2) LENZE Inverter OC5 Fault
OC5 faults are frequently encountered in 8220/8240 series inverters, typically indicating an overload condition. This is detected using a Hall sensor that measures the current of the UV phase. The signal is then processed by a two-input or gate CMOS circuit to determine if an overload has occurred. Common causes of OC5 faults include damaged Hall sensors or issues with the gate circuit. Hall sensors are sensitive to environmental changes and may experience drift, while the gate circuit can be damaged by high voltages or signal spikes. Replacing the faulty components generally resolves the issue.
(3) LENZE Inverter Output Phase Loss
Output phase loss is another frequent problem. In such cases, a three-phase motor cannot start, and an overcurrent alarm may occur. After disconnecting the motor, measuring the 3-phase output voltage usually shows a significant phase difference. At this point, checking the power module and drive waveform is essential. In some 8240 series inverters, the drive circuit may have no voltage, so the switching power supply must be checked. Unlike other inverters, the 8240 series isolates the drive power supply from the switching power supply, so the isolation transformer should also be inspected. Ensuring the drive power supply is functioning correctly is key to resolving this issue.
(4) LENZE Inverter Switching Power Supply Failure
Switching power supply failures are common in 8200 series inverters. The main failure points are usually the power switch transistor or the control circuit. While replacing the switch transistor is straightforward, repairing the control circuit can be more complex. These circuits are often integrated onto ceramic substrates, making component replacement difficult. This requires experienced technicians who understand the design and can perform precise repairs.
(5) Heat Dissipation Issues in LENZE Inverters
The heat sink separation cooling technology is a key feature of LENZE inverters. Unlike traditional fans, which are prone to failure in dusty environments like textile factories, LENZE’s system reduces this risk. However, after prolonged use, some units may struggle with heavy loads. Our analysis suggests this could be due to poor heat dissipation, leading to accelerated aging of components. Replacing the aged parts usually solves the problem.
Additionally, the LED status on the inverter panel can help diagnose its condition, especially when the panel is not available. A green light on and red off indicates normal operation. If the green light flashes and the red is on, it means the panel is locked out. A flashing red light every second suggests a fault. Understanding these signals helps in quick troubleshooting.
Although LENZE inverters are reliable, they can still face various issues during operation. Their complex wiring and multi-layer PCBs require skilled maintenance personnel. We encourage collaboration among professionals to address real-world challenges more effectively.
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