Hi all,
My Fronius just froze in one front setting and no welding power at all. Dismantled it and found two of the transistors in the power module gone. No info available for this module ( P281B07 - TYCO ) on every site I looked. It might be a custom made module for this inverter. Can anybody help.
Hi!
This module is custom made for the TP1500! It was made by Tyco or Vincotech and it's only available at Fronius. But it is very expansive!
If you find a low cost solution to replace this module, please let me know! So I don't have to find it out?
I am about to see for replacement even with some pin rearrangement but my problem is - the front panel froze, I mean I could not switch the different welding positions with the green button - it's just stuck on the top one and I am not sure if the controller is ok. Having said that temp. warning is alive so controller reacts in a way. I read you posts from Artic guy and if you could check this for me I would appreciate it. Only thing you have to do is to disconnect one side of the trasformer going to the block so there will not be any output voltage. Tell me what do you think. Thanks
Normally when only the power modul fails, the green button is still functional! Sometimes the welder works, but has no power!
There are several things that should be checked in your case!
First check TVS diodes (small PCB on top of diode modul)!
Second check all gate driver circuits!
I have one leg of the H bridge of the igbt block damaged - bottom one but it is not shorten - the opposite, high resistance. Small PCB board is ok, checked. That is why I need to know if without that PCB and power to output the good unit behaves the same. If not than there is no point to go any further. The drivers are ok from low voltage side of the gate transformers and there are pulses coming from Altera chip. From igbt side the one of the driver circuits is gone but it is no problem to restore. Again I need to know if the control is good in order to go further. Thanks
If there are gate pulses from the chip then it works! (That's my conclusion!)
After a start up pulse sequence the chip needs voltage feedback from secondary side! Otherwise it will turn off (or restart again and again) and light up front panel led including the yellow led (temperature Led) which indicates a problem with the machine!
How will you test the control without a working H bridge?
Have you an idea about replacing the broken module and how to install it in the welder?
I had never got yellow light to show any problem I mean blinkng, just could not switch between different welding setups. If I disconnect tem. sensor then yellow light comes on and fan kicks on so there is a response from the control. By the way all voltages are good - +15 volts +5volts all good, AC relay at input AC is turning on when main switch is on. Could you replicate my problem to see if the front panel freezes? I have to make the H bridge from 4 transistor to replace the faulty module but as I said if control is bad there is no point for doing that. The other thing is I have to get some parts to fix some components which are blown as I mention before one side of the H bridge is bad, there is a NPN transistor and 2 diodes that are gone and one of the drivers SG3644 have to be replaced as well -I will change both of them on a general principle anyway.
I am on holiday and I can't do any testings right now!
I would replace all components on the gate driver circuit. 2x 3644 driver ic, all 4 npn transistors, all 4 zener diodes, all 4 fast switching diodes and 4 smd capacitors! Check resistors but these should not have any problems!
Then work out an "new H bridge" based on mosfet instead of igbt! Include an 4k NTC for temperature monitoring near the H brigde!
Take care to isolate the "new H bridge" proper from the cooling element, because of ground connection! But focus also on good heat transfer because of cooling issuses!
Because of space issues place bridge rectifier somewhere else on the cooling block and use cabels to reconnect AC and DC site!
If all is tested and works use isolation spray to cover all newly installed parts on the PCB!
Optional you can install new capacitors (3x 470 uf - use only best quality ones) for good performance!