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中頻電爐常見故障及處理方案

發布:amwqaqoc 瀏覽:3562次

     1、開機,設備不能正常起(qi)動

  故障現象:起(qi)動(dong)時直流(liu)電流(liu)大,直流(liu)電壓(ya)和中頻電壓(ya)低,設備聲音(yin)沉悶。

  分析處理:逆變橋(qiao)有一橋(qiao)臂(bei)(bei)的(de)(de)晶(jing)(jing)閘(zha)(zha)管(guan)可能(neng)短(duan)路(lu)或開(kai)路(lu),造成逆變橋(qiao)三臂(bei)(bei)橋(qiao)運(yun)行。用(yong)示(shi)波器分別觀察逆變橋(qiao)的(de)(de)四個橋(qiao)臂(bei)(bei)上(shang)的(de)(de)晶(jing)(jing)閘(zha)(zha)管(guan)管(guan)壓降波形(xing),若有一橋(qiao)臂(bei)(bei)上(shang)的(de)(de)晶(jing)(jing)閘(zha)(zha)管(guan)的(de)(de)管(guan)壓降波形(xing)為(wei)一線,該晶(jing)(jing)閘(zha)(zha)管(guan)已穿通(tong);若為(wei)正弦(xian)波,該晶(jing)(jing)閘(zha)(zha)管(guan)未(wei)(wei)導(dao)通(tong)。更(geng)換已穿晶(jing)(jing)閘(zha)(zha)管(guan);查找晶(jing)(jing)閘(zha)(zha)管(guan)未(wei)(wei)導(dao)通(tong)的(de)(de)原因。

  2、設備能起動,但工作狀態不對

  故(gu)障現象:設備能正(zheng)常順(shun)利(li)起動(dong),當功(gong)率升到某一值時,過(guo)(guo)壓或過(guo)(guo)流(liu)保護。

  分(fen)析處(chu)理:分(fen)兩(liang)步查(cha)找故(gu)障原因:

  (1)、先(xian)將設備(bei)空載運行,觀(guan)察電(dian)壓能否升(sheng)到(dao)額定值。若電(dian)壓不(bu)能升(sheng)到(dao)額定值,并且多次在電(dian)壓某一(yi)值附近過流保護。這可能是補償電(dian)容或晶閘管壓不(bu)夠造成的(de),但也不(bu)排除是電(dian)路某部(bu)分打火造成的(de);

   (2)、若電壓能(neng)(neng)(neng)升到額定值,可將設備轉入重載運行,觀察(cha)電流(liu)值是否能(neng)(neng)(neng)達到額定值,若電流(liu)不能(neng)(neng)(neng)升到額定值,并且多次在電流(liu)某一值附近過流(liu)保(bao)護,這可能(neng)(neng)(neng)是大電流(liu)干擾(rao)。要特別注意中頻(pin)大電流(liu)的電磁場(chang)對控制(zhi)部分(fen)和信(xin)號線(xian)的干擾(rao)。

  3、設備正常運行時,易出現的故障

  故(gu)障(zhang)現象:設備(bei)運行(xing)正常,但在(zai)正常過流保護動作(zuo)時,燒毀多支KP晶閘管和快熔。

  分(fen)析處理(li):過流保(bao)護時,為了向電(dian)網釋(shi)放平波電(dian)抗器的(de)能量,整(zheng)流橋由整(zheng)流狀(zhuang)態(tai)轉(zhuan)到逆(ni)變(bian)狀(zhuang)態(tai),這(zhe)時如果а>1500就有可能造成有源逆(ni)變(bian)顛覆,燒毀多支晶閘(zha)管和快熔,開關跳閘(zha),并(bing)伴隨有巨(ju)大的(de)電(dian)流短路爆(bao)炸聲(sheng)。對變(bian)壓器產(chan)生較大的(de)電(dian)流和電(dian)磁力沖擊,嚴重時會損壞變(bian)壓器。

  4、晶閘管

  故障現象(xiang):更換晶閘管后,一開機就燒毀晶閘管。

  分(fen)析處理:設備(bei)出(chu)故障(zhang),燒(shao)毀(hui)晶閘(zha)(zha)管(guan)(guan)(guan)(guan)(guan)。在更換(huan)新晶閘(zha)(zha)管(guan)(guan)(guan)(guan)(guan)后,不要馬上(shang)開機(ji),首先應對設備(bei)進行系統檢(jian)查(cha),排除(chu)故障(zhang)。在確認設備(bei)無故障(zhang)的情(qing)況下,再開機(ji)。否則,就會出(chu)現(xian)一(yi)(yi)開機(ji)就燒(shao)毀(hui)晶閘(zha)(zha)管(guan)(guan)(guan)(guan)(guan)的現(xian)象。在壓裝新晶閘(zha)(zha)管(guan)(guan)(guan)(guan)(guan)時,一(yi)(yi)定要注意壓力均衡(heng),否則,就會造成晶閘(zha)(zha)管(guan)(guan)(guan)(guan)(guan)內部芯片機(ji)械(xie)損傷(shang),導致晶閘(zha)(zha)管(guan)(guan)(guan)(guan)(guan)的耐壓值大幅降,出(chu)現(xian)一(yi)(yi)開機(ji)就燒(shao)毀(hui)晶閘(zha)(zha)管(guan)(guan)(guan)(guan)(guan)的現(xian)象。

  一般(ban)情況(kuang)下,可以把中頻(pin)電(dian)源的(de)故障(zhang)按照故障(zhang)現(xian)象分(fen)為完全不(bu)能(neng)起(qi)動和起(qi)動后(hou)不(bu)能(neng)正常(chang)工(gong)作兩大類。作為一般(ban)的(de)原則,當出(chu)現(xian)故障(zhang)后(hou),應(ying)在斷電(dian)的(de)情況(kuang)下對整(zheng)個系統作全面檢(jian)查,它(ta)包括以下幾個方面: 

  (1)、電源:用萬用表測一下(xia)主電路開關(接觸器(qi))和控制保險絲后面是否(fou)有電,這將排除這些元件斷路的可能性。 

   (2)、整(zheng)流器(qi):整(zheng)流器(qi)采用三相全控橋(qiao)式整(zheng)流電路,它(ta)包(bao)括六(liu)個(ge)快(kuai)(kuai)速熔(rong)斷(duan)(duan)(duan)器(qi)、六(liu)個(ge)晶閘管(guan)、六(liu)個(ge)脈沖變(bian)壓器(qi)和一(yi)個(ge)續(xu)流二極管(guan)。在(zai)快(kuai)(kuai)速熔(rong)斷(duan)(duan)(duan)器(qi)上有(you)一(yi)個(ge)紅色的指(zhi)示(shi)(shi)器(qi),正常時指(zhi)示(shi)(shi)器(qi)縮在(zai)外(wai)殼里邊,當(dang)快(kuai)(kuai)熔(rong)燒(shao)斷(duan)(duan)(duan)后它(ta)將彈出,有(you)些快(kuai)(kuai)熔(rong)的指(zhi)示(shi)(shi)器(qi)較緊,當(dang)快(kuai)(kuai)熔(rong)燒(shao)斷(duan)(duan)(duan)后,它(ta)會(hui)卡在(zai)里面,所以為可(ke)靠起見,可(ke)以用萬(wan)用表(biao)通斷(duan)(duan)(duan)檔測一(yi)下快(kuai)(kuai)熔(rong),以判斷(duan)(duan)(duan)它(ta)是(shi)否燒(shao)斷(duan)(duan)(duan)。 

  測(ce)量(liang)晶閘管(guan)的簡單方法(fa)是用萬用表電(dian)阻(zu)擋(200Ω擋)測(ce)一下(xia)(xia)(xia)其陰(yin)(yin)極(ji)(ji)—陽極(ji)(ji)、門極(ji)(ji)—陰(yin)(yin)極(ji)(ji)電(dian)阻(zu),測(ce)量(liang)時晶閘管(guan)不用取下(xia)(xia)(xia)來(lai)。正常情況下(xia)(xia)(xia),陽極(ji)(ji)—陰(yin)(yin)極(ji)(ji)間電(dian)阻(zu)應為無窮大(da),門極(ji)(ji)—陰(yin)(yin)極(ji)(ji)電(dian)阻(zu)應在10—50Ω之間,過大(da)或過小都(dou)表明這只(zhi)晶閘管(guan)門極(ji)(ji)失效,它(ta)將不能(neng)被觸發導通。 

  脈沖變壓器次邊(bian)接(jie)(jie)在晶閘管上,原(yuan)邊(bian)接(jie)(jie)在主控(kong)板上,用萬用表(biao)測(ce)量原(yuan)邊(bian)電阻約為50Ω。續流(liu)二極(ji)管一般不容易出現故障,檢查時用萬用表(biao)二極(ji)管擋測(ce)其(qi)二端,正向時萬用表(biao)顯示結壓降(jiang)約有500mV,反向不通。 

  (3)、逆變(bian)器(qi)(qi):逆變(bian)器(qi)(qi)包括四只快速晶(jing)閘管和四只脈沖變(bian)壓器(qi)(qi),可以按上(shang)述方(fang)法檢查。 

  (4)、變(bian)壓(ya)器:每個變(bian)壓(ya)器的每個繞組(zu)都應該(gai)是通的,一般原邊阻(zu)值(zhi)(zhi)約有幾(ji)十(shi)歐(ou)姆(mu),次極幾(ji)歐(ou)姆(mu)。應該(gai)注意(yi):中頻電壓(ya)互感器的原邊與(yu)負載并聯,所(suo)以其電阻(zu)值(zhi)(zhi)為零。 

  (5)、電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi):與負載并聯的(de)(de)(de)(de)電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)可(ke)能被擊穿,電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)一(yi)(yi)般(ban)(ban)分組(zu)(zu)安裝在(zai)電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)架上,檢查時(shi)應先確(que)定被擊穿電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)所在(zai)的(de)(de)(de)(de)組(zu)(zu)。斷開(kai)每組(zu)(zu)電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)的(de)(de)(de)(de)匯(hui)流(liu)母排(pai)與主匯(hui)流(liu)排(pai)之(zhi)間的(de)(de)(de)(de)連接點(dian),測量每組(zu)(zu)電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)兩(liang)個(ge)(ge)(ge)(ge)匯(hui)流(liu)排(pai)間的(de)(de)(de)(de)電(dian)(dian)(dian)(dian)阻,正常時(shi)應為無窮大(da)。確(que)認壞的(de)(de)(de)(de)組(zu)(zu)后,再斷開(kai)每臺電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)引至(zhi)匯(hui)流(liu)排(pai)的(de)(de)(de)(de)軟(ruan)銅皮,逐臺檢查即可(ke)找到(dao)擊穿的(de)(de)(de)(de)電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)。每臺電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)由四個(ge)(ge)(ge)(ge)芯子組(zu)(zu)成,外(wai)殼為一(yi)(yi)極(ji),另(ling)一(yi)(yi)極(ji)分別通過四個(ge)(ge)(ge)(ge)絕(jue)(jue)緣(yuan)子引到(dao)端蓋上,一(yi)(yi)般(ban)(ban)只(zhi)會有一(yi)(yi)個(ge)(ge)(ge)(ge)芯子被擊穿,跳開(kai)這(zhe)個(ge)(ge)(ge)(ge)絕(jue)(jue)緣(yuan)子上的(de)(de)(de)(de)引線,這(zhe)臺電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)可(ke)以繼續使(shi)用,其容(rong)(rong)(rong)(rong)(rong)(rong)量是原來的(de)(de)(de)(de)3/4。電(dian)(dian)(dian)(dian)容(rong)(rong)(rong)(rong)(rong)(rong)器(qi)(qi)(qi)(qi)的(de)(de)(de)(de)另(ling)一(yi)(yi)個(ge)(ge)(ge)(ge)故障(zhang)是漏油(you),一(yi)(yi)般(ban)(ban)不影(ying)響使(shi)用,但要注(zhu)意防火。 

  安裝(zhuang)電(dian)(dian)容(rong)器的(de)角鋼與電(dian)(dian)容(rong)器架是絕緣(yuan)的(de),如果絕緣(yuan)擊穿將(jiang)使主回(hui)路接(jie)地,測量電(dian)(dian)容(rong)器外殼引線和電(dian)(dian)容(rong)器架之(zhi)間的(de)電(dian)(dian)阻,可以判斷這(zhe)部分的(de)絕緣(yuan)狀(zhuang)況。 

  (6)、水(shui)(shui)(shui)冷(leng)(leng)電(dian)(dian)纜:水(shui)(shui)(shui)冷(leng)(leng)電(dian)(dian)纜的(de)(de)作(zuo)用(yong)是(shi)(shi)連(lian)(lian)接中(zhong)頻(pin)電(dian)(dian)源(yuan)和感應線(xian)圈(quan),它是(shi)(shi)用(yong)每根直徑Φ0.6–Ф0.8紫銅(tong)線(xian)絞合(he)而(er)(er)成。對于500kg電(dian)(dian)爐(lu)(lu),電(dian)(dian)纜截(jie)面(mian)積(ji)為480mm2,對于250kg電(dian)(dian)爐(lu)(lu),電(dian)(dian)纜截(jie)面(mian)積(ji)采用(yong)300至400 mm2。水(shui)(shui)(shui)冷(leng)(leng)電(dian)(dian)纜外膠(jiao)管采用(yong)耐壓5kg的(de)(de)壓力橡膠(jiao)管,里面(mian)通以冷(leng)(leng)卻水(shui)(shui)(shui),它是(shi)(shi)負(fu)載(zai)回路(lu)的(de)(de)一(yi)部分,工作(zuo)時(shi)受(shou)到拉力和扭(niu)力,與(yu)爐(lu)(lu)體一(yi)起(qi)(qi)傾動(dong)而(er)(er)發生曲折(zhe),因此時(shi)間(jian)長后(hou)容(rong)易(yi)在柔性連(lian)(lian)接處(chu)斷(duan)裂開。水(shui)(shui)(shui)冷(leng)(leng)電(dian)(dian)纜斷(duan)裂過(guo)程,一(yi)般(ban)是(shi)(shi)先斷(duan)掉大(da)部分后(hou),在大(da)功率運(yun)行時(shi)把(ba)未斷(duan)小(xiao)部分很(hen)(hen)快燒斷(duan),這時(shi)中(zhong)頻(pin)電(dian)(dian)源(yuan)就(jiu)會(hui)產生很(hen)(hen)高的(de)(de)過(guo)電(dian)(dian)壓,如果過(guo)電(dian)(dian)壓保護不可靠,就(jiu)會(hui)燒壞晶(jing)閘管。水(shui)(shui)(shui)冷(leng)(leng)電(dian)(dian)纜斷(duan)開后(hou),中(zhong)頻(pin)電(dian)(dian)源(yuan)無法啟(qi)動(dong)工作(zuo)。如不檢查出原因而(er)(er)反復(fu)啟(qi)動(dong),就(jiu)很(hen)(hen)可能燒壞中(zhong)頻(pin)電(dian)(dian)壓互感器。檢查故障時(shi)可用(yong)示波(bo)器,把(ba)示波(bo)器探頭(tou)夾(jia)在負(fu)載(zai)兩端,觀察按啟(qi)動(dong)按鈕時(shi)有無衰(shuai)減波(bo)形。確定(ding)電(dian)(dian)纜斷(duan)芯(xin)時(shi)先把(ba)水(shui)(shui)(shui)冷(leng)(leng)電(dian)(dian)纜與(yu)電(dian)(dian)容(rong)器輸出銅(tong)排脫(tuo)開,用(yong)萬用(yong)表(biao)電(dian)(dian)阻(zu)(zu)擋(dang)(200Ω擋(dang))測(ce)量電(dian)(dian)纜的(de)(de)電(dian)(dian)阻(zu)(zu)值(zhi),正(zheng)常時(shi)電(dian)(dian)阻(zu)(zu)值(zhi)為零,斷(duan)開時(shi)為無窮大(da)。用(yong)萬用(yong)表(biao)測(ce)量時(shi),應把(ba)爐(lu)(lu)體翻到傾倒位置,使水(shui)(shui)(shui)冷(leng)(leng)電(dian)(dian)纜掉起(qi)(qi),這樣使斷(duan)處(chu)徹(che)底脫(tuo)離,才能正(zheng)確判斷(duan)是(shi)(shi)否斷(duan)芯(xin)。 

  通過(guo)以上幾個(ge)方(fang)面(mian)的檢查(cha),一(yi)般能(neng)查(cha)出(chu)大部分的故(gu)障原因,接(jie)下(xia)來可(ke)以接(jie)通控(kong)制(zhi)電源,作進一(yi)步的檢查(cha)。

  中頻電(dian)(dian)(dian)(dian)爐的(de)電(dian)(dian)(dian)(dian)源(yuan)主(zhu)電(dian)(dian)(dian)(dian)路(lu)(lu)合(he)閘有(you)手動和自動兩種。對于自動合(he)閘的(de)系統,應該先將電(dian)(dian)(dian)(dian)源(yuan)線暫(zan)時斷開(kai),以確(que)保主(zhu)電(dian)(dian)(dian)(dian)路(lu)(lu)不(bu)會(hui)合(he)上。接通控制電(dian)(dian)(dian)(dian)源(yuan)后,可以作下面(mian)幾個方面(mian)的(de)檢查(cha)。 

  (1)、將示(shi)波(bo)器探(tan)(tan)頭接(jie)在整(zheng)流晶閘(zha)管(guan)的(de)門(men)極(ji)和陰極(ji)上,示(shi)波(bo)器置于電源同步,按(an)下啟(qi)動按(an)鈕(niu)后(hou)即(ji)可(ke)看到觸發脈(mo)沖波(bo)形(xing),應為(wei)雙(shuang)脈(mo)沖,幅(fu)度應大(da)于2V。按(an)一(yi)(yi)下停止按(an)鈕(niu),脈(mo)沖將立即(ji)消失。重復六次(ci),將每個晶閘(zha)管(guan)都看一(yi)(yi)下,如果門(men)極(ji)沒(mei)有脈(mo)沖,可(ke)以(yi)將示(shi)波(bo)器的(de)探(tan)(tan)頭移到脈(mo)沖變壓(ya)器的(de)原(yuan)邊看一(yi)(yi)下,如果原(yuan)邊有脈(mo)沖而(er)次(ci)邊沒(mei)有,說(shuo)明(ming)脈(mo)沖變壓(ya)器損壞,否則問題可(ke)能出在傳(chuan)輸線(xian)或主控(kong)板上。 

  (2)、將示(shi)(shi)波器探頭接在逆變晶(jing)閘管的門(men)極(ji)和陰極(ji)上(shang),示(shi)(shi)波器置(zhi)于(yu)內(nei)同步(bu),接通控制電(dian)源后(hou)可以看到逆變觸發脈(mo)沖,它是一串尖脈(mo)沖,幅度(du)應大(da)于(yu)2V,通過(guo)示(shi)(shi)波器的時標(biao)讀出(chu)脈(mo)沖周期,算出(chu)觸發脈(mo)沖頻率(lv)(lv),正常時應比電(dian)源柜的標(biao)稱(cheng)頻率(lv)(lv)高約20%,這個頻率(lv)(lv)稱(cheng)為啟動頻率(lv)(lv)。按(an)(an)下啟動按(an)(an)鈕(niu)后(hou),脈(mo)沖的間距加大(da),頻率(lv)(lv)變低,正常時應比電(dian)源柜的標(biao)稱(cheng)頻率(lv)(lv)低約40%,按(an)(an)一下停止(zhi)按(an)(an)鈕(niu),脈(mo)沖頻率(lv)(lv)立即(ji)跳回(hui)啟動頻率(lv)(lv)。 通過(guo)上(shang)列檢(jian)查(cha),基本(ben)上(shang)能(neng)排(pai)除完全不(bu)能(neng)啟動的故障。

  啟動以后(hou)工作不(bu)正常(chang),一般表現在下列(lie)幾(ji)個方面: 

   (1)、整(zheng)流器(qi)缺(que)相(xiang):故障表現為工作時(shi)聲(sheng)音不(bu)正(zheng)常(chang),最大輸出(chu)電壓(ya)(ya)升不(bu)到額定(ding)值,且電源柜(ju)怪叫聲(sheng)變大,這時(shi)可(ke)以調低輸出(chu)電壓(ya)(ya)在200V左(zuo)右,用示(shi)波(bo)器(qi)觀察整(zheng)流器(qi)的輸出(chu)電壓(ya)(ya)波(bo)形(示(shi)波(bo)器(qi)應置于電源同步),正(zheng)常(chang)時(shi)輸入電壓(ya)(ya)波(bo)形每周期有六個(ge)波(bo)形,缺(que)相(xiang)時(shi)會缺(que)少二個(ge)。這一故障一般是(shi)由于整(zheng)流器(qi)某(mou)只晶閘管沒有觸(chu)發(fa)脈沖或(huo)觸(chu)發(fa)不(bu)導通引起(qi)的,這時(shi)應先用示(shi)波(bo)器(qi)看(kan)一下六個(ge)整(zheng)流晶閘管的門極脈沖,如果有的話,關機后用萬用表200Ω檔測量一下各個(ge)門極電阻,將不(bu)通或(huo)者門極電阻特別大的那只晶閘管換掉即可(ke)。 

  (2)、逆變(bian)器(qi)三(san)橋臂工(gong)(gong)作(zuo):故(gu)障(zhang)表現(xian)為(wei)輸出電流(liu)特(te)別大,空爐時(shi)(shi)也一樣(yang),且電源(yuan)柜工(gong)(gong)作(zuo)時(shi)(shi)聲(sheng)音很沉重,啟動后把(ba)功率旋鈕(niu)調(diao)到最小位置,會發現(xian)中頻輸出電壓比正常時(shi)(shi)高。用示(shi)波(bo)器(qi)依(yi)次(ci)觀察四(si)個逆變(bian)晶閘管的(de)(de)(de)陽(yang)極(ji)—陰(yin)極(ji)之(zhi)間(jian)的(de)(de)(de)電壓波(bo)形(xing)。如果三(san)橋臂工(gong)(gong)作(zuo),可以(yi)看到逆變(bian)器(qi)中有(you)相鄰的(de)(de)(de)二(er)只晶閘管的(de)(de)(de)波(bo)形(xing)正常,另(ling)外相鄰的(de)(de)(de)二(er)只有(you)一只沒有(you)波(bo)形(xing),另(ling)一只為(wei)正弦波(bo),KK2觸發不(bu)通,其(qi)陽(yang)極(ji)—陰(yin)極(ji)之(zhi)間(jian)的(de)(de)(de)波(bo)形(xing)就(jiu)是正弦波(bo);同時(shi)(shi)KK2不(bu)導(dao)通會導(dao)致KK1無(wu)法(fa)關斷,所以(yi)KK1二(er)端就(jiu)沒有(you)波(bo)形(xing)。 

  (3)、感應線圈故障:感應線圈是中頻電源的負載,它采用壁厚3至5毫米的方形紫銅管制成。它的常見故障有以下幾種: 感應線圈漏水,這可能引起線圈匝間打火,必須及時補焊才能運行;鋼水粘在感應線圈上,鋼渣發熱、發紅,會引起銅管燒穿,必須及時清除干凈;感應線圈匝間短路,這類故障在小型中頻感應爐上特別容易發生,因為爐子小,在工作時受熱應力作用而變形,導致匝間短路,故障表現為電流較大,工作頻率比平常時高。