Veichi Ac310 User manual

AC310 Universal AC Drive Service Manual

(Veichi Electric Technical Service Department)

(Note 1: This maintenance manual related circuit diagrams, using the AC310 series

2.2KW machine as a reference, the control board screen printing diagrams and other

power segments of the power board different points, in the appendix will be prompted,

the appendix according to each power segment circuit is divided into 3 power segments,

each power segment select a specific power segment.

There will be tips in the appendix, the appendix according to the different circuits in

each power section, roughly divided into three power sections, each power section to

select a specific power as a practical example to explain the differences and similarities,

details.

(Note 2: AC310 general-purpose AC drive is still in the process of continuous

optimisation of the hardware circuit, so sometimes there may be inconsistencies

between the specifications of the actual components and the specifications on the circuit

diagram.

(Note 3: This service manual involves hardware design circuit diagrams, and should

not be distributed privately.)

                                                           
AC310 Universal AC Drive Service Manual
 
I
 
 
Catalog 
 
Chapter 1 Summarize ................................................................................................................ 3 
1 The Working Principle of the AC Drive ......................................................................... 3 
1.1 Rectifier Bridge ........................................................................................................ 3 
1.2 Detachable Capacitor................................................................................................ 4 
1.3 Switching Mode Power Supply ................................................................................ 4 
1.4 Inverter Module ........................................................................................................ 4 
2 Common Device Overhaul Method................................................................................. 5 
2.1 Detect Diode............................................................................................................. 5 
2.2 Detect Triode............................................................................................................ 5 
2.3 Optocoupler .............................................................................................................. 6 
2.4 Static Measurements of Rectifier Bridges ................................................................ 6 
2.5 Static Measurements of AC Drive Continuity Diodes ............................................. 7 
2.6 Static Measurement of Brake Units.......................................................................... 7 
Chapter 2 Testing and Repairing of Power Supply Boards....................................................... 8 
1 Driver Circuit .................................................................................................................. 8 
2 Brake Driver Circuit...................................................................................................... 12 
3 Current Detection Circuit .............................................................................................. 14 
4 Busbar Voltage Detection Circuit ................................................................................. 16 
5 Relay Control Circuit .................................................................................................... 18 
6 Fan Control Circuit........................................................................................................ 20 
7 Switching Power Supply ............................................................................................... 22 
Chapter 3 AC300CON-A1.0 Control Board Introduction and Brief Detection and 
Maintenance ............................................................................................................................ 27 
1 Summary of IC Related Information............................................................................. 27 
2 Access to Voltage Points on the Control Board ............................................................ 28 
3 Detection and Maintenance Optocoupler Unit Circuits ................................................ 32 
3.1 X Input Circuit Detection and Maintenance........................................................... 33 
3.2 Y Output Detection and Maintenance .................................................................... 34 
3.3 Relay Detection and Maintenance.......................................................................... 34 
4 Analogue Signal Detection and Maintenance ............................................................... 35 
4.1 Analogue Input Signal Test (AI1, AI2): Voltage 0-10V; Current 0-20mA ........ 35 

                                                           
AC310 Universal AC Drive Service Manual
 
II 
 
 
4.2 Analogue Output Signal（AO1, AO2）:Voltage 0-10V; Current 4-20mA ,0-
20mA;Frequency Signal 0-50KHZ ................................................................................ 38 
5 RS485 Communication Circuit ..................................................................................... 41 
6 Drive Signal Processing Circuit .................................................................................... 44 
7 Keyboard Circuitry........................................................................................................ 46 
7.1 Keypad Key Circuit:............................................................................................... 47 
7.2 Keypad Display Circuit .......................................................................................... 48 
8 VPN Detection and Maintenance .................................................................................. 51 
9 OH Fault Detection and Maintenance ........................................................................... 52 
10 Current Acquisition Detection and Maintenance ........................................................ 53 
11 OC Fault Detection and Maintenance ......................................................................... 54 
12 Wave-by-Wave Current Limit Comparison Circuit .................................................... 56 
Chapter 4. Common Faults Quick Maintenance ..................................................................... 58 
1 No Display on Power-up ............................................................................................... 58 
2 Power-up or Operating Undervoltage (L.U.1, E.LU2), Overvoltage (E.OU1/2/3/4) Fault
............................................................................................................................................. 59 
3 OC Fault (OC1, OC2, OC3, OC4) ................................................................................ 59 
4 E.SC Fault ..................................................................................................................... 60 
5 OH Fault........................................................................................................................ 61 
6 Relay Non-suction Fault................................................................................................ 61 
7 Inconsistent Voltage Values Generated by the Switching Power Supply ..................... 61 
8 Output Out of Phase (E.OLF)........................................................................................ 61 
9 Current Detection Fault (E.HAL).................................................................................. 62 

AC310 Universal AC Drive Service Manual

Chapter 1 Summarize

1.1 The Working Principle of the AC Drive

The working principle of the AC drive is shown in Fig. 1, the input of the AC drive

is AC, which is rectified by the rectifier bridge composed of six diodes and filtered into

DC by capacitor C. The voltage at the primary side of the switching power supply

transformer is taken from the busbar voltage, and the switching power supply voltage

is obtained through the switching power supply related devices, which provides the

voltage for the drive circuits, fan relays, and control boards, etc.; the DC power is then

inverted into the frequency-variable and voltage-variable alternating current (AC)

through the AC drive module composed of the IGBTs and the renewal diodes, and the

waveforms of the voltages are Pulse-width modulation (PWM) waveforms.

1.1.1 Rectifier Bridge

The rectifier section consists of six rectifier tubes forming a three-phase rectifier

bridge to rectify the three-phase AC full-wave rectification of the power supply into

DC. If the line voltage of the power supply is UL, then the average DC voltage UD

after three-phase full-wave rectification will be: UD=1.35×UL

The line voltage of our three-phase power supply is 380V, so the average voltage

after full-wave rectification: UD = 1.35 × 380V = 513V. This is calculated to be the

average value of the bus voltage, corresponding to there is a maximum value: UDmax

AC310 Universal AC Drive Service Manual

= 1.414 × 380 = 538V

1.1.2 Detachable Capacitor

Electrolytic capacitors in the AC drive is the main role of filtering, filtering capacitors

are connected in parallel at the output of the rectifier power supply circuit, to reduce the

AC pulsating ripple coefficient, smooth the DC output of a kind of energy storage device;

filtering capacitors not only make the power supply DC output is stable, reduce the

alternating pulsating ripples on the impact of the electronic circuits, and at the same time

can absorb the current fluctuations generated in the course of the electronic circuits and the

interference through the AC power string into the electronic circuits to make the work of

the electronic circuit more stable performance.

1.1.3 Switching Mode Power Supply

The voltage at the primary side of the switching power supply transformer is

taken from the DC bus voltage, and through the switching power supply circuit, it

gets +24V, ±15V, +5V, 16.5V and other voltages are obtained through the switching

power supply circuit to provide voltages for the drive circuit, current detection, fan

relay circuit, voltage detection and so on, so as to ensure the normal operation of the

frequency converter.

1.1.4 Inverter Module

It consists of IGBT tubes and six diodes. By controlling the switching sequence

and switching time of the IGBT tubes, the AC drive turns the DC power into AC power

with variable frequency and voltage, and the voltage waveform is pulse width

modulated waveform.

（Note: The output voltage waveform of the AC drive is a pulse-width modulated

waveform, but the output current is measured as a sinusoidal waveform in practice,

because the motor is an inductive load, which makes the output sinusoidal waveform）

AC310 Universal AC Drive Service Manual

1.2 Common Device Overhaul Method

1.2.1 Detect Diode

Digital multimeter diode file open-circuit voltage of about 2.8V, the red pen is

connected to the positive, the black pen is connected to the negative, the measurement

of the current provided by about 1mA, the display value for the diode forward voltage

drop approximation, the unit is mV or V. Silicon diode forward conduction voltage drop

of about 0.3 ~ 0.8V, reverse bias shows the diode open-circuit voltage. The germanium

diode germanium forward conduction voltage drop is about 0.1~0.3V. And the forward

voltage drop of the more powerful diode is smaller, and the reverse bias shows the open-

circuit voltage of the diode. If the measured value is less than 0.1V, it means that the

diode breaks down, at this time both forward and reverse conduction. If the forward

and reverse are open, it means that the diode is open.

1.2.2 Detect Triode

The triode has two PN junctions, the emitter junction (be) and the collector

junction (bc), which can be measured in the same way as the diode. In the actual

measurement, the forward and reverse voltage drops between each two pins should

be measured, a total of 6 times, of which 4 times show open circuit, only two times

show the voltage drop value (why only 2 times show the data, because the triode is

in the triode, the voltage drop value is not displayed).

There are two times to show the voltage drop value (why only two times to show

the data, because the transistor in the measurement of the static value of the

equivalent diagram shown in the figure below), otherwise the transistor is bad or

special transistors (such as resistance transistors, Darlington transistors, etc., can be

distinguished by the model number and the ordinary transistors). In two

measurements with values, if the black or red pen is connected to the same pole, the

pole is the base pole, the smaller measurement value is the collector junction, and

the larger one is the emitter junction, because the base pole has been judged, and the

collector and emitter can be judged accordingly. At the same time, it can be judged:

if the black pen is connected to the same pole, the transistor is PNP type; if the red

pen is connected to the same pole, the transistor is NPN type; the one with a voltage

AC310 Universal AC Drive Service Manual

drop of about 0.7V is a silicon tube, and the one with a voltage drop of about 0.3V

is a germanium tube.

1.2.3 Optocoupler

The circuit principle and symbols of commonly used optocouplers are shown in

the following figure:

One side is a light-emitting diode, the voltage drop is about 1V, the other side is a

transistor, some only lead out c, e, measurement of forward and reverse are cut off, if

all three legs lead out, the measurement characteristics are the same as the above

transistor (mostly NPN tubes). When using a multimeter to make the diode forward

conduction, at this time with another multimeter to measure the transistor c to e

conduction voltage drop of about 0.15V; disconnect the diode connected to the

multimeter, the transistor c to e cutoff, indicating that the optocoupler is good.

1.2.4 Static Measurements of Rectifier Bridges

Three-phase bridge rectifier electrical schematic diagram, points 1, 2 and 3 are RST

inputs, points 4 and 5 are P and N. Measurement method is the same as that of a normal

diode.

AC310 Universal AC Drive Service Manual

1.2.5 Static Measurements of AC Drive Continuity Diodes

Schematic diagram of the AC drive unit, the measurement method is the same as ordinary

diodes. Measurement of the IGBT diode to determine the damage. Just put a meter pen into the

U, V, W output, a meter pen on the P or N, you can measure the good or bad.

1.2.6 Static Measurement of Brake Units

Brake Unit Schematic

GBRK is the braking signal in the diagram. Connect a braking resistor between

terminals P and PB, refer to the instruction manual for specifications.

No.

Description

①

DC-side fuse (optional)

②

Liquid-cooled converter module

③

Motor

Table 2-7 Main circuit description

AC310 Universal AC Drive Service Manual

Chapter 2 Testing and Repairing of Power

Supply Boards

2.1 Driver Circuit

1. Circuit components driver circuit

According to the received DSP drive signal to control the switch of IGBT, optocoupler

primary drive signal sampling interlocking form. ACPL-W314 drive optocoupler minimum

output current is 0.4A, the maximum output current is 0.6A, to meet the IGBT drive

AC310 Universal AC Drive Service Manual

capability. Due to the bootstrap topology does not have a negative voltage, the need to

shorten the shutdown time to ensure that the dead zone, drive to increase a shutdown loop,

shutdown

After the diode is on, the driver resistor is connected in parallel.

Diodes such as D40 are used to reverse clamp the output of the optocoupler, preventing

the optocoupler pin 5 to pin 4 ground from generating too large a negative voltage when the

IGBT is turned on, resulting in optocoupler output abnormalities.

The value of the gate capacitance is related to the small voltage spike caused by the

continuity of current to the tube after the IGBT is turned off, and a too small value of this

voltage spike may lead to false turn-on.

2. Fault type

No output, output out of phase, module damage, SC

3. Inspection Method:

Static detection:

W314 On-circuit detection

Multimeter Diode

1.22

0.23

0.64

0.76

Detection of IGBT gate resistance (2.2kw machine)

UG+

VG+

WG+

UG-

VG-

WG-

GBRK

5.2K

10K

Problems with the drive resistor may be due to a damaged drive resistor, or a damaged

module.

Dynamic detection:

◼Voltage between VDR and N when not running: 16.5±1V (DC)

Note: R151 is a 0Ω resistor on the P-line. Failure of this resistor will result in no power to

the bus voltage disconnect and thus no power to the switching power supply.

◼Measurement of relevant drive voltage points during operation:

Red pen

VG+

WG+

UG-

VG-

WG-

AC310 Universal AC Drive Service Manual

Black pen

AC file

8-9V

Single measurement

measurement

8.03V

8.01V

8.20V

When the drive voltage is at a positive value, the drive is turned on, and at a negative

value, the drive is turned off, so use the AC gear to measure it.

◼Measurement of normal voltage points during operation:

Red pen

UTP

VTP

Black pen

DC grade

16V

The UTP, VTP, and WTP voltages are generated by the VDR, if there is a problem there,

the drive voltage generated by the switching power supply is faulty Problems.

Measure the voltage of the drive signal on the control board when it is not in operation

(DC phase).

GND

Waveforms of one of the drive signals and GND outputs during operation: as follows

(if the output waveforms are abnormal, the control board is abnormal)

Measure the voltage of each drive signal and GND is about 11.5v when running with

ACgear.

◼Use two ripple probes (pay attention to isolation) to connect to the upper and lower arm

drivers of the same phase (directly soldered to the IGBT pins), power up and run the

whole machine, and test the driving waveforms. (If there is no waveform, the module

may be damaged, or the UH, UL, VH, VL, WH, WL provided on the control board may

be defective.).

AC310 Universal AC Drive Service Manual

4. Damage-prone devices

Driver optocoupler, voltage regulator

5. Device bit number and specification

Driver Resistors

R126=R127=R128=R129=R130=R131=68R0

/1206

R42=R50=R60=R67=R46=R53=1000/1206

Gate Resistor/Capacitor

R43/R54/R61/R68/R47/R55=1002/080

C41/C45/C49/C52/C43/C47=472/0805

Voltage regulator

BZT52C16

Z2/Z3/Z4/Z5/Z6/Z7/Z8/Z9/Z10/Z11/Z12/Z13

Driver Optocoupler

ACPL-W314-500E

O40/O42/O44/O45/O41/O43

Thyristor

MBR0540T1G D40/D42/D44/D45/D41/D43

1N4148WS D17/D18/D19/D20/D21/D22

Other

R40/R48/R56/R65/R44/R51=3000/080

R41/R49/R57/R66/R45/R52=5101/080

C40/C44/C48/C51/C42/C46=104/0805

AC310 Universal AC Drive Service Manual

2.2 Brake Driver Circuit

1. Circuit composition

Isolation photocoupler, transistor, voltage regulator

2. Fault type:

Overvoltage fault, braking resistor burned out, module damage 3, overhaul mode

Static detection

According to the appendix provides a variety of device detection methods for overhaul,

but also need to test the braking circuit of the brake diode is good or bad.

Dynamic detection

⚫When the brake is not consumed, the control signal BRK voltage is 5V, and when the

brake is turned on, the BRK voltage point is 0.455 (the pulse voltage changes from 5V

to 0.455V).

Before braking, the voltage of GBRK and N point is zero, and when braking is on, the

voltage of GBRK and N point is about 16V. Use the oscilloscope to capture the graph

as follows: (Note: to turn on the energy consumption braking) Use the ripple probe to

connect to the brake tube driver (directly soldered to the IGBT pin), regulate the power

supply to the energy consumption braking point (the default is about 680VDC), and

observe whether the brake tube is turned on or not. CH2: Braking current CH4: Brake

AC310 Universal AC Drive Service Manual

tube driver

Brake circuit schematic:

The braking resistor is connected between PB and PJ when the voltage between GBRK

and N is about 16 V. Refer to the selection manual for the braking resistor.

4. Damage-prone devices

Optocouplers, transistors

5. Device bit number and specification

Transistors

Q40=MMBT4401LT1(NPN)

Q41=MMBT4403LT1(PNP)

Gate Resistor/Capacitor

R64=1002/0805 C50=472/0805

Voltage regulator

Z14/Z15= BZT52C16

Driver Optocoupler

U40=EL2501S(K)

R58=3000/0805

R59/R62=5101/0805

R112=1001/0805

R63=1500/1206

AC310 Universal AC Drive Service Manual

2.3 Current Detection Circuit

1. Circuit composition

ACS720 current chip is used for sampling, the chip outputs 1.5V bias voltage with zero

current and provides a 1.5V REF. The sampling signal is calculated by the operational

amplifier and sent to the control board.

In addition, the internal circuit of the chip detects a delay of 4us, which is a large delay

for the overcurrent protection function, so the internal overcurrent protection function is

introduced.

The ACS720 has a user-configurable double-fault function, with fast and slow fault

outputs for short-circuit and overcurrent fault detection. Using the fast protection pins

VOC_F and FAULT_F/, the device sends out a low FAULT signal within 1.5us when the

AC310 Universal AC Drive Service Manual

current reaches the set overcurrent point, which is connected to the FAU pin to protect the

system from SC; and using the slow protection pins VOC_S and FAULT_S/, the

corresponding OC signal is pulled low, causing the COLSE signal to go high and blocking

the outputs. When the current reaches the set overcurrent point, the chip sends out a low-

level signal of FAULT within 1.5us, and connects this signal to the FAU pin to protect the

system from SC.

2. Fault type

E.HAL, E.OL2, E. OC, E.OLF

3. Detection method

Static detection

(Note that the current detection chip ACS720 is on at pins 1 to 8 during measurement

because the detection chip is differential current detection, which can well suppress external

magnetic field interference). (Note that pins 1 to 8 of the current detection chip ACS720 are

energized during measurement because the detection chip is a differential current detection chip,

which can well suppress the interference of external magnetic field)

Dynamic detection:

When powering up, look at pin 14 of the current detecting chip to see if there is 5V voltage,

pin 12 and REF pin correspond to 1.5V, which corresponds to 5V at pins 13, 15, and 16 when

normal, if the output voltage of pin 12 is abnormal when other voltages are normal, then the

current detecting chip is abnormal.

4. Damage-prone devices ICs, op amps

5. Device bit number and specification

Capacitors

C31/C37=1nf/0805

C14/C62/C33/C34=100nf/

0805 C32/C38=1uf/0805

C35/C36/C55/C54=330pf/

0805

Resistive

R30/R69/R70/R86/R87/R37=5101

/0805

R7/R36/R74/R76/R90/R92=4701/

0805

R78/R81/R38/R39=2000/0805

R75/R77/R91/R94=1002/0805

Sampling chip

U3/U5=ACS720KLATR-65AB-T

Op amp

U4=LF353DRG4

AC310 Universal AC Drive Service Manual

2.4 Busbar Voltage Detection Circuit

1. Circuit composition

The bus voltage sampling circuit is a high-resistance isolation circuit that utilizes multiple

resistors in series for isolation and then differential amplification by operational amplifiers.

2. Fault type

Inaccurate bus voltage display, overvoltage, undervoltage

3. Inspection methods

Static detection

If the VPN voltage value is incorrect during the test (dynamic detection has a

measurement method), please test the following parts

(i) Op-amp U75=LF353DRG4; (ii) Test the voltage divider resistor; (iii) Diodes D70 and

D71 to replace the damaged devices, and then test the

VPN voltage point to ensure that the detection value is correct.

Dynamic detection

AC310 Universal AC Drive Service Manual

1. Use the DC adjustable voltage regulator to connect to the P-N terminal of the machine

under test, and hang the multimeter pen on the P-N, and set the multimeter to DC voltage

(DC); note that the software voltage correction factor is 100% before testing. Compare the

value displayed by multimeter and keyboard

2. Measure the voltage at this point of the VPN: (get the VPN voltage from the voltage

scaling relationship)

S2 model

T3 model

579V homologous 5V

1000V homologous 5V

4. Vulnerable components op amps

5. Device bit number and specification

Resistive

R82/R83/R84/R85/R2/R3=470K/1206

R4/R5/R95/R96/R97/R98=470K/1206

Double diode

D70/D71=BAV99LT1G

Op amp

U75=LF353DRG4

R79/R99=10K/0805

R80/R100=4.02K/0805

C82/C87=10Nf/0805

C86/C81=100NF/0805

AC310 Universal AC Drive Service Manual

2.5 Relay Control Circuit

1. Circuit composition

Controls the 24V power switch according to the received DSP drive signal to control

the relay to close and disconnect

2. Failure type

Operation undervoltage, soft start resistor burned out, no vibration

3. Inspection Methods

Static test Overhaul according to the various device detection methods provided in the

appendix Dynamic test

After static testing, rule out device abnormalities.

When the DC adjustable voltage source is used to energize the bus voltage, the signal

source from the CPU changes from high level (5V) to low level (RCE level changes from

high to low and the main relay opens), and when the voltage is under-voltage, the signal

source from the CPU changes from low to high (5V) (RCE level changes from high to low

and the main relay opens), and the signal source from the CPU changes from low to high

(5V) (RCE level changes from high to low and the main relay opens).

AC310 Universal AC Drive Service Manual

(RCE level changes from high to low, the main relay is disconnected), when

undervoltage, the signal source from CPU changes from low level to high level (5V).

After normal power-on, check whether the primary side of the optocoupler is about

0.5V, and whether the secondary side and COM voltage is 24V, if both are normal, then

consider whether the relay is damaged.

Measure the resistance value, if there is resistance value and the same as the silkscreen

value, the resistance is normal, if different and infinity, it means burned out, replace it.

Put the relay into DC24V, when it is good, the coil will absorb, and the multimeter

will measure that the coil is on. Relay is good. Measurement does not conduct, the relay is

damaged

4. Damage-prone devices

Optocouplers, transistors

5. Device bit number and specification

Resistance

R6=300Ω/0805 R141=5.1K/0805

R110/R11=10K/0805

Capacitance

C1/c114=100nf/0805

Triode

Q110=MMBT4401LF1

Optocoupler

O10=EL2501S(K)

Relay

SQM:6W150RJ

Table of contents

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