1. Current detection failure (such as E019, E001):
(1) The control board Q1 (15050026) is damaged.
(2) 7840 IC is faulty: When the inverter is powered on, use a DC multimeter to measure. Connect black lead to pin 5 and red lead to pins 6, 7, 8 respectively. If the readings are 2.5V, 2.5V, and 5V, it's normal. Otherwise, the 7840 is bad.
(3) The small board is faulty: When the inverter is on, connect the black lead to pin 5 of the 7840 and the red lead to the small board. The left side should read 2.5V, 2.5V, 2.5V, 3.41V, 0V, and 1.6V. If not, replace the three small ICs (39030024LMV393). If still not working, replace the small board.
2. Display POFF:
The driver board’s POFF should be around 2.6–2.7V. If it reads 1.9V, check R51, R52, C36, C37. The electrolytic capacitors are most likely to be the issue. POFF is reported only when the motor is running. If the driver board transformer is damaged, this could also cause the issue.
3. Snubber resistor failure:
The snubber resistor and filter bulk capacitor often work together. If one is faulty, the other might be too. A bad snubber resistor can also result from a relay that doesn’t engage (due to a faulty relay or control board component). For single-phase 220V inverters, check if the user accidentally connected to 380V. Check the control board fault record for bus voltage changes from 310V to 540V. In such cases, the IPM rectifier bridge and filter capacitor may be damaged. If you replace the IPM without checking the capacitor, you may hear a “pop†sound, which indicates another failure. Replace the capacitor if found bad, as capacitors tend to age over time.
4. Unstable display:
If the display appears then disappears, and the fan stops with only 12V, it’s usually an issue with U1 thick film. If E015 is reported (power-on indicator on, keyboard off, fan on), the fan is shorted.
5. No braking:
The brake pipes (01180099, 01180100, etc.) are not inside the IPM. Braking issues after stopping may occur. After replacing the IPM, ensure the brake circuit is properly checked. Check the brake optocoupler, brake transistor (MOSFET), gate resistance, and series freewheeling diodes. If the voltage between P (+) and PB is 17–30V, the braking is normal. For TD900F093, set to 150. For TD3200F133, check if the DC voltage is 270–350V.
6. Blown rectifier bridge:
If some rectifier bridges are damaged but the inverter bridges are good, it could be due to sparking between the positive and negative busbars. High humidity is a common cause, with water droplets causing short circuits. Insulation degradation requires replacement. Another reason is a shorted filter capacitor (bulged or hardened top surface). Replace the capacitor if found faulty.
7. Machine humming:
The fan speed fluctuates and there’s no display. This is typically a shorted control board. Remove the board and power on again. If the hum continues, check components near the thick film. For example, a high resistance value on R56 (27 ohms) may indicate a broken snoring protection circuit. If the switching power supply isn't working, measure the voltage across a resistor. If it jumps, the rear circuit is shorted. If no voltage, the switching power supply isn’t starting—usually due to a bad thick film or nearby components like 2844.
8. Weak fan speed:
D6 breakdown on EV1000. For FECDF21U1 board, U8 is faulty with visible cracks. For EV1000 models like 01180128, a load stop report may indicate poor transformer inductance or insufficient insulation between primary and secondary coils of PC9.
9. Operation report 8888: Drive optocoupler is shorted.
10. EV1000 large volume: Original fault was a blown fuse. After running, no output or E019. Commonly, U9 is faulty. Sometimes Q2 is bad.
11. EV1000 small volume: Original fault was a blown fuse. After repair, no output. Usually, R13 is faulty. Always check R13 is 10 ohms during repairs.
12. TD3000 power-on POFF:
Check the driver board CVD voltage (2.5–2.8V). Verify IU, IV, IW voltages (current detection circuit). Check the VREF reference voltage on the control board (should be 2.5V via T1 regulator U24). If all are normal, reprogram two DSP programs. After erasing, wait a few seconds before writing, otherwise the DSP may fail.
After full repair, perform these steps to reduce the risk of a blow-up:
Connect the DC multimeter red lead to "ten", black to UVW. Single-phase TD900/ TD3200 should read 310V. Three-phase TD900 should read 540V. TD1000, TD3000, EV1000, EV2000 should read 5–10V. If not, do not press, otherwise a blow-up is likely. Stop the corresponding optocoupler and diode, and repeat until correct.
13. Display E010:
Power-on E010 indicates Hall sensor failure. If the inverter is on but shows E010, the current detection circuit is faulty. No output yet, but current is detected. Small machines often have TL082C issues; large machines usually have Hall sensor problems. To identify the phase, use a mv meter to test IU, IV, IW. Normal should be 0V. If one is +10 or -10, that phase has a problem. For example, IV = 1000mV means V phase Hall is faulty. If E010 appears immediately upon operation, the module may be faulty. Check by measuring the DC voltage between "10" and UVW. Normal is 5–10V. If one phase is much higher, that module is faulty.
14. Output imbalance:
If IPM and optocoupler resistances are good, the optocoupler may be degraded. Replace it. Control board or IPM could also be faulty. To determine if the upper or lower bridge is bad, power on and press the start button. Measure DC voltage between "10" and UVW. Normal is 210V. If one phase is 0, the lower bridge is bad. Measure between "-" and UVW. If one phase is 0, the upper bridge is faulty.
15. Insulation or withstand voltage:
(1) Heat sink not flat, IGBT is bad. (2) Hard foreign matter (e.g., tin slag) in silicone grease causes IGBT damage. (3) Brake pipe insulation film is broken or ceramic piece cracked. (4) High-power machine insulation column defective. (5) Board grounding capacitor is bad. One pair of secondary withstand voltage: drive plate optocoupler is poor.
16. EV2000 health disk: Display 4 8 and all lights bright (darker): CN1 second row, left to right second foot solder joint.
17. Control panel no display repair steps:
(1) Check voltage. (2) Test crystal oscillator. (3) Check reset signal. (4) Rewrite software.
18. POFF or E019 troubleshooting:
After aging, FECD machine may show POFF or E019. If U1 is slightly hot, replacing it fixes the issue. If software cannot be written, check for 5V short circuit. Even with normal resistance, many devices may be removed. Now, install U329. Observe the board carefully for any signs of tin, solder, reverse, or wrong parts.
19. EV2000 control board troubleshooting:
Power-on POFF: Measure U1’s C18, C19, 76, 77. Normal voltage is 1.6V. If low (e.g., 3.8V, 0.5V), U19, U20 is faulty. No display: Check Q10 and GND resistance (0.6K). If abnormal, DSP is faulty. No display: U24’s 8th pin is 1.5V (normal is 2.5V). L3 is unreachable, so L3 is faulty. Otherwise, DSP is bad. No display: LM324 4 and 11 pins (-+15V) shorted. If LM324 is hot, remove and test. U17 and U18 are faulty. No display: 5V shorted. U6 is faulty. E004: U1’s C18 is 3.8V (normal is 1.6V). U19, U20 is faulty. One press to run and blow: U5, U9 is faulty. VRF no 10V: U42, C107, C108 is faulty. E010: U9 is faulty. BRAKE lamp always on, K1 relay rings: U6 is faulty. E019: U21 is faulty.
20. EV2000 power-on keyboard 4 8 plus 5 lights flash: U8 is faulty.
EV1000 small volume control board 03025856: no display. Check CN3 6-pin (SPISIMO-OUT) voltage is 0V (should be 5V). Pin corresponds to U4 16-pin, 4-pin to DSP 21-pin (3.3V). Measured 0V → U1-DSP is faulty. Frequency of EV1000 size and volume control board cannot be lowered (50HZ unchanged): L8 is soldered or bumped.
TD900 small volume frequency less than 50HZ (about 49.80): D10 reference drift, 5.1V regulator tube is faulty.
TD1000 small volume control panel 03023847: E001 → U7 is faulty.
TD3000 control board: Power-on mode change → E016. EEPROM sometimes fails when changing mode.
TD3200 control panel: POFF appears when changing model. Factory parameters restore → E028. Before repair, RS1 signal of DSP changed to R19 by U19. U11 changed to RSEEPROM signal to U4. R19 cracked (not visible) → EEPROM cannot reset.
21. All control board software writing:
(1) No power (110 appears): (A) Short circuit. (B) Crystal oscillator not vibrating. (Normal power-on voltage: 3.3V, frequency output terminal 1.6V. If wrong, oscillator is faulty).
(2) Cannot write software (appears 113, 114): Usually DSP is faulty.
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