maxo

Hi Christo Good to hear that you were able to put it back in operation. So, you have changed just the ELCO's on power supply lines +12V, +5 V and -12V DC and negative voltage regulator LM7912, (I assume you have the same part designation on your board, like are on mine mainboard). Check if you have stable voltage on this outputs, possibly yes, check also C117 in front of LM7912. For voltage fluctuations described in case when battery voltage is under 51,5V could be several reasons (output power level fluctuation or some bad part on other supply lines). Advice: Check also all other ELCO's on board (dry, leakage, high ESR), especially around TX7, check possible hot areas (changed color of the board around any part is possible bad point ), but the mot possible reason could be ELCO's or even cold solder spot somewhere. Have fun maxo

Hi Bernardf Just quick estimation and info: My brother in law has PV set with 25 kWp on roof with 38 degrees inclination. It can not be clean manully at all (it is to big) and at the same time you need some direct ortogonall pressure power and enough water to efficciently clean up all the dirty from PV surface. He ussually order cleaning to proffesionals annually or latest every second year, professionals has appropriate equipment (lifting unit, saddles, water pressure pump etc). The difference in PV power before and after cleaning is approx 5% to 7%, all depend what is the dirty amount on PV panels and of caorse what kind of dirty is this (smog, dust, birds picks etc.). maxo

Hi Coulomb All measured in- circuit first (must have some skill to know where the parts are in parallel connection, especially in case of diodes and small value resitors; or in case of BJT and resistors or chokes), but it could be done with no problems. Resistors check was done by precise multimeter with automatic range in Ohms/kOhms/MOhms range; btw diodes, zener diode, BJT, mosfets and IGBT was checked in diodes range. For ELCO's check I'm using analog (home made) ESR meter (Homo Ludens circuit), used already for a long time and have skill to work with it. I was built it with two measuring ranges (0-2 Ohm) and (0-20 Ohm), it operates at 100 kHz and is really very usefull instrument. I have also digital ESR meter (PIC chip operation), but analog indication works better for me, I have also RC3563 low ESR meter, works best on Li-ion batterys for very low internal resistance check, but it works just on 1kHz, what is a little bit low frequency for good in-circuit elco's internal resistance testing. On main board is more than one point or areas, where in circuit measuring is tricky, for me there was with great help old main board (2014 version), to check or compare measured values on it and on actual board under repair. One of such a point is D40 diode- it shows complete short on diodes range, on resistance range shows very small resistance (about 0,4 Ohms or something around), just because its wiring- after desodering and measure out of circuit shows it is OK. With great help was also partial scetches done by Coulomb and Weber published on Aeva forum and also my circuit diagram made recently on old board - like I said in previous email - will be shortly published here when finished- still working on it. Just another word about IGBT testing - in circuit is almoast immpossible except if you have another good board like I have to make comparision. Best is to desolder them out off (if you are not sure what is real) and check them out of circuit with one of quick method, methods are published on web all around- best way for me is very simple circuit with DC supply 7-15V and with few resistors and two tact switches and one led disode for visual control if IGBT works properly (on- off) check. The internal diode could be checked with no problem in-circuit too, the IGBT funcionality is best to check out of circuit like written. Last word about the board check: version 2017 was factory laquired by transparent spray, especially on back side of the main board on high-voltage part with thick layer. For in circuit check you need to use very sharp tips to come through this laquired layer and have appropriate connection with the measuring tips- it is not easy somethimes and took a lot of time and nerves. Have fun maxo

High again just for case- photo of fault parts, mybe zener diode is not there. Maxo

Hi again This time, some more about my findings around the Error 08, Error 51 and Error 09. Meanwhile, since my last post back from June 17 2020, I have occasionally Erorr 08, or sometimes error 51 and finally error 09 on my Axpert 5kVA (main board produced in 2017 with SN. 16-500449-00G). I have decided to describe in details about the findings and repair after the Error 09, it could help to somebody here with the same or similar problems. It happened aprox. 6 days ago, and there after error 09, only the battery charger still works OK (MPPT chrager with PV suppl), all the rest was dead and have short to utility power supply (circuit breaker out). In mean time I have almost finished the complete circuit diagram of the old main board (produced back in 2014), so it will be published here when will be really finished with all details, just break this and start to repair actual Axpert. After dissasembly , on first look there could be seen: 1. exploded IGBT's QB2, QD2, QA1 and QC1 (type IRGP 4066D) 2. after complete check and measuring of all elements on main board (front and back side), the following was concluded: - C6 (47 uF, 25V) - big internal reistance - C2, C24, C25 (22uF, 25V) (around TX7) have internal resistance on upper acceptable limit - C116, C132 (power supply around TX9) : big internal resistance - IGBT gate drivers ACPL- T350 (U12, U4, and another one = in total 3 of 5 on board) have short between leg 8 (Vcc) and leg 7,6 (output) - gate resistors R140, R152 (47R0) -no continuity - gate resistors R48, R132 (47R) - show 52,3 Ohm - diode D40 (type RS1J) -could be seen overheating around it on the board)- was still OK, but later replaced - zener diode ZD3 (18V)- no continuity 3. All other parts shows appropriate and expected measured values, except diodes D65,D12, D44, D4 and D45, so I have firherest desolder out IGBT's and measured again the mentioned parts here and they was OK. 4. I have ordered all needed spares , got them in 1 day and already replaced yesterday. Today I have assembled all back and installed the unit. It works as expected, still OK after 5 hours in operation, all normal. 5. VERY IMPORTANT ADVICE (from my knowledge in electronics and findings here ) FOR ALL AXPERT USERS: 1) when you get error 08, or even error 51 and it repeated several times: first and the most important advice: ASAP detach the unit from operation and put it into the nearest service shop. !! Do no start to repair it, if you do not have enough acknowledge and needed test equipment.!!! With upper given advice: possibly you have much lower repair costs than I have in my case (you will save money for costly spares like IGBT's and etc.) 2. Or even better if you are familiar with electronics- disasemble the unit and make first visual and later also the complete measuring check for potential faults. - check all around the TX9 power supply and TX 2 power supply, especially the electrolytic capacitors, diodes, resistors. - check also all other electrolytic capacitors on the board (measure internal resistance) and if is out of the limits or close to them- replace them all . Use only ELCO's with low ESR!!, due all power supplies here are switching types which require elko's with low ESR and of coarse with appropriate switching current capability. Sorry I have not finished writings before: In short, my findings here are very similar like elsewhere in switching power supplies: first problems (after just 3 years in operation 24/7)- are very close connected with dry, ripped or very high ESR on ELCO's, what consequently produce overheating around the side elements and finally not correct voltages on it's output (in my case on +15V, on +5V and on -12V). Due to not correct voltages, we have error 08 (bus overvoltage) and also error 51 (current surge) - meanwhile I'm sure it was not the case in reality, but due to incorrect voltages we get this wrong errors (OP-07 for current control) and also UC3845 current IC's can not work correct with to low or with unbalanced supply voltages. Additionally - elco's around the TX7 have made also the mess with + PS voltage for ACPL-T350 gate IGBT drivers and when they was not any more in correct cycle- bang on IGBT's was obvious. Hope all this will help to somebody here or elsewhere on other forums to AXPERT users. maxo

Hi again This time, some more about my findings around the Error 08, Error 51 and Error 09. Meanwhile, since my last post back from June 17 2020, I have occasionally Erorr 08, or sometimes error 51 and finally error 09 on my Axpert 5kVA (main board produced in 2017 with SN. 16-500449-00G). I have decided to describe in details about the findings and repair after the Error 09, it could help to somebody here with the same or similar problems. It happened aprox. 6 days ago, and there after error 09, only the battery charger still works OK (MPPT chrager with PV suppl), all the rest was dead and have short to utility power supply (circuit breaker out). In mean time I have almost finished the complete circuit diagram of the old main board (produced back in 2014), so it will be published here when will be really finished with all details, just break this and start to repair actual Axpert. After dissasembly , on first look there could be seen: 1. exploded IGBT's QB2, QD2, QA1 and QC1 (type IRGP 4066D) 2. after complete check and measuring of all elements on main board (front and back side), the following was concluded: - C6 (47 uF, 25V) - big internal reistance - C2, C24, C25 (22uF, 25V) (around TX7) have internal resistance on upper acceptable limit - C116, C132 (power supply around TX9) : big internal resistance - IGBT gate drivers ACPL- T350 (U12, U4, and another one = in total 3 of 5 on board) have short between leg 8 (Vcc) and leg 7,6 (output) - gate resistors R140, R152 (47R0) -no continuity - gate resistors R48, R132 (47R) - show 52,3 Ohm - diode D40 (type RS1J) -could be seen overheating around it on the board)- was still OK, but later replaced - zener diode ZD3 (18V)- no continuity 3. All other parts shows appropriate and expected measured values, except diodes D65,D12, D44, D4 and D45, so I have firherest desolder out IGBT's and measured again the mentioned parts here and they was OK. 4. I have ordered all needed spares , got them in 1 day and already replaced yesterday. Today I have assembled all back and installed the unit. It works as expected, still OK after 5 hours in operation, all normal. 5. VERY IMPORTANT ADVICE (from my expiriences in electronics and findings here ) FOR ALL AXPERT USERS: 1) when you get error 08, or even error 51 and it repeated several times: first and the most important advice: ASAP detach the unit from operation and put it into the nearest service shop. !! Do no start to repair it, if you do not have enough acknowledge and needed test equipment.!!! With upper given advice: possibly you have much lower repair costs than I have in my case (you will save money for costly spares like IGBT's and etc.) 2. Or even better if you are familiar with electronics- dissasemble the unit and make first visual and later also the complete measuring check for potential faults. - check all around the TX9 power supply and TX 2 power supply, especially the electrolytic capacitors, diodes, resitors. - check also all other electrolytic capacitors on the board (measure internal resistance) and if is out of the limits or close to them- replace them all . Use only ELKO's with low ESR!!, due all power supplies here are switching types which require elko's with low ESR and of coarse with appropriate switching current capability.

Hi Coulomb Just info (Elisol does not react to your last post), where he is written: "in solve to this problem for 5K MKS, change the C74 + D 26", just be good to know, what fault he had - error 51 or ?? I have checked today on my old main board: this is on back side of main board, just opposite side of MOSFET DC - SIDE Q44, Q45,Q58 and Q42 (IRFB3006G) and small TO-92 NPN and PNP transistors Q46, Q47, Q48 and Q49, look attached photo (lower left corner on photo).

Hello to all included in this debate about Error 08 I'm coming back here to this forum after few years (last time back in 2017), when I have need to changed main board due to malfunction around TX6 and parts around. I have Axpert MKS 5kVA_4kW, 48V, max 145VDC from PV, 3000MPPT, produced back in year 2013 or maybe 2014. I believe software and also hardware in my case is different than in case described here for MKS II 5kW, but fault 08 means the same = bus voltage to high. I read all what is said here and also on some other related forums about fault 08 on Axpert's. My PIP operates with utility 230V, 50 Hz (utility voltage varies between 230 to max. 242V and frequency varies between 49,6 to 50,2 Hz.) My setup is follows: (battery off at 46V - back to utility supply, battery charge during the night at 2A), bypass operation during the night, in the morning PV panels and/or utility supply up to moment when battery reach 52V, then bypass off and operation from PV and battery , followed buck charge up to 58,4V and then charge go down to 54V or 53,9V and then happened error 08 very soon, but only in case described in next sentence. Namely in my case, error 08 started aprox.1 month ago (never before in past years), it's happened only during the very sunny day and PIP operates from PV with battery charge (4*12 V lead acid battery, 180 Ah) and load's supply in the house. On days when is there more diffuse light or partly cloudy day, we never encountered error 08 (nor during the day, nor during the night, nor during the rain period). But error 08 happen only in case (battery at 54V) and the load in house is small (less than 20%). From my observations, software bug mybe is not the case here (it works 6 years without error 08), more real possible reason is hardware malfunction, maybe leak capacitors, changed value of resistors on OP-AMP, maybe cold connection somewhere or etc. If I look StrikerX log, his battery was also very close to 54,0V and at low load (10-20%) every time, when error 08 comes out. Maybe is good to thought abut that situation, namely when charge of the battery is higher what is really needed to sustain at 54,0V - This is similar what thought about Coulomb , some part of excess energy must go somewhere and could possible over charge 2 capacitors on bus to near or even over 500V, as could we see from logs (it's rise could be very rapid). Sorry I do not have yet the final solution what to do in my case, I just thought to wait a bit, maybe we could all together find the real reason for error 08, besides seem's not to be the same in all cases here. maxo

About the Plonkster view from battery supply I agree, in all cases, when the grid is not present or even in cases when the battery is charged only from sun (type of setup work of the inverter), all internals are supplied from battery, but how long - depends only of the Ah of the battery and their quality. It could happened, if the setup for AC out from battery shut off is for instance at 46V at the evening and if charge from grid is off, you have at the next morning just 45V or even less, if during the next day is cloudy or rainy, charge of the battery from sun is null or lousy, the battery voltage would drop additionally. Once happend to me during the winter period, when we have snow on PV, the battery voltage has dropped below 36V and inverter stops work because of that- it was complettely dead , mean also bypass AC out from grid was off and LCD dispaly was dead too - blank. After recharge the battery from outside charger to voltage when the inverter was in operation again and recharge the battery from grid - resetup of software to charge the battery from grid and from sun at the same time, charge from grid only with the smallest possible curent (2A) setup since then for a winter period. During the rest of season, charge only with sun is OK and good enough. During the sunny period, even in winter time period (February, March) and without snow on PV, the battery is fully charged alrady around 10 or 11AM (180Ah, 48V). So in case you want to charge the battery from grid, this internal charge system must work. But in my case- fault -like was written several times by me, inverter system does not recognize the sun and sun charger does not charge the battery at all, not provide the power through the inverter to AC out- with short words - the sun not exist at all for inverter. Because of that, my first estimation was the SCC board has problems, but when I opened the unit, the fault described in my first blog's was found. maxo

Hi Coulomb again I do not know if your assumption to flash with new software will help or not to work without TX6 and it's souroundings. My inverter works also just with battery (of coarse only for a short period when it reached setup voltage to switch power output AC only from battery- on that time my setup was to charge the batery with 2Amp from grid, because the charge from PV was not able) and works also from grid to output AC household supply, but it does not see the PV supply and not charge the battery from PV supply - that was my reason to dissasemble and open the inverter. After oppening , my foundings are already known. I believe this SMPS with TX6 must work in my case , because when diode inside of U3 - optocoupler on SCC board activate CE output of U3 , then through connection cable SCC makes connection between pins 1 and 2 on mainbord connector SCC and we get base supply voltage of Q9 through D74 and R276. If this happened, Q10 will conduct and provide power supply on leg 7 of the U10 =UC3845, then U10 provide PWM signal from leg 6 throug resistor R216 (10 OHM) to gate of mosfet Q36 which drives TX9 ransformer on primary side. TX9 transformer then provide on secondary side all the voltages like could be seen from Figure 3 in Voltronic power service manuals. That's my view of operation , please correct me if I'm wrong. br maxo

Thank's Coulomb for details about the TX2 function, like I assume it seves with different voltages and is wounded completlly different. Go forward to find the TX6 possibly, all the rest could be done more easilly. Meanwhile: thanks for plonkster reply, UC3845 is not the problem to find and change at all, there on main board are 3 pcs UC3845, one in DIL8 and two in SMT case, function all of them is to serve 3 separate SMPS, but the output voltages of this SMPS are for sure different, also their currents. Coulumb: do you have any idea, what is the output voltage on TX6 secondary , for VCC for U15 is probably somwhere between 15 and 30V DC , btw. max supply volatge for UC3845 is like I know 36V DC and turn ON = 8,4V and turn off= 7,6 V DC by IC specification . wbr maxo

Hi Coulomb Thank's for your replys and directions what to do. Let start from your first post answer, the circuit diagram in your post No. 65232 is correct and agree's with mine backengineering. For your info, gate resitor in your schematic marked with question is R233 = 22 OHM . Another infos about TX6: - winding AC_PS_OUT is done by two parallel enameled Cu wires fi 0,25 mm in diameter each (bifilar winding) between pins 8 and 11 on TX6 transformer, winding has 62 turns - primary winding (AC through diodes D17-D21 and 33uF capacitor) is done by enamled Cu wire with diameter 0,21 mm between pins 3 and 2 - 90 turns and then between pins 1 and 2 another 90 turns, so primary winding has in total 180 turns - start up winding and at the same time VCC supply winding for UC3845 (U15) is done between pins 5 and 6, consist 24 turns of Cu enameled wire with diameter 0,21 mm. Winding princip: start with start up winding 24 turns, followed by 1/2 half of primary winding =90 turns between 1 and 2, followed by 62 secondary bifilar turns betwwn 8 and 11 pin and finally with 90 primary turns of second half or primary winding between pins 3 and 2. That's all main inportants about TX6 transformer , was found when I dissasemble it. About the second link (59548), my circuit is the same, except the connections to U10 , where I have drawn different, but not known in this moment, what is correct, mine or yours - need still to be checked again. About the output from secondary winding of TX6: I believe it must be something over 58V DC = max charge voltage for battery , but I'm not shure about that, if we compare primary transformer voltage - must be around 310V DC and 180turns and secondary turns (62 turns), this AC_PS_OUT could be even higher, but the current is not known and this secondary out possibly be different. About the TX2 comparing: it looks similar like TX6, but I suspect it is wound for different voltages, but the idea to check the initial permeability is good idea, but at the same time we do not know if there is the central leg gap also, we do not know the turns etc, so we could not compare it and also the big mistake could be done with comparision of unknown values. I will try on mpp solar page to find the TX6 like you suggest, will reply about the findings. with all the best maxo

Hello again just another info, btw CCM board was checked also, there seems to be all OK ( checked all power mosfets, diodes, elecrolytes etc), also checked all power elements on main board, also the parts on other two SMPS on main board), so far seems all is OK. I have tried to find the reason for initial mulfunction, mybe U15 has the problem with CS input - leg 3 which should limit the current (current resistor R242 =0,6 OHM) to Q37 and avoid further burn of the transformer TX6, but it was not happened. I will change U15 for any case also, but need transformer TX6 first. by maxo

Hello to Chris and others Finally find time to write about the findings (Faults) in my Axpert 5kVA: I have to dissasemled complete inverter, due on first view, there on main board I have the problem (diode D62=UF304 - it's souronding was slighntly overheated ) and also SMPS transformer TX6 is burnt (outer insulation is completelly brown). Souroundings on bottom of the PCB have also the signs of overheating. Diode D62 is short also. Due in manuals I have got from Chris (thanks to him again) just this SMPS on main board (there are another two) is not shown and desribed at all. I have checked all the parts and connections around, I have evein make the circuit diagram (backingeeniring) for complete souroundings on main board, so I know now this SMPS is supplied directly from utility. IC driver for this SMPS is UC3845L- U15 indication on PCB and MOSFET IRF630 (Q37) drives primary side of the TX6 transformer. So far so good, it is not the problem to get electronic parts (diodes, mosfets, etc. ) from electronic shops here in Europe, but TX6 transformer is the problem. Producer of the tansformer is company CLICK and the transformer indication is 41-070185-00G. I have tried on there web page , but there 's no any similar product, they probably produce this part especially for Voltronic. I have tried also to dissesemble the TX6 trasformer (I have success several times in the past with the same method), but this time EEL25 ferrite was initially broken and after then when I have tried to dissasemble the rest of parts, aslo the PVC housing of the transormer was broken (believe because all was already overheted and burned during mulfunction of the unit). I have count all the windings on primary, secondary and VCC windings, measured the Cu wire diameter of different windings, measured also the EEL 25 ferrite central leg gap (0,5mm), but due the wiring was burnt initially, I could not measure the original inductivity of all windings, later on due to broken of one parts EEL25 have no chance to measure the original permability of the ferrite material, so could even order new EEL 25 ferrite cores. All in all - bad infos. But if somebody would need this data for complete wiring , are avaliable with no problem. Mybe somone has already broken main board of the Axpert 5K, which could be used for spare parts, mybe someone around has this part TX6 on stock , or ??? - PLEASE HELP, any idea where to get the trafo TX6 (I have written even e-mail to Voltronic Power, but no answe yet) With the best regards maxo

Hello Chris Thank'y in advance. on your e-mail is my e-mail adress. later on (hopefully tomorrow) about my findings, will report to forum to help another members with the similar problems. maxo

Thanks Terrible Triplett. Hope, like you mentioned, Chris could help me, i mean time I got notification from plonkster member, he concluded probably the SCC - solar charge controller is fault, but I'm still looking for service manuals anyway, this is only possible way look's to me at this moment, to go further to electronice service repair center with the manuals, otherwise I could expect only big eyes fro the service guys here. P.S.: there's no any error message on the screen, also red fault LED is off, there's no sound beeeps -alarm at all, but it is enabled in software setup and beeps are active whene change of setup is in action, so strange, but the fact is - there is no any sign for solar panels. Mybe somebody could help with the service manuals Thank's anway maxo

Hello plonkster Thank you for your reply and answer, I know the functions of the unit, like you wrote, failure of the SCC- this is also mine conclusion. Do you know, what was the another member procedure- repair or , since here in Slovenia, we do not have any reperesentative service for Axpert inverters, so I'm looking for service manuals to go further to electronic repair service and make a deal possiblly. Thanks for reply in advance maxo

Hi to all I'm newbie here in this forum, but anyway: On first page of this forum was the question: "how reliable are Axpert 5kVA inverters. " Here are my expiriencies with this type of inverter: it works very good with no problems almost 4 years up to today, when I noticed malfunction in operation. What happened - the unit does not recognize the solar panels supply at all - there is no panel sign on screen, there is indicated 0 voltage and 0 current on screen, but all other funcions are works Ok, so only charging of batteries and direct power supply output from solar pannels supply is dead and not works. I have checked - solar power supply is avaliable on inverter input and it is Ok like usual, so the internal electronis seem's to have a fault. How to repair, I'm waiting for appripriate service manuals from somebody from forum - I know there is avaliable the file, but not for newbies, I can not download it yet. In any case , when recieve it from somebody from forum, I will disconnect the unit, open it and after then you would be informed about the findings and procedure. Mybe could this repair help to somebody on forum with the same or similar problems. Thanks' maxo

Hi to all My name is Maks and I'm new member here, so few words about my problem: I have Axpert 5 kVA 48V inverter installed and in operation several years (actually 3,5 years) and since today there was not problem with it . I have 3 kWpp panels on roof installed and connected to the inverter and inverter operates only off-grid - means charge only the household units and not in parallel mode with the utility . I have installed 4 batteries 200Ah connected in series to have 48V system. What is the problem: The inverter suddenly not recognized the solar panels (there's no solar panel indication on LCD screen), the voltage and current are zero. I have checked solar panel connection to the inverter, there of coarse is the voltage present (more than 100V of coarse), so my final conclusion is- there is the malfunction in electronics of the inverter. I have tried all known to do ( off the grid power supply, off the battery supply, waiting for longer period without any connection of power supply (grid and solar and battery off), and after powering on again, nothing was changed. The solar supply is not recognized, all the rest funcions are Ok and works (utility bypass, battery charging from utility, battery operating and output power to the house , etc). So , there is another problem, here in Slovenia we do not have any service wich deals with the Axpert servicing. Meanwhile, I'm delaing with electronics, so I need at least service manuals for help and recognize the parts which are possibly dead in the inverter - I assume there is the problem in the DC inverter-charger stage, but before the disconneting the unit from house operation, I need to prepared in advance. Finally , please for help, if mybe somebody could proceed the service manuls - file, which is avaliable on POWER forum page , but unfortunatelly I canot download, because I'm newbie on this forum. Please reply and help. maxo