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 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 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 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