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On 9/21/2017 at 3:22 PM, jussclay said:

Hallo everyone could anyone have a direct cause of the error code 09 on an Axpert inverter.

I'm working on another axpert 5kva inverter all the zener diode are shorted z24 thru z31. Does anyone know the value. Thanks

 

4 hours ago, Compupower said:

Im working on axpert inverter 5kva Is it possible for U16 to be bad even if the resistor R245 is good. I've checked everything on the board yet im still having error 09

It is possible - check U16 pin 7 to 5  42k and pin 6 to pin 5  30k.

For bus soft start failure you should also be looking at diodes D65 and D73 and MOSFET(Q6) next to the power supply transformer.

Thanks Chris, Yes I will have to change U16 all the other component are ok

seriously speaking I have large quantity of axpert 5kva for repairs and almost all of them are reporting error 09. what could be the reason why axpert is suspectible to that error

@EnergyThanks, admittedly I also suffered from this issue when just started...

Now back to the issue of Axpert error:
* My experience has tought me, that the error 9 (09) is related to many errors, usually hardware issues rather than software. Something on the circuit boards is causing an issue. In my case it was blown mosfets.

21 hours ago, Compupower said:

I'm working on another axpert 5kva inverter all the zener diode are shorted z24 thru z31. Does anyone know the value. Thanks

 

The ones marked BN are likely 15 V and the ones marked BL are likely 12 V. I can't make out the markings from your photo.

See

http://www.s-manuals.com/pdf/datasheet/b/z/bzt52h_series_nxp.pdf

10 hours ago, Compupower said:

seriously speaking I have large quantity of axpert 5kva for repairs and almost all of them are reporting error 09. what could be the reason why axpert is suspectible to that error

They really don't like heat. Are you from an area with a hot climate?

The capacitors dry out, and that allows spikes to kill the MOSFETs, which have a very narrow voltage margin. I've upgraded both my capacitors and MOSFETs almost from new. If you wait for the MOSFETs to blow, then you also take out various gate drive components, so you run the risk of blowing up the new set (which are moderately expensive) at first switch-on after repair. That can be heartbreaking.

http://forums.aeva.asn.au/viewtopic.php?title=pip4048ms-inverter&p=64358&t=4332#p64358

5 minutes ago, Coulomb said:

If you wait for the MOSFETs to blow, then you also take out various gate drive components

This reminds me so much of a car I used to own, a 3-series BMW 320d (E46). These cars had swirl flaps in the intake. In cold weather or during part throttle, the swirl flaps close and causes extra turbulence in the intake air. This apparently cuts down on emissions. All good and well, except the flaps sit on 2.5mm axles which gradually gets clogged up with soot (due to the EGR function) and over time this bit of clogging is enough to introduce metal fatigue and break them. When they break, they are ingested by the engine leading to a fire-path of disaster: Sometimes it jams a valve open and you smack a piston into it, in most cases it is sucked into the combustion chamber and riddles the aluminium cylinder head with hail-like indentations, and in a few rare cases it gets blown out the exhaust valve into the turbo's impeller.

The answer was to remove the flaps before the car hits 200 000km. Sure, it will smoke a bit more in the mornings... it doesn't matter in South Africa.

I desperately need help.. On my birthday... 

Been running my axpert for sometime with no issues. This morning I did a test to see how long it would last off batteries. 

After awhile system turned off and I turn power back on. 

The unit turned off and now error 09...

Anyone Wana come round and fix it? Gladly pay... In jhb. 

If not, anyone know guys that are able to fix it? 

Thanks 

Peter 

On 2018/09/22 at 10:23 AM, Petum said:

I desperately need help.. On my birthday... 

Been running my axpert for sometime with no issues. This morning I did a test to see how long it would last off batteries. 

After awhile system turned off and I turn power back on. 

The unit turned off and now error 09...

Anyone Wana come round and fix it? Gladly pay... In jhb. 

If not, anyone know guys that are able to fix it? 

Thanks 

Peter 

I could take a look for you. Where in JHB are you?

On 2018/08/12 at 12:23 PM, Coulomb said:

They really don't like heat. Are you from an area with a hot climate?

The capacitors dry out, and that allows spikes to kill the MOSFETs, which have a very narrow voltage margin. I've upgraded both my capacitors and MOSFETs almost from new. If you wait for the MOSFETs to blow, then you also take out various gate drive components, so you run the risk of blowing up the new set (which are moderately expensive) at first switch-on after repair. That can be heartbreaking.

http://forums.aeva.asn.au/viewtopic.php?title=pip4048ms-inverter&p=64358&t=4332#p64358

@Coulomb would you mind telling me which capacitors and mosefts you put in? i.e. which model did you use?

2 hours ago, SilverNodashi said:

@Coulomb would you mind telling me which capacitors and mosefts you put in? i.e. which model did you use?

This post, available from the AEVA thread index (first post) has all the details:

http://forums.aeva.asn.au/viewtopic.php?title=pip4048ms-inverter&p=64358&t=4332#p64358

That thread is getting huge, so it's difficult to find information even with the index.

The information in the post refers to 4 kW models; I have no idea about what's in the 5 kW models. But we may well find out tomorrow or soon thereafter. We'll update that post if there is new information.

Time to revive the post again. JIP. This evening I Switch on my inverter just to check if everything is ok, and then Error 9 pop UP!!! uuurrrggggg!! everything was still working fine last night, float the batteries and everything looked ok. 

Now the big question is, where do you start to check for problems inside it and to find someone in Cape Town side to repair it if it can be repair. 

4 hours ago, Gerlach said:

This evening I Switch on my inverter just to check if everything is ok

So are you saying that you had your inverter switched off for a long time before turning it on recently? If so, it might be a capacitor reforming issue. Try restarting it a few times; otherwise, you'd need to slowly bring up the bus voltage, perhaps with a current limited power supply; maybe a dual 30 V power supply might do (60 V total). Leave this power supply on at 60 V, and note the current. If it goes down slowly over say 24-48 hours, then you are reforming the big bus capacitors. Try restarting again after that.

If you find that the bus is just a dead short, them no need for this; the problem is likely shorted IGBTs.

4 hours ago, Gerlach said:

Now the big question is, where do you start to check for problems inside it and to find someone in Cape Town side to repair it if it can be repair. 

Well, taking the main board out and examining the IGBTs and/or MOSFETs is a good start. Sometimes there are obvious faults, like parts with legs blown off, at other times there are subtle cracks, some barely visible. Any such cracks tell you for sure that you have to replace sets of semiconductors.

I can't help with where to get repairs done in South Africa, though I've heard Mecer / Mustek suggested as a possibility.

The AEVA PIP-4048MS and PIP-5048MS index page has links to several repair posts. These could be useful to you, if you are electronics minded, or perhaps to suggest to your repairer if not.

6 hours ago, Coulomb said:

So are you saying that you had your inverter switched off for a long time before turning it on recently? If so, it might be a capacitor reforming issue. Try restarting it a few times; otherwise, you'd need to slowly bring up the bus voltage, perhaps with a current limited power supply; maybe a dual 30 V power supply might do (60 V total). Leave this power supply on at 60 V, and note the current. If it goes down slowly over say 24-48 hours, then you are reforming the big bus capacitors. 

 

If a inverter is put into storage is there anything you can do to prevent this .

5 hours ago, Chris Louw said:

If a inverter is put into storage is there anything you can do to prevent this

I'm not aware of anything, except perhaps periodic re-powering. I think the idea is to do the reforming after the storage, soon before active service.

YES!!!!!!!!!!!!!!!!!!! happy dans!!! Got it sorted. Called some places and voltronics and voltronics was really nice. Ask them some questions and i Informed them that i will be opening the inverter to inspect. So this afternoon I switch on the inverter but disconnect the batteries from it, it starts up and bypass go's on from 230v in and out. Connect  batteries, relay clicks and fans kicks in and then 10sec error 9 pops up. lets test solar side. Disconnect batteries, connect solar, switch 230v in on, inverter switch on, fans kicks in, connect batteries, batteries start charging from solar side, switch on output side of 230v, 10sec error 09 pops up. solar is still charging but no power output. HHHmmmmmm

So i open the inverter to inspect.  Everything looked ok inside and nothing burned or IGBTs and/or MOSFETs blown up. Pulled the mother board to check if everything is ok and cleaned the pins, plug it everything in and guess what, it starts up and charging and do things it must do!!!!!!!!!!!!!!! 

Thanks for everyone help and input!!!  

9 hours ago, Gerlach said:

do things it must do!

Hopefully, that includes inverting (powering loads from the battery). [ Edit: since that seems to be where your problem is. ]

That's the first time I've heard that. Glad to hear it's working again.

Edited April 11, 20197 yr by Coulomb

4 hours ago, Coulomb said:

Hopefully, that includes inverting (powering loads from the battery). [ Edit: since that seems to be where your problem is. ]

That's the first time I've heard that. Glad to hear it's working again.

Jip. Had it running last night for 4hours from the batteries inverting and after that connected power to it again to charge batteries 9 hours and still running. Goingto leave it running for 48hours to see what it will be doing. 

@Coulomb The error 09 is back, ai!!! 🙄 Inverter was running without any problems, charging and inverting. So I decided to switch it off to see if the error will pop up. left if for a hour, switch on, error 09 pops up. Took the mother board out again and the solar charging board and plugs, but I spotted something, small spider webs in the inverter and then spotted this little bugger. 

   

Now I wonder if this little one maybe have something to do with my problem, by shorting something? 

Here some more photos of the IGBTs and/or MOSFETs, I can see no problem there. 

It is using a TL3845P ic and i already check where i buy some if i need to replace this. 

Another step what did was by testing the caos. The are both 470fu and 500V. On the left and right side of the caps is testing points where you can test the caps.

When you switch on the inverter with only the batteries connected and then the 230v side, the caps start charging but really slowly in that 15sec startup, only get it to like between 220 and 230v with the multi meter and then the error 09 kicks in, so the bus don't get it's full charge . I got it to 337v by disconnecting the battery and power and by then connecting the battery and power again, till it gives the error. I did this like 8/9 times to ramp it up, but no luck. I tested the caps with ohm side and the cap charge and if you switch the multi meter around it discharge the caps and charge it again. 

Where ells can i start checking and test on the board? 

2 hours ago, Gerlach said:

Inverter was running without any problems, charging and inverting.

So it seems that the inverter itself (the DC to AC power converter part) is fine.

Quote

So I decided to switch it off to see if the error will pop up. left if for a hour, switch on, error 09 pops up.

So it sounds like the soft start circuit itself. It is a small power supply that pushes current into the bus capacitors via a transformer (technically a multi-winding inductor since it has an air gap) and a single diode.

Quote

I spotted something, small spider webs in the inverter and then spotted this little bugger. 

Liveware bug!  🙂 🕷️

But that doesn't seem to be the cause, or at least not any more.   

Quote

It is using a TL3845P ic and i already check where i buy some if i need to replace this. 

At the usual on-line places: Mouser, Digi-Key, RS-Online. But that through-hole one marked U10 is most likely the one for the main power supply. If that wasn't working, you'd have no display.

Quote

Another step what did was by testing the ca[p]s. 

Excellent.

Quote

When you switch on the inverter with only the batteries connected and then the 230v side, the caps start charging but really slowly in that 15sec startup, only get it to like between 220 and 230v with the multi meter and then the error 09 kicks in, so the bus don't get it's full charge .

So it certainly sounds like the soft start circuit is struggling to charge the bus. Once it's charged, it will work fine, by your reports.

Quote

I got it to 337v by disconnecting the battery and power and by then connecting the battery and power again, till it gives the error.

So... sometimes it comes at lot closer?. So it seems intermittent, and it would need to get to over 400 V (8 times the battery voltage) to pass the test (under the most common conditions.)

Quote

Where ells can i start checking and test on the board? 

You need to pull the mother board again, and check the soft start circuit. Partial schematic trace here. There is another UC3845, U16, but surface mount. (Purchase from the same places, but make sure you get the surface mount version, and the 8-pin version, not the 14-pin version). Typically it will be a UC3845D1, but it could have an 8 near the end. But first check the hard working components, Q6 D65 R39 R40 R251 C14, then all the other passives. I'd say U16 is working, since you get some charging of the bus, just not enough. It's possible but highly unlikely that U16 is producing too weak (or narrow) a pulse to perform an effective soft start. So it's likely to be one of a dozen parts in the soft start circuit.

Edited April 14, 20197 yr by Coulomb

Thanks for the help there @Coulomb I really appreciate it.   I took some photos, can you maybe check and point out for me where i must check on the mother board. 

Sorry to jump the queue, but it seems there's some solder bridges on the components I marked in red. Do you have a fine tipped soldering iron, perhaps you can clean those pins up?

On the 2nd image, on the right circle, that one pin seems a bit short. Is it loose or broken?

Edited April 14, 20197 yr by SilverNodashi

8 hours ago, Gerlach said:

I took some photos

Ah. The smaller board is the daughter board; the much larger main board that it plugs into is the mother board. Sorry for the confusion.

@SilverNodashi, those solder bridges are presumably normal. There are several pairs of pins on the processor chip that connect to the same place. I don't see evidence of problems with the control (daughter) board at this point.

The area of interest will be under the main board, near multi winding inductor TX2 (large chunk of ferrite with yellow tape over the windings).

I wish I had a board to photograph, or photos of that part of the board, but I don't.

Edit: you may find my disassembly and reassembly instructions useful.

 

Edited April 14, 20197 yr by Coulomb