Axpert Charger/ Inverter
Contents
1. tree erre rire nennen nnn nnnm nnne nnns 24 Table 2 Invert Mode SpecificatiONS e 25 Table 3 Charge Mode SpecificatiONS enne nennen eene ener nennen nnne nns 26 ETEN T 26 CHANGES eacueaavastotacu E A T A A A E 26 da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 1 General information 1 1 Getting start This manual is for Axpert MKS 4KVA 5KVA series it can help service personal perform the basic maintenance and repair service This manual focus on the service so you should get the basic operation of the Inverter Charger from the user manual and make sure you had read and understood user manual before you use this service manual The manual include 8 sections as follows e General Information this section show you the general information of the service manual e Functional Block this section show you the major functional block of the Inverter Charger e Working Principle of the major Functional Block this section show you the major functional block e Function explanations for each PCB this section show you all the PCBs of the Inverter Charger e Interface this section show you the LCD interface include display and setting e Trouble shooting this section will give you the way to find the trouble e Test step this section tell you how to test the Inverter Charger after you repair the unit e Electric Specifications this section sho2. da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual Advancing Power Please refer to INSTALLATION section of this manual for the details 10 Fuses 40A 32VDC 4pcs for 1KVA 2KVA and 6pcs for 3KVA are provided as over current protection for the battery supply 11 GROUNDING INSTRUCTIONS This inverter charger should be connected to a permanent grounded wiring system Be sure to comply with local requirements and regulation to install this inverter 12 NEVER cause AC output and DC input short circuited Do NOT connect to the mains when DC input short circuits 13 Warning Only qualified service persons are able to service this device If errors still persist after following troubleshooting table please send this inverter charger back to local dealer or service center for maintenance e 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 2 Functional block Axpert MKS 4KVA 5KVA series production employ a double conversion topology comprise following functional blocks as shown in figure 2 1 PV MPPT Solar Charge PV Controller NTC Sensor Li p Input Breaker Nye Safety Relay Inverter Relay Output Relay Load Detection Battery i 5 Isolation or DC DC Converter DC AC Inverter EE use Battery AC DC Rectifier x Charger FEE a p Reverse Polarity Protection Thermal Switch Protection NTC Sensor db
3. 4 1 Main board The main board consists of SPS DC DC converter inverter Many semiconductors and easy failure components on the board so it should be play more attention when the system is abnormal 4 2 Cntl board The cntl board consists of AD sample MCU control and communication module It control the other module work orderly 4 3 SCC board The solar current control SCC board based on a PW control mode When the solar source is presented battery charged from solar source MAX charge current is 50A if solar panel with enough energy 11 h d n 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 4 4 COMM board This inverter charger is equipped with a communication port to communicate with a PC with corresponding software Please use supplied communication cable to connect to communication port of this inverter and RS 232 port of the PC 4 5 LED board The LED display panel includes there indicators and four functional keys 4 6 MPPT board The MPPT board consists of SPS BUCK converter MCU control It integrated the MOSFET driver board and SPS driver board on it Many semiconductors and easy failure components on the board so it should be play more attention when the system is abnormal 5 Interface The operation and display panel shown in below chart is on the front panel of the inverter It includes three indicators four function keys and a LCD display indicating the operating status and input out
4. et aa i Axpert MKS 4000 KS 5000 Service manual Axpert MKS Charger Inverter Service manual te 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual ne agi Prepared Approved Revision Description p PP by by V00 Initial draft rel Me nitial Grail release 2013 11 4 da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual Table of contents Eee MM OFT el OMT EU T mem 4 S 4 1 2 Important safety instructions iii 4 FEMINA SEE TEE 6 Working principle of the major functional DIOCK nnne 7 3 1 Switch Power Supply mrrasnrronavernavesonvesannsrannsnrnavesnnvesnnnsrannsranasnsnasesnavesnnnssannsrenasnsnnnesnnnssennsrannsnenasesnese 7 3 2 DC TO DC dual converter Full bridge converter sse 8 55 MENT FANE eee ET LTEM 8 Pk 9 39 Ve NER EE 9 Functional explanations for each PCB iii 11 MI 11 40 OT 11 4 EEG 00 6 RP 11 44 TM 12 lo a E Bye 02 10 SR ene nen eee E ee ee ee ee ee 12 45 PI DIN 12 ER AE 12 5 1 LE BEATE 10 FE RE EE 12 52 CISA ren Ta 14 IO UDIESROO RA E T T Uu TP 17 61 Fault Reference COS irreali 17 SE VETA Ga 0 1 052 de m 18 6 3 Trouble shooting according to fault indication i 18 ET MUNN 20 ESS JE ENE 23 FEE ANON EET Er 24 Table 1 Line Mode SpecificatiONS
5. H mm 468 295 120 Charging Controls Voltage Setting Boost CC CV Flooded 58 4 AGM Gel 26 n e Voltronic Power Axpert MKS 4000 KS 5000 Service manual Charging Curve Battery Voltage per cell Charging Current 96 2 43Vdc 2 35Vdc Voltage 2 25Vdc T1 10 TO minimum 10mins maximum 8hrs Bulk Absorption Constant Current Constant Voltage 27
6. R52 R62 R81 R64 R41 R59 R70 R76 R80 R78 R75 R42 Resistance R93 R92 R87 R533 R91 R96 R102 R101 22 ohm short or open R55 R60 R79 R63 Resistance R45 R58 R68 R69 R77 R73 R74 R46 Resistance R86 R85 R88 R56 R95 R89 R100 R101 47K short or open R1 R4 R47 R20 R51 R49 R61 R54 ROSA 10 ohm short or open Resistance short or open PIN12 PIN13 11 DC DC Converter IGBT IRGP4063 Q27 Q28 Q29 Q30 e lt 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual gt 180K CE short or open IGBT IRGP4066 QA1 QC1 QD2 QB2 Resistance 250K GC short or open 23K GE short or open R48 R137 R144 R140 DC AC Inverter Resistance Resistance 47 ohm short or open R139 R150 R145 R152 64K PIN 8 7 Photo coupler U1 U2 U4 43 Resistance gt 1M PIN 5 6 short or open Control IC UC3845 Resistance 46 5K PINS PIN7 short or open SPS L gt 400K_ DS gt 400K DS MOSFET IRF640NPBF Q36 Resistance short or open gt 230K DS short or open MOSFET IRFB3421PBF Q3 Q7 Resistance 0 7M GD short or open 440K GS short or open MPPT short or open Transistor Q23 Resistance short or open short or open short or open Transistor Q24 Resistance short or open short or open MPPT charger board please followed the issue as below block function Q2 Q4 Q6 Q7 Q8 10k 300k DS MOSFET IRFB4321 Q10 Q11 Q12 Q13 Resistance 10k 300k GD Q14 4 99k GS Diode V30200C 1 100k PN 16 600656 XXG Main board Q16 Short or open SOL to SOL BAR2 to BAR6
7. gt 100K BAT to BAT BAR7 to BAR3 gt 100K 16 500285 XXG R19 R25 R29 Resistor 75ohm Resistance 75ohm Driver board for R40 R46 the MOSFET on Resistor 100hm R2O R2G RGO 21 MOSFET IRF640NPBF sete feg da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual main board IC IR2011S 800K PIN3 PIN8 16 500225 XXG R7 R11 R15 Resistor 75ohm Resistance 750hm Driver board for R19 R23 the MOSFET on R8 R12 R16 Resistor 100hm Resistance 75ohm right side of the R20 R24 22 e lt 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 7 Test Step Repair the Inverter Charger according to the trouble shooting Power on and SPS failure and press ON button repair it check the wire and correct it LCD display and fan FRE input rotates wire connecte is DES YES El NO inverter or voltage 230v7 Na control block failure and repair it Turn on the line voltage breaker relay or relay driver circuit output voltaze followed the AC input charge current and voltage 15 DE NO Charger failure and repair it Si NO PV Charger failure and PV charger is OK repair it TES 23 ba 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 8 Electrical specification Table 1 Line Mode Specifications Input Voltage Waveform Sinusoidal utility or generator Nominal Input Voltage 230Vac 170Vac 7V UPS Lo
8. Figure 2 1 function block diagram d n 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 3 Working principle of the major functional block 3 1 Switch Power Supply The switch power supply SPS supplies DC power for Inverter Charger operation The input voltage of the SPS is the battery or AC Charger output voltage UZG L791 20V O 057 m S m gt RS1JSM N ad NA un ma C118 R265 F RAA ST 681M 1KV 22ohm 1WSM 881M 1KV 22ohm WSM F TXS UF202 D53 Y BAT i 17 C99 Cu LO 2 11 x Es NZ 681M 1kV 53 IRF640NPBE D 1 un L 036 t 8 UF3 2 2j cag 104MSM 9605 3 BAT 5 K R D28 ee re EE28 070194 HFPW NNN R R D54 47KSMF B683 UF3 4 R206 z La a s caz YN gt ay M Set iP Ap ud E 3 581M 1kv 220hm TWSM CN oy C h r R ag 5 Q T N K C H pag 16v C78 AC Figure 3 1 basic circuit of power supply This is the fly back DC DC converter fly back operation can be easily recognized from the position of the dots on the transformer primary and secondary these dots show starts of the winds When Q36 is ON the dot ends of all winds are negative with respect to their no dot ends Output rectifier diodes D54 D57 D67 and D70 are reverse biased and all the output load currents are supplied from storage filter capacitors C78 C75 C79 and C116 The primary coil of the transformer acts as an inductor and s
9. and low referenced output channels To construct a high frequency PWM inverter the drivers receive switching signals from PWM generation circuit through a pair of photo couplers to trigger the upper IGBT and the lower IGBT alternately The output of IGBT s is filtered by an LC circuit to reduce the o p voltage harmonics distortion da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual Advancing Power Figure 3 3 Full bridge topology 3 4 Buck converter The Buck circuit Figure 3 3 is active only when the line charging the battery When the battery is discharging S12 is ON and S10 is OFF D10 is reversed cut off L15 is used as a filter inductor d S2 1621 DI2 i 161 M ISION DI0 P2 L 777 NE Figure 3 4 Buck topology 3 5 MPPT solar chager It employed an interleave buck converter comprise following functional blocks as shown in figure as below e 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual alt Vin b Il Controller dl Control Signals Figure 3 5 MPPT topology ba 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 4 Functional explanations for each PCB i E comm mise 1 KS4000 comm risse 1 KS5000 Note XX in the serial number is the version of the PCB A
10. attery voltage LCD Display lt 2V cell 4 bars will flash in turns Constant 2 2 083V cell Bottom bar will be on and the other three C t d bars will flash in turns urrent mode 2 083 2 167V cell Bottom two bars will be on and the other Constant two bars will flash in turns Bottom three bars will be on and the to Voltage mode 2 167 V cell P bar will flash Floating mode Batteries are fully charged 4 bars will be on In battery mode it will present battery capacity Load Percentage Battery Voltage LCD Display 1 717V cell 1 8V cell Load gt 50 1 8 1 883V cell 1 883 V cell lt 1 817V cell FT 7 F 1 FT 7 gt 1 983 lt 1 867V cell 1 867V cell gt 1 95V cell Load lt 20 1 95 2 033 V cell 50 gt Load gt 20 1 9 gt 1 983 V cell i da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual Load Information Indicates overload Indicates the load level by 0 24 25 50 50 74 and 75 100 096725976 2570750976 50 75 15 100 Mute Operation Indicates unit alarm is disabled da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 6 Troubleshooting This section describes how to find the trouble when the system is abnormal We suggest you can follow the service procedure a Check the system status by LED and LCD display the sounds of buzzer Observe the failure b
11. oard static checking Replace the failure components Static checking Power up checking f Test after repair Following section will help service person to solve most of problem o ooo 6 1 Fault Reference Code Mea se o a CT oo o mme C S C ws pupasmonoranziorger iene D C C jew Mu 09 Bus Bus soft start failed start failed Is da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual PN Battery connection is open J LIN Current sensor failed ad 6 2 Warning Indicator ar Warning Event Audible Alarm Icon flashing Beep three times ever Fan is locked p y VIA second J Beep once every l mM 15econd gt Beep once every 1 LIA Low battery due y U Di gt So son second Beep twice every 3 seconds Power limitation 6 3 Trouble shooting according to fault indication LCD LED Buzzer Explanation Possible cause What to do Unit shuts down LCD LEDs and automatically buzzer will be active The battery voltage is too low 1 Re charge battery during startup for 3 seconds and lt 1 91V Cell 2 Replace battery process then complete off 1 The battery voltage is far too 1 Check if batteries and the No response after Ko indication low lt 1 4V Cell wiring are connected well power on 2 Battery polarity is connected 2 Re charge battery reversed 3 Replace battery Input voltage Is Check if AC breaker is displayed as 0 on the LCD and green Mains exist bu
12. put power information LCD display LED indicators Function keys 5 1 LED Indicator 12 A FAULT lt 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual AC INV Solid On Output is available in bypass mode DE Flashing Output is powered by battery in inverter mode Flashing Battery is charging Solid On Fault mode Flashing Warning mode Solid On Battery is fully charged gt 209 Voltronic Power Advancing Power Axpert MKS 4000 KS 5000 Service manual Function Keys ESC 5 2 LCD Display Icons INPUTBATTTEMP lO gt OUTPUTBATTLOAD noo UA RAS Il T T 1 2 1 OVER LOAD r W 100 1 Il 25 CHARGING lon Function description Input Source Information Indicates the AC input Indicates the PV input YE F Indicate Input voltage Input frequency PV voltage battery voltage and ODI fo charger current Configuration Program and Fault Information Indicates the setting programs Indicates the warning and fault codes M m Warning flashing with warning code i d a 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual EYE Indicate output voltage output frequency load percent load in VA and T mj je load in Watt Battery Information Indicates battery level by 0 24 25 49 50 74 and 75 100 in battery CHARGING mode and charging status in line mode In AC mode it will present battery charging status B
13. s Fault code 06 voltage below than 190Vac or is load continuously and higher than 260Vac 2 Return to repair center Fault code 08 Fault code 09 Fault code 11 Fault code 51 Fault code 52 Fault code 53 Fault code 54 Fault code 55 Fault code 56 Battery is disconnected Check if battery wires are connected well 1 Restart the inverter again 2 If the problem still exists please return to repair center red LED is on 1 Restart the inverter again 2 If the problem still exists please return to repair center Internal components may be failed Fault code 57 Internal components may be failed e lt 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 6 4 Quick start Before any detail check of the system please check the components listed as follow table NOTE It is important to check the capacitor s voltage on the board lower than the safety voltage before any check action Functional Instruction l Checked components Reference value Failed status block function Q13 Q18 Q23 Q19 pue MOSFET IRFB3307 ee Resist esistance Q38 Q21 Q22 Q12 271k GD iena EET Diode 30D0608G Q51 Q52 Q54 Q56 11 9K PIN1 2 short or open Driver NPN PNP Resistance Q50 Q53 Q55 Q57 11 9K PIN1 3 short or open BUCK MOS Q32 Q31 Resistance short or open short or open gt 400K Driver IC UC3525 Resistance short or open PIN14 PIN13 12 Resistance 184K GC short or open 22 50hm GE short or open
14. t the LED is flashing unit works in 1 Check if AC wires are too battery mode thin and or too long 2 Check if generator if applied is working well or check if input voltage range Input protector is tripped tripped and AC wiring is connected well Green LED is Insufficient quality of AC power flashing Shore or Generator da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual UPS Appliance Green LED is Set Solar power as the priority of Change output source flashing output source priority to Utility first LCD display and LEDs are flashing Overload error The inverter is Reduce the connected load Fault code 07 loaded with more than 110 by switching off some load and time is up equipment Check if wiring is connected Output short circuited well and remove abnormal load When the unit IS turned on internal relay is switched on and off repeatedly Check if battery wires are Battery is disconnected connected well Fault code 05 Temperature of internal Check whether the air flow er COMBO of the unit Is blocked or Internal Inverter component over mener ambient Fault code 02 100 C temperature is too high Battery is over charged Return to repair center Fault code 03 Check if spec and quantity The battery voltage is too high of batteries are meet requirements Fault code 01 Fan fault Replace the fan Output abnormal Inverter 1 Reduce the connected Buzzer beep
15. tored energy When Q36 is OFF the stored energy in the primary coil is delivered to secondary filter capacitors C78 C75 C79 and C116 As shown in figure 3 1 this circuit may generate several output voltage such as 12V 12V 15V 5V HFPW da 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual 3 2 DC TO DC dual converter Full bridge converter The full bridge topology is a transformer isolated forward mode regulator Unlike the Fly back transformer the push pull transformer does not store any energy and output current is drawn when either power switches S1 S4 or S2 53 is conducting P1 is the battery P2 is the BUS This is dual converter it means that battery can feed power to BUS and also BUS can charge the battery And it is an open loop control the transformer N1 N2 is 1 8 when the battery voltage is transformed through the converter to more than the BUS voltage the battery discharge power to the BUS or the BUS can charge the battery Figure 3 2 DC TO DC dual converter 3 3 Inverter Full bridge The Inverter circuit Figure 3 3 and PWM control are can both active under battery mode and line mode In line mode the inverter can convert power from gird to BUS for charging The Inverter circuit of Axpert series is based on a full bridge circuitry and its output is driven by photo couplers The photo couplers are capable to drive high energy and high speed power of MOSFET and IGBT with independent high
16. w Loss Voltage 90Vac 7V Appliances 180Vac 7V UPS Low Loss Return Voltage 100Vac 7V Appliances High Loss Voltage 280Vac 7V High Loss Return Voltage 270Vac 7V Max AC Input Voltage 300Vac Nominal Input Frequency 50Hz 60Hz Auto detection Low Loss Frequency 40 1Hz Low Loss Return Frequency 42 1Hz High Loss Frequency 65 1Hz High Loss Return Frequency 63 1Hz Output Short Circuit Protection Circuit Breaker Efficiency Line Mode gt 95 Rated R load battery full charged 10ms typical UPS Transfer Time 20ms typical Appliances Output Power A Rated Power Power Limitation 50 Power gt 280V Input Voltage 24 ba 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual Table 2 Invert Mode Specifications Rated Output Power 4KVA 3 2KW 5KVA 4KW 5502150 load 10s 110 150 load Nominal DC Input Voltage 48Vdc Cold Start Voltage 46 0Vdc Low DC Warning Voltage load lt 20 44 0Vdc 20 x load 50 42 8Vdc load gt 50 40 4Vdc Low DC Warning Return Voltage load 20 46 0Vdc 20 x load 50 44 8Vdc load gt 50 42 4Vdc Low DC Cut off Voltage load lt 20 42 0Vdc 20 lt load lt 50 40 8Vdc load gt 50 38 4Vdc 25 ba 9 Voltronic Power Axpert MKS 4000 KS 5000 Service manual Table 3 Charge Mode Specifications Max PV Array Open Circuit Voltage 000000 d Vvd Table 4 General Specifications Dimension D W
17. w you the basic electric specification of the Inverter Charger 1 2 Important safety instructions AN WARNING This chapter contains important safety and operating instructions Read and keep this manual for future reference 1 Before using the unit read all instructions and cautionary markings on the unit the batteries and all appropriate sections of this manual 2 CAUTION To reduce risk of injury charge only deep cycle lead acid type rechargeable batteries Other types of batteries may burst causing personal injury and damage 3 Do not disassemble the unit Take it to a qualified service center when service or repair is required Incorrect re assembly may result in a risk of electric shock or fire 4 To reduce risk of electric shock disconnect all wirings before attempting any maintenance or cleaning Turning off the unit will not reduce this risk 5 CAUTION Only qualified personnel can install this device with battery 6 NEVER charge a frozen battery 7 For optimum operation of this inverter charger please follow required spec to select appropriate cable size It s very important to correctly operate this inverter charger 8 Be very cautious when working with metal tools on or around batteries A potential risk exists to drop a tool to spark or short circuit batteries or other electrical parts and could cause an explosion 9 Please strictly follow installation procedure when you want to disconnect AC or DC terminals
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