BRAND Axpert VM II-5000 - User Manual

SERVICE MANUAL
Axpert VM II-5000
and VM II-3000
1
Axpert VM II-5000/ VM II-3000
Service manual

Summary

General Information

Getting Started and Manual Overview

Introduces the manual's purpose, structure, and basic inverter knowledge.

Basic Topology Introduction

Explains the inverter's hybrid operational topology.

Inverter Family Overview

Lists inverter models and their key parameters.

Inverter Component Overview

Identifies the main internal components of the inverter.

Anti-Dust Kit Maintenance

Provides instructions for clearing and maintaining the anti-dust kit.

Troubleshooting Inverter Faults

Troubleshooting Methodology

Guides on diagnosing, reporting, and checking inverter faults.

Common Fault Conditions and Checks

Details common faults like 'No display', '09 fault', '56 fault' with diagnostic steps.

Post-Repair Testing Procedure

Outlines the steps for testing the inverter after repairs are completed.

Checking and Measuring Guide

Main Board: Battery Side Components

Checks for fuses, capacitors, resistors, and MOSFETs on the battery side.

Main Board: Bus Side Components

Checks for DC/DC IGBTs and driver resistors on the bus side.

Main Board: Buck Circuit Components

Checks buck circuit MOSFETs, diodes, and driver resistors.

Main Board: INV Full Bridge Components

Checks INV full bridge IGBTs and driver resistors.

Main Board: Battery & Power SPS Components

Checks components for battery and main power supply sections.

MPPT Board: AC SPS Component Check

Checks AC power supply components on the MPPT board.

MPPT Board: Bus Soft Start Circuit Check

Checks the bus soft start circuit on the MPPT board.

MPPT Board: Boost Circuit Check

Checks boost circuit IGBTs and diodes on the MPPT board.

Disassembling Guide

Inverter Disassembly Steps

Detailed steps for disassembling the inverter, including removing covers and cables.

Total Wiring Diagram

Overview

1. Function Description
2. Important Technical Specifications
3. Main Board Components (Battery Side)
4. Main Board Components (Bus Side)
5. Main Board Components (Buck Circuit)
6. Main Board Components (INV Full Bridge)
7. Main Board Components (BATT and Main Power SPS)
8. MPPT Board Components (AC SPS)
9. MPPT Board Components (Bus Soft Start Circuit)
10. MPPT Board Components (Boost)
11. Usage Features
12. Maintenance Features

This document serves as a service manual for the Axpert VM II-5000 and VM II-3000 hybrid inverters. It provides detailed information for checking, repairing, and maintaining these devices.

Function Description:

The Axpert VM II-5000 and VM II-3000 are hybrid inverters that integrate a solar charger. This design allows the inverter to utilize solar power to supplement battery charging, especially when grid power is unavailable, or for energy-saving purposes. The inclusion of a solar charger enables more versatile working modes compared to traditional UPS or normal inverters. The inverter's topology includes a Boost stage for PV input, a DC BUS, and a bi-directional DC/AC inverter, facilitating power flow to the grid, load, and battery, with BMS integration for battery management.

Important Technical Specifications:

The manual covers two main models:

• Axpert VMII-5000: Power rating of 5KVA, MPPT charger type, 1 charger number.
• Axpert VMII-3000: Power rating of 3KVA, MPPT charger type, 1 charger number.

Key components and their specifications for the VMII-5000 and VMII-3000 models are detailed throughout the service manual, including:

Main Board Components (Battery Side):

• Fuses:
  • F3: FUSE 150A (common for both models).
  • F1 (BATT Power SPS): FUSE 3A 125V for VMII-5000, FUSE 5A 125V for VMII-3000.
• Capacitors:
  • C18/C13/C8: 6800uF 63V for VMII-5000.
  • C18/C13/C11/C8: 4200u 35V for VMII-3000.
• DC/DC MOSFETs (Q11/Q17/Q20/Q24 & Q38/Q21/Q22/Q12 & Q13/Q18/Q23/Q19 & Q40/Q26/Q25/Q14):
  • VMII-5000: TK100E08N1 214A 80V TO-220.
  • VMII-3000: IRFB3206PBF 210A 60V TO-220.
• Drivers (Transistors):
  • Q46/Q48 and Q41/Q43: 2SC2655 2A 50V NPN TO-92.
  • Q47/Q49 and Q15/Q16: A1020 2A 50V PNP TO-92.
  • Q54/Q56 and Q51/Q52: 2SD1624 2A 50V NPN SOT-89.
  • Q55/Q57 and Q50/Q53: 2SA1020 3A 50V PNP SOT-89.
  • Q60/Q61 (MOSFET): UT3404G 5.8A 30V SOT-23.
• IC PWM Controller: U9 (SG3525ANG DIP-16).

Main Board Components (Bus Side):

• DC/DC IGBTs (Q27/Q28/Q29/Q30):
  • VMII-5000: 4063DPBF 48A 600V TO-247.
  • VMII-3000: 45HF60WDA 45A 600V TO-247.
• Drivers (Resistors and Diodes): R91/R102/R96/R101 (22R 1206), R90/R99/R94/R97 (0R 1206), D32/D35/D33/D34 (1N4148W 0.15A 75V SMD).

Main Board Components (Buck Circuit):

• BUCK MOSFET/IGBT (Q32):
  • VMII-5000: 4063DPBF 48A 600V TO-247.
  • VMII-3000: 45HF60WDA 45A 600V TO-247.
• Diode (D13): RHRP1560 15A 600V TO-220.
• Drivers (Resistors and Diode): R125 (47R 1206), R124 (10R 1206), D38 (1N4148W 0.15A 75V SMD).

Main Board Components (INV Full Bridge):

• INV IGBTs (QA1/QC1/QB2/QD2): 4063DPBF 48A 600V TO-247.
• Drivers (Resistors and Diodes): R48/R144/R140/R137/R139/R145/R150/R152 (47R 1206), D5/D6/D12/D16 (1N4148W 0.15A 75V SMD).
• Optocouplers (U1/U2/U3/U4/U12): FOD3150ASD SO-8.

Main Board Components (BATT and Main Power SPS):

• NTCs: NTC2 (10ohm 3A for VMII-5000, 5ohm 5A for VMII-3000).
• MOSFET (Q65): IRF740 10A 400V TO-220 for VMII-5000, IRF640NPBF 18A 200V TO-220 for VMII-3000.
• Resistors: R246 (NC for VMII-5000, 3W 0.15ohm for VMII-3000), R245 (3W 0.15ohm).
• Transformers: TX2 (FER EC28), TX3 (TX 16:16:16).
• Diodes: D61 (MUR4100ERLG 4A 1000V UFST), D60 (RHRP860 8A 600V SFST), D65 (RS1006FL 1A 600V SOD-123FL).
• ICs: U14 (UC3845BNG DIP-8), Q6 (PMBT2907A 0.6A 60V SMD).

MPPT Board Components (AC SPS):

• Fuses: F1 (FUSE 5A 125V).
• NTCs: NTC1 (10 OHM 3.0A).
• PTCs: PTC1 (6 OHM 4.1A).
• Rectifiers: REC1 (GBU4M 4A 1000V UFST).
• Diodes: D9 (MUR4100ERLG 4A 1000V UFST).

MPPT Board Components (Bus Soft Start Circuit):

• Diodes: D6 (RHRP8120 8A 1200V UFST), D7 and D10 (MUR4100ERLG 4A 1000V UFST).
• Resistors: R29 (0.62 J), R23 (22R 1206).
• MOSFET: Q3 (IRFBG30 3.1A 1000V TO-220).
• IC: U2 (UC3845BNG DIP-8).
• Transformer: TX1 (FER EEL16).

MPPT Board Components (Boost):

• Diodes: D1 (30DQ60BG 30A 600V TO-247).
• IGBTs: Q1 and Q6 (4063DPBF 48A 600V).
• Optocoupler: U1 (FOD3150ASD SO-8).
• Diodes: D13 and D2 (1N4148W 0.15A 75V SMD).
• Resistors: R12 and R50 (10R 1206), R52 and R47 (47R 1206).

Usage Features:

The manual is primarily for service and repair, not end-user operation. However, it implicitly highlights the inverter's robust design for various power management scenarios, including solar charging and grid interaction. The hybrid nature allows for flexible energy sourcing and distribution.

Maintenance Features:

The service manual provides comprehensive guidance for maintenance and troubleshooting:

• Troubleshooting Steps:
  • Identifies two main symptoms of faulty inverters: no display or fault/warning codes on the LCD.
  • Emphasizes recording fault information and following specific checking procedures.
  • Provides detailed checks for common issues like "Not working at all/No display" (SPS module damage), "09 fault" (Bus soft start failure, DC-DC module, or BUS soft start module damage), and "56 fault" (Battery not detected, wire connection, or fuse issues).
• Component-Level Checking and Measuring:
  • Detailed instructions for measuring resistance and diode forward voltage of critical components like MOSFETs, IGBTs, and drivers on both the main board and MPPT board.
  • Provides reference values and expected failure statuses (e.g., "Short or explosion," "Open or other values").
  • Specific notes on how to measure components accurately, often requiring removal from the board to avoid misleading readings due to circuit capacitors.
  • Recommends replacing all related components if one or more in a group are damaged (e.g., all MOSFETs in a stage, or driver transistors and control IC if resistors are burnt).
• Anti-Dust Kit Maintenance:
  • The inverter comes with a pre-installed anti-dust kit to enhance reliability in harsh environments.
  • Instructions for cleaning the air filter foam and dustproof case, recommending cleaning every month.
• Disassembling Guide:
  • Step-by-step instructions for disassembling the inverter, including removing screws, cables (LED, LCD, comm, MPPT comm, anti-dust, I/P, O/P, AC SPS, MPPT power supply, fan, PV IN, SW, BUS, BUS soft, NTCs), and boards (main board, MPPT board).
  • Crucial warnings about careful handling of plastic screws and ensuring proper reassembly of plastic sheets for heat dissipation.
• Total Wiring Diagram:
  • Includes a comprehensive wiring diagram to aid in correct reassembly and troubleshooting.
  • A critical note warns that "Wrong connection of wires may cause inverter damage!" and advises connecting wires with care.

The manual is designed for technicians with electrical or electronic backgrounds, enabling them to perform repairs and maintenance effectively.

BRAND Axpert VM II-5000 Specifications

General

Brand	BRAND
Model	Axpert VM II-5000
Category	Inverter
Language	English