Axpert VM-1000 User manual

专案名称： AxpertVM1KW/VM2KW
专案编号： S1701112修订版次： 00 PAGE 1 / 30
V-RDP-004-73 A
旭隼 日月元
维修手册
Prepared by：郭佳威 Date：2018‐3‐19
Checked by： Date：
Approved by： Date：

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1 00A Initial draft release 2018-3-19

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V-RDP-004-73 A
Axpert VM-1000/ VM-2000
Charger/ Inverter
Service manual

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V-RDP-004-73 A
Table of contents
1.GENERAL INFORMATION...........................................................................................................................5
1.1GETTING START ...........................................................................................................................................5
1.2IMPORTANT SAFETY INSTRUCTIONS............................................................................................................5
2.FUNCTIONAL BLOCK...................................................................................................................................7
3.WORKING PRINCIPLE OF THE MAJOR FUNCTIONAL BLOCK........................................................8
3.1SWITCH POWER SUPPLY ............................................................................................................................8
3.2DC TO DC CONVERTER (PUSH-PULL)........................................................................................................9
3.3DC TO AC INVERTER (FULL-BRIDGE).......................................................................................................10
3.4CHARGER ..................................................................................................................................................11
4.FUNCTIONAL EXPLANATIONS FOR EACH PCB .................................................................................12
4.1MAIN BOARD ..............................................................................................................................................12
4.2SCC BOARD ..............................................................................................................................................12
4.3COMM BOARD ..........................................................................................................................................12
4.4LED BOARD...............................................................................................................................................13
5.INTERFACE....................................................................................................................................................13
5.1LED INDICATOR.........................................................................................................................................13
5.2LCD DISPLAY ICONS .................................................................................................................................14
6.TROUBLESHOOTING..................................................................................................................................18
6.1FAULT REFERENCE CODE.........................................................................................................................18
6.2WARNING INDICATOR ................................................................................................................................18
6.3TROUBLE SHOOTING ACCORDING TO FAULT INDICATION..........................................................................19
6.4QUICK START .............................................................................................................................................20
7.TEST STEP......................................................................................................................................................22
8.ELECTRICAL SPECIFICATION.................................................................................................................23
8.1TABLE 1LINE MODE SPECIFICATIONS......................................................................................................23
8.2TABLE 2INVERT MODE SPECIFICATIONS..................................................................................................23
8.3TABLE 3CHARGE MODE SPECIFICATIONS ...............................................................................................25
9.ASSEMBLING GUIDE...................................................................................................................................26
9.1THE VM 1K ASSEMBLY ..............................................................................................................................26
9.2THE VM 2K ASSEMBLY ..............................................................................................................................29

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V-RDP-004-73 A
1. General information
1.1 Getting start
This manual is for Axpert VM-1000/VM-2000 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
General Information, this section shows you the general information of the service manual
Functional Block, this section shows you the major functional block of the Inverter/Charger
Working Principle of the major Functional Block, this section shows you the major functional block
Function explanations for each PCB, this section shows you all the PCBs of the Inverter/Charger
Interface, this section shows you the LCD interface, include display and setting
Trouble shooting, this section will give you the way to find the trouble
Test step ,this section tells you how to test the Inverter/Charger after you repair the unit
Electric Specifications, this section shows you the basic electric specification of the Inverter/Charger
1.2 Important safety instructions
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

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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.
Please refer to INSTALLATION section of this manual for the details.
10. One piece of fuse(150A, 32VDC) 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.

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2. Functional block
Axpert VM-2000/VM-1000 series production employ a double conversion topology, comprise following
functional blocks, as shown in figure 2.1
Figure 2.1 function block diagram

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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.
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 Q1 is ON, the
dot ends of all winds are negative with respect to their no-dot ends. Output rectifier diodes D1, D2, D34
and D38 are reverse-biased and all the output load currents are supplied from storage filter capacitors
CE6, CE7,CE8 and CE9.The primary coil of the transformer acts as an inductor and stored energy.
When Q1 is OFF, the stored energy in the primary coil is delivered to secondary filter capacitors CE6,
CE7,CE8 and CE9.
As shown in figure 3.1, this circuit may generate several output voltage, such as +12V,-12V, +VCC, +5V,
HFPW+, GTDRV3.

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3.2 DC to DC Converter (push-pull)
The push-pull 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 (Q9-Q11 or Q2-Q4) is conducting.（Q22 and Q5 NC）
A push-pull topology is shown in figure 3.2, power switch Q9-Q11 and Q2-Q4 receive 180 out-of-phases.
Refer to figure 3.2, the battery voltage is transformed through a push-pull DC-DC converter to >330Vdc
as DC BUS for inverter. When the line fails, the DC BUS voltage is caught up to supply the power needed
by the inverter immediately.
The output voltage (DC BUS) must be higher than the input voltage (BAT+) .It mentioned by the primary
turns and secondary turns. In this circuit, BAT= + 12V or BAT=+24V,DC BUS voltage above 330Vdc.
Figure 3.2 Push-pull topology

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3.3 DC to AC Inverter (full-bridge)
The Inverter circuit (Figure 3.3) and PWM control are only active under battery mode. 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 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 is filtered by an LC circuit to reduce the O/P voltage harmonics distortion.
Figure 3.3 Full-bridge topology

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3.4 Charger
The Charger of utility is to recharge and maintain the batteries at fully charged condition .The charger
charges the batteries with a constant current at initial stage, and as battery voltage keep increasing, the
charge current decrease accordingly until the charge voltage reached the constant voltage level, and
then the charger turn to the floating charge mode.
As shown in figure 3.4, the charger also employed a fly-back topology like the SPS.
Figure 3.4 Charger fly-back topology

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4. Functional explanations for each PCB
Item Model PCB type PCBA number QTY Remark
1 VM-2000 Main 71-501052-XXG 1
2 CNTL 71-501090-XXG 1
3 MPPT CNTL&PANEL 71-501054-XXG 1
4 MPPT Choke 71-501084-XXG 1
5 COMM 71-500900-XXG 1
5 VM-1000 Main 71-501051-XXG 1
6 CNTL 71-501090-XXG 1
7 MPPT CNTL&PANEL 71-501054-XXG 1
8 MPPT Choke 71-501085-XXG 1
COMM 71-500900-XXG 1 Same with VM-2000
Note: “XX” in the sheet of PCBA number is the version of semi-finished PCBA.
4.1 Main board
The main board consists of SPS, DC-DC converter, inverter, charger, MCU control. Many semiconductors
and easy-failure components on the board, so it should be pay more attention when the system is
abnormal.
4.2 SCC board
The solar current control (SCC) board based on a MPPT control mode for VM-2000 and VM-1000 .When
the solar source is presented, battery charged from solar source; MAX charge current is 40A@ VM-2000
and VM-1000, if solar panel with enough energy.
4.3 COMM board
This inverter/charger is equipped with a communication port to communicate with a PC with corre
sponding software. Please use supplied communication cable to connect to communication port of
this inverter and USB port of the PC.

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4.4 LED board
The LED display panel includes there indicators and four functional keys.
5. Interface
The operation and display panel, shown in below chart, It 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/output
power information.
5.1 LED Indicator
LED Indicator Messages
Green Solid On Output is powered by utility in Line mode.
Flashing Output is powered by battery or PV in battery mode.
Green Solid On Battery is fully charged.
Flashing Battery is charging.
Red Solid On Fault occurs in the inverter.
Flashing Warning condition occurs in the inverter.
Function Keys
Function Key Description
ESC To exit setting mode
SCROLL To go to next selection
ENTER To confirm the selection in setting mode or enter setting mode

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5.2 LCD Display Icons
Icon Function description
Input Source Information
Indicates the AC input.
Indicates the PV input
Indicate input voltage, input frequency, PV voltage, battery voltage.
Configuration Program and Fault Information
Indicates the setting programs.
Indicates the warning and fault codes.
Warning: flashing with warning code.
Fault: lighting with fault code
Output Information
Indicate output voltage, output frequency, load percent, load in VA, load in
Watt
Battery Information
Indicates battery level by 0-24%, 25-49%, 50-74% and 75-100% in battery
mode and charging status in line mode.
In AC mode, it will present battery charging status.
Status Battery voltage LCD Display
Constant <2V/cell 4 bars will flash in turns.
2 ~ 2.083V/cell Bottom bar will be on and the other three

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Current mode /
Constant
Voltage mode
bars will flash in turns.
2.083 ~ 2.167V/cell Bottom two bars will be on and the other
two bars will flash in turns.
> 2.167 V/cell Bottom three bars will be on and the top
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
Load >50%
< 1.85V/cell
1.85V/cell ~ 1.933V/cell
1.933V/cell ~ 2.017V/cell
> 2.017V/cell
Load < 50%
< 1.892V/cell
1.892V/cell ~ 1.975V/cell
1.975V/cell ~ 2.058V/cell
> 2.058V/cell
Load Information
Indicates overload.
Indicates the load level by 0-24%, 25-50%, 50-74% and 75-100%.
0%~25% 25%~50% 50%~75% 75%~100%
Mode Operation Information
Indicates unit connects to the mains.
Indicates unit connects to the PV panel.
Indicates load is supplied by utility power.
Indicates the utility charger circuit is working.
Indicates the DC/AC inverter circuit is working.

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Mute Operation
Indicates unit alarm is disabled.
Icon Function description
Input Source Information
Indicates the AC input.
Indicates the PV input
Indicate input voltage, input frequency, PV voltage, battery voltage
Configuration Program and Fault Information
Indicates the setting programs.
Indicates the warning and fault codes.
Warning: flashing with warning code.
Fault: lighting with fault code
Output Information
Indicate output voltage, output frequency, load percent, load in VA and
load in Watt.
Battery Information
Indicates battery level by 0-24%, 25-49%, 50-74% and 75-100% in battery
mode and charging status in line mode.
In AC mode, it will present battery charging status.
Status Battery voltage LCD Display
Constant
Current mode
/ Constant
Voltage mode
<2V/cell 4 bars will flash in turns.
2 ~ 2.083V/cell Bottom bar will be on and the other three
bars will flash in turns.
2.083 ~ 2.167V/cell Bottom two bars will be on and the other
two bars will flash in turns.
> 2.167 V/cell Bottom three bars will be on and the top
bar will flash.
Floating mode. Batteries are fully charged. 4 bars will be on.

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In battery mode, it will present battery capacity.
Load Percentage Battery Voltage LCD Display
Load >50%
< 1.85V/cell
1.85V/cell ~ 1.933V/cell
1.933V/cell ~ 2.017V/cell
> 2.017V/cell
Load < 50%
< 1.892V/cell
1.892V/cell ~ 1.975V/cell
1.975V/cell ~ 2.058V/cell
> 2.058V/cell
Load Information
Indicates overload.
Indicates the load level by 0-24%, 25-50%, 50-74% and 75-100%.
0%~25% 25%~50% 50%~75% 75%~100%
Mode Operation Information
Indicates unit connects to the mains.
Indicates unit connects to the PV panel.
Indicates load is supplied by utility power.
Indicates the utility charger circuit is working.
Indicates the DC/AC inverter circuit is working.
Mute Operation
Indicates unit alarm is disabled.

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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.
b. Observe the failure board, static checking.
c. Replace the failure components.
d. Static checking.
e. Power up checking.
f. Test after repair.
Following section will help service person to solve most of problem.
6.1 Fault Reference Code
Fault Code Fault Event Icon on
01 Fan is locked when inverter is off.
02 Over temperature
03 Battery voltage is too high
04 Battery voltage is too low
05 Output short circuited or over temperature is detected by
internal converter components.
06 Output voltage is abnormal. (For 3KVA model)
Output voltage is too high. (For 3KVA Plus/5KVA model)
07 Overload time out
08 Bus voltage is too high
09 Bus soft start failed
6.2 Warning Indicator
Warning
Code Warning Event Audible Alarm Icon flashing
01 Fan is locked when
inverter is on. Beep three times every second
03 Battery is over-charged Beep once every second

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04 Low battery Beep once every second
07 Overload Beep once every 0.5 second
10 Output power derating Beep twice every 3 seconds
Battery equalization None
6.3 Trouble shooting according to fault indication
Problem LCD/LED/Buzzer Explanation / Possible cause What to do
Unit shuts down
automatically
during startup
process.
LCD/LEDs and buzzer
will be active for 3
seconds and then
complete off.
The battery voltage is too low
(<1.91V/Cell) 1. Re-charge battery. 2. Replace battery.
No response after
power on. No indication. 1. The battery voltage is far too
low. (<1.4V/Cell)
2. Internal fuse tripped.
1. Contact repair center
for replacing the fuse.
2. Re-charge battery.
3. Replace battery.
Mains exist but the
unit works in
battery mode.
Input voltage is
displayed as 0 on the
LCD and green LED is
flashing.
Input protector is tripped Check if AC breaker is tripped and AC wiring is
connected well.
Green LED is flashing. Insufficient quality of AC power.
(Shore or Generator)
1. Check if AC wires are
too thin and/or too long.
2. Check if generator (if
applied) is working well
or if input voltage range
setting is correct.
(UPSAppliance)
Green LED is flashing. Set “Solar First” as the priority of
output source. Change output source priority to Utility first.
When the unit is
turned on, internal
relay is switched on
and off repeatedly.
LCD display and LEDs
are flashing Battery is disconnected. Check if battery wires are connected well.
Buzzer beeps
continuously and
red LED is on.
Fault code 07 Overload error. The inverter is
overload 110% and time is up.
Reduce the connected
load by switching off
some equipment.
Fault code 05
Output short circuited. Check if wiring is connected well and
remove abnormal load.
Temperature of internal converter
component is over 120°C. (Only
available for 1-3KVA models)
Check whether the air
flow of the unit is
blocked or whether the
ambient temperature is
too high.
Fault code 02 Internal temperature of inverter
component is over 100°C.

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Fault code 03
Battery is over-charged. Return to repair center.
The battery voltage is too high. Check if spec and quantity of batteries are
meet requirements.
Fault code 01 Fan fault Replace the fan.
Fault code 06/58 Output abnormal (Inverter voltage below than 190Vac or is higher
than 260Vac)
1. Reduce the connected
load.
2. Return to repair
center
Fault code
08/09/53/57 Internal components failed. Return to repair center.
Fault code 51 Over current or surge. Restart the unit, if the
error happens again,
please return to repair
center.
Fault code 52 Bus voltage is too low.
Fault code 55 Output voltage is unbalanced.
Fault code 56 Battery is not connected well or
fuse is burnt.
If the battery is
connected well, please
return to repair center.
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
block Checked components Instruction function
Reference
value Failed status
DC-DC
Converter
Fuse F1 Resistance 0.14 ohm short or open
MOSFET：
CSD19505KCS VM-2000
IRFB3306GPBF VM-1000
Q2---Q4
Q9---Q11 Resistance
310k DS short or open
290k GD short or open
5k GS short or open
Diode: RHRP1560 VM-2000
BYC8-600P VM-1000 D17---D20 Resistance
165k short or open
Resistance R6-R9，R13-R15
R21 Resistance 10 ohm short or open
DC-AC
Inverter
IGBT:
STGW60H65DFB VM-2000
STGW30H60DFB VM-1000
Q16---Q19 Resistance
178K-200K DS short or open
220K-250K
GD short or open
50K GS short or open
Resistance R54,R56,R61,R64 Resistance 33 ohm short or open