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：

维修手册
专案名称：AxpertVM1KW/VM2KW
专案编号：S1701112修订版次： 00PAGE2/30
V-RDP-004-73 A
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1 00A Initial draft release 2018-3-19

维修手册
专案名称：AxpertVM1KW/VM2KW
专案编号：S1701112修订版次： 00PAGE3/30
V-RDP-004-73 A
Axpert VM-1000/ VM-2000
Charger/ Inverter
Service manual

维修手册
专案名称：AxpertVM1KW/VM2KW
专案编号：S1701112修订版次： 00PAGE4/30
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

维修手册
专案名称：AxpertVM1KW/VM2KW
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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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专案名称：AxpertVM1KW/VM2KW
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V-RDP-004-73 A
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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专案名称：AxpertVM1KW/VM2KW
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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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专案名称：AxpertVM1KW/VM2KW
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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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V-RDP-004-73 A
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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V-RDP-004-73 A
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