Voltronic Power Axpert VM III-5000 User manual

专案名称：
Axpert VM III-5000/VM III-3000
专案编号：
S1711171
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V-RDP-004-73 A
旭隼 日月元
维修手册
Prepared by：
Clay Lin
Date：
Checked by：
Date：
Approved by：
Date：

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专案名称：
Axpert VM III-5000/VM III-3000
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S1711171
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V-RDP-004-73 A
变更记录
**00 版之前的版次以 0A,0B,0C…表示，00 版后之版次以 00A,00B,00C…表示** 回首页
项
次
版次
变更内容
制定
制定日期
审核
生效日期
1
00
Initial release
Clay
2018-2-5
2
01
HC
2019-01-22

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专案名称：
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专案编号：
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V-RDP-004-73 A
Axpert VM III-5000/ VM III-3000
Service manual

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Axpert VM III-5000/VM III-3000
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S1711171
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V-RDP-004-73 A
Table of contents
1. GENERAL INFORMATION.................................................................................................................................5
1.1 GETTING START .................................................................................................................................................5
1.2 BASIC TOPOLOGY INTRODUCTION.....................................................................................................................5
1.3 INVERTER FAMILY...............................................................................................................................................5
1.4 OVERVIEW THE INVERTER.................................................................................................................................6
2. TROUBLESHOOTING.........................................................................................................................................6
2.1 HOW TO DO........................................................................................................................................................6
2.2 FAULT CONDITION ..............................................................................................................................................6
2.3 TEST STEP..........................................................................................................................................................7
3. CHECKING AND MEASURING GUIDE............................................................................................................8
3.1 CHECK THE BATTERY SIDE COMPONENTS ON MAIN BOARD............................................................................8
3.2 CHECK THE BUS SIDE COMPONENTS ON MAIN BOARD..................................................................................15
3.3 CHECK THE BUCK CIRCUIT ON MAIN BOARD..................................................................................................16
3.4 CHECK THE INV FULL BRIDGE ON MAIN BOARD............................................................................................18
3.5 CHECK BATTAND MAIN POWER SPS ON MAIN BOARD ..............................................................................21
3.6 CHECKAC SPS ON MPPT BOARD.................................................................................................................25
3.7 CHECK THE BUS SOFT START CIRCUIT ON MPPTBOARD (TX1: ESPECIALLY FOR 09 FAULT)......................26
3.8 CHECK THE BOOST ON MPPTBOARD............................................................................................................28
4. DISASSEMBLING GUIDE.................................................................................................................................30
TOTAL WIRING DIAGRAM:........................................................................................................................................33

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V-RDP-004-73 A
1. General information
1.1 Getting start
This manual is used as a checking and repairing guide for Axpert VMIII-5200 and
VMIII-3200. Before read this manual, it’s better to have some electrical or electronic
background knowledge. With this guide, you can fix the inverter by yourself firstly.
There are five main parts of this guide:
General information: This part is the basic information of the inverter; you can start to know
the inverter from this chapter.
Troubleshooting: This part will tell you how to do when you face a problem.
Checking and measuring guide: This part will teach you how to check or repair the
inverter by measuring the critical components.
Assembling guide: This part teaches you how to take the board outside and fix the new
one.
Cables connection guide: This part will present the signal cables connection of the
inverters.
1.2 Basic topology introduction
The topology of the inverter shows as below:
Hybrid Inverter (VM III)
From GRID
DC BUS
From PV
Charge/Discharge
Charge/Discharge To Battery
To LOAD
Bi-directional
DC/AC Inverter
Bi-directional
DC/AC Inverter
Boost
Boost
Battery
Battery
BMS
BMS
Compare with UPS or normal inverter, INVERTER combines a solar charger inside. Solar
charger can be a supplement for battery when there is not grid. And with the solar charger,
the inverter can have more working modes than UPS. For detail information please refer to
our user manual.
1.3 Inverter family
This service manual includes different models of the inverter, the table as below contains some important
parameters with different models.
These models names are only neutral names; please match the real model name of your inverter to the
model name in the table by comparing the typical characteristics.
Model name
Power rating
Charger type
Charger number
Axpert VMIII-5000
5.2KVA
MPPT
1
Axpert VMIII-3000
3.2KVA
MPPT
1

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V-RDP-004-73 A
1.4 Overview the inverter
Axpert VMIII
1Troubleshooting
1.5 How to do
When the inverter was faulty, normally there are two main symptoms:
No display at all;
Fault code or warning code on the LCD;
When the fault occurred, please help to record the fault information and follow “How to
check” of part 2.2 to check the inverter, then feedback the checking result to the service
center. It will be very helpful for solving the problem as soon as possible.
1.6 Fault condition
Note:
When open the top cover, please have a look first, are there any obviously damaged
parts?
When take the main board out, please have a look around, are there any obviously
damaged parts?

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V-RDP-004-73 A
2.2.1. Not working at all/ No display
Description
The inverter couldn’t startup completely.
Possible reason
1. SPS module damaged.
How to check
1. Firstly, please measure the resistor between BAT+ and BAT-. If it is
not shorted, only connect the inverter with battery, and press “ON”
button, could the inverter startup? If not, please check the fan.
2. If the LCD couldn’t light up and fan doesn’t work, please disconnect all
the wires and open the top cover, and then take the main board outside
by following part 4.
3. Check the main board by following “3.5 and 3.6”
How to solve
Repair the main or replace it directly.
2.2.2. 09 fault
Description
Bus soft start fails.
Possible reason
DC-DC module was damaged or BUS soft start module was damaged.
How to check
1. Check the main board by following“3.6; 3.7”;
2. Check the main board by following“3.1; 3.2; 3.3; 3.4”.
How to solve
Repair the main board or replace it directly.
2.2.3. Warning
Description
Battery couldn’t be detected.
Possible reason
Wire connection or fuse was burnt.
How to check
1. Check the wire connection, the priority of the battery cable;
2. Check the main board by following “3.1”.
How to solve
Repair the main board or replace it directly.
1.7 Test step
After replacing all defected components, testing steps can be used to confirm the repair
result and the reliability of the Inverter.
Set up the testing system as below:

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V-RDP-004-73 A
2. Checking and measuring guide
2.1 Check the battery side components on MAIN board
Fuse and capacitors
For VMIII-3000 FUCE 150A
For VMIII-5000 FUCE 150A
Parts
Attribute
Reference values
Failure status
F5
Resistor
0.1 ohm
Open
For VMIII-3000 C9/C11/C12/C196/C152: (4200uF 35V)
For VMIII-5000 C9/C18/C196: (6800uF 63V)

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V-RDP-004-73 A
If the capacitors explode as below, they need to be replaced.
Power devices
DC/DC MOSFET: Q13/Q18/Q23/Q35 & Q25/Q26/Q39/Q40
For VMIII-3000 ALL of the MOSFET are (CSD19505KCS 201A 80V TO-220)

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V-RDP-004-73 A
For VMIII-5000 ALL of the MOSFET are (MOSFET TOSHIBA/TK100E08N1 214A 80V N BULK TO-220)
Parts
Attribute
Reference values
Failure status
CSD19505KCS (VMIII-3200)
TK100E08N1 (VMIII-5200)
Resistor
GS: 11.75k
GD: 115.8k
DS: OL
Short or explosion
Diode
SD: 0.463V
DS: OL
Note1: When you use the multimeter to measure the resistor of the transistor, because of
the capacitor in the circuit, it will cause the changing of the values when you measure the
DS and GD. So we recommend you measure the diode forward voltage of SD, and the
resistor of GS. These two values can reflect the situation of the transistor more correctly.
Note2: If one or more of them were damaged, please replace all of them.
3.1.1. Drivers (This part is only used for repair checking)
Note: Drivers usually need to be checked when users want to repair the boards. Because
when power devices were damaged, the high voltage will rush to driver circuit through the
gates of power devices.
The reference of the resistors list as below:
R52/R62/R81/R87/R92/R93/R115/R119 All of the resistors are (22R 1206)

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V-RDP-004-73 A
Use multimeter to measure each resistor, find the burnt resistors and replace them; don’t
need to replace them all.
Parts
Attribute
Reference values
Failure status
All: 22ohm
Resistor
22 ohm
Open or other values
If the resistors need to be replaced, please also check the driver transistors and control IC.
The Q46and Q48 are (2SC2655 2A 50V NPN TAP TO-92)
The Q47and Q49 are (2SA1020L-Y-T9N-B 2A50V PNP TAP TO-92NL)
The Q41and Q43 are (2SC2655 2A 50V NPN TAP TO-92)
The Q15and Q16 are (2SA1020L-Y-T9N-B 2A 50V PNP TAP TO-92NL)
Parts
Attribute
Reference values
Failure status
Q46/Q48
Resistor
BE: 430k
BC: 430k
Short or explosion

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V-RDP-004-73 A
EC: 16k
Diode
BE: 0.65V
BC: 0.65V
CE: 0.28V
Q41/Q43
Resistor
BE: 430k
BC: 425k
EC: 104k
Short or explosion
Diode
BE: 0.65V
BC: 0.65V
CE: 0.28V
Q47/Q49
Resistor
BE: 430k
BC: 430k
EC: 8k
Short or explosion
Diode
BE: 0.65V
BC: 1.75V
CE: 0.20V
Q15/Q16
Resistor
BE: 430k
BC: 430k
CE: 8k
Short or explosion
Diode
BE: 0.65V
BC: 1.5V
CE: 0.28V

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V-RDP-004-73 A
The Q52and Q56 are (2SD1624 2A 50V NPN SOT-89)
The Q53and Q57 are (2SA1020 3A 50V PNP SOT-89)
Parts
Attribute
Reference values
Failure status
Q52/Q56
Resistor
BE: 12k
BC: 280k
CE: OL
Short or explosion
Diode
BE: 0.64V
BC: 0.64V
CE: OL
Q53/Q57
Resistor
BE: 12k
BC: OL
CE: 280k
Short or explosion
Diode
BE: 0.64V
BC: OL
CE: 1.09V

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V-RDP-004-73 A
The Q60 and Q61 the MOSFET are (UT3404G 5.8A 30V NPN SOT-23 SMD)
Parts
Attribute
Reference values
Failure status
Q60/Q61
Resistor
GS: 5.637k
GD: 107k
SD: 98k
Short or explosion
Diode
SD: 0.28V
DS: 1.14V

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V-RDP-004-73 A
The U9 is (IC PWM CNTL TI/UC3525AN DIP-16)
Parts
Attribute
Reference values
Failure status
U9
Resistor
PIN13 TO PIN12: 8.8k
PIN11 TO PIN12: 432k
PIN14 TO PIN12: 432k
Short or explosion
2.2 Check the bus side components on MAIN board
Power devices
DC/DC IGBT: Q27/Q28/Q29/Q30
For VMIII-5000 ALL of the IGBTs are (IGBT ST/STGW60H65DFB 60A 650V N BULK TO-247)
For VMIII-3000 ALL of the IGBTs are (STGW45HF60WDA 45A 600V NPN BULK TO-247)
Parts (VMIII-3200)
Attribute
Reference values
Failure status
Q27/Q28/Q29/Q30
Resistor
GE: 22 ohm
GC: 184k
EC: 184K
Short or explosion
Diode
EC: 0.37V
CE: OL
Parts (VMIII-5200)
Attribute
Reference values
Failure status
Q27/Q28/Q29/Q30
Resistor
GE: 22 ohm
GC: 205k
EC: 205K
Short or explosion
Diode
EC: 0.39V
CE: OL
Note1: When you use the multimeter to measure the resistor of the transistor, because of
the capacitor in the circuit, it will cause the changing of the values when you measure the
CE and GE. So we recommend you measure the diode forward voltage of EC, and the
resistor of GE. These two values can reflect the situation of the transistor more correctly.
Note2: If one or more of them were damaged, please replace all of them.

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V-RDP-004-73 A
Drivers (This part is only used for repair checking)
Meanwhile, we also need to check the driver tubes of these power tubes.
R91/R102/R96/R101: (22R 1206)
R90/R99/R94/R97: (0R 1206)
D32/D35/D33/D34: (1N4148W 0.15A 75V SMD)
Parts
Attribute
Reference values
Failure status
R91/R102/R96/R101
Resistor
22 ohm
Open or other values
R90/R99/R94/R97
Resistor
0 ohm
D32/D35/D33/D341
Resistor
+ to -: 270k
- to +: OL
Short or explosion
Diode
+ to -: 0.6V
- to +: OL
Note1: When test the diode; please remove the R90/R99/R94/R97 from the board, or the
test result is not right.
2.3 Check the buck circuit on MAIN board
Power devices
BUCK MOSFET and Diode: Q31/D13

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V-RDP-004-73 A
For VMIII-5000 the IGBTs Q31 is (IGBT ST/STGW60H65DFB 60A 650V N BULK TO-247)
For VMIII-3000 the IGBTs Q31 is (STGW45HF60WDA 45A 600V NPN BULK TO-247)
The D13 is (RHRP1560 15A 600V UFST RAD BULK)
Parts
Attribute
Reference values
Failure status
Q31
Resistor
GE: 22.8k
GC: 49.5k
CE: OL
Short or explosion
Diode
CE: OL
EC: 0.393V
D13
Resistor
+ to -: 195k
- to +: OL/OL
Diode
+ to -: 0.39V
- to +: OL
Drivers (This part is only used for repair checking)

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V-RDP-004-73 A
The R103 are (10R 1206)
The R106 are (47R 1206)
The D36 are (1N4148W 0.15A 75V SMD)
Parts
Attribute
Reference values
Failure status
R106
Resistor
47 ohm
Open or other values
R103
Resistor
10 ohm
D361
Resistor
+ to -: 240k
- to +: OL
Short or explosion
Diode
+ to -: 0.6V
- to +: OL
Note1: When test the diode; please remove the R103 from the board, otherwise the test
result is not right.
2.4 Check the INV full bridge on MAIN board
Power devices
INV IGBT: QA1/QC1/QB2/QD2

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V-RDP-004-73 A
All of the IGBT are (STGW60H65DFB 60A650V N BULK TO-247)
Parts
Attribute
Reference values
Failure status
QA1/QC1/QB2/QD2
Resistor
GE: 23k
GC: 235k
CE: 700k
Short or explosion
Diode
EC: 0.4V
CE: OL
Note1: If one or more of them were damaged, please replace all of them.
Drivers
R48/R144/R140/R137: (39R 1206)
R139/R145/R150/R152: (10R 1206)
D5/D6/D12/D16: (1N4148W 0.15A 75V SMD)

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V-RDP-004-73 A
Parts
Attribute
Reference values
Failure status
R48/R144/R140/R137
Resistor
39 ohm
Open or other values
R139/R145/R150/R152
Resistor
10 ohm
Open or other values
D5/D6/D12/D161
Resistor
+ to -: 270k
- to +: OL
Short or explosion
Diode
+ to -: 0.6V
- to +: OL
Note1: When test the diode; please remove the R139/R145/R150/R152 from the board,
ortherwise the test result is not right
Optocoupler: U1/U2/U3/U4/U12
ALL of the optocoupler are (AVAGO/T350-560E DIP-8 8/300 MIL SMD)