Axpert VM IV

Service Manual

V-RDP-004-73 A
 Table of contents

1. GENERAL INFORMATION .................................................................................................................................1

1.1 GETTING START .................................................................................................................................................1

1.2 BASIC TOPOLOGY INTRODUCTION .....................................................................................................................1
1.3 INVERTER FAMILY ...............................................................................................................................................1
1.4 OVERVIEW THE INVERTER .................................................................................................................................1

2. TROUBLESHOOTING .........................................................................................................................................2

2.1 HOW TO DO ........................................................................................................................................................2

2.2 FAULT CONDITION ..............................................................................................................................................2
2.3 TEST STEP..........................................................................................................................................................3

3. CHECKING AND MEASURING GUIDE............................................................................................................4

3.1 CHECK THE BATTERY SIDE COMPONENTS ON MAIN BOARD ............................................................................4

3.2 CHECK THE BUS SIDE COMPONENTS ON MAIN BOARD..................................................................................13
3.3 CHECK THE BUCK CIRCUIT ON MAIN BOARD ..................................................................................................16
3.4 CHECK THE INV FULL BRIDGE ON MAIN BOARD ............................................................................................17
3.5 CHECK BATT AND MAIN POWER SPS ON MAIN BOARD ..............................................................................22
3.6 CHECK AC SPS ON MPPT BOARD.................................................................................................................26
3.7 CHECK THE BUS SOFT START CIRCUIT ON MPPT BOARD (TX1: ESPECIALLY FOR 09 FAULT) ......................28
3.8 CHECK THE BOOST ON MPPT BOARD ............................................................................................................30

4. DISASSEMBLING GUIDE.................................................................................................................................34

TOTAL WIRING DIAGRAM:........................................................................................................................................38

V-RDP-004-73 A
1. General information
1.1 Getting start
This manual is used as a checking and repairing guide for Axpert VMIV-3600 and VMIV
-5600. 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 IV)

DC BUS Bi-directional
From PV Boost From GRID
DC/AC Inverter

To LOAD

Charge/Discharge To Battery Battery

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 or for saving energy purpose.
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 VM IV 5600 5.6KVA MPPT 1
Axpert VM IV 3600 3.6KVA MPPT 1
1.4 Overview the inverter
Axpert VMIV

1
2. Troubleshooting
2.1 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.
2.2 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?

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”

2
 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 and MPPT 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.

2.3 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:

3
3. Checking and measuring guide
3.1 Check the battery side components on MAIN board
Fuse and capacitors
For VMIV-3600 FUCE 200A
For VMIV-5600 FUCE 200A

Parts Attribute Reference values Failure status

F5 Resistor 0.1 ohm Open
For VMIV-3600 C9/C11/C12/C196/C152: (4200uF 35V)
For VMIV-5600 C9/C18/C196: (6800uF 63V)

4
If the capacitors explode as below, they need to be replaced.

Power devices
DC/DC MOSFET: Q13/Q18/Q23/Q35 & Q25/Q26/Q39/Q40

5
For VMIV-3600 ALL of the MOSFET are (CSD19505KCS 201A 80V TO-220)

For VMIV-5600 ALL of the MOSFET are (MOSFET TOSHIBA/TK100E08N1 214A 80V N BULK TO-220)

6
Parts Attribute Reference values Failure status
CSD19505KCS (VMIV-3600) Resistor GS: 11.75k Short or explosion
TK100E08N1 (VMIV-5600) GD: 115.8k
DS: OL
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)

7
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.

8
The Q46and Q48 are (2SC2655 2A 50V NPN TAP TO-92)
The Q47and Q49 are (2SA1020L-Y-T9N-B 2A 50V PNP TAP TO-92NL)

9
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 Short or explosion
BC: 430k
EC: 16k
Diode BE: 0.65V
BC: 0.65V
CE: 0.28V
Q41/Q43 Resistor BE: 430k Short or explosion
BC: 425k
EC: 104k
Diode BE: 0.65V
BC: 0.65V
CE: 0.28V
Q47/Q49 Resistor BE: 430k Short or explosion
BC: 430k
EC: 8k
Diode BE: 0.65V
BC: 1.75V
CE: 0.20V
Q15/Q16 Resistor BE: 430k Short or explosion
BC: 430k

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 CE: 8k
Diode BE: 0.65V
BC: 1.5V
CE: 0.28V

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 Short or explosion
BC: 280k
CE: OL
Diode BE: 0.64V
BC: 0.64V
CE: OL
Q53/Q57 Resistor BE: 12k Short or explosion
BC: OL
CE: 280k

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 Diode BE: 0.64V
BC: OL
CE: 1.09V

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 Short or explosion
GD: 107k
SD: 98k
Diode SD: 0.28V
DS: 1.14V
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The U9 is (IC PWM CNTL TI/UC3525AN DIP-16)
Parts Attribute Reference values Failure status
U9 Resistor PIN13 TO PIN12: 8.8k Short or explosion
PIN11 TO PIN12: 432k
PIN14 TO PIN12: 432k
Note: If you are not sure about these components, we recommend you replacing them all.

3.2 Check the bus side components on MAIN board

Power devices
DC/DC IGBT: Q27/Q28/Q29/Q30
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For VMIV-5600 ALL of the IGBTs are (IGBT ST/STGW60H65DFB 60A 650V N BULK TO-247)
For VMIV-3600 ALL of the IGBTs are (STGW45HF60WDA 45A 600V NPN BULK TO-247)

Parts (VMIV-3600) Attribute Reference values Failure status

Q27/Q28/Q29/Q30 Resistor GE: 22 ohm Short or explosion
GC: 184k
EC: 184K
Diode EC: 0.37V
CE: OL
Parts (VMIV-5600) Attribute Reference values Failure status
Q27/Q28/Q29/Q30 Resistor GE: 22 ohm Short or explosion
GC: 205k
EC: 205K
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.
Drivers (This part is only used for repair checking)
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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
R90/R99/R94/R97 Resistor 0 ohm values
D32/D35/D33/D341 Resistor + to -: 270k Short or explosion
- to +: OL
Diode + to -: 0.6V
- to +: OL
Note1: When test the diode; please remove the R90/R99/R94/R97 from the board, or the

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test result is not right.
3.3 Check the buck circuit on MAIN board
Power devices
BUCK MOSFET and Diode: Q31/D13

For VMIV-5600 the IGBTs Q31 is (IGBT ST/STGW60H65DFB 60A 650V N BULK TO-247)
For VMIV-3600 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 Short or explosion
GC: 49.5k
CE: OL
Diode CE: OL
EC: 0.393V
D13 Resistor + to -: 195k
- to +: OL/OL
Diode + to -: 0.39V
- to +: OL

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Drivers (This part is only used for repair checking)

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 Short or explosion
- to +: OL
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.

3.4 Check the INV full bridge on MAIN board

Power devices
INV IGBT: QA1/QC1/QB2/QD2

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All of the IGBT are (STGW60H65DFB 60A 650V N BULK TO-247)

Parts Attribute Reference values Failure status

QA1/QC1/QB2/QD2 Resistor GE: 23k Short or explosion
GC: 235k
CE: 700k
Diode EC: 0.4V
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 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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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 Short or explosion

- to +: OL
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

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ALL of the optocoupler are (AVAGO/T350-560E DIP-8 8/300 MIL SMD)

Parts Attribute Reference values Failure status

U2/U4/U12 Resistor PIN8 TO PIN5: 57k Short or explosion
PIN7 TO PIN5: 145k

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U1/U3 Resistor PIN8 TO PIN5: 355k
PIN7 TO PIN5: 410k

3.5 Check BATT and Main Power SPS on MAIN board

BATT Power SPS
For VMIV-5600 the F1 are (FUSE 3A 125V)
For VMIV-3600 the F1 are (FUSE 5A 125V)
For VMIV-5600 the NTC2 are (THERMISTOR NTC 5OHM 5A SCK13055LSY)
For VMIV-3600 the NTC2 are (NTC 5ohm 5A)
For VMIV-5600 the MOSFET Q69 are (MOSFET IR/IRF740 10A 400V N BULK TO-220)
For VMIV-3600 the MOSFET Q69 are (IRF640NPBF 18A 200V N BULK TO-220)
For VMIV-5600 the R246 are NC
For VMIV-3600 the R246 are (RES 3W 0.15ohm)
The TX2 are (TX 2:5:45:3 FER EC28)
The R245 are (RES 3W 0.15ohm)
The D61 are (MUR4100ERLG 4A 1000V UFST)
The D60 are (RHRP860 8A 600V SFST)
The U14 are (IC UC3845BNG DIP-8)
The Q6 are (PMBT2907A 0.6A 60V SMD)
The TX3 are (TX 16:16:16 FER EE16)
The D65 are (RS1J 1A 600V SMD)

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Parts Attribute Reference values Failure status
F4 Resistor 0 ohm Open or explosion
VMIV-5600 NTC2 Resistor 5.48ohm Open or explosion
VMIV-3600 NTC2 Resistor 5 ohm Open or explosion
D61 Diode + to -: 0.468V Short or explosion
- to +: OL
D60 Diode + to -: 0.435V Short or explosion
- to +:OL
VMIV-3600 R245 Resistor 0.65ohm Open or other
VMIV-5600 R245 values
VMIV-3600 R246 Resistor 0.65ohm Open or mother
VMIV-5600 R245 NC values
Q691 Resistor GS: 45.51k Short or explosion
GD: 57k(VMIV-5600)
GD: 44.6k(VMIV-3600)
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 SD: 528K(VMIV-5600)
SD: 115K(VMIV-3600)
Diode SD: 0.463V
GS: OL
U14 Resistor PIN7 TO PIN5: 77.5K Short or other
PIN6 TO PIN5: 45.48K values
Q6 Resistor EB: 512k Short or other
CB: 456k values
Diode CB: 0.688V
EB: 0.691V
VMIV-5.6K TX2 Resistor PIN7 to PIN9: 0.57 ohm Short or other
values
VMIV-3.6K TX2 Resistor PIN7 to PIN9: 0.4ohm Short or other
values
TX3 Resistor PIN9 to PIN10: 0.3ohm Short or other
values
D652 Diode + to -: 0.52V Short or explosion
- to +: OL
Note1: When test the Q69; please remove the R245 from the board, otherwise the test result is not right
Note2: When test the D69; please remove the D65 from the board, otherwise the test result is not right

Main Power SPS

The MOSFET Q9 are (IRFBG30 3.1A 1000V TO-220)
The Q8 are (2SC5353BL 3A 750V TO-126C)
The U8 are (IC PWM UC3845BNG DIP-8)
The R203 are (RES 5W 0.5ohm)
The R204 are (RES 1/4W 100ohm 1206)
The D53 are (1N4148W 0.15A 75V SMD)
The R67 are (RES 1/4W 10ohm 1206)
The D3 are (MUR460RLG 4A 600V UFST)
The D49 and D57 are (HER303 3A 200V UFST)
The U7 are (IC L7912CV 3P TO-220)
The U10 are (IC MC78M05CDTRKG DPAK-3)
The TX4 are (TX 8:21:2:4:8:21:7 FER EC28)

24
Parts Attribute Reference values Failure status
Q9 Resistor GS: 45k Short or explosion
SD: 300K
Diode SD: 0.52V

25
 SG: 0.73V
Q8 Resistor BC: 356k Short or explosion
BE: 413k
Diode BC: 0.59V
BE: 0.61V
U8 Diode PIN5 TO PIN7: 0.48V Short or other
PIN5 TO PIN6: 0.64V values
R203 Resistor 0.5 ohm Open or other
values
R204 Resistor 100 ohm Open or other
values
D531 Diode + to -: 0.52V Short or explosion
- to +: OL
R67 Resistor 10 ohm Open or other
values
D3 Diode + to -: 0.4V Short or explosion
- to +: 0.7V
D49/D57 Diode + to -: 0.45V Short or explosion
- to +: OL
U7 Diode PINI to PINO: 0.56V Short or explosion
PINO to PING: 0.44V
PINI to PING: 0.45V
U10 Diode PINA TO PINI: 0.45V Short or explosion
PINA TO PINO: 0.5V
TX4 Resistor PIN1 TO PIN3: 0.4 ohm Short or other
values
Note1: When test the D53; please remove the R67 from the board, otherwise the test
result is not right
3.6 Check AC SPS on MPPT board
The F7 are (FUSE 3A 125V)
The NTC4 are (NTC 10 OHM 3.0A)
The REC3 are (GBU4M 4A 1000V UFST)
The D83 are (RHRP8120 8A 1200V)
The Q20 are (IRFBG30 3.1A 1000V)
The Q19 are (2SC5353BL 3A 750V)

26
The U23 are (IC PWM UC3845BNG DIP-8)
The TX12 are (TX 26:4:42:27 FER EC28)
The C176 are (33uF 450V)

Parts Attribute Reference values Failure status

F7 Resistor 0.1 ohm Open or explosion
NTC4 Resistor 11.4 ohm
D83 Diode + to -: 0.458V Short or explosion
- to +:OL
Q20 Resistor GS: 45.27k Short or explosion
SD: 4.711K
Diode SD: 0.536V Short or other
SG: OL values

27
Q19 Resistor BC: 361.9k Short or explosion
BE: 411.6k
Diode BC: 0.598V
BE: 0.611V
U23 Diode PIN5 TO PIN7: 0.492V Short or other
PIN5 TO PIN6: 0.639V values
Resistor PIN1 TO PIN3: ohm Short or other
values
C176 33uF/450V
Capacitance

3.7 Check the bus soft start circuit on MPPT board (TX1: Especially for 09 fault)
The D82 are (RHRP8120 8A 1200V UFST)
The R238 are (RES 0.62 J)
The MOSFET Q17 are (IRFBG30 3.1A 1000V TO-220)
The D67 and D73 are (MUR4100ERLG 4A 1000V UFST)
The U18 are (IC PWM UC3845BNG DIP-8)
The TX1 are (TX 55:200:44 FER EEL16)
The R260 are (22R 1206)
The R235 are (1KR 1206)
The R258 are (1.2KR 1206)
The C176 are (33uF 450V)
Note: If R260 is damaged, please replace U18 together.

28
29
Parts Attribute Reference values Failure status
D82 Resistor + to -: 237k Short or explosion
- to +: OL
Diode + to -: 0.458V
- to +: OL
D67/D73 Diode + to -: 0.47V Short or explosion
- to +: OL
Q17 Resistor GS: 1.195k Short or explosion
SD: 4.692k
DS: OL
Diode SD: 0.535V
DS: OL
R238 Resistor 0.7 ohm Open or other values
R235 Resistor 0.999K ohm Open or other values
R258 Resistor 1.195K ohm Open or other values
R260 Resistor 22 ohm Open or other values
U18 Resistor PIN7 TO PIN5: 72k Short or explosion
PIN6 TO PIN5: 1.21k
TX1 Resistor PIN2 to PIN4: 2.7ohm Short or other values
PIN7 to PIN9: 1.4ohm
When 09 fault happens, and you couldn’t find other damage, please check TX1!!
3.8 Check the Boost on MPPT board
Power devices
Boost IGBT Q1/Q6 and Diode D1

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 The D52 are (30DQ60BG 30A 600V TO-247)
The Q10 and Q11 IGBT are (STGW60H65DFB 60A 650V TO-247)

Parts Attribute Reference values Failure status

Q10, Q11 Resistor GE: 18.29k Short or explosion
GC: 206.1k
CE: 358.7k
Diode EC: 0.389V
CE: OL
D52 Diode + to -: 0.39V
- to +: OL

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Drivers
The U11 are (FOD3150ASD SO-8)
The D27 and D28 are (1N4148W 0.15A 75V SMD)
The R60 and R223 are (10R 1206)
The R225 and R229 are (39R 1206)

Parts Attribute Reference values Failure status

U11 Resistor PIN8 TO PIN5: 350.7k
Short or other values
PIN7 TO PIN5: 388k
D27/ D28 Diode + to -: 0.6V
Short or explosion
- to +: OL
R60/ R223 Resistor 10 ohm
Open or other values

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R225/ R229 Resistor 39 ohm
Open or other values

Note: When test the diode; please remove the R60/ R223 from the board, or the test result
is not right.
3.9 Check the ED & SW board

The LED6 are (RSBHGHC-A88-4T RGB 1.6*1.6 SMD)

Parts Attribute Reference values Failure status

LED6 Diode PIN6 to R1: 1.985V Short or explosion
PIN6 to R2: 1.748V
PIN6 to R5: 1.988V
R1 to PIN6: 1.501V
R2 to PIN6: 1.501V
R5 to PIN6: 1.501V

Drivers
The R1 and R2 and R4 and R5 are (0R 0603)
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4. Disassembling guide
Remove 10
screws on top
cover and rear
panel.

Remove the
remote panel
and control
cables.

34
Remove Bat SW
cable and LCD
cable, and take
out the Remote
cover.
(Note: If you just
only need to
replace the
control board,
you can replace
it at this step.)

Remove the
plastic screws of
wind pipeline.
Be careful not to
damage them.
You can use an
oblique mouth
clamp to help
you to remove
the clip.

35
Note:
Please make
sure that put
the plastic
sheet back and
fix well.
Otherwise it
will affect the
heat
dissipation.

Remove
AC SPS cable
Comm cable
LCD cable and
Bat SW cable.

36
Remove I/P and
O/P cables.

Remove the fan

cables.

Remove PV IN
cable

37
MPPT NTC and
Converter NTC
and INV NTC

Remove 13
screws on main
board, and take
out the main
board

1.1 Total wiring diagram:

Note: Wrong connection of wires may cause inverter damage!
Please connect wires with care!

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