PIP inverter repairs and hardware modifications

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Roman khan
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Re: PIP inverter repairs and hardware modifications

Post by Roman khan »

Text on 1000uf 35v capacitor.
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Re: PIP inverter repairs and hardware modifications

Post by paulvk »

That board has a lot of dirt on it I would be cleaning it.

Did a bit of searching 3300uF 35V (Ωmax/100kHz 0.012 18 x 40 mm 4.080 amps ripple 100kHz 8000 hours EKY-350E□□332ML40S
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Re: PIP inverter repairs and hardware modifications

Post by weber »

@Roman khan, This is my suggestion to replace the 4 x 4200 µF capacitors:
https://www.digikey.com/product-detail/ ... ND/4843891

I understand now, why these capacitors were not where I expected them to be. It's because the battery side of the DC-DC converter is not a full bridge but rather it is push-pull, with a centre tap on the transformer winding.

Have you checked that the two TVS diodes, on either side of the transformer, are not open circuit?

If the 2 x 1000 µF capacitors are connected in parallel with the 4 x 4200 µF capacitors then this is my suggestion to replace the 2 x 1000 µF capacitors:
https://www.digikey.com/product-detail/ ... ND/4843880

I know your replacement MOSFETs are CSD19505, but I ask for the third time, what was the part number of the original MOSFETs?
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Re: PIP inverter repairs and hardware modifications

Post by JAmBer »

I've just purchased a "King" unit, and am wondering if the RJ45 connector can supply enough current to power a RaspberryPI via a little DC-DC SMPS on the 12V line. This'd offer 1) no need for a higher-voltage capable SMPS, and 2) neater wiring.

I note a 1A fuse mentioned in this thread, but no indication of what a safe continuous operating current might be.

Any insights from the wisdom of the forum?
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Re: PIP inverter repairs and hardware modifications

Post by coulomb »

JAmBer wrote: Tue, 04 Feb 2020, 22:10 I've just purchased a "King" unit, and am wondering if the RJ45 connector can supply enough current to power a RaspberryPI via a little DC-DC SMPS on the 12V line.
I don't know the King's circuitry, and I assume that you're talking about the RS-232 port (on an RJ-45 connector). In a PIP-5048MS, the 12 V power is isolated through a small power supply, almost certainly a flyback type, with a tiny isolating "transformer". This post suggests that the power available is very modest, probably some 50 mA or well under one watt.
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Re: PIP inverter repairs and hardware modifications

Post by paulvk »

I think it will the PiB4 is 3.2 watts doing video , 4.5 watts loading XDE which is less than 400ma at 12v and I measure 15v on my units.
Note I run HLK-RM04 off my inverters via 1A DC-DC power supplies from ebay.
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Re: PIP inverter repairs and hardware modifications

Post by weber »

[Assuming the King is like the Axpert MKS 5K] If it is a Raspberry Pi A+ or Rasperry Pi Zero with the HDMI turned off, and any other unneeded hardware turned off, so that the average current is less than 170 mA, then you might just barely be able to power it. In that case, the best interface might be a direct connection, with a 5.1 V 5 W zener diode in parallel with a 1 F 5.5 V supercapacitor across the Pi, rather than a DC-DC converter, since maximum power is obtained from a resistive source at half the open circuit voltage anyway. But there's no guarantee that it's purely resistive.
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Re: PIP inverter repairs and hardware modifications

Post by paulvk »

I went and measured the voltage on the input of the DC-DC power supply its 13v while powering the HLK-RM04 which has a 160ma draw at 5v.
I will later try loading it a bit more to see how it goes as I want to drive a 7 inch Nextion display.
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Re: PIP inverter repairs and hardware modifications

Post by paulvk »

I measured the Nextion display and it was 350ma , I hooked it up to the 5v output from the DC-DC power supply
this is running the HLK-RM04 .
The input voltage (from pip4048) went to 10.5v and I had both the HLK-RM04 and 7 inch Nextion display running so 450 to 500ma at 5v.
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Re: PIP inverter repairs and hardware modifications

Post by catalincre »

For those who have tried to change the fan and ended with 01 error or for those who want to alter the fan (not the original one) speed accordingly with the original fan speed variation (run cooler in hot environment) I have a solution, its a hardware/software one but dirt cheap. If are interested person, I will post sometime later a tutorial. Here is a video proof: https://youtu.be/sArdenUJkcc
The left one is 40% faster but that procentaje can be altered (increase or decrease).
Enjoy
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Re: PIP inverter repairs and hardware modifications

Post by aim120 »

catalincre wrote: Wed, 05 Feb 2020, 15:48 For those who have tried to change the fan and ended with 01 error or for those who want to alter the fan (not the original one) speed accordingly with the original fan speed variation (run cooler in hot environment) I have a solution, its a hardware/software one but dirt cheap. If are interested person, I will post sometime later a tutorial. Here is a video proof: https://youtu.be/sArdenUJkcc
The left one is 40% faster but that procentaje can be altered (increase or decrease).
Enjoy
Did you use a seperate pwn fan controller.?
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Re: PIP inverter repairs and hardware modifications

Post by catalincre »

I have used a pwm multiplayer from an arduino board (Leonardo Pro micro).
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Re: PIP inverter repairs and hardware modifications

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weber wrote: Mon, 03 Feb 2020, 14:52 @Roman khan, This is my suggestion to replace the 4 x 4200 µF capacitors:
https://www.digikey.com/product-detail/ ... ND/4843891
Thanks for your kind help once again.
Sir these capacitors are 35v 3300uf on my inverter and you have recomended 4200uf 50v, Will this voltage and capacitance difference matters?and secondly can i order this from china?
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Roman khan
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Re: PIP inverter repairs and hardware modifications

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weber wrote: Mon, 03 Feb 2020, 14:52 I know your replacement MOSFETs are CSD19505, but I ask for the third time, what was the part number of the original MOSFETs?
Most inverter comes with original mosfes K100 and some comes with csd19505.this one was with csd19505.
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Re: PIP inverter repairs and hardware modifications

Post by catalincre »

coulomb wrote: Tue, 28 Jan 2020, 08:44
daimyo wrote: Tue, 28 Jan 2020, 05:55 What is the difference between old and new ssc board?
Basically, the new board is much longer, the new SCC heatsink is better positioned in front of the fans, and the PV terminal block connects to the SCC PCB via a pair of metal bars attached to the PCB.

Old board (sorry for the poor photo, all I could find in a hurry):
Image
The two SCC inductors are one on top of the other at the top left of the box. The SCC PCB is all at the top of the box.


New board:
Image
The SCC inductors are much further apart, and the SCC PCB takes up nearly the full height of the box.
This looks like my clone

The IGBT on the left side are 75g60hd, are they good?
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Re: PIP inverter repairs and hardware modifications

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Roman khan wrote: Thu, 06 Feb 2020, 02:41
weber wrote: Mon, 03 Feb 2020, 14:52 @Roman khan, This is my suggestion to replace the 4 x 4200 µF capacitors:
https://www.digikey.com/product-detail/ ... ND/4843891
Thanks for your kind help once again.
Sir these capacitors are 35v 3300uf on my inverter and you have recomended 4200uf 50v, Will this voltage and capacitance difference matters?and secondly can i order this from china?
I understand you meant to write: "these capacitors are 35 V 4200 µF on my inverter and you have recommended 3300 µF 50 V".

The capacitance difference will not matter. What matters in this application is low impedance at 100 kHz (which is accompanied by a high ripple current rating). I could not find a datasheet that shows the original 4200 µF 35 V in Aishi's RF series. They are probably a custom design for Voltronic Power. But extrapolating from the others in that series, suggests that, when new, they would have an impedance of 10 mΩ to 12 mΩ.

The 50 V rating will make them last much longer. But you can fall back to 35 V if you can't find low enough impedance in a 50 V capacitor.

I do not know if you can buy them in China. You can search Chinese suppliers for:
Manufacturer: United Chemi-Con
Part number: EKZN500ELL332MM40S

Or failing that, you can use any capacitor with a voltage rating of 35 V or more, and a 100 kHz impedance of 12 milliohms or less, with the same lead spacing, that will fit in the available space. It must also have a temperature rating of 105 °C or more, and should have an endurance of 10 000 hours or more.

Are the two 1000 µF capacitors connected in parallel with the four 4200 µF capacitors?
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Re: PIP inverter repairs and hardware modifications

Post by coulomb »

catalincre wrote: Thu, 06 Feb 2020, 03:11 The IGBT on the left side are 75g60hd, are they good?
It depends. If they are genuine Fuji Electric parts, I'd say yes. If they are clones of these, then who knows.
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, 2xPIP-4048MS inverters, 16 kWh battery.
1.4 kW solar with 1.2 kW Latronics inverter and FIT.
160 W solar, 2.5 kWh 24 V battery for lights.
Patching PIP-4048/5048 inverter-chargers.
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Re: PIP inverter repairs and hardware modifications

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Roman khan wrote: Thu, 06 Feb 2020, 02:54 Most inverter comes with original mosfes K100 and some comes with csd19505.this one was with csd19505.
I'm guessing the "K100" are Toshiba TK100E08N which are 3.4 mΩ 80 V. The Texas Instruments CSD19505KCS are 3.8 mΩ 80 V.
Those MOSFETs should be fine. There is no need to upgrade to a higher voltage rating.
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Re: PIP inverter repairs and hardware modifications

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weber wrote: Thu, 06 Feb 2020, 05:05
Are the two 1000 µF capacitors connected in parallel with the four 4200 µF capacitors?
Sir the two 1000uf capacitors are connected in parallel with 4200uf capacitors.
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Re: PIP inverter repairs and hardware modifications

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weber wrote: Thu, 06 Feb 2020, 05:41 I'm guessing the "K100" are Toshiba TK100E08N which are 3.4 mΩ 80 V. The Texas Instruments CSD19505KCS are 3.8 mΩ 80 V.
Those MOSFETs should be fine. There is no need to upgrade to a higher voltage rating.
Yes Sir these are K100E08N1
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Re: PIP inverter repairs and hardware modifications

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paulvk wrote: Wed, 05 Feb 2020, 13:55 I measured the Nextion display and it was 350ma , I hooked it up to the 5v output from the DC-DC power supply
this is running the HLK-RM04 .
The input voltage (from pip4048) went to 10.5v and I had both the HLK-RM04 and 7 inch Nextion display running so 450 to 500ma at 5v.
Very helpful feedback, thanks Paul! It sounds like 800mW is no problem (150mA@5V), but 2.5W is pushing it (500mA at 5V) with some significant voltage sag.

From https://www.pidramble.com/wiki/benchmar ... onsumption it sounds like it might just about be do-able if I use one of the baby Pi models (A+ or zero) and disable unnecessary peripherals. I could even try declocking it, I guess.
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Re: PIP inverter repairs and hardware modifications

Post by Vissie »

Good day
Its been a long time since I asked questions here. I tend to repair every Axpert 5KVa I lay my hands one. The more fets and IGBT's blown the easier
But every now and then one comes along with hardly any blown components and they are the terrible ones to repair
I got this one today.
Fault code: 53 Inverter soft start failed
All I can find that was faulty was QD2 and QA1. The most left IGBTs from the final inverter stage. Even all the components from the drive circuits are fine. The optos measure ok and I did not replace them
After replacing this two IGBTs the inverter comes one and shows 230V for an instant before the same two IGBTs explode again! A few times already!
I check C33 and L2 and all the final filter components . They are all fine . I even replaced IC u21 although I have no idea what it does. The number on it does not exist on google
I used different control boards and the same thing happens. So my control board is ok
Im ready to scrap this thing for spares but hope anybody can shed some light on my problem
It will be so much easier if a man can get hold of the main board circuit diagrams, but it seems like they only released that service manuals with block diagrams....

I have a second one with switched power supply problems. The pwm ic gets voltage with switch-on on its pins 5 and 7 and then it disappears and I cannot find out why. I replaced all the capacitor on the output. If I force the supply on the outputs are only half the voltage it should be. Has anybody had that before?

Regards
Vissie
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Roman khan
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Re: PIP inverter repairs and hardware modifications

Post by Roman khan »

Vissie wrote: Fri, 07 Feb 2020, 02:24 Good day
Its been a long time since I asked questions here. I tend to repair every Axpert 5KVa I lay my hands one. The more fets and IGBT's blown the easier
But every now and then one comes along with hardly any blown components and they are the terrible ones to repair
I got this one today.
Fault code: 53 Inverter soft start failed
All I can find that was faulty was QD2 and QA1. The most left IGBTs from the final inverter stage. Even all the components from the drive circuits are fine. The optos measure ok and I did not replace them
After replacing this two IGBTs the inverter comes one and shows 230V for an instant before the same two IGBTs explode again! A few times already!
I check C33 and L2 and all the final filter components . They are all fine . I even replaced IC u21 although I have no idea what it does. The number on it does not exist on google
I used different control boards and the same thing happens. So my control board is ok
Im ready to scrap this thing for spares but hope anybody can shed some light on my problem
It will be so much easier if a man can get hold of the main board circuit diagrams, but it seems like they only released that service manuals with block diagrams....

I have a second one with switched power supply problems. The pwm ic gets voltage with switch-on on its pins 5 and 7 and then it disappears and I cannot find out why. I replaced all the capacitor on the output. If I force the supply on the outputs are only half the voltage it should be. Has anybody had that before?

Regards
Vissie
There are three J3 smd diodes and three BC diodes in inverter soft start circuit.the encircle with blue line are j3 diodes and indicated by arrows are BC diodes.you should replace them even if they shows ok value.and the two 10nf smd capacitors indicated. Mostly fault53 comes from here.
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Re: PIP inverter repairs and hardware modifications

Post by weber »

Roman khan wrote: Thu, 06 Feb 2020, 16:39 Sir the two 1000uf capacitors are connected in parallel with 4200uf capacitors.
Here is a datasheet that shows the original 1000 µF 35 V in Lelon's RGA series. They are not a low impedance type, and only have 2000 hour endurance. But since they are across the DC bus of the battery side of the DC-DC converter, the MOSFETs can benefit if we make them low impedance. It appears that they may also be filtering the output of the SCC. This too can benefit from lower impedance, and it doesn't matter if they are lower capacitance than the original.

As with the larger capacitors, a 50 V rating will make them last much longer. But you can fall back to 35 V if you want.

I do not know if you can buy them in China. You can search Chinese suppliers for:
Manufacturer: United Chemi-Con
Part number: EKZN500ELL471MK20S

Or failing that, you can use any capacitor with a voltage rating of 35 V or more, and a 100 kHz impedance of 32 milliohms or less, with the same lead spacing, that will fit in the available space. It must also have a temperature rating of 105 °C or more, and should have an endurance of 10 000 hours or more.
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Re: PIP inverter repairs and hardware modifications

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There are three J3 smd diodes and three BC diodes in inverter soft start circuit.the encircle with blue line are j3 diodes and indicated by arrows are BC diodes.you should replace them even if they shows ok value.and the two 10nf smd capacitors indicated. Mostly fault53 comes from here.
Thank you Roman
I googled J3 and Bc diodes but that left me in the dark
Googlre images shows J3 smd diodes as 18V zeners. Is that correct?
I cant find much on BC diodes
Do you have the diode values if zeners or the diode names that must be replaced?
Can this faulty components cause the 2 left hand side IGBTs to blow by maybe switching them at the same time and cause a short. I believe they work in an H bridge configuration
Thanks
Vissie
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