PIP Inverter Error "error 09" bus soft start failed

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Walde
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PIP Inverter Error "error 09" bus soft start failed

Post by Walde » Sat, 18 May 2019, 00:50

PIP Inverter Error "error 09" bus soft start failed

Solar SM 5kw 48vdc = EASUN POWER 5000W Solar Inverter 80A MPPT Off Grid Inverter 48V 220V Hybrid Inverter Pure Sine Wave Inverter 60A Battery Charger

Type 2018

Maybe one of you can help me.

On the motherboard, a diode is apparently defective.
Designation on the diode is only GFZ without manufacturer and without values. The mounting space is labeled TVS.

The board is the new model (with the ID 16-500558-02G)
Inverter 5kva / 48v

Image
Image





Thanks in advance to all who help me

Greetings Dirk

Please, please, please
Thank you thank you thank you

[ Edited Coulomb: replaced [image=] tags with [img] or [image=640]. Also fixed image URL where required. Use browser "show image" or "show image in new tab" option to zoom into the last three images. ]

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by weber » Sat, 18 May 2019, 08:07

It's an SMCJ51A, a 51 volt unidirectional transient voltage suppressor (TVS) in an SMC package. Datasheet here:
https://www.diodes.com/assets/Datasheets/ds19003.pdf
It is likely to be available from many suppliers, such as Element14, Digikey, Mouser and RS Components.

Since that TVS has failed, it's possible that the MOSFET it was protecting has also failed, and possibly other MOSFETs and their driver components.
One of the fathers of MeXy the electric MX-5, along with Coulomb and Newton (Jeff Owen).

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by coulomb » Sat, 18 May 2019, 08:23

Walde wrote:
Sat, 18 May 2019, 00:50
PIP Inverter Error "error 09" bus soft start failed
Hi, Dirk. Fault code 09 is the dreaded one. It often indicates a lot of damaged components. But you may be lucky with this one.
Solar SM 5kw 48vdc = EASUN POWER 5000W Solar Inverter 80A MPPT Off Grid Inverter 48V 220V Hybrid Inverter Pure Sine Wave Inverter 60A Battery Charger
Type 2018
Thanks for the very full model description. It's so infuriating when people say that they have an "Axpert 5kVA", which could mean about a dozen different models.
On the motherboard, a diode is apparently defective.
Designation on the diode is only GFZ without manufacturer and without values. The mounting space is labeled TVS.
That's not technically a diode, it's a Transient Voltage Suppressor. It's something like two high powered zener diodes back to back. Also, "GFZ" is the SMD (Surface Mount Device) code; it's a small code, usually 2 or 3 alphanumeric characters, which represents a compact code leading to the actual part number, which is so long it would not fit legibly on most SMD parts. I Googled "SMD code "GFZ"" (without the outer quotes), and it led to this:

https://www.vishay.com/docs/88394/smcj.pdf

Search in that PDF for "GFZ" without the quotes to find the one you have now. The minimum voltage that these start conducting at seems to be 56.7 V, so presumably it's across the battery-side full bridge MOSFETs. That voltage seems a little low, so maybe that's the reason it got hot and eventually blew, and maybe the replacement should be slightly higher voltage. However, its "maximum clamping voltage" is 82.4 V, presumably protecting an 80 V rated part. Find a replacement at the usual on-line suppliers: RS Online (free delivery even for small orders), Digi-Key, Element-14/Farnell/Newark, Mouser, etc. Perhaps buy a few (there may be a minimum order quantity), and perhaps order a few different voltages to experiment with. If you replace it with a slightly higher voltage version, perhaps replace the other three as well. They may also be getting hot at higher battery voltages. You don't want to go too high in voltage, or the protection will be useless.

[ Edit: "across the battery" → "across the battery-side full bridge MOSFETs". ]
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, PIP-4048MS inverter, 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 Error "error 09" bus soft start failed

Post by Walde » Sat, 18 May 2019, 19:05

OK thank you for the info.
Get the TVS Diodes now at Mouser.com.
They have the TVS SMCJ51A (identification GFZ).
In Germany, the ESD suppressors diodes.

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by Walde » Fri, 24 May 2019, 20:58

Has anyone already repaired the "error 09"?

I replaced the TVS which was defective (only One TVS was defective).
All other TVS are OK (but still changed) ( SMCJ51A 1.5kW 51V - GFZ )
All MOSFET are OK (the defective TVS has been replaced by the Mosfet) ( CSD19505KCS 80V N-CH NexFET Pwr )

Still get the mistake.
Have now ordered the following parts.
the
- D65 - RHRP8120 8A, 1200V, Hyperfast diode
- U16 - IC PWM CNTL - uc3845ad1 SOP-8

But maybe someone has already fixed such a problem with the error 09

Info: I have a service manual from Voltronic :roll:

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by coulomb » Sat, 25 May 2019, 09:09

Walde wrote:
Fri, 24 May 2019, 20:58
But maybe someone has already fixed such a problem with the error 09
Alas, there are many faults that can result in the dreaded fault code 09. There are three basic groups:
  • Something shorts the bus, often a pair of IGBTs. Note that there are two sets of IGBTs: the inverter proper (4), and the higher voltage end of the DC-DC converter (another 4, I think Q27-Q30).
  • The soft start power supply, consisting of U16/Q6/TX2 and associated components. Schematic here.
  • Something breaks down at a voltage lower than the working bus voltage, e.g. carbonised muck on the PCB (Weber had this problem), or a weakened IGBT or capacitor that can stand a hundred volts but not 400 V.
If you can see non-zero resistance across the bus (there are large marked pads on the top of the board for this), then it's more likely to be the second item.

[ Edit: Added link to schematic. ]
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, PIP-4048MS inverter, 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 Error "error 09" bus soft start failed

Post by Walde » Fri, 31 May 2019, 20:49

Does anyone have a article number / manufacturer for the TX2 !!! Attention, the 48V device !!!

According to the service manual, it should be a transformer seemingly with the data ( TX 15:200:15 FER EEL16 )

But at RS, Farnell and Mouser I have not found anything yet and needed your help.

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by coulomb » Sat, 01 Jun 2019, 06:20

Walde wrote:
Fri, 31 May 2019, 20:49
it should be a transformer seemingly with the data ( TX 15:200:15 FER EEL16 )
Transformers are not usually stock parts. It's actually a Multi-winding inductor, i.e. it has an air gap for storing energy; the power supply is a flyback type. The 15:200:15 part might be the turns ratio, possibly even the actual number of turns. It may be that one of the 15 turn windings is not used. The last part might indicate the grade of ferrite in the core. It is possible that you might be able to get a replacement custom made to those specifications from a specialist winding company. I imagine that buying just one or a few would be prohibitively expensive.

If you really need to replace the soft start power supply, it might be more practical to find a small brick type DC-DC with a suitable enable pin, and replace the whole thing (up to but excluding the final diode) with the brick. Vicor make such things; you'd need a 48 volt to ~450 volt model rated at about 5 watts. A quick search indicates that they make mostly low output voltage products, the highest I saw was 95 V. But there may be higher output voltage products, perhaps from other manufacturers, like Meanwell.

The other possibility is finding a "transformer" from a main board that is not repairable, for example many companies won't replace 16 MOSFETs if they blow. One hazard there is that there seems to be two slightly different transformers in use. If you replace with the wrong version, it might not work or other parts might blow.
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, PIP-4048MS inverter, 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.

Walde
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Re: PIP Inverter Error "error 09" bus soft start failed

Post by Walde » Wed, 12 Jun 2019, 21:51

I have a new Tester Tool 10$/10Euro with Shipping

A pair of values from the components.

TVS / SMCJ51A 1.5kW 5 1V - GFZ
IMG_20190612_152604-k.jpg
IMG_20190612_152604-k.jpg (550.3 KiB) Viewed 602 times
MOSFET / CSD19505KCS 80V N-CH NexFET Pwr
IMG_20190612_152435-k.jpg
IMG_20190612_152435-k.jpg (621.29 KiB) Viewed 602 times
D65 - RHRP8120 8A, 1200V, Hyperfast diode 
IMG_20190612_152505-k.jpg
IMG_20190612_152505-k.jpg (648.32 KiB) Viewed 602 times
I'm impressed by what the little tester can do 😍

😎 Have a nice day.

I will continue to test and hope that I get my fix times. 

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by Walde » Mon, 17 Jun 2019, 22:40

how can I test the IGBTs.

For me GW80H65DFB are installed

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by coulomb » Tue, 18 Jun 2019, 06:24

Walde wrote:
Mon, 17 Jun 2019, 22:40
how can I test the IGBTs.
A bit difficult to test completely. But seeing the anti-parallel diode is a pretty good test in practice, since 99% of MOSFETs and IGBTs fail either short circuit or open circuit.

[ Edit : added "and IGBTs" ; "back diode" → "anti-parallel diode" ]
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, PIP-4048MS inverter, 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 Error "error 09" bus soft start failed

Post by weber » Tue, 18 Jun 2019, 07:12

Walde wrote:
Mon, 17 Jun 2019, 22:40
how can I test the IGBTs.

For me GW80H65DFB are installed
That's a great little tester for $10. But I see from eBay that it doesn't claim to test IGBTs. However, since your IGBTs have a built-in anti-parallel diode (free-wheeling diode), they might test as MOSFETs, if you can get their 0.2"-spaced pins into test holes 1, 2 and 3. If your ZIF socket is arranged like some other testers I see on eBay, then you should be able to bend the pins to get them into the holes shown bolded and underlined below:
1231111    or    1231111
2223333          2223333

Failing that, if you short the gate to the emitter, then it should test as a diode between emitter and collector, as per Coulomb's suggestion. You can do that by using the holes shown bolded and underlined below:
1231111
2223333

And if you short the collector to the emitter, then it should test as a capacitor between gate and emitter (about 11 nF). You can do that by using the holes shown bolded and underlined below:
1231111
2223333

I see there are some $30 component testers on eBay, that do claim to test IGBTs (although they don't say if they can test IGBTs that have an integral diode).
https://www.ebay.com.au/itm/1pc-LCR-T7- ... ctupt=true
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Re: PIP Inverter Error "error 09" bus soft start failed

Post by weber » Tue, 18 Jun 2019, 10:33

I just did a bit of research on these low-cost component testers. It turns out they consist of a microcontroller and 6 resistors! I kid you not. This design, and the clever software that makes it all work, was invented, and open-sourced for non-commercial use, by one Markus Frejek, German. He deserves a medal. We should at least call them "Frejek testers", presumably pronounced "FRAY-eck".

Image

Here's a Google translation:
http://translate.google.com/translate?s ... stortester

There's no mention of IGBTs, apparently because the algorithm first checks for diodes between all pairs of terminals (with the third terminal floating), and if it finds none, it assumes the component is not a semiconductor. A plain IGBT will not register as a diode between any pair of terminals, unless the third terminal is also correctly biased.
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Re: PIP Inverter Error "error 09" bus soft start failed

Post by Walde » Tue, 18 Jun 2019, 20:21

Ho have now been able to test the IGBT as follows.

Pin 1 and Pin 2 = Capacitor with 3700pf approx.
and
Pin 2 and Pin 3 = Diode Uf = 440mv approx. / C = 6.35 nf

For me, the following IGBT are apparently defective
Q32, Q27, Q28
and the TVS, TVS1

If one is broken everything else comes
defective = e.g. Pin 2 and Pin 3 = Risistor 0.00
defective = Pin 1 and Pin 2 = Capacitor 17nf

I'm still sending pictures

Have ordered the IGBT now and will report how it looks like who I have changed.

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by Walde » Thu, 20 Jun 2019, 21:26

IGBT Type: GW80H65DFB
IMG_20190618_141035-k2.jpg
IMG_20190618_141035-k2.jpg (683.48 KiB) Viewed 480 times
IMG_20190618_141041-k.jpg
IMG_20190618_141041-k.jpg (674.17 KiB) Viewed 480 times
IMG_20190618_141105-k.jpg
IMG_20190618_141105-k.jpg (579.26 KiB) Viewed 480 times
IMG_20190618_141110-k.jpg
IMG_20190618_141110-k.jpg (656.46 KiB) Viewed 480 times

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by Walde » Thu, 04 Jul 2019, 07:17

I have had the IGBT Q27, Q28, Q29, Q30 and the Q32 changed (have no Q31). After a try to start with battery pack again came Error 09 at the second start attempt. In another subsequent test, the IGBT were partially defective again.

What else can I check or someone has a tip why the new IGBT are through again.

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Re: PIP Inverter Error "error 09" bus soft start failed

Post by weber » Thu, 04 Jul 2019, 08:10

It may be that some of the gate driver components for those IGBTs are damaged, causing some IGBTs to be permanently or easily turned on, resulting in shoot-thru. See pages 18 and 19 of the service manual
https://forums.aeva.asn.au/uploads/4111 ... 01506A.pdf
and see Coulomb's schematic
http://forums.aeva.asn.au/viewtopic.php ... 332#p65151

These and other helpful documents are linked from the index post here:
https://forums.aeva.asn.au/viewtopic.ph ... 691#p53691
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Re: PIP Inverter Error "error 09" bus soft start failed

Post by coulomb » Thu, 04 Jul 2019, 08:13

Walde wrote:
Thu, 04 Jul 2019, 07:17
In another subsequent test, the IGBT were partially defective again.
Similarly to what Weber has just posted: Have you checked the IGBT gate drivers? Often when an IGBT or MOSFET fails, the gate shorts to other terminals, and can blow up resistors and transistors in the gate driver circuit.

There is a small chance that something else is dragging down the bus voltage, and the "partially defective" IGBTs are actually OK. Or the bus soft start circuit may have faulty components. These links are from the index in the first post of the PIP-4048MS and PIP-5048MS topic.

[ Edit: "this topic" -> "PIP-4048MS and PIP-5048MS" with link]
Nissan Leaf 2012 with new battery May 2019.
5650 W solar, PIP-4048MS inverter, 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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