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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weber
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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". ]
Learning how to patch and repair PIP-4048 inverter-chargers and Elcon chargers.

Walde
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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. ]
Learning how to patch and repair PIP-4048 inverter-chargers and Elcon 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.
Learning how to patch and repair PIP-4048 inverter-chargers and Elcon chargers.

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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 41 times
MOSFET / CSD19505KCS 80V N-CH NexFET Pwr
IMG_20190612_152435-k.jpg
IMG_20190612_152435-k.jpg (621.29 KiB) Viewed 41 times
D65 - RHRP8120 8A, 1200V, Hyperfast diode 
IMG_20190612_152505-k.jpg
IMG_20190612_152505-k.jpg (648.32 KiB) Viewed 41 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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