Service Manual

Product Axpert Max 3600-24

Doc No. P1911061 Version 00 PAGE

Axpert Max 3600

Service manual
Service Manual
Product Axpert Max 3600-24
Doc No. P1911061 Version 00 PAGE

Table of contents

1. GENERAL INFORMATION ............................................................................................................................ 3

1.1 GETTING START ............................................................................................................................................ 3

1.2 BASIC TOPOLOGY INTRODUCTION ................................................................................................................ 3
1.3 INVERTER FAMILY .......................................................................................................................................... 4
1.4 OVERVIEW THE INVERTER ............................................................................................................................ 4

2. TROUBLESHOOTING .................................................................................................................................... 4

2.1 HOW TO DO ................................................................................................................................................... 4

2.2 FAULT CONDITION ......................................................................................................................................... 4
2.3 TEST STEP..................................................................................................................................................... 5

3. CHECKING AND MEASURING GUIDE....................................................................................................... 6

3.1 CHECK THE BATTERY SIDE COMPONENTS ON MAIN BOARD ....................................................................... 6

3.2 CHECK THE BUS SIDE COMPONENTS ON MAIN BOARD............................................................................. 12
3.3 CHECK THE BUCK CIRCUIT ON MAIN BOARD ............................................................................................. 14
3.4 CHECK THE INV FULL BRIDGE ON MAIN BOARD ....................................................................................... 15
3.5 CHECK BATT AND MAIN POWER SPS ON MAIN BOARD ......................................................................... 17
3.6 CHECK AC SPS ON MPPT BOARD............................................................................................................ 21
3.7 CHECK THE BUS SOFT START CIRCUIT ON MPPT BOARD (TX1: ESPECIALLY FOR 09 FAULT) ................. 22
3.8 CHECK THE BOOST ON MPPT BOARD ....................................................................................................... 24

4. DISASSEMBLING GUIDE............................................................................................................................ 26

TOTAL WIRING DIAGRAM:................................................................................................................................... 30

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1. General information
1.1 Getting start
This manual is used as a checking and repairing guide for Axpert Max-3600. 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.
AXPERT MAX

DC BUS Bi-directional From GRID

From PV Boost DC/AC Inverter

To AC LOAD
From PV
(7.2KW only) Boost

Charge/Discharge To Battery Battery

BMS

DC Converter
To DC LOAD

1.2 Basic topology introduction

The topology of the inverter shows as below:

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.
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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 Max-3600 3.6KVA MPPT 1
1.4 Overview the inverter
Axpert Max-3600

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:
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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”
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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2. Checking and measuring guide

2.1 Check the battery side components on MAIN board
Fuse and capacitors
For Axpert Max-3600 FUCE 200A
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Parts Attribute Reference values Failure status

F3 Resistor 0.2 ohm Open
For Axpert Max-3600 C11/ C18/C23: (6800uF 63V)

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

Power devices
DC/DC MOSFET: Q58/Q72/Q73 & Q42/Q74/Q59 & Q67/Q36/Q38 & Q31/Q70/Q40
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For Axpert Max-3600 ALL of the MOSFET are

(TOSHIBA/TK100E08N1 214A 80V N BULK TO-220)
Parts Attribute Reference values Failure status
TK100E08N1 Resistor GS: 11.75k Short or explosion
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:
R232/R236/R127/R128/R233/R237/R216/R190
R192/R241/R223/R224//R197/R243/R234/R225 All of the resistors are (22R 1206)
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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 2A 50V 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 Short or explosion
BC: 430k
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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
CE: 8k
Diode BE: 0.65V
BC: 1.5V
CE: 0.28V

The Q52and Q56 are (2SD1624 2A 50V NPN SOT-89)

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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
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
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Diode SD: 0.28V

DS: 1.14V

The U9 is (IC PWM CNTL TI/UC3525ANG 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

2.2 Check the bus side components on MAIN board

Power devices
DC/DC IGBT: Q27/Q28/Q29/Q30

For Axpert Max-3600 ALL of the IGBTs are (IGBT ST/STGW60H65DFB 60A 650V N BULK TO-247)
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Parts 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
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)

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
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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: Q32/D13

For Axpert Max-3600 the IGBTs Q32 is (IGBT ST/STGW60H65DFB 60A 650V N BULK TO-247)
The D13 is (RHRP1560 15A 600V UFST RAD BULK)

Parts Attribute Reference values Failure status

Q32 Resistor GE: 22.8k Short or explosion
GC: 49.5k
CE: OL
Diode CE: OL
EC: 0.393V
D13 Resistor + to -: 195k
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- to +: OL
Diode + to -: 0.39V
- to +: OL

Drivers (This part is only used for repair checking)

The R124 are (10R 1206)

The R125 are (30R 1206)
The D36 are (1N4148W 0.15A 75V SMD)
Parts Attribute Reference values Failure status
R125 Resistor 30 ohm Open or other values
R124 Resistor 10 ohm
D38 Resistor + to -: 40 ohm Short or explosion
- to +: OL
Diode + to -: 0.6V
- to +: OL
Note1: When test the diode; please remove the R124 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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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
CE: OL
Note1: If one or more of them were damaged, please replace all of them.

Drivers
R48/R144/R140/R137: (30R 1206)
R139/R145/R150/R152: (47R 1206)
D5/D6/D12/D16: (1N4148W 0.15A 75V SMD)

Parts Attribute Reference values Failure status

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R48/R144/R140/R137 Resistor 30 ohm Open or other values

R139/R145/R150/R152 Resistor 47 ohm Open or other values

D5/D6/D12/D16 Resistor + to -: 80 ohm 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

ALL of the optocoupler are (TI/UCC23513DWYR 6/SOIC SMD)

Parts Attribute Reference values Failure status
U2/U4/U12 Resistor PIN4 TO PIN5: 0.63V Short or explosion
PIN4 TO PIN6: 0.43V
U1/U3 Resistor PIN4 TO PIN5: 0.63k
PIN4 TO PIN6: 0.52k

2.5 Check BATT and Main Power SPS on MAIN board

BATT Power SPS
The F1 is (FUSE 5A 125V)
The NTC2 is (THERMISTOR NTC 5OHM 5A SCK13055LSY)
The MOSFET Q65 is (IRF640NPBF 18A 200V N BULK TO-220)
The R246 is (RES 3W 0.15ohm)
The TX2 are (TX 2:5:45:3 FER EC28, DMR40 )
The R245 is (RES 3W 0.15ohm)
The D61 are (MUR4100ERLG 4A 1000V UFST RAD TAP)
The D60 are (RHRP860 8A 600V SFST RAD BULK)
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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)

Parts Attribute Reference values Failure status

F1 Resistor 0 ohm Open or explosion
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
R245 Resistor 0.15ohm Open or other
values
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R246 Resistor 0.15ohm Open or other

values
Q65 Resistor GS: 45.51k Short or explosion
GD: 44.6k
SD: 115k
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
TX2 Resistor PIN7 to PIN9: 0.4ohm Short or other
values
TX3 Resistor PIN9 to PIN10: 0.3ohm Short or other
values
D65 Diode + to -: 0.52V Short or explosion
- to +: OL
Note1: When test the Q65; 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 (IXFP7N100P 7A 1000V N BULK 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 10ohm 1206)
The D53 are (1N4148W 0.15A 75V SMD)
The R67 are (RES 1/4W 22ohm 1206)
The D3 are (RHRP860 8A 600V SFST RAD BULK)
The D49 and D57 are (MUR460RLG 4A 600V 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)
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Parts Attribute Reference values Failure status

Q9 Resistor GS: 45k Short or explosion
SD: 300K
Diode SD: 0.52V
SG: 0.73V
Q8 Resistor BC: 356k Short or explosion
BE: 413k
Diode BC: 0.59V
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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 10 ohm Open or other
values
D531 Diode + to -: 0.52V Short or explosion
- to +: OL
R67 Resistor 22 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
2.6 Check AC SPS
The F7 are (FUSE 3A 125V)
The NTC4 are (NTC 10 OHM 3.0A)
The REC3 are (GBU4M 4A 1000V UFST)
The D68 are (RHRP8120 8A 1200V)
The Q20 are (IRFBG30 3.1A 1000V)
The Q14 are (2SC5353BL 3A 750V)
The U12 are (IC PWM UC3845BNG DIP-8)
The TX7 are (TX 26:4:42:27 FER EC28)
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The C86 are (33uF 450V)

Parts Attribute Reference values Failure status

F7 Resistor 0.1 ohm Open or explosion
NTC4 Resistor 11.4 ohm
D68 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
Q14 Resistor BC: 361.9k Short or explosion
BE: 411.6k
Diode BC: 0.598V
BE: 0.611V
U12 Diode PIN5 TO PIN7: 0.492V Short or other
PIN5 TO PIN6: 0.639V values
C86 33uF/450V
Capacitance

2.7 Check the bus soft start circuit (TX1: Especially for 09 fault)
The D6 is (RHRP8120 8A 1200V UFST)
The R29 is (RES 0.62 J)
The MOSFET Q3 is (IRFBG30 3.1A 1000V TO-220)
The D10 and D7 are (MUR4100ERLG 4A 1000V UFST)
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The U2 is (IC PWM UC3845BNG DIP-8)

The TX1 is (TX 55:200:44 FER EEL16)
The R23 is (22R 1206)
The R27 is (1KR 0603)
The R28 is (1.2KR 0603)
Note: If R23 is damaged, please replace U2 together.

Parts Attribute Reference values Failure status

D6 Resistor + to -: 237k Short or explosion
- to +: OL
Diode + to -: 0.458V
- to +: OL
D10/D7 Diode + to -: 0.47V Short or explosion
- to +: OL
Q3 Resistor GS: 1.195k Short or explosion
SD: 4.692k
DS: OL
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Diode SD: 0.535V

DS: OL
R29 Resistor 0.7 ohm Open or other
values
R27 Resistor 0.999K ohm Open or other
values
R28 Resistor 1.195K ohm Open or other
values
R23 Resistor 22 ohm Open or other
values
U2 Resistor PIN7 TO PIN5: 72k Short or explosion
PIN6 TO PIN5: 1.21k
TX1 Resistor PIN2 to PIN4: 2.7ohm Short or other
PIN7 to PIN9: 1.4ohm values
When 09 fault happens, and you couldn’t find other damage, please check TX1!!
2.8 Check the Boost on MPPT board
Power devices
Boost IGBT Q1/Q6 and Diode D1

The D1 is (30DQ60BG 30A 600V TO-247)

The Q1 and Q6 IGBT are (STGW60H65DFB 60A 650V TO-247)

Parts Attribute Reference values Failure status

Q1, Q6 Resistor GE: 18.29k Short or explosion
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GC: 206.1k
CE: 358.7k
Diode EC: 0.389V
CE: OL
D1 Diode + to -: 0.39V
- to +: OL

Drivers
The U1 are (FOD3150ASD SO-8)
The D2 and D13 are (1N4148W 0.15A 75V SMD)
The R12 and R50 are (10R 1206)
The R252 and R7 are (39R 1206)

Parts Attribute Reference values Failure status

U1 Resistor PIN8 TO PIN5: 350.7k
Short or other values
PIN7 TO PIN5: 388k
D2/ D13 Diode + to -: 0.6V
Short or explosion
- to +: OL
R12/ R50 Resistor 10 ohm
Open or other values

R52/ R7 Resistor 39 ohm

Open or other values

Note: When test the diode; please remove the R12/ R50 from the board, or the test result
is not right.
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3. Disassembling guide
Remove 8
screws on top
cover and rear
panel.

Remove LED
cable and LCD
cable, and take
out the Remote
cover.
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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.

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

O/P cables.

Remove the fan

cables.

Remove PV IN
cable
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MPPT NTC and

Converter NTC
and INV NTC

Remove 18
screws on main
board and take
out the main
board
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1.1 Total wiring diagram:

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