How to Inverter Charger Repair?

How to Inverter Charger Repair?

This article will discuss How to inverter charger repair. The process will address everything from finding the source of the issue to fixing broken parts.

Diagnose the Problem

Identifying the issue with an inverter charger requires a methodical approach to diagnosis. Here are the measures to take:

Verify that the battery inverter/charger switches on. If it does not power up, ensure the switch is not turned off.

Check the inverter charger’s condition to ensure it hasn’t sustained any physical harm. Examine the batteries for signs of damage, such as leakage or swelling.

Use a voltmeter to check the AC voltage sent into the inverter charger. If it’s less than 90VAC, investigate the source for insufficient power or faulty wiring.

Use a multimeter to examine the battery’s voltage. Low voltage indicates a need to charge or replace the batteries.

During starting, disconnect the inverter’s loads and check the battery voltage at the inverter’s input terminal. If the input voltage is above 16V, ensure the charging equipment sends a voltage over 16V to the battery. In such a case, take the device away from the battery.

Verify if the inverter charger’s surrounding temperature is above 104 degrees Fahrenheit. If that’s the case, the inverter charger must cool down, thus turning off the loads.

Inspect all DC and AC cables for signs of wear and abrasion. If broken, get a replacement and make sure strain reliefs and cable protection are in place.

The AC cover plate of the inverter charger must have all of its terminal block connections double-checked and tightened.

Gather the Necessary Tools and Equipment

The tools and parts required for fixing an inverter charger are as follows.

A Multimeter –

the ability to evaluate potential, present, and resistance

Soldering iron –

to diagnose and fix broken parts

Solder –

connecting parts

Wire cutters –

to adjust the length of the wires

Wire strippers –

to strip wires of their insulation

Screwdrivers –

for the inverter charger’s on/off switch

Fuses, capacitors, and diodes (if required) are examples of components that may be replaced.

Some suggested implements and gadgets are as follows.

Electronic Multi-Meter

such that precise readings of voltage, current, and resistance may be obtained

Adjustable temperature soldering iron –

to fine-tune the soldering iron’s temperature to the specifics of the soldered parts.

Shrinkable tube by heat –

to keep cables safe from the elements

Pliers –

During soldering, components need to be held in position.

Pump/wick desoldering system –

to clean up the soldering

Signal generator –

to provide diagnostic signals for use in identifying problems.

Open the Inverter Charger

These are the procedures to disassemble an inverter charger:

Disconnect power:

Disconnect the inverter charger from any DC or AC power sources.

Get rid of the AC’s cover:

Take the AC cover off by unscrewing the screws holding it on. Most inverter chargers have the AC cover on the front or the top.

Inspect the inside of the inverter charger:

You can inspect the inverter charger’s inner workings for damage by removing the AC cover. When opening the item, please refer to the manual provided by the manufacturer.

When working on an inverter charger, follow all necessary safety procedures. To prevent harm or damage to the item, it is imperative that you always follow the manufacturer’s recommendations and turn off the power supply.

Inspect the Components

The next step, after disassembling the inverter charger, is to check its parts for wear and tear. Some parts to look for are:

Fuses –

Ensure that no fuses have blown. If a fuse is blown, replace it with another fuse of the same amperage rating.

Capacitors –

Look for swelling or leakage in the capacitors. If a capacitor fails, install a replacement with the same capacitance and voltage rating.

The Diode –

Look for evidence of wear and damage on the diodes. Measure the diodes’ reverse polarity and continuity using a multimeter. In the event of a malfunctioning diode, use a replacement of the same kind and wattage.

Transformers –

Look for wear and damage on the transformers. Make sure there is continuity and resistance between the main and secondary windings. If a transformer malfunctions, install a new one of the same kind and rating.

Wires and connections –

Inspect the sturdiness of the wiring and the integrity of the connections. Check for any damaged or loosened cables or connections. Repair or replace any damaged wires and connections.

Batteries –

Battery life and condition should be checked. Each battery’s voltage may be measured using a multimeter.

Replace Faulty Components

Some of the inverter charger’s parts are broken and must be replaced after a thorough inspection. The following are instructions for replacing malfunctioning parts:

Identify the faulty component:

To figure out which of the components is malfunctioning, use your multimeter.

Remove the faulty component:

Get out your soldering iron and get rid of the broken part. When soldering, make sure you strictly adhere to all manufacturer guidelines.

Replace the faulty component:

Substitute a replacement part of the same kind and rating for the broken one. Connect the new part to the board using a soldering iron.

Test the inverter charger:

After you have repaired the inverter charger by replacing the broken part, you should test it to ensure it functions correctly. Check the inverter charger’s output using a multimeter. If the results are reasonable, put the unit back together and give it another go.

If you need to replace a defective component, do it carefully and follow the manufacturer’s guidelines. A qualified technician or the product manual should be consulted if you have doubts about replacing a part. It may also be impossible to have your inverter charger fixed if replacement components aren’t readily accessible. 

Test the Inverter Charger

To test an inverter charger, follow these steps:

  1. Apply battery power to the inverter by engaging the fuse, switching the breaker on, or switching the battery disconnect switch to the ON position.
  2. Turning off the main breaker or each breaker will disconnect all AC loads from the panel.
  3. The inverter charger’s power switch must be turned on. Make that the inverter powers up and the indication light is glowing bright green (ON).
  4. Plug a 25W light bulb into the inverter’s output after turning it off. When you turn on the inverter, you should see the light turn on and shine properly. A low AC output will result in a dimmer light. If you set up the remote, you can see the precise results. The “INV” icon in the bottom left corner of the remote’s screen should show when the inverter is in Inverting mode.
  5. The inverter must be turned back on. Inverter chargers need utility or generator-generated AC shore power. The inverter/charger will click after about 10 seconds, allowing the incoming power to flow through and lighting up the bulb. The inverter’s status light will be illuminated in green. The inverter’s CHR mode status should be shown on the remote control.
  6. Make sure the voltage of each battery is the same (load test the ones with a value below 12.0V).
  7. Verify the input voltage to the inverter using a multimeter. If the reading is under 10V, check the battery and the wire gauge to ensure it’s adequate. You should use a higher gauge wire if the current one is too tiny.

Close the Inverter Charger

To shut off an inverter charger, do the following actions:

Shut off any DC and AC sources connected to the inverter charger.

Reattach all of the inverter’s AC and DC wires. Make sure there isn’t any AC or DC voltage by using a meter.

Put the AC plate back in place and fasten it with screws.

Put the AC cover back on and fasten it with screws.

Reattach the battery to the charger for the inverter.

Make sure the inverter charger is operating correctly by giving it a test. To test the inverter charger’s output, use your multimeter. You may shut down the device and test it again to see whether the output satisfies the manufacturer’s criteria.

When shutting off an inverter charger, it’s crucial to adhere to the manufacturer’s recommendations and take safety measures. Seek advice from an experienced technician or reference the manufacturer’s literature if you are unclear on how to shut the unit.