Xantrex SW4024 schematics for parts available ?

Added Category: Advanced Solar Electric Technical Forum - Content was added: 15 10 2011 Sat, 15:06:51 - Author: HalisTurk
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Hi All - I just picked up a Xantrex SW4024 to convert my existing single Trace SW4024 120V setup to a stacked 240V setup. That old Trace has been going solid for 12 years, hasnt skipped a beat. I got Xantrex for a steal with the caveat that the seller didnt know if it was working or not ... Sure enough, its not working. I apply 24V to it, and the LCD just displays a top row of dark blocks, bottom row is black, and no LEDs on at all. With 120V into AC Hot IN 1, theres nothing being switched
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Xantrex SW4024 schematics for parts available ?

Hi All -

I just picked up a Xantrex SW4024 to convert my existing single Trace SW4024 120V setup to a stacked 240V setup. That old Trace has been going solid for 12 years, hasn skipped a beat. I got Xantrex for a steal with the caveat that the seller didn know if it was working or not ...

Sure enough, its not working. I apply 24V to it, and the LCD just displays a top row of dark blocks, bottom row is black, and no LEDs on at all. With 120V into AC Hot IN 1, theres nothing being switched to the AC OUT. So I pulled off the cover to start looking around.

Its definitely been mistreated. The mounting flanges are bent, and the AC board is actually LOOSE, having snapped off the corners of the muffin fans. I get the feeling someone took off the back of a truck and went "OMIGAWG its HEAVY!" and dropped it.


(Click for higher-resolution image)

There is also a coiled cable there with a gray connector on it that comes from the control board - that doesn seem to be in my older Trace SW4024. Any idea what thats for ? I haven pulled the AC board completely, but from eyeballing it, it seems to be OK. Hopefully.

The control board though - that has a blown diode, D12 on the upper right of the component side. I think transistor Q6 next to it is OK, but can be sure.



(Click for higher-resolution images)

The Control board is PN 110-0066 rev 8 from 06/12/14. Does anyone have the schematics for it ? Or do you know what the diode is ? Looks like a typical small meaningful diode, and since its accessible should be easily replaceable. I would much rather attempt the repair here myself before heading to an Authorized Service Center to spend at least $800+ on a new control board ...

Thanks -

Dean.

you do realize that bad parts aren always going to be easily identified as not all will be blown apart. if you fix this then you can consider yourself lucky.

Yeah, I know. Wishful thinking, but who knows, meanwhile Ill save $800+ :)

D.

That looks like a Zener diode protecting the communications channel likely a 5v Zener and it would only blow like that from being way over driven buy some form of surge. The bad news is if the Zener failed then the surge got through into whatever the diode is protecting likely frying it as well.

Yeah - chances are if it was in circuit as a typical zener it was shunting excess voltage to GND. Since it blew, there is/was no path to GND, and all the excess voltage went on through the circuit.

Nothing else looks suspicious though - no burn or browning marks that I can see without dismounting the main control board. Anyway, its a cheap and easy fix to test, and if it doesn work, nothing lost but a $0.04 diode ... The control board will have to be replaced anyway.

Couple of typical choices if its a 5V ...

1N4688 4.7V
1N4733A 5.1V
1N5523 5.1V
1N4690 5.6V

Any ideas whats supposed to be there ?

Thanks -

D.

Any luck anyone ? No-one has the schematics ?

Thanks -

D.

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