Replacing and Testing Components on WS

MPPT Module: 

If you suspect your MPPT module of not working, there is a test to verify that it is indeed the MPPT module at fault. The first is all about observing the WaterSecure screen over time, specifically the “Total Energy Generated”. You want to see the KWh’s going up throughout a sunny day. An important note is that the KWh’s only go up if solar inversion is occurring, and if there is a load  discharging the batteries. The KWh's will stay the same if you’re using AC to charge the batteries, or if there is no load on the WaterSecure unit. If there is no change on the KWh’s over time, it is likely that the MPPT module has gone bad. To replace it, follow the below instructions.

MPPT Module Swap (Before beginning, power down inverter, Switch DC Disconnect to OFF, Disconnect Battery Circuit, Wait 20 Minute before beginning)

1. Remove Gray faceplate. There are six Phillips heads, three running up each side. Remove the bright finish allen screws on the front cover, two on the top and two on the bottom.

2. The faceplate has some ribbon cables. Take them off and set the faceplate aside, if desired. The face plate does not need to be disconnected but a second set of hands would help or a way to hold and support the faceplate while work is being done in a mounted position.

3. Once out of the way, the right side panel can be removed. There are additional Phillips head(4) screws.

4. Removal of the panel will grant access to the MPPT Module. There are two connectors: one two-pin connector on the top and a four-pin connector on the side. Use a pick or fine point razor to get under the red adhesive and lift it off so excess tension isn’t imparted during removal to prevent connector damage.

5. Next remove the + and - cables that lead to the battery. These are located on the outboard side on the bottom and are removed with a 7mm socket.

6. Next will be removal of the solar input wires. Give the Molex terminal strip a little more freedom of movement by loosening the two right most of the three flat head screws. This will allow a flat head to be inserted on the back terminals to remove the final bit of wiring.

        

7. The final step of removal is taking out the four screws that affix the MPPT module to the inverter frame. After that, installation is the opposite of removal. We will need the MPPT module back to complete our RMA process. If you didn’t get a return label for it please email [e-mail]

Control Module component: 

 There is no single issue that can be tested on the WaterSecure Control Module. Essentially, the control module is the motherboard, the main controlling unit of the WaterSecure and governs everything the inverter does. Because of this, it means that in the very rare case that it needs to be swapped out, the issues with it are so varying, it’s impossible to give a suggestion on troubleshooting it. Our best suggestion is if you are having an issue with the WaterSecure operation, to always call the RPS Support Engineers. 

Control Module Swap(Before beginning, power down inverter, Switch DC Disconnect to OFF, Disconnect Battery Circuit, Wait 20 Minute before beginning)

1. Remove Gray faceplate. There are six Phillips heads, three running up each side. Remove the bright finish allen screws on the front cover, two on the top and two on the bottom.

2. The faceplate has some ribbon cables. Take them off and set the faceplate aside, if desired. The face plate does not need to be disconnected but a second set of hands would help or a way to hold and support the faceplate while work is being done in a mounted position.

3. Now that the cover is removed, it doesn’t hurt to check and see first if there is anything obvious that could point to the problem before continuing, such as a loose connector.

4. The control and relay modules are front and center behind the face plate. The Control Module communicates with all the other modules. There are 12 connectors. Fortunately most of them are unique to their wire length, number of wires on the connector or the type of connector. An image of the control board is shown below along with a key to ensure a proper reassembly.
   
   
    

1	MPPT Module Connector	Ye/Rd/Bu/Bk to MPPT module
2	Fr. Display LED	Wh 1x4 Pin to front cover
3	Dry Contact Connector	Bk/Rd/-- to green connector bottom of inverter
4	Load Center Harness	Wh 1x6 Pin to relay board
5	Txformer Temp Sensor	Bk/Bk to Transformer
6	MOSFET Temp Sensor	Bk/Bk to MOS Drive Module below main board
7	Com Board Sw1 Connector	Rd/Bk to Com board bottom of inverter
8	Aux Fan Connector	Rd/Bk/Ye to fan on bottom of inverter
9	Inverter Power Switch	Ye/Bk to On/Off switch on bottom of inverter
10	Load Center Connector	Rd/Bk to relay board
11	Com Board Harness	Gy 2x8 Pin to Com board bottom of inverter
12	Txformer Harness	Bk 1x8 Pin to MOS Drive Module below main board

5. The connectors have an adhesive to prevent them from working themselves loose. Use a pick or fine point razor to get under the red adhesive and lift it off so excess tension isn’t imparted during removal to prevent connector damage.
6. Once the connectors have been removed from the main board locate the four Phillips head mounting screws and remove them to remove the board from the heat heat sinks it is mounted to.
7. Insert the new board by pulling the wires to the side to allow it to be inserted and reinstall the mounting screws into their proper location, usually denoted by the image of a screw printed on the circuit board.
8. Plug the connectors back into their respective locations using the image and table above as your guide. Re application of the adhesive is not necessary.
9. If you have removed the connectors from the LCD display, reinsert them and return the front cover to its installed position on the inverter frame. Get all the fasteners threaded to loosely fit the front cover in place and then go through one more time to give them a final tightening.

Power Switching Module

All WaterSecure models have an internal control for switching between the various power sources. In the 3k and 6k WaterSecure, the powering switching module is on the main motherboard. In the 12k WaterSecure models, the switching modules are on a whole separate board. In very rare cases these units require a circuit board swap. Issues with getting power in from solar or AC to charge the batteries are the main symptom of needing to swap this board, We’ve seen this occur from generators faulting out and sending a very large surge of power to the unit. 

Power Switching Module Swap (Before beginning, power down inverter, Switch DC Disconnect to OFF, Disconnect Battery Circuit, Wait 20 Minute before beginning)

Step 1: Remove Gray faceplate. There are six Phillips heads, three running up each side. Remove the bright finish allen screws on the front cover, two on the top and two on the bottom. The faceplate has some ribbon cables. Take them off and set the faceplate aside, if desired. The face plate does not need to be disconnected but a second set of hands would help or a way to hold and support the faceplate while work is being done in a mounted position.

Step 2: The module in question is in the middle, pictured below with a red square around it. We will start by taking a photo of the circuit board as it is, just to ensure we’ve reconnected everything back as it was at the end. 

Step 3: The first wires you remove are brown, black and then the green and yellow ground wire. Remove the brown and blue wires, then remove the three remaining wiring harnesses. The last thing to do is to unscrew the 4 small screws that are holding the board in place. To help you locate them, there is an image of a screw printed on the board next to the screws that is pictured below.

Step 4: There are still quite a few wires from other boards, but now you can simply slide the board out from under them. The replacement board is pictured below. The last step is to do the reverse of the wiring from the above steps. Don’t forget to screw the 4 screws to hold the board back in place, give a gentle tug on all the connections to make sure they’re tight. With the new board now installed, it is safe to re-energize the system.