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FranklinWH•aGate

Analysis by Marcus & Team

FranklinWH aGate: Error 6012 DC Bus Overvoltage

Troubleshoot FranklinWH aGate Error 6012: DC bus overvoltage. Identify causes, solutions, safety protocols & expert tips for residential ESS.

Frequently Asked Questions

•What is the maximum DC input voltage for the FranklinWH aGate?

Refer to the FranklinWH aGate datasheet for the maximum DC input voltage specification. Exceeding this voltage can damage the inverter and void the warranty.

•How do I perform a rapid shutdown on the FranklinWH aGate system?

Locate the rapid shutdown switch (RSD) near the inverter or PV array. Activate the switch to disconnect the PV array from the inverter, reducing the DC voltage to a safe level in accordance with NEC 690.12.

•Where can I find the latest firmware updates for the FranklinWH aGate?

Visit the FranklinWH website or contact their technical support team to download the latest firmware updates. Follow the manufacturer's instructions for installation.

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Marcus leads the technical research department at Storage Faults. Together with a team of systems analysts, he specializes in translating complex solar storage error codes into actionable diagnostic steps for the US market.

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Important Warnings:

High DC voltage is present in the FranklinWH aGate inverter system. Disconnect all power sources before performing any maintenance or troubleshooting. Only qualified electricians should work on this equipment. Follow all applicable NEC codes and manufacturer's safety guidelines. Arc flash hazard exists. Wear appropriate personal protective equipment (PPE), including arc-rated clothing, gloves, and eye protection.

Why This Happens:

Incompatible PV string configuration resulting in exceeding the maximum input voltage specification of the inverter. (Refer to the FranklinWH aGate datasheet for voltage limits).
Battery overcharge due to a malfunctioning battery management system (BMS) or incorrect charging parameters.
Grid voltage surges or instability causing feedback into the DC bus during grid-tie operation.
Failure of the DC bus capacitor bank, leading to voltage ripple and potential overvoltage spikes.
Software or firmware glitch causing erroneous DC bus voltage readings or incorrect control actions.
Damaged or improperly connected DC combiner box resulting in voltage spikes.

Technical Overview:

The aGate inverter uses a DC bus to regulate voltage levels during power conversion between PV array, battery, and AC grid. The DC bus voltage is maintained by sophisticated power electronics and control algorithms (MPPT, DC/DC converters). Overvoltage protection is a critical safety feature. The inverter's firmware monitors the DC bus voltage and triggers a fault (Error 6012) when the upper limit is exceeded, preventing damage to components. The DC bus voltage depends on PV input, battery SOC and charging state, and grid conditions.

Recommended Action:

1

*Safety First**: Ensure the PV array is disconnected using the DC disconnect switch. Verify proper rapid shutdown functionality according to NEC 690.
2

Use a calibrated multimeter to confirm zero voltage on the PV input terminals before proceeding.
3

*Check PV String Configuration**: Verify that the PV string voltage and current are within the aGate's specified limits using a clamp meter and multimeter. Consult the FranklinWH system manual for correct string sizing.
4

*Inspect Battery Voltage and SOC**: Use the FranklinWH monitoring app or a compatible battery diagnostic tool to check the battery voltage and state of charge (SOC). If the battery is overcharged, investigate the BMS functionality and charging parameters. (Qualified technician).
5

*Evaluate Grid Voltage**: Monitor the AC grid voltage using a power quality analyzer. Check for voltage surges or instability that may be contributing to the DC bus overvoltage. Correct any grid-side issues before resuming operation.
6

*Inspect DC Bus Capacitors**: Visually inspect the DC bus capacitors for signs of bulging, leakage, or other damage. (Qualified technician only - high voltage hazard!).
7

*Update Firmware**: Ensure the aGate inverter has the latest firmware installed. Check the FranklinWH website for updates and follow the manufacturer's instructions for system.
8

*Contact FranklinWH Support**: If the problem persists, contact FranklinWH technical support for further assistance. Provide them with the fault code, system logs, and any other relevant information.

What to Look For:

The FranklinWH aGate hybrid inverter displays Error 6012, indicating a DC bus overvoltage condition. The system may shut down or reduce power output. Monitoring app displays abnormal DC bus voltage readings exceeding the manufacturer's specified limit (typically above 450V).

Expert Tip:

Access the FranklinWH aGate service menu (consult the service manual) to view real-time DC bus voltage readings and error logs. Compare the readings with the expected values to identify the source of the overvoltage. Note any abnormal fluctuations or spikes in voltage.

Prevention:

Regularly monitor PV string voltage and current using the FranklinWH monitoring app or a compatible monitoring system.
Periodically check the battery voltage and SOC to ensure proper charging operation.
Implement surge protection devices (SPDs) on both the AC and DC sides of the system to protect against voltage surges.
Schedule routine maintenance checks by a qualified technician to inspect the system components and ensure proper operation.
Keep firmware updated to ensure you have the latest features, security patches, and bug fixes.