Analysis by Marcus & Team

FranklinWH aGate: Scorched Smell Diagnostic

Diagnose a scorched smell from a FranklinWH aGate hybrid inverter. Focus on safety, troubleshooting, and NEC compliance. Qualified electrician required.

Frequently Asked Questions

•What is the DC voltage of the PV array?

Important for assessing potential DC overvoltage issues.

•Are there any recent changes to the PV array configuration?

New panels, string additions, or wiring modifications can cause imbalances.

•What is the ambient temperature around the inverter?

High ambient temperatures can contribute to overheating.

Critical Safety Precautions:

The FranklinWH aGate operates with high DC voltages (up to 600V+). Always disconnect both AC and DC power before performing any inspection or maintenance. Arc flash hazards exist. Only qualified electricians with proper PPE should work on the inverter. Failure to follow safety procedures can result in serious injury or death. Verify system is fully de-energized before proceeding.

Recommended Action:

1

Disconnect AC power to the aGate at the main breaker panel. Ensure the breaker is properly labeled and locked out.
2

Disconnect DC power to the aGate. Follow the manufacturer's rapid shutdown procedure and verify voltage is 0V using a calibrated multimeter. Refer to NEC 690.12 for rapid shutdown compliance.
3

Visually inspect the aGate unit for any signs of physical damage, such as bulging capacitors, burn marks, or melted components.
4

Using an infrared (IR) thermometer, scan the internal components of the inverter (after verifying it is de-energized) for hot spots. Compare temperature readings with manufacturer specifications.
5

Check all wiring connections for tightness and corrosion. Use a torque wrench to ensure connections are within the manufacturer's specified torque range. Look for signs of heat damage on wiring insulation.
6

If visual inspection reveals damaged components, replace them with manufacturer-approved replacements. A qualified electrician must perform this task.
7

After repairs, re-energize the system and monitor its performance. Check for proper voltage and current readings using a clamp meter and multimeter. Ensure the cooling fan is operating correctly.

Possible Causes:

Component Failure: Overheated or failed capacitors, inductors, or semiconductors (IGBTs/MOSFETs) within the inverter.
Overload Condition: The inverter is consistently operating at or above its rated power output.
Inadequate Cooling: Blocked vents, failed cooling fans, or a thermally stressed environment preventing proper heat dissipation.
Loose Connections: Loose wiring connections creating resistance and heat, particularly in high-current DC circuits.
Battery Overcharge: Malfunctioning Battery Management System (BMS) causing battery overcharge, leading to off-gassing and potentially a burning smell.
Arc Fault: Undetected DC arc fault within the unit, caused by damaged insulation or loose connections.

What to Look For:

A distinct scorched or burning smell emanating from the vents of the FranklinWH aGate hybrid inverter unit. This indicates overheating and potential component failure.

Technical Overview:

The FranklinWH aGate is a hybrid inverter system responsible for DC/AC conversion, battery management, grid synchronization, and providing backup power. Internally, it contains high-power semiconductors (MOSFETs, IGBTs), capacitors, inductors, and transformers. Overloading, component aging, or inadequate cooling can cause these components to overheat and release a burning odor. The system monitors voltage, current, and temperature via a Battery Management System (BMS) and internal sensors.

Preventative Care:

Regularly inspect the aGate unit for dust and debris buildup, cleaning vents with a vacuum as needed.
Monitor inverter performance via the monitoring app, paying close attention to power output, temperature, and fault codes.
Ensure adequate ventilation around the inverter, avoiding direct sunlight and obstructions.
Schedule periodic system checks by a qualified technician, including battery capacity testing and BMS calibration.
Keep the inverter firmware up to date to ensure optimal performance and safety features.