Stay Powered Up: Tackling ABB Aurora Power-One Inverter Errors
Who is ABB?
ABB is a Swiss-Swedish multinational corporation that has been a significant player in the energy sector since the 20th century.
ABB's roots trace back to the merger of two electrical equipment manufacturers, Allmänna Svenska Elektriska Aktiebolaget (Asea) from Sweden and Brown, Boveri & Cie (BBC) from Switzerland in 1988. Whilst it was mainly focused on the robotics industry in the 1990s, ABB turned to renewable energy in the 2000s after selling its boiler and fossil fuel operations.
After investing in several US-based companies in the electric vehicle and wireless technology industries, ABB acquired Power-One in 2013 at the boom of domestic solar installations. Power-One was an established innovator of solar inverters, ranging from residential rooftops to utility-grade power plants.
The ABB Aurora Power-One inverters were very popular in residential installations in the early to mid 2010s, however due to the increased competition from China and the increased production across the industry, equipment prices fell sharply. In the UK the average price of a residential solar PV system dropped from £20,000 in 2010 to approximately £7,500 in 2019.
This led to ABB deciding to sell the solar inverter leg of the business in 2019, after sales dropped from $743 million in 2012 to $290 million in 2018. The Italian inverter manufacturer FIMER SpA were the recipients, having operated in the industry since 2007, and acquired it for $480 million.
FIMER experienced its own financial difficulties in 2022, resulting in a bankruptcy filing. This was attributed to shortage of components and raw materials on a global scale, alongside management-related factors. It was then acquired by a UK investment firm in 2023, allowing it to keep operating following a restructure.
Components and Electrics
A solar inverter is made up of various components, each with a specific role in ensuring efficient power conversion and system performance. Key parts include:
DC Input: Connects to solar panels, receiving DC electricity.
Power Inverter Circuit: Converts DC to AC electricity.
Transformer: Changes voltage levels, though some modern inverters are transformerless.
Cooling System: Keeps components cool, either through fans or passive heat sinks.
Display & Control Panel: Shows system performance and allows settings adjustments.
MPPT (Maximum Power Point Tracking): Optimises energy harvest by adjusting the electrical operating point of the modules.
Safety Components: Include disconnect switches, surge protection, and ground fault protection.
These components work together to ensure your solar system delivers clean, reliable energy.
A solar inverter's circuit board is a complex assembly of various electronic components that work together to convert DC power from solar panels into AC power. Here are some key components you'll typically find on the circuit board:
Microcontroller: Acts as the brain of the inverter, managing operations and communication.
Power Transistors: Switch the DC current on and off to create an AC waveform.
Capacitors: Store and release energy, helping to smooth out voltage fluctuations.
Resistors: Control the flow of current within the circuit.
Diodes: Allow current to flow in one direction, protecting against reverse current.
Inductors: Store energy in a magnetic field, aiding in filtering and energy transfer.
These components ensure the inverter operates efficiently and reliably. Over time, inverter components can degrade due to exposure to electrical and thermal stress. Capacitors are especially prone to degradation. Electrolytic capacitors are a common cause of inverter failure because they wear out quickly and are sensitive to temperature. High current can increase the inverter's operating temperature, which causes the electrolytes to evaporate and the capacitors to wear out. Environmental factors like extreme heat, humidity, and dust can also accelerate these issues with your inverter.
ABB Aurora Power-One Inverters will be prone to these failures, as they are some of the earlier models to be installed in UK domestic solar PV systems. While solar panels typically have a performance output guarantee of around 25 years, inverters tend to last around half this time frame, between 10 and 15 years. This is due to the internal components such as the electrolytic capacitors, which are prone to wear and tear at a much more rapid rate.
Aurora Power-One Inverter warranty was generally 5 years, with the option to extend this to up to 20 years.
Aurora Power-One Error Messages
E002
The inverter is measuring too much voltage from the solar panels. This could be a problem with the solar panels.
E010
This error code indicates low voltage input to the solar inverter. This can be caused by faulty solar panels, wiring issues, or inverter malfunction.
E017
This error code indicates a startup timeout issue with the solar inverter, often occurring during low irradiance conditions (early morning, evening, or cloudy days). This might be a temporary issue as the inverter waits for sufficient sunlight to fully start.
E025
This error code indicates a leakage current detected on the DC side of the solar inverter. It could be caused by a ground fault in the solar panel array, wiring issues, or a malfunction within the inverter itself. This may require a solar system health check to test the DC wiring.
E031
This indicates that the inverter has a relay failure and is unable to read incoming voltage. This is a terminal fault and means the inverter will need to be replaced.
You can also check the AC cable connection and the grid voltage and connection on the inverter. If the voltage is outside the tolerance range, you can contact your utility grid supplier.
Which Aurora Power-One Inverter do I have?
There are different models and sizes of the ABB Aurora Power-One Inverter range:
PVI-2000
PVI-3600
UNO-2.0-I
UNO-2.5-I
PVI-2000-OUTD
PVI-3.0-OUTD
PVI-3.0-OUTD-S
PVI-3.6-OUTD
PVI-3.6-OUTD-S
PVI-4.2-OUTD-S
PVI-4.2-OUTD-S
PVI-5000-OUTD
PVI-5000-OUTD-S
TRIO-5.8-TL-OUTD
TRIO-7.5-TL-OUTD
TRIO-8.5-OUTD
PVI-10.0-TL-OUTD
PVI-12.5-TL-OUTD
TRIO-20.0-TL-OUTD
Swapping vs. Repairing: Why Replacing Your ABB Aurora Power-One Inverter Might Be More Affordable
There are two main reasons why homeowners often opt to replace their entire inverter rather than repair individual parts when failures occur. An ABB Aurora Power-One Inverter replacement might be the best solution for your solar generation issues.
Firstly, inverter parts typically are not covered under the standard warranty. These warranties usually focus on the entire inverter unit, and once it is expired, replacing a single faulty component can be expensive. Acquiring the specific replacement part might be difficult and may not be much cheaper than a new inverter, especially for older models.
Secondly, troubleshooting and replacing specific parts within an inverter requires qualified technicians and specialised tools. The labour cost associated with such repairs can be significant, especially compared to the price of a new inverter that comes with a fresh warranty.
In many cases, the cost-benefit analysis favours replacing the entire inverter. This ensures a reliable system with renewed warranty protection and avoids the potential risks of a repair not being entirely successful.
Having been established in the industry for over 14 years, Atlantic Renewables is well-accomplished with both new and older solar manufacturers such as ABB, and other inverter and battery products that may no longer be on the market. We can provide guidance and expertise for your ABB Aurora Power-One inverter, and what your next steps are for getting your solar system back up and running. Don't hesitate to get in touch if you have any questions or need further assistance.
