Inverter Repair Whistler Pro-1600W Part 1 - Disassembly + Diagnosis

I decided to record how I went about repairing this particular inverter. Some are repairable and some are not, but most all of them take a lot longer to fix than you might think to do it correctly.
Watch and find out if I was successful or not on this one!

[@shadowwolf225]

I know this is probably way too late but this is a JCS640C N channel mosfet from JILIN SINO-MICROELECTRONICS. The datasheet for it is here: pdf1.alldatasheet.com/datasheet-pdf/view/410934/JSMC/JCS640C-O-C-N-B.html Also, I'd like to add another vote for more repair videos like this, repetitive or not this is great information.

[@knurlgnar24]

Wow, thanks for finding the part number!

[@Charliemmafan]

Could you do a complete review video on the 5 newest Harbor Freight Jupiter Inverters? I'm most interested in the 2,000 watt model but I'm also interested in the 1,500 watt and 3,000 watt models but I would also like to learn about the 1,000 and 5,000 watt models also, let us know if they're worth the money, if there's any improvements made since they were sold as Centech and Chicago Electric before that? if they put out the advertised wattage or not? what's the resting power they use under no loads etc? And if any in your view would be decent or worthwhile for fairly small off grid applications to run a TV, low wattage Microwave, small portable water cooler, charge phones, tablets, computers etc. Thanks!

[@wadesmith9483]

You could re-create the aerospace circuitry in like 1 second boom! Dang I bet you get all the hottest chicks. Your so awesome and really humble too man. You never critic anything you didn’t make yourself. And Ha, as obviously you know you built 95.3% of all electronics. Keep it up oh great one!

[@FroggieTheR0gue]

Exactly, when people do crap like that they usually only tell a few other people, so if something goes wrong there is a very short list of suspects and now I'm on it. Plus with the hydroponic people, I'm one of the few friends they have that doesn't smoke weed, this means that everyone else they've told is on drugs for the most part, drug addicts can't keep their mouths shut. If you want to get away with anything you can't tell anyone, remember, it's only a secret when only 1 person knows.

[@knurlgnar24]

Most people don't get why I like inverters and I admit I don't get it myself. Inverters don't really do anything interesting but for some reason I can't get enough of them! Thanks for the support. The next videos in this short series are already recorded and will be uploaded soon.

[@k7iq]

Then there are inverter/chargers that go both ways... A bit more difficult but no less interesting. Thanks for the video on this one !

[@beageek2]

Please supply more repairs like this, please. I find the diagnostics and repair very interesting. -BAG2

[@knurlgnar24]

Thanks for the feedback. I had stopped doing repair videos like this because I thought they would be too repetitive.

[@acklan3]

I agree. For the hobbyist we learn something new from each of your videos. Even if you do not realize it. Great videos by the way.

[@polarunion]

You made this 4 years ago and it's become so relevant to me today. Thanks for the lessons.

[@kf7tkj]

I share your love of inverters! Keep up the great videos!

[@jaguarking11]

I have to say, You love inverters. Awesome hobby. Looking forward to seeing the next video on this inverter.

[@guillermoiturriaga7863]

I like your multimeter... :3

[@hoagybob]

Super helpful video! Thanks for making.

[@edwardnundahl4886]

I have a 1600 whistler that is older but built much better with outstanding heatsinks that i pick up for free and went through. It handles 1300 watt continuous with no problems. I thought that your model would be improved but looks much cheaper built.

[@kwoods3379]

Where do you get those broken inverters?

[@OneCoolDude08]

Whistler makes the best dag gum inverters ever to grace the face of God's green earth! I'm not an employee of theirs, nor did they pay me to say that. But I have undying loyality to them because I won a free flashlight from them in a Facebook contest. They sent it in green, my favorite color, how cool is that?

[@faffaflunkie]

I used to Charge a Deep Cycle Battery in a Vehicle- To use for General Lighting purposes around the House/Garage. However this turned out to be a bad Idea as the Inverters- Most Chinese "No Name" Brands- Also "Maxx Power", "Traveler's Power", "Coleman" (The Gas Lantern People)- ALL burned out after several hours of continuous use over 100w. The "Maxx Power" 800w unit ALWAYS would shut off if used with more that a few hundred watts. My Energy Conservation attempt was Undermined by Chinese Junk.

[@faffaflunkie]

What Brands are any good? I picked up all of my MSW units for almost nothing (After Rebates) and they are ALL the same save for wattage. They MAY power a Laptop or Cellfone charger but usually burn out when powering anything that draws much over 75 watts- Like Electric Blankets, Space Heaters and Video Monitors. The most amusing thing is that they all seem to be based around the 555 timer from 40 years ago. I can't believe a sinewave unit is so hard to make- It's Basically just a 170v Amplifier.

[@AlexanderPresident]

And yes, now you are on their Shit List, if something goes wrong with their little ''business'', they will immediately think of you, among other people they told about what they are doing, so its basically like a family business, if the girlfriend knows about that too lol

[@faffaflunkie]

All the "Modified Sinewave" Inverters are both Crap and Pretty much the same. They predate CFL's, Laptops, Cellfones etc. They are meant to drive 120v Incandescent lights and not much else.

[@Dc_tech386]

Exactly I can’t use mosfets for output that really bad design mosfets can’t handle high output only igbt can the mosfets will allow burn out i igbt it’s the best and I don’t see a gate drivers at all making the mosfet burn very quickly

[@knurlgnar24]

IGBTs are used for high voltage high current applications given their BJT behavior instead of resistance based behavior. For 120V output inverters they generally aren't an optimal technology. For 240V applications they start to make sense but only for higher amperage designs.

[@swedensy]

My mosfets keep blowing out after each replacement, now looking for WHY THEY KEEP BLOWING OUT. AAAAAAAGHHHHH BEFORE I BLOW TOOO; SO MUCH TIME INVESTED AND EFFORT

[@Marc_Wolfe]

I see this is old, but i hope you can reply. I have a faulty inverter, too. I wire it up and it stays on for about half a second, whether there is load or not. I was testing it with an angle grinder; for the half second, it will run as well as it would with mane line power. Any advice for where to start? It's a Xantrex Xpower 1750 plus. A cheap model from what I can tell; it looks to have the same insulator strips for all it's mosfets, without any paste on either side. Nothing looks burnt, no burning smell, nothing obvious. Unfortunately I don't have a multi-meter. Any advice appreciated.

[@faffaflunkie]

No- DO NOT tamper with an Electric Meter. It's a Misdemeanor punishable by up to Six Months in Jail and a $500.00 fine.

[@AlexanderPresident]

No it does not matter now, you can keep her blocked just as well, who cares now she can remove her comments anyway

[@JahanZeb1976]

Excellent tutorial on inverter repair dear friend. What I am proposing for output transistors could be IRF730.

[@Nkokaran]

I just got me a used Samlex power1500wt inverter , and connected it to a single 12v Battery , very light goes on for 3 second and goes off, will somebody tell me what 's wrong with the inverter. thank you all

[@knurlgnar24]

I do wish MSW inverters would die - there's really no reason for them to exist. But there are 'high quality' MSW inverter out there if you look for them. I don't own any and don't work on them because if I'm going to spend that kind of money I'm getting a sine unit.

[@knurlgnar24]

You've had really terrible luck with MSW products. I've never had even the cheapest ones burn out on purely resistive loads even when stress testing. (Assuming proper assembly from the factory) Pure Sine is fairly easy to make, but MSW is slightly cheaper hence the number of MSW vs Pure Sine. Also, I have never seen a 555 based unit - that would be more expensive than necessary. What brands have you tried?

[@mikerama4724]

I found this inverter in the dump so I figured it’s a fun project for the weekend I’m a hobby based interest in electronics, I followed your process until I dawned on me all the fuses ere missing? Lol the inverter shows no sign of being worked on so I assume it was shipped in this condition. Talk about quality control

[@knurlgnar24]

That's funny! Maybe it didn't work and someone took out the fuses to use in their car? Either way I hope it fires up for you when you replace the fuses! Note that you will need to replace all of them or it won't turn on properly.

[@mikerama4724]

@@knurlgnar24 thanks for the advice, looking for a circuit diagram now for fuse sizes. Odd thing was the case appears to have never been opened and to reach the fuses is a bit of a pia. I’m hoping the fuses solve the mystery.lol.

[@AlexanderPresident]

So what is he saying? Did it happen to him to? Did they cut off his energy supply?

[@ajw6715]

So sorry! The replacement mosfet is IRF640N. The P on some stand for Power mosfet. No such thing as a P channel IRF 640 mosfet. Sorry!

[@knurlgnar24]

I'm honestly not very familiar with battery isolators as I've never personally used one. I'd just wire the batteries together myself as it has the most benefit and is most flexible, but the 'idiot proof' way to do it is to use an isolator and I cannot argue with that installation method. Another argument might be: You bought yourself an nice isolator so you might as well use it. :)

[@carlos_sacalul]

Hello. What can I do if I applied 230v on its 230v output? Do you think there is any chance to do something with it?

[@knurlgnar24]

There are arguments on both sides for the isolator vs. no isolator. I have an opinion but I won't comment as it is preference. I do believe that Noco uses a diode setup so make sure you connect the sense wire of the alternator correctly or both batteries will end up charging at too low a voltage and be damaged. The 4AWG cable from front to back is probably heavier than needed (not a bad thing) since it only carries alternator current with the isolator installed.

[@Electrolab28Ag]

I know this is probably late as well but You can use the IRF640 as replacement. Most Inverters carries this part no.

[@knurlgnar24]

The battery in your trunk will be the inverter's limiter for output power. I'd estimate 1000W to 1500W depending on battery type and condition. Without the isolator you should be able to max out the inverter with that 4AWG help from the front. (I'm assuming a 10ft run which drops 500mV per 100A). It sounds like a nice setup, I like your component choices. Good luck!

[@williamstaten8102]

Looks like the same third party as AIMS and centech

[@knurlgnar24]

Interesting. I've personally never seen an Aims product built this well (which is saying something)

[@knurlgnar24]

Yes! The inverter would have run just fine with only 3 transistors in parallel with some risk of overheating when both hot and at low power factor loads. A slight imbalance in the AC waveform may also manifest which is undesirable. On the output board for modified sine inverters matching the FET capacitances and RDSon isn't very important. On the voltage boosting board it is usually important so best practice is to keep things balanced whenever practicable.

[@knurlgnar24]

Yeah, send me pics if you would! I'd like to see it. I'm also curious about your impression on the Cobra 2575 since I've never taken a look at one. Unfortunately you cannot buy my scopemeter anymore since it is long discontinued. It really puzzles me why 14 years ago I could buy this for a little over $100, and now there's nothing similar available in that price range. It seems really odd.

[@ajw6715]

The mosfets can be replaced with IRF640p mosfets which are a little better.

[@calimanmancali]

is it possible to change the input volt from 24v into 36v to match with solar panel. thanks

[@FroggieTheR0gue]

No, Faffa didn't do that and he won't because it's illegal. The guy I know who did it lives in SF. I wish he hadn't told me because now I'm on The Shit List if he gets caught. I don't like it when people tell me that sort of thing, I went to a friends house for dinner and his gf took me down to their basement and showed me their hydroponic system and I got mad at her. I don't want to be a suspect if anything goes wrong. That's exactly how people get caught, they tell others what they're doing.

[@eddiedekerf3902]

what to do when the voltage is to high(where )around 265 volt

[@knurlgnar24]

If your multimeter is an RMS meter and the voltage is actually too high, then the inverter is likely out of calibration. Many inexpensive ones have cheap potentiometers that fail over time and you may just be able to find the pot and adjust it back to where it should be. Others are hard-set and you will need to find the aged/failed resistor/component and change it out. (I am assuming it is supposed to be 240V.)

[@itsjustaname7721]

Hi I bought a Ford E350 van/passenger wagon to convert into living space. Long story short there is a xantrex 2000w inverter connected under the passenger seat can someone tell me what it is for ? It has no plug outlets like modern inverters. It has a landline plugged into it and an antenna. Keep it or replace it ? I need an inverter with modern plugs . I can't figure out what this is for before I mess with it.. thanks anyone with advice or real knowledge ✌️

[@emeltea33]

Might it be an amplifier for the stereo?

[@FroggieTheR0gue]

It's happened to me a couple of times. Then we would talk on one of my vids or at the Vic vid. I blocked her too, then I unblocked her because I wanted to see what she would say next. Now it doesn't matter because she just removes her comments anyway. Faffa just showed up. Remember what I said would happen if someone got caught tampering with their meter? He's saying the same thing.

[@FroggieTheR0gue]

Oh, I didn't think you were watching this. I know a guy who did it and hasn't gotten caught, yet. I heard that once caught they don't have to turn your power back on again, plus the fine and jail time, so I agree, it's a bad idea.

[@FroggieTheR0gue]

I was beginning to wonder when that was going to happen. Yes, it probably wouldn't be worth it at this point but if she gives you trouble down the line, let me know and I'll follow through with the plan. What do you think of the comment I made to Faffa?

[@FroggieTheR0gue]

She wanted to show off, that's what I think and the truth of the matter is that they did a really good job. They owned the house so that made it more feasible, it's not like a landlord could drop in and bust them. Also since I don't smoke weed she knew I wouldn't ask them for free pot. This is what I think.

[@FroggieTheR0gue]

That's the only way to do it, unless your a farmer. I talked to one here, he's making big bucks. He sells to the government medicinal outlets, it's totally legal. That takes a lot of start up money though, it's ideal if you own the land your farming of course. I notice Faffa didn't respond to your comment. Zebby is on the Vic vid, do you want to go there?

[@kionekeapelesi5038]

Same as a Harbor Freight 2OOO watt and the Coleman powermate inverters

[@runningbear4666]

Good show Mr harms

[@FroggieTheR0gue]

Absolutely, when I told her I wasn't happy that she had shown me what was in her basement, she was shocked, I had to spell it out for her, then of course I asked her to tell my friend she showed me, if she didn't I was going to tell him. The entire thing started to suck right out of the gate, I just went there for dinner after all.

[@AlexanderPresident]

No of course, thats what I thought, faffa would never do anything illegal. What happened to you was awkward, it also could be dangerous, thats how people get caught, I wonder why she told you about that

[@AlexanderPresident]

I can't send messages for now again, I'll have to wait for a while, and yes approaching her would probably bring more trouble than its worth, thats what I think too, its not worth the effort

[@thewhistlergroup]

Wow amazing video!

[@AlexanderPresident]

But I wonder, why would they even tell that to anyone? I mean I can understand that she wanted to show off in front of someone but when there are such dangers involved, as jail or a huge fine, wouldn't it be better if they kept their mouth shut and did not show off to people? But I agree, drug addicts can't keep their mouths shut, they would immeidately start extorting money from them

[@Darryl603]

To find loose screws, use a different mat for your bench...

[@AlexanderPresident]

Yes it always happens to me whenever I send many messages, does it happen to you too or have you found a way to avoid it? I don't think she's going to give me any more trouble, for that I'd have to uninstall the friend lock and start talking to her again, then I would more certainly get in trouble with her again lol, as you might have guessed already, I have no intention of doing that haha Your comment to faffa is ok, its a joikng comment, there should be no reason for him to be upset lol

[@AlexanderPresident]

Yeah apparently they did a good job, it was a good decision to become owner of the house in which they wanted to install such a device, and what about the people from the company, don't they come there from time to time to see how their equipment works or it never happens that way?

[@johngoeke2451]

Hi knurlgnar24, your videos are awesome! Any thoughts on the quality of the power bright 1100 watt msw inverter? I know you have done a teardown on some of their other inverters. Especially curious about the advertised 2200 watt surge. Is it like a lot of these cheap inverters, just lasting for a millisecond? Thanks, John

[@knurlgnar24]

I haven't tested out the specific unit you're asking about but the majority of PowerBright's inverters surge for about 0.5s and while they don't produce the rated 2x surge capability advertized they do have some and don't immediately shut down either and allow the voltage to sag for the duration which is good enough for many loads. They're generally a decent value for mid-range inverter products. If you don't expect too much from them you'll likely be satisfied.

[@johngoeke2451]

Thanks

[@AlexanderPresident]

Sounds like a very dangerous thing to do, its probably not worth the risk because if you get caught...

[@barrasin1]

thanks mate i seen your video i now have repard my inverter 500w

[@FroggieTheR0gue]

I'll bet when you lived here you tampered with your PG&E meter.

[@StephenSF26]

Old man Whistler says they're the best on the planet.

[@AlexanderPresident]

Yeah lets go there, there is not much for me to do here

[@RaulSchay]

Hi knurlgnar24.. I have a pure sine power inverter that I used to run an air conditioner that used 450 watts without problems until the other day that will not turn on the ac compressor , the inverter is rated up to 1500 watts, I tested with a watt meter, and I load a toaster that used 1300 watts and it work with no problems , but will no turn the compresor ac no more. Do you have any idea what could be the problem? Thank you Jerry in advance ! 

[@knurlgnar24]

My first guess would be that your batteries are getting weak and can no longer maintain proper voltage during the compressor startup surge.

[@RaulSchay]

No, that's not the case , I have 4 brand new marine deep cycle batteries . My Go Power 1500 W turn the A/C easily but the Doxin 1500 W doesn't, and it's rated for 300 W surge. Any other idea? Thank's for your help !

[@knurlgnar24]

Raul Schay Aside from possible cabling issues that you have probably already looked into, that inverter is somewhat marginal for even a small AC unit. The 'surge' rating on most inverters is nothing but marketing and I would suspect your Doxin has no actual surge capability - this wouldn't be true of the Go Power which makes much better quality inverters and should handle your AC unit just fine. You could open up the case and make sure the connections inside are all tight as they sometimes come loose over time but it's probably a case of the inverter being marginal for the application and the components inside aging and becoming less capable of supporting that compressor startup surge.

[@RaulSchay]

Do you think that change the capacitors will help?, the inverter it's only two months old. I will check for loose connections . Thank you for your help !

[@knurlgnar24]

Raul Schay If it is only a couple of months old then the capacitors will (should?) still be just fine. It may just be a case of an underpowered inverter for that application unfortunately.

[@beyondupnorth]

I have a 3000 watt continuous inverter with 24 mosfet on it. One has the gate burned off and is fried and the rest test fine (open). How do I go about selecting a replacement? The numbers on the mosfet seem to be no value to anyone in determining what I have. P8dnf55080 or (perhaps ends in D8Q) Then next number G4dsy-v6 (or 64dsy-v6) Then chn040 Any suggestions. We purchased this Tripplite new and it inadvertently had 24vdc connected to the input blowing the main 175 amp fuse. it continued to work for a short time after being connected to 12V b4 blowing this mosfet. It still lights up and test runs the fans, so I believe this is all it needs.

[@knurlgnar24]

I'm glad you're going to attempt a repair. It probably is just one or two transistors as you suspect given the 24V connection issue. The closest reasonable part# I could find was a fairchild FDP55N06, but really knowing that it is a 12V->120V modified sine inverter with a large # of FETs in it is about all that is necessary to know. If the above mentioned fairchild part is the correct body size and is positioned on the input side then it will work in your application. FDP80N06 is a good choice as well.

[@beyondupnorth]

***** Ok thanks we are going to try that. I had the case open and could see nothing else burnt looking. Only a few bucks to lose trying. I need a small soldering iron too.

[@beyondupnorth]

***** Well I finally got back to this and its up and running a low wattage ac load. My main concern now is getting the heat sink conected back to to the replaced mosphet. There was some sort of tape between the mosphets and the aluminum case to transfer the heat. 23 chips were stuck to the case and clamped with a bar bolted over them in sets of 2. Of course the bar over the fried chip got red hot. Is there anything I should do before bolting the chips to the heat sink to improve the heat transfer besides clean up the bar? Thanks

[@chan8190]

are you hireable?

[@johnconrad5487]

IRF640