Documente Academic
Documente Profesional
Documente Cultură
Photovoltaic Inverter
(KSG-1-3K)
VI. Installation............................................................................................................................ 9
X. Appendix.............................................................................................................................. 31
I. Product Introduction:
1.1 Features
Local load
1.2 Appearance
H4 full-bridge inverter
III. KSG-1K-3K Parameters
Consist of two internal independent board components: control board and power
board. There are power board, communication board and GFCI board on the power
board. KSG-1K-3K is in common board structure, and only BUS capacitance and
inductance are different.
Boost inductor
INV inductor
Control board
GFCI board
DC switch
BUS capacitor
Auxiliary power supply
Inverter
Booster
Output relay
GFCI board
Auxiliary power supply
VI. Installation
6. 1 Installation Environment
Refer to the following guide before installation:
◆ To extend the life of the inverter, keep the inverter dry as much as possible.
◆ Select the right place to install the inverter; do not install it in a place where
people often touch, and ensure that it is easy for the staff to install and maintain.
◆ Keep the minimum clearance between the inverter and other objects about
30CM on each side.
◆ Do not expose the inverter directly to sunlight, because the high temperature will
reduce the energy output of the PV system. The inverter achieves the best working
condition and the longest life when the ambient temperature is kept below 40°C.
◆ Maintain good ventilation to ensure quick heat dissipation.
◆ When installing in a residential environment, do not mount the inverter on plastic
plate or wooden board in order to avoid noise. Instead, install it on a solid cement
wall.
◆ The inverter will generate heat during normal operation. Do not install the
inverter on flammable solids or in places storing flammable materials. In addition, do
not install it in areas with potentially explosive atmosphere.
6.2 Installation location
Installation diagram
Wrong installation
1. The inverter is suitable for installation on a wall that is vertical or tilted backwards,
but the wall can’t be tilted back over 20°.
2. Do not install the inverter on a leaning wall.
3. Do not install the inverter on a level surface.
4. Install the inverter at the same height as the eyes for easy operation and readings
6.3 Installation steps
1. Drill holes according to the marks identified in the figure. The boring tool should
be Ø10 percussion drill and the drilling position should be as accurate as possible.
2. Clean the dust inside and outside the holes, insert the expansion tubes vertically
into the holes, knock into the wall with a hammer directly, and then screw the
tapping screws into the expansion tubes. Keep the screw caps at least 10mm from
the wall.
3. Hang the inverter on the screws lightly from the top down, check both sides to
make sure they are in the correct position, and then tighten the screws.
VII. Turning on and Running System
7.1 Connection
Wiring precautions:
◆ Wiring can only be performed when the inverter has been fixed to a suitable
place on the wall.
◆ Ensure that the maximum open circuit voltage and short-circuit current of the
solar cell do not exceed the specifications of the inverter.
◆ Select cables of appropriate thickness for input and output wiring.
◆ When wiring the inverter, make sure that both the DC side and the AC side are
disconnected from the power source and that they will not be reconnected due to an
accident.
◆ First determine the polarity of the wires and the wiring holes and then connect
the inverter to the solar cell and the public power grid.
7.1.1 Connecting to public power grid
First, disconnect from the power grid (disconnect the circuit breaker) to ensure that
it will not be reconnected due to accidents. Then, unscrew the four screws on the
front right side of the inverter, remove the wiring cover and put the wires through
the wiring cover. Use the screwdriver in the accessories to insert the ends of the L, N,
and PE wires into the cable. Finally, tighten the four screws.
7.1.2 Connection of solar cell array (DC)
In order to ensure the safe installation and operation of the equipment, an external
manual circuit breaker must be configured on the DC side. The device selection
should meet basic over-current and over-voltage capabilities. Also note to disconnect
the AC side before disconnecting the DC side. Before connecting the solar PV array
and the inverter, measure the maximum series voltage of the PV array and its value
must not exceed the maximum input voltage of the inverter. In addition, the
short-circuit current of the solar PV array should not be greater than the maximum
DC current of the inverter. Before connecting, check the polarity of the PV array.
Connect the positive pole of the PV array to the DC positive terminal of the inverter
and the negative pole to the negative terminal.
7.2 System parameter settings
After connecting the DC and AC connections, ensure that the DC voltage does not
exceed the maximum open circuit voltage of 500V. Disconnect the AC power and
close the DC distribution switch. The inverter LCD lights up and the system enters
mains power outage error mode. Check the parameter settings of the system,
including the grid standard, input mode and RS485 address. If it does not match the
actual situation, set the corresponding parameters as follows. Then, reconnect the
DC power and the inverter will reset the MCU to make the settings take effect.
7.2.1 Main menu
When the inverter is in error mode, press and hold this button to enter the Settings
menu. When the cursor points to the menu title, press and hold this button to return
to the previous menu or exit the setting mode.
2. After removing the machine cover, loosen the screws on both sides of the control
board with a cross screwdriver and gently pull out the control board.
3. After removing the control board, slowly unplug the inductor wire and AC output
wire with sharp nose pliers, unscrew the DC switch, and unplug the PV input wire.
Use a cross screwdriver to unscrew the fixing screws of the power board (M3*8) and
IGBT fixing screws (M3*15) and lift the power board smoothly.
4. After removing the power board, observe whether the insulating silicone sheet is
damaged, and replace it if yes.
8.4.2 Assembly
(1) Install the power board. Note: Replace the yellow silicone sheet under the power
switch if it is damaged. Align all the holes of the power board with the holes in the
chassis and heat sink. Fasten the chassis screws (M3*8), and then fasten the screws
(M3*15) of the power tube to the heat sink. Do not apply excessive torque to avoid
twisting the fixing screws.
(2) After locking the fixing screws, insert the PV input wire into the power board and
install the DC switch (unavailable on some machines). Insert the inductor line and AC
output line.
(3) Install the control board and lock the fixing screws. Use a multimeter to measure
if the PV input and AC output are short-circuited. Measure if the IGBT is
short-circuited. If not, plug in the display board, power the PV and check if the
machine can boot normally.
8.5 Types of machine failure
Table 8.1 Machine Status
Machine operation status Display Description
information
Shutdown No display PV voltage <70V, machine shut down
Standby Wait 100V <PV voltage <150V (settable)
Self-test Self-test PV voltage <150V (settable), machine
enters self-test state and detects each
function module
Normal work Normal Self-test completes and supplies power
to the grid normally
High bus voltage F05 BUS voltage is too high, machine protection
enabled
Bus voltage imbalance F06 Positive or negative BUS voltage difference
exceeds 20V, machine protection enabled
Low insulation resistance F07 PV panel insulation resistance is too low, machine
protection enabled
High input current F08 PV input current exceeds allowable input current,
machine protection enabled
High hardware inverter F09 Inverter output current is too high, machine
current protection enabled
High inverter current F10 Inverter output current is too high, machine
protection enabled
High inverter DC current F11 Inverter output DC component is too high,
machine protection enabled
High ambient temperature F12 Ambient temperature is too high, machine
protection enabled
High radiator temperature F13 Radiator temperature is too high, machine
protection enabled
High leakage current F20 Leakage current is too high, machine protection
enabled
Leakage current self-test F21 Leakage current self-test error, machine
failed protection enabled
Voltage consistency error F22 Inconsistent control board voltage, machine
protection enabled
Frequency consistency F23 Inconsistent control board frequency, machine
error protection enabled
DSP operation error F24 Control board DSP communication failure,
machine protection enabled
DSP communication lost F32 Control board DSP communication failure,
machine protection enabled
8.5 Troubleshooting
1. Machine can’t be started and screen has no display
Check if the PV input wire is loose. If not, use a multimeter to measure if the positive
and negative voltages of the PV wire are 100V~500V. If yes, the machine has internal
failure.
(1) Measure if PV input of the machine has short circuit.
(2) Measure if pin 2 and pin 3 of the boost IGBT and inverter IGBT are
short-circuited.
(3) Measure the auxiliary power sections C60 (5V), C20 (7V), C1 (15V) and C6
(12V) of the power board.
(4) Observe if the control board indicator is on.
2. Display board of the machine reports F00, F02
There are several reasons for this failure:
(1) Caused by external signal interference.
Turn off the DC input switch of the machine, and turn on the DC input switch when
the LCD has no display; the machine can be normally connected to the grid for power
generation.
(2) The AC switch of inverter output is disconnected.
To deal with this situation, first use a multimeter to measure if the output L wire of
the machine is short-circuited to the N wire and if L wire is short-circuited to the
ground wire. If yes, disassemble the machine enclosure in correct way, and
disconnect the wires between the boards. Use a multimeter to measure where there
are short circuits in the power board, and repair or replace the board.
(3) The AC wire of inverter output is loose.
To deal with this situation, first use a multimeter to measure the voltage at the
connection switch on the AC output of the inverter. If yes, check whether the
connection terminal between the AC output and the switch is loose. If yes, first
disconnect the AC switch, connect the loose wire, and then close the AC switch. The
machine is reconnected to generate electricity.
(4) There is no voltage in the power grid. In this case, the machine will report this
error.
(5) Inverter output FUSE is blown out. The machine reports an error when the
blowout is caused by machine output overcurrent or the FUSE.
To deal with this situation, first check if the input power of the inverter has exceeded
the maximum input power of the inverter. In this case, the machine is overloaded for
a long period of time, and FUSE is blown out due to over-current. Therefore, the
number of solar panels should be reduced accordingly. If the machine is blown up, a
short circuit of power devices such as MOSFETs and IGBTs may cause FUSE blowout.
In this case, the relevant board needs to be replaced and the measurement must be
made. In addition, defects in FUSE can also cause blowouts.
(6) Power tubes of the power board are broken down and short-circuited and the
machine can’t be connected to the grid.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and repair or replace the power board.
(7) Control board failure. The machine reports an error due to the failure of mains
detection circuit or an error in the CPU data processing.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and repair or replace the control board.
(8) The control board inside the machine is loose from the motherboard’s 40PIN
connector or has poor contact. The AC voltage signal detected by the motherboard is
sent to the control board for analysis through the 40P cable. When the connector is
in poor contact, the AC voltage signal can’t be transmitted to the control board, CPU
has error in data processing and the machine reports an error.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, reinsert the control board, and replace the connector if it still has
error.
(1) Analyze and determine the failure type and the cause according to the LCD
display.
(2) Eliminate the causes of the failure from simple to complex. For example, restart
the failed machine first, and observe if the machine can work normally. After
disassembling the enclosure, check if the cable is loose.
(3) Replace the defective board with a board confirmed normal.
(4) For the repaired machine, input low power first and observe if the machine is
stable. Input full power when the machine runs stably.
(5) The wires inside the machine must be plugged in properly, or else the machine
will be damaged.
(6) Determine the machine failure according to the sounds and waveforms.
X. Appendix