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Principles and Maintenance Manual of KSG-SM3 Series

Photovoltaic Inverter
(KSG-1-3K)

Shenzhen KSTAR New Energy Co., Ltd.


New Energy and Low Power
Contents
I. Product Introduction: ............................................................................................................. 2

II. Electrical Diagram of the system ........................................................................................... 4

III. KSG-1K-3K Parameters ......................................................................................................... 6

IV. Internal Diagram of the Machine ......................................................................................... 6

V. PCB boards and Interface Signals .......................................................................................... 7

VI. Installation............................................................................................................................ 9

VII. Turning on and Running System ....................................................................................... 12

VIII. Machine Maintenance ..................................................................................................... 15

IX. Inverter Maintenance Essentials ........................................................................................ 31

X. Appendix.............................................................................................................................. 31

Appendix: Differences between key components .................................................................. 31

I. Product Introduction:

1.1 Features

String inverter Metering meter Two-way metering meter Grid


PV array

Local load

A typical photovoltaic power generation system includes at least three parts: PV


panel, inverter and public power grid. KSG-1-3K-SM is a single-phase grid-connected
PV inverter. It converts the unstable DC power of the solar panels into the AC power
to the public power grid through the boost and inverter links. The inverter has two
main functions, namely maximum power point tracking (MPPT) and inversion. MPPT
function refers to outputting the maximum power under certain lighting by adjusting
the input voltage of the PV panel. The inversion function refers to inverting the
stabilized DC voltage on the BUS to AC power adaptable to the grid. SM series has
single MPPT input.

1.2 Appearance

1.3 External interfaces

1.4 Operation panel


II. Electrical Diagram of the system

2.1 Block diagram

2.2 Power schematic diagram


The preceding stage of KSG-1-3K is a boost circuit with maximum input power
tracking. The backward stage is full-bridge inverter of H4.
Boost circuit

H4 full-bridge inverter
III. KSG-1K-3K Parameters

IV. Internal Diagram of the Machine

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

BUS capacitor Power board

Control board

GFCI board
DC switch

V. PCB boards and Interface Signals

BUS capacitor
Auxiliary power supply

Inverter
Booster

Output relay

GFCI board
Auxiliary power supply

Front View of Power Board


Inverter IGBT Boost IGBT, diode

Rear View of Power Board

Power level DIP

ARM chip DSP chip

Front View of Control Board

Rear View of Control Board


Front View of Display Board

Rear View of Display Board

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

Tilt forward Tilt backward Horizontal Inverted

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.

7.2.2 Setting grid standards


7.2.3 RS485 protocol and address settings
7.3 Commissioning
Do not start the inverter until the following checks are correct:
◆ The AC cable is properly connected.
◆ All PV arrays (solar panels) are properly connected to the inverter.
◆ All screws are fastened.
◆ Close the circuit breakers on DC side and AC side.
◆ When the solar PV array generates enough voltage, the inverter starts
automatically.

VIII. Machine Maintenance

8.1 Inverter maintenance instructions


KSG-1K-3KW solar single-phase grid-connected inverter is an outdoor product with
IP65 waterproof rating. The disassembly and assembly of the machine enclosure
should be carried out according to the steps and requirements, or else the
waterproof performance of the machine will be reduced or damaged, causing the
machine malfunction and chassis corrosion due to water ingress.
Before disassembly and assembly of the inverter, be sure to disconnect the switch
between the DC input and the AC output, and ensure that the temperature of the
enclosure is not hot. If it is necessary to repair or replace the board inside the
machine, turn off the power and wait at least 5 minutes to avoid being injured by the
residual electricity of the BUS capacitor inside the machine or being burned by the
radiator.
Please read the supplied inverter user manual and this maintenance manual carefully
before servicing the inverter in order to better understand the machine and related
precautions.
8.2 Cautions for inverter disassembly
(1) Since the inverter is a product with a high waterproof rating, its components
should be protected from scratches and collisions during the disassembly process.
(2) The fixing screw of the machine enclosure is a hexagon socket screw and the
disassembly and assembly require M4 hexagon tools.
(3) Some screws have plastic waterproof gaskets. When assembling the machine,
these screws must be put back in place, and the gaskets must be well protected.
(4) The waterproof seal in the chassis must be installed properly to prevent rain from
seeping into the machine.
(5) Lock the screws when the machine is assembled. Excessive force makes it easy to
twist the screws. If the screws are too loose, the waterproof seal of the machine will
be loose and water enters the machine easily.
(6) Before the machine is assembled, it is necessary to check if the wiring inside the
machine is connected correctly and if the PV input and AC output are short-circuited
to ground; use a multimeter to measure if the IGBT and the diode are short-circuited
to ground. After confirmed, turn on the power again to test the machine, and then
assemble the shell if the test is OK.
8.3 Inverter disassembly tools
Cross screwdriver, slotted screwdriver, M4 hex tool, sharp-nose pliers, cutting pliers,
tweezers, multimeter, soldering iron, solder sucker
8.4 Inverter disassembly/assembly steps
1. Use the M4 hex tool to open the inverter cover. Note: Remove the LCD cable and
then remove the inverter panel slowly to prevent breaking off the LCD cable or
damaging the control board.

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

Table 8.2 Machine Error Information


Low mains voltage F00 Mains voltage is too low, machine protection
enabled
High mains voltage F01 Mains voltage is too high, machine protection
enabled
Low power frequency F02 Mains frequency is too low, underfrequency
protection enabled
High mains frequency F03 Mains frequency is too high, over-frequency
protection enabled
Low bus voltage F04 BUS voltage is too low, machine protection
enabled

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

AC relay abnormal F14 AC relay works abnormally, machine protection


enabled
Low PV input voltage F15 One PV channel isn’t connected in machine
parallel mode, machine protection enabled
Remote shutdown F16 Machine is in remote shutdown state
*** F17 ***
SPI communication failure F18 Machine control board communication failure
*** F19 ***

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.

3. Display board of the machine reports F01


(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 machine doesn’t have a corresponding grid connection standard
Follow the instructions to enter the setting options and set grid standards in
accordance with local standards.
(3) High external grid voltage
The external power grid is abnormal. The machine resumes its grid connection when
the local power grid is normal.
(4) Control board failure. The machine reports an error due to a failure of the mains
detection circuit or an error in CPU data processing.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and repair or replace the control board.
(5) 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.
4. Display board of the machine reports F07
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) ISO detection circuit failure. When the resistor in the ISO detection circuit is
damaged, damage to the relay will cause the machine to report an ISO error.
To deal with this situation, remove the machine in the correct way, disassemble the
machine enclosure, detect and repair the ISO test circuit or replace the power board.
(3) The control board ISO detection circuit has failure or bad CPU and the machine
reports an error.
To deal with this situation, it is necessary to detect and repair the ISO detection
circuit or replace the control board.
(4) The control board inside the machine is loose from the 40PIN connector of the
power board or has poor contact. The ISO signal detected by the power board is sent
to the control board for analysis through the 40PIN connector. When the cable is in
poor contact, the ISO 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, and re-plug the 40PIN connector. Replace the connector if it still
has error.
(5) The insulation resistance of the solar panel is low. Use a multimeter to measure if
the impedance of the anode of the solar panel to the ground and the cathode to the
ground is higher than 1 Mohm. If not, check if the lead wires of the solar panel are
damaged. If there is any damage, use an insulating waterproof material to wrap it. If
there is no damage, the solar panel has problem and should be handled by the
manufacturer.
5. Display board of the machine reports F11
(1) The inverter drive circuit of the power board has failure, a drive semiperiod is lost.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and repair or replace the power board.
(2) The inverter drive circuit of the control board has failure, a drive signal is lost.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and repair or replace the control board.
(3) Loose or poor contact of the drive signal cable
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and re-insert the drive signal cable to see if the machine is
working properly. If not, replace the drive signal cable.
6. Display board of the machine reports F20
(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) There is leakage between the L wire of AC output and the ground.
To deal with this situation, first use the clip-on ammeter to measure if there is
current flowing through the grounding wire of the machine. If yes, disconnect the DC
input and AC output switch first, and find the damaged part of the L wire of machine
output by visual inspection, and wrap the damaged area with insulating tape or
replace the AC cable.
(3) Failure of the GFCI board causes an error in the GFCI signal transmitted to the
control board.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and replace the GFCI board soldered to the main board.
(4) Control board failure results in errors in CPU data processing.
To deal with this situation, remove the machine as required, disassemble the
machine’s enclosure, and repair or replace the control board.
7. Display board of the machine reports F05
(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 DC input voltage of the inverter exceeds the range.
To deal with this situation, first use a multimeter to check if the voltage at the DC
input terminal of the inverter exceeds the highest working voltage allowed by the
machine. If yes, properly reduce the number of solar panels in series to ensure that
the DC input voltage of the machine is within the allowable operating voltage range.
(3) Control board failure. The machine reports an error due to a failure in the PV
voltage sampling circuit or an error in CPU data processing.
To deal with this situation, remove the machine in the correct way, disassemble the
machine enclosure, and repair or replace the control board.
8. Display board of the machine reports F08
(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 DC input current of the inverter exceeds the range.
To deal with this situation, first use the clip-on ammeter to check if the current at the
DC input terminal exceeds the maximum input current allowed by the machine. If yes,
properly reduce the number of solar panels in series to reduce the input power and
ensure that the DC input current of the machine is within the allowable operating
range.
(3) The damage of power element of the power board, the inverter failure or
short-circuit of boost circuit causes overshooting of the PV input current. Check if the
MOSFET, IGBT and fast recovery diodes of the power board has short-circuit or
open-circuit with a multimeter, and repair or replace the power board if any.
(4) Failure of the control board results in failure of the machine inverter or inaccurate
acquisition of input current. To deal with this situation, repair or replace the control
board.
9. Display board of the machine reports F13
(1) The temperature of real inverter is too high due to the high ambient temperature;
turn off the inverter and place it in a cool place, and it can be connected to the grid
to generate electricity after cooling down.
(2) 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.
(3) Temperature sensor failure
To deal with this situation, remove the machine in the correct way, disassemble the
machine enclosure, pull out the terminal of the temperature sensor inserted in the
CN2 position of the power board, and measure if the resistance of the temperature
sensor is 15K±5% with a multimeter; if not, replace the sensor and the machine can
work normally.
(4) The machine reports an error due to control board temperature sampling circuit
failure or CPU failure. To deal with this situation, repair or replace the control board.
(5) The 12P connector of the internal control board and the power board is loose or
has poor contact. The data detected by the temperature sensor is sent to the control
board through the connector. When the cable is loose or the contact is poor, the
signal can’t be sent to the CPU and the machine reports an error. Re-plug or replace
the 12P connector to solve the problem.
10. Display board of the machine reports F14
(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) Power board RY1 or RY3 relay has failure, and can’t be actuated or contact is
bonded.
Remove the machine in the correct way, disassemble the machine enclosure and
replace the RY1 or RY3 relay on the power board.
(3) The control circuit of the power board RY1 or RY3 relay has failure.
Check and repair the control circuit of the power board RY1 or RY3 relay or replace
the power board.
(4) The control circuit of the RY1 or RY3 relay on the control board has failure. The
relay can’t actuate due to the failure of the control board and the machine reports an
error.
To deal with this situation, repair the control circuit of the RY1 or RY3 relay on the
control board or replace the control board.
(5) The 40PIN connector of the internal control board and the power board is loose
or has poor contact. The relay actuation signal from the control board controls the
actuation of RY1 or RY3 relay on the power board through 40PIN connector. The
machine reports an error when the connector is in poor contact and the relay fails to
actuate.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and re-insert the 40PIN connector. Replace the connector if the
problem can’t be eliminated.
11. Display board of the machine reports F32
(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 circuit between the two CPUs on the control board has failure or CPU is
damaged.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, repair the faulty circuit or replace the CPU or control board.
12. RS485 of the inverter can’t communicate
(1) External interference interrupts PC communication.
Restart the monitoring software and observe if RS485 can communicate normally. If
not, restart the computer.
(2) The connection between the inverter RJ45 holder and the PC is loose or contact is
poor.
Re-lock the loose connection cable to see if it is OK. If not, check if the pins of the
RJ45 holder are in poor contact. If not, remove the machine as required, disassemble
the machine enclosure and replace the RJ45 holder.
(3) RS485 communication pins T/R- and T/R+ are connected incorrectly or reversed.
Reconnect the wires according to the RS485 pin definition provided in the user
manual.
(4) RS485 converter is damaged.
RS485 can communicate normally after RS485 converter is replaced.
(5) The internal network cable of the inverter or the 12P communication cable is
loose or has poor contact.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and reinsert the network cable and the connector between the
12PIN control board and the motherboard. If the failure can’t be eliminated, replace
the network cable or communication cable.
(6) The communication board circuit of the inverter has failure.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and repair the communication circuit.
(7) The inverter control board has failure.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, repair the communication circuit or replace the control board.
13. Large noise when the inverter works
There are several reasons for this failure:
(1) The output harmonics of the inverter are large.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, and use an oscilloscope to test if the drive waveform of the
inverter is normal and if the inverter power device is damaged, or directly replace
the power board. If the failure can’t be eliminated, replace the control board.
(2) There is leakage in the EMI filter capacitor on the power board.
To deal with this situation, remove the machine as required, disassemble the
machine enclosure, replace the leaky capacitor, or replace the power board.
(3) The impedance of the contact terminal and the tab terminal which are induced by
the inverter inductor is large.
To deal with this situation, the machine should be removed as required, disassemble
the machine enclosure, and replace the connector terminal or tab terminal of the
inverter inductor.
14. The output power of the inverter is only a few watts
(1) The machine can’t recover due to the power tracking to the open circuit voltage
of the solar panel.
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 output power normally.
(2) The output relay control circuit of the inverter power board has failure and the
relay fails to actuate (one relay actuates and the other doesn’t).
Restart the machine and listen whether the actuation sound of the relay is normal
when the machine enters grid connection at the end of countdown. If not, remove
the machine as required, open the machine enclosure, repair the faulty circuit of the
power board or replace the power board.

IX. Inverter Maintenance Essentials

(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

Appendix: Differences between key components


Differences 1k 1.5K 2K 3K
1.63mH 1.63mH 1.63mH 1.29mH
Boost inductor
1pcs 1pcs 1pcs 1pcs
Inductor
1.82mH 1.35mH 1.35mH 0.99mH
Inverter inductor
2pcs 2pcs 2pcs 2pcs
Bus Number of
2 3 3 4
capacitor capacitors
Power
board
Proportional
output R60=R103=0ohm, R60=R103=10k ohm,
amplification
current R106=R107=0ohm R106=R107=7.5k ohm
resistor
sampling
circuit

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