Service Manual

PH18-4K/5K MPK (F)

Inverter/Charger
PH1800 4K/5K MPK (F)

Service Manual
 Service Manual
PH18-4K/5K MPK (F)

Table of Contents
1. General Information.................................................................................................... 1
1.1 Brief Introduction ....................................................................................................1
1.2 Basic Topology Introduction....................................................................................1
1.3 Overview of Inverter/Charger..................................................................................2
2. Fault and Troubleshooting.......................................................................................... 3
3. Maintenance Step....................................................................................................... 4
3.1 Maintenance...........................................................................................................4
3.1.1 To Check DC FUSE and Capacitance............................................................4
3.1.2 DC/DC Boost Module.....................................................................................5
3.1.3 Divers.............................................................................................................7
3.2 To Check BUS Module...........................................................................................11
3.2.1 Power Devices...............................................................................................11
3.2.2 IGBT Diver Circuit..........................................................................................12
3.3 To Check BUCK Circuit..........................................................................................13
3.3.1 Power Devices...............................................................................................13
3.3.2 Divers.............................................................................................................14
3.4 To Check Invert Full Bridge.....................................................................................15
3.4.1 To Inspect Power Components as below........................................................15
3.4.2 To Check Drivers............................................................................................15
3.5 To Check BUS Soft Start Circuit.............................................................................17
3.5.1 Plug-in Components.......................................................................................17
3.6 To Check the AC Switch-on Power Supply Circuit..................................................19
3.7 To Check the Battery Switch-on Power Supply Circuit...........................................21
3.8 To Check the MOSFETS for Reversed Protection on DC Terminal.......................23
3.9 To Check NTC Circuit.............................................................................................23
3.9.1 NTC in Position of HS1 Plug-in Position of CN8 on Main Board....................24
3.9.2 NTC1 Under Transformer...............................................................................26
3.9.3 NTC4 in HS3..................................................................................................26
3.10 To Check Fan Driver Circuit on Main Board..........................................................28
4. Other Common Faulty Cases......................................................................................28
4.1 MOSFET Burnt.......................................................................................................28
4.2 Input Cable Disconnection......................................................................................29
4.3 Dust-covered Control Board...................................................................................29
5. Assembling Guidance..................................................................................................29
6. Test Guidance after Repairing.....................................................................................33
 Service Manual
PH18-4K/5K MPK (F)

1. General Information

1.1 Brief Introduction

This manual is used as a tool of inspection and repairing guidance for
PH18-4K/5K MPK (F), as well as instructions of assembling and testing. It is
best to have some electrical or electronic background knowledge. With this
guidance, hope it will help you to check and inspect the inverter/charger first by
yourself.

1.2 Basic Topology Introduction

The topology for 4KVA/5KVA shows as below:

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1.3 Over review and Introduction of Inverter /charger Parts

Solar Charge
Controller Board

LCD Display

Main Board

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2. Fault and Troubleshooting

No LCD First to test battery volt to check whether it is in range of 44v-52v;
display when If it is in the range, to switch the inverter one to check whether the
inverter turns unit starts. If the unit does not run yet, please disconnect all
on connections and open the surface panel, take out the main board,
then to check and repair according to 3.7
01 First to replace the fan, to check whether it is okay; if NG, please
inspect the main board and repair according to 3.11
02 Please to check the main board and repair according to 3.9
03 Please to check first and then to repair the main board according
to 3.1, 3.6 and 3.7
06 First to start up the inverter by only connecting battery, if the fault
is still on, please inspect the main board following 3.4
08 To restart the inverter, to check whether the fault repeats, if yes, it
requires to replace the control boards.
09 To Check the main board following 3.1.2, 3.2.1, 3.4.1 and 3.5 and
to repair accordingly
52 First to restart inverter by only connecting to battery, if fault
continues, then to check the main board according to 3.1.2 and
3.4
56 First to check the connection of battery cable, if good connection,
then please to check and repair the main board following 3.1.1
and 3.1.2 accordingly
57 To replace the control board
58 First to restart inverter by connecting battery only, to check
whether it is good?
Second to connect battery and Utility but to keep switch off,
checking whether inverter charges battery? Otherwise, to check
and repair main board according to 3.1.2, 3.2.1 and 3.4.1
accordingly
72 To replace the control board

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3. Steps to Repair
3.1 Battery Working Mode Test

3.1.1 To Check DC FUSE and Capacitance

F3: 180-00045-00 (Fuse, 42*12*0.6mm, Purple Copper Plate with tin plated)

Positioning Attribute Reference Value Failure Status

F3 Resistor 0 ohm open

C8,C9,C12,C13: 140-00103-00 (Electrolytic Capacitor, AL 3300uF/63V 105℃ 18*45.5 BULK RAD)

If the capacitors explode as below, they need to be replaced.

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3.1.2 DC/DC Boost Module

DC/DC MOSFET:

Q14/Q25/Q26/Q40, Q12/Q22/Q21/Q38, Q20/Q17/Q11/Q24, Q13/Q18/Q13/Q19

150-00052-00: MOSFET TI/CSD19505KCS 201A 80V N BULK TO-220

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G D S

Positioning Attribute Reference Value Failure Status

All MOSFET, 16pcs Diode SD:0.44V Short-circuit
DS:OL or Explosion
Note 1: When you use multi-meter to measure the resistance of MOSFET, due to the
capacitor in the circuit, it will cause the continuous wave of the value when you measure the
DS and GD; therefore we would recommend to measure the diode forward voltage of SD and
the resistor of GS; these two values can reflect the situation of the transistor correctly.
Note 2: If one or more than one of them were broken, please replace all of them. For 4K, the
main board has just 12pcs MOSFETS.

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3.1.3 Divers

Note: when there are power devices or components are damaged, Divers are
usually required to check.

The reference resistors listed as below.

R53/R87/R92/R93, R42/R75/R78/R80, R70/R59/R41/R76, R81/R62/R52/R64

All the resistors are 100-10022-00 (RES CHIP TF1/4W 22F (1206))

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To use Multi-meter to measure each resistors till to find out the broken ones
and to replace them, no need to change all the resistors.

Positioning Attribute Reference Value Failure Status

All Resistors: Resistor 22 ohm Open Circuit
22 ohm or other value

If resistors are need to replace, please check the diver transistors and
controlling IC.

Q48
Q46
Q47
Q49

Q46/Q48/Q41/Q43:150-00005-00 (Plug-in Transistor TOSHIBA/2SC2655-Y 2A 50V)

Q15/Q16/Q47/Q49:150-00004-00 (Plug-in Transistor TOSHIBA/2SA1020-Y 2A 50V)

Q41

Q15

Q43
Q16 E
B C

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Positioning Attribute Reference Value Failure Status
Q46/Q48/Q41/Q43 Diode BE:0.6V Short-circuit or burnt
BC:0.6V
CE:1V
Q15/Q16/Q47/Q49 Diode BE:0.6V Short-circuit or burnt
BC:1.3V
CE:0.2V

Q51/Q52/Q54/Q56:120-20035-00(SMD Transistors UTC/2SD1624 2A 50V NPN SOT-89)

Q50/Q53/Q55/Q57:120-20036-00 (SMD Transistors UTC/2SA1020 3A 50V PNP SOT-89)

E C B

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Positioning Attribute Reference Value Failure Status
Q51/Q52/Q54/Q56 Diode BE:0.6V Short Circuit or Burnt
BC:0.6V
CE:OL
Q50/Q53/Q55/Q57 Diode BE:0.6V
BC:OL
CE:1V

S S

Q60/Q61:120-20071-00 (MOSFET UTC/UT3404 5.8A 30V NPN SOT-23 SMD)

Positioning Attribute Reference Value Failure Status

Q60/Q61 Diode SD:0.18V DS1.2V Short Circuit or Burnt

U9:160-00018-00(IC LINEAR SG3525ANG MOTOROLA L-1)

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PH18-4K/5K MPK (F)

Positioning Attribute Reference Value Failure Status

U9 Resistor Pin11-Pin12:5.4M Short Circuit
Pin13-Pin12:60K or Broken
Pin14-Pin12: 5.4M
Note: If you are not sure which component broken, we would like to suggest you to
replace them all.

3.2 To Check BUS Module

3.2.1 Power Devices

DC/DC IGBT: Q27/Q28/Q29/Q30

Q30 Q29 Q27 Q28

G D S
Q27/Q28/Q29/Q30: 150-00048-00 (IR/IRGP4750DPBF 50A 650V)

Positioning Attribute Reference Value Failure Status

Q27/Q28/Q29/Q30 Diode EC:0.37V Short Circuit
CE:OL or Broken
Note: If there is one or more than one components broken, please replace them all.

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3.2.2 IGBT Diver Circuit

R96/R91/R101/R102:100-10022-00 (Resistor CHIP TF 1/4W 22 F (1206))

R94/R90/R97/R99:100-10000-00 (Resistor CHIP TF 1/4W 0 F (1206))

D33/D32/D34/D35:120-20001-00(Diode PANJIT/1N4148W 0.15A 75V SOD123)

+
-

Positioning Attribute Reference Value Failure Status

R96/R91/R101/R102 Resistor 22ohm Open Circuit
R94/R90/R97/R99 Resistor 0ohm or other value
D33/D32/D34/D35 Diode + to -:0.6V Short Circuit
- to +:OL or Broken
Note: When to test Diode, please remove the R94/R90/R97/R99 from main board,
otherwise test result will be not accurate.

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3.3 To Check BUCK Circuit

3.3.1 Power Devices

BUCK MOSFET and Diode: Q32/D13

Q32 D13

- +
G D S
Q32:150-00048-00 (IGBT IR/IRGP4750DPBF 50A 650V N BULK TO-247)

D13:150-10115-00 (Plug-in Diode APT30DQ60BG 30A 600V TO-247 2P)

Note: D13 is 150-10042-00 (Plug-in Diode FAIR/RHRP1560_NL 15A 600V)

Positioning Attribute Reference Value Failure Status

Q32 Diode SD:0.44V Short Circuit
D13 Diode + to -:0.36V or Broken
- to +:OL

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3.3.2 Divers

R125:100-10047-00 (SMD Resistor CHIP TF 1/4W 47 F (1206))

R124:100-10010-00 (SMD Resistor CHIP TF 1/4W 10 F (1206))

D38: 120-20001-00 (SMD Resistor PANJIT/1N4148W 0.15A 75V SOD123)

-
-

Positioning Attribute Reference Value Failure Status

R125 Resistor 47 ohm Short Circuit
R124 Resistor 10 ohm or other Value
D38 Diode + to -: 0.6V Short Circuit
- to +: OL or Broken
Note: When testing diodes, please remove R124, or the result will be not accurate.

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3.4 To Check Invert Full Bridge

3.4.1 To Inspect Power Components as below

INV IGBT: QA1/QB2/QC1/QD2

QB2
QD2 QA1 QC1

G C E

QA1/QB2/QC1/QD2: 150-30082-00 (IGBT IR/IRGP4066D-EPBF 75A 600V TO-247)

Positioning Attribute Reference Value Failure Status

QA1/QB2/QC1/QD2 Diode EC:0.4V Short Circuit
CE: OL or Burnt
Mark 1: if one or more than one IGBT broken, all IGBT components should be replaced.
Mark2: this is for PH18-4K model.

A1/QB2/QC1/QD2: 150-30088-00 (IGBT IR/IRGP4063D-EPBF 48A 600V TO-247)

3.4.2 To Check Divers

R150/R137/R139/R48/R152/R140/R145/R144: 100-10047-00
(Chip Resistor, CHIP TF 1/4W 47 F (1206))

D16/D5/D12/D6: 120-20001-00 (Chip Diode, PANJIT/1N4148W 0.15A 75V SOD123)

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+
--
Positioning Attribute Reference Value Failure Status
All Resistors Resistor 47 ohm Other value or
Open Circuit
D16/D5/D12/D6 Diode EC: 0.6V Short Circuit
CE: OL or Burnt
Mark: When testing the diodes, please remove the R139/R150/R150/R145, or the test
result is not current.

Optocoupler: U12/U2/U4/U1/U3

11

U12/U2/U4/U1/U3:120-10065-00(Chip Optocoupler: FOD3120 SMT)

Positioning Attribute Reference Value Failure Status

U12/U2/U4/U1/U3 Resistors Pin8-Pin5:2K Short Circuit
Pin7-Pin5:2K or Burnt

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3.5 To Check BUS Soft Start Circuit

3.5.1 Plug-in Components

D65:150-10012-00(Plug-in Transistor FAIR/RHRP8120 8A1200V TO-220)

D73: 150-10089-00 (Plug-in Diode PAJ/UF202 2A 200V UFST AXI TAP)

Q6: 150-00035-00 (Plug-in Transistor IR/IRF840 8A 500V N BULK TO-220)

R251: 130-00225-00 ( Plug-in Resistor 2W 0.62 J Vertical F4 No-Sensing)

R245: 100-10022-00 (SMD Resistor CHIP TF 1/4W 22 F (1206))

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Pin4

U16

Pin2

TX2: 240-00144-00 (Transformer TX 15:200:15 FER EEL16 PH18)

Positioning Attribute Reference Value Failure Status

D65 Diode + to -:0.44V;
- to + :OL
D73 Diode + to -:0.47V; Short Circuit
- to +:OL or Burnt
Q6 Diode SD:0.5V ;
DS: OL
R251 Resistor 0.8 ohm Open Circuit
R245 Resistor 20 ohm or Other Value
TX2 Resistor Pin2-Pin4: 14 ohm
Short Circuit
U16 Resistor Pin7-Pin5:42K ;
or Burnt
Pin6-Pin5:30K

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3.6 To Check the AC Switch-on Power Supply Circuit

(Note: This part only used in 250-00285-xx)

Q37:150-30008-00 (Plug-in Transistor TOSHIBA/2SK2608 3A 900V)

C87:140-00002-00 ( Electrolytic Capacitor AL 33uF/450V M 7.5mm 13*32mm 105℃

TXC330M2WK32MC4 )

D17/D18/D20/D21:150-10079-00 (Diode PAJ/1N4007S-P 1A1000V RAD TAP0.6D)

C87: If Capacitor explodes, please replace it.

Q37

C87

R233:100-10022-00 (SMD Resistor CHIP TF 1/4W 22 F(1206))

U15:120-10052-00(IC PWM ON/UC3845BD1R2G L-1 SMD SOP-8)

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Positioning Attribute Reference Value Failure Status

Q37 Diode SD:0.5V; Short Circuit
DS: OL or Burnt
D17/D18/D20/D21 Diode + to -:0.47V;
- to +: OL
R233 Resistor 22 ohm Open Circuit
or Other Value
U15 Resistor Pin7-Pin5:42K; Short Circuit
Pin6-Pin5: 30K or Burnt

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3.7 To Check the Battery Switch-on Power Supply Circuit

Q36:150-30005-00 (MOSFET IR/IRF640NPBF18A 200V)

D53: 150-10089-00 (Plug-in Diode PAJ/UF202 2A 200V UFST AXI TAP)

R215: 130-00211-00 ( Plug-in Resistor 3WS 0.15 Vertical F4)

D54: 150-10078-00 (Plug-in Diode ON/MUR460 4A600V UFSTTAP DO-201AD)

D67/D70: 150-10075-00 (Plug-in Diode HER303 3A 200V DO-27 TAP MIC)

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R126/R217: 100-10010-00 (SMD Resistor CHIP TF 1/4W 10 F (1206))

U10: 160-00005-00 (Plug-in IC LINEAR ON/UC3845BNG)

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Positioning Attribute Reference Value Failure Status

Q36 Diode SD:0.53V ; Short Circuit
DS: OL or Burnt
D53 Diode + to -:0.52V ;
- to +: OL
R215 Resistor 0.15 ohm Open Circuit
or other value
D54 Diode + to -:0.45V; Short Circuit
- to +: 0.7V or Burnt
D67/D70 Diode + to -:0.43V ;
- to +: 2.6V
R126/R217 Resistor 10 ohm Open Circuit
or other value
U15 Resistor Pin7-Pin5: 42K; Short Circuit
Pin6-Pin5:30K or Burnt
D51 Diode + to -:0.62V; Short Circuit
- to +:OL or Burnt

3.8 To Check the MOSFETS for Reversed Protection on DC

Terminal

Please open the closure and measure it as below

PVPV- -

BAT -
BAT -

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Positioning Attribute Reference Value Failure Status

PV – to BAT - Resistor >10K Short Circuit

If it is in short circuit, it requires replacing the MOSFETS on main board.

Q42/Q58/Q44/Q45: 150-00060-00 (MOSFET IRFB3006GPbF 270A 60V N TAP TO-220)

Q42
Q42 Q58 Q44
Q44 Q45

3.9 To Check NTC Circuit

On Main Board, there are three NTC, one is in DC-DC Boost Heat Sink, one is
under boost transformer and one is in inverting heat sink.

When 02 fault code appears, it requires to check this step, please kindly note.

3.9.1 NTC in position of HS1 plugs in position of CN8 on main board.

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NTC
NTC33

CN8
CN8

R272:

Positioning Attribute Reference Value Failure Status

R272 Resistor 700-750ohm Short Circuit
NTC3 Resistor 15K ohm or other value
NTC3 CN8 Resistor 4-6K ohm

If it is not possible to check functioning, please pull out NTC and test the inverter again;
if the fault disappears, it means the NTC is wrong.

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3.9.2 NTC 1 Under Transformer

NTC1: 130-20031-00 (Thermistor NTC47K2.5mA)

R267: 100-11200-00 (SMD Resistor CHIP TF 1/4W 2K F (1206))

R267
R267

NTC1
NTC1

Positioning Attribute Reference Value Failure Status

R267 Resistor 2K ohm Short Circuit
NTC4 Resistor 8-9K ohm or Other Value

3.9.3 NTC 4 in HS 3

NTC4-HS3: 130-20005-00 ( Thermistor NTC 15K 2.5mA)

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NTC4
NTC4

CN4
CN4

R270: 100-10750-00 (SMD Resistor CHIP TF 1/4W 750 F (1206)) SMD Resistor CHIP
TF 1/4W 750 F (1206)

Positioning Attribute Reference Value Failure Status

R270 Resistor 700-750ohm Short Circuit
NTC4 Resistor 15K ohm or other Value
NTC4 CN4 Resistor 4-6K ohm

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3.10 To Check Fan Driver Circuit on Main Board

Positioning Attribute Reference Value Failure Status

R122 1K ohm
R119 10K ohm
R127 2K ohm
R126 2K ohm
R115 Resistor 100 ohm
Short Circuit
R121 4K ohm
or other Value
R120 10K ohm
R114 100 ohm
R118 10K ohm
D56/D48 Diode + to -:0.6V ;
- to +: OL

4. Other Common Faulty Cases

4.1 MOSFET Burnt

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4.2 Input Cable Disconnection

4.3 Dust-covered Control Board

5. Assembling Guidance

5.1 Unfix Upper Cover

5.1.1 Unscrew four screws of the cover as following

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5.1.2 Pluck LCD disconnection cable and take the cover

5.2 Unfix Power Board

5.2.1 To take the Air-duct Paper

To take five plastic nails in heat sink and take out the air-duct paper

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5.2.2 To pluck AC input and output cable and fan connection cable

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5.2.3 To Remove PV Connection Cable

5.2.4 To Remove the two screws on the side and take out the middle clapboard

5.2.5 Unscrew the two screws in control board and take the control board out.

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5.2.6 Unscrew the eleven screws in main boards and take main board out.

5.3 Assembling the Inverter

When Assemble the unit, please take opposite order of dissembling.

6. Test after Repairing

6.1 Before test, please connect to battery bank.

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+ --

Afterwards, please Turn ON the unit.

6.2 To connect with AC Grid for testing

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6.3 To connect PV for testing

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