Service Manual PV18-2K/3K HM. Inverter/Charger PV1800 2K/3K HM. Service Manual
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1 Inverter/Charger PV1800 2K/3K HM Service Manual
2 Table of Contents Service Manual 1. General Information Brief Introduction Basic Topology Introduction Overview of Inverter/Charger Fault and Troubleshooting Steps to Repair Maintenance To Check DC FUSE and Capacitance DC/DC Boost Module Divers To Check BUS Module Rectifier Diode To Check Full Bridge Invert Circuit Power Devices Divers To Check Drivers To Check AC Charging Circuit To Inspect Power Components as To Check Drivers To Check Rectifier Circuit Charging Circuit To Check Power Circuit To Check MOSFETS for Reversed Protection on DC Terminal To Check NTC Circuit NTC in position of HS3 plugs in position of SW1 on main board NTC1 under Transformer NTC in HS To Check Fan Driver Circuit Other Common Faulty Cases MOSFET Burnt Input Cable Disconnection Dust-covered Control Board Assembling Guidance Test Guidance after Repairing...26
3 1. General Information 1.1 Brief Introduction This manual is used as a tool of inspection and repairing guidance for, 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 2KVA/3KVA shows as below: - 1 -
4 1.3 Over review and Introduction of Inverter /charger Parts Main Board Solar Charge Controller & Control Board - 2 -
5 2. Fault and Troubleshooting No LCD display when inverter turns on First to test battery volt to check whether it is in range of 44v-52v; If it is in the range, to switch the inverter one to check whether the unit starts. If the unit does not run yet, please disconnect all connections and open the surface panel, take out the main board, then to check and repair according to First to replace the fan, to check whether it is okay; if NG, please inspect the main board and repair according to Please to check the main board and repair according to Please to check first and then to repair the main board according to 3.1, 3.6 and First to start up the inverter by only connecting battery, if the fault is still on, please inspect the main board following 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, 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 and First to check the connection of battery cable, if good connection, then please to check and repair the main board following and 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, and accordingly 72 To replace the control board - 3 -
6 3. Steps to Repair 3.1 Battery Working Mode Test To Check DC FUSE and Capacitance F1-F6: (Fuse, F40A/32VDC UL) F1-F6 Resistor 0 ohm open C19,C20,C39,C40: (Electrolytic Capacitor, 4200uF 35V M RAD 7.5mm 105 ) - 4 -
7 If the capacitors explode, they need to be replaced. Service Manual DC/DC Boost Module :MOSFET TI/CSD19505KCS 201A 80V N BULK TO-220 G D S All MOSFET, 8pcs Diode SD:0.44V DS:OL Short-circuit or Explosion Note If one or more than one of them were broken, please replace all of them. For 2K, the main board has just 6pcs MOSFETS
8 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. R373,R7,R8,R9,R10,R11,R12,R13,R14,R79,R257 All the resistors are (RES CHIP TF 1/4W 10 F(1206)) 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. All Resistors: Resistor 22 ohm Open Circuit 10 ohm or other value If resistors are need to replace, please check the diver transistors and controlling IC
9 UC2 UC1 UC3 UC4 E C B UC2,UC4: (Plug-in Transistor TOSHIBA/2SC2655-Y 2A 50V) UC1,UC3: (Plug-in Transistor TOSHIBA/2SA1020-Y 2A 50V) - 7 -
10 UC2,UC4 Diode BE:0.6V BC:0.6V CE:1V UC1,UC3 Diode BE:0.6V BC:1.3V CE:0.2V Short-circuit or burnt Short-circuit or burnt Pin16 Pin16 Pin9 Pin9 Pin1 Pin1 Pin8 U3: ( Plug-In : IC LINEAR FAIRCHILD/KA3525A) U3 Diode Pin11-Pin12:5.4M Pin13-Pin12: 60K Pin14-Pin12: 5.4M Short Circuit or Burnt If unable to make sure which components, we would like to suggest to replace them all
11 3.2 To Check BUS Module Rectifier Diode Rectifier Diode: D17,D18,D19,D20 D20 D19 D18 D D17,D18,D19,D20: (FAIR./RHRP1560_NL 15A 600V) D17,D18,D19,D20 Diode +to-: 0.37V Q28Short Circuit -to+: OL or Broken Note: If there is one or more than one components broken, please replace them all
12 3.3 To Check Full-Bridge Invert Circuit Power Parts Q16,Q17,Q18,Q19: (IGBT IR/IRGP4063D-EPBF 48A 600V TO-247) Q19 Q18 Q18 Q17 Q17 Q16 G C E Q16,Q17,Q18,Q19 Diode EC: 0.4V Short Circuit CE: OL or Broken Divers INV IGBT: Q16,Q17,Q18,Q
13 R64 R63 R61 R60 D12 ZD3 R53,R55,R60,R63: (SMD Resistor CHIP TF 1/4W 4.7 F(1206)) R54,R56,R61,R64: (SMD Resistor CHIP TF 1/4W 100 F(1206)) ZD2,ZD3: (SMD Zen-er Diode PAN JIT 1SMA V 1W SMD) D10,D12: (SMD Diode PANJIT/SS14 1A 40V SMD) R54 R53 D10 ZD3 R56 R55 R53,R55,R60,R63 Resistor 4.7 ohm Open Circuit or R54,R56,R61,R64 Resistor 100 ohm other value ZD2,ZD3 Diode + to -: 0.6V - to +: OL D10,D12 Diode + to -: 0.6V - to +: OL Short Circuit or Broken
14 3.3.3 To Check Drivers U24,U25,U26,U27: (IC Driver Chip FOD3120 SMT) 8 1 U24,U25,U26,U27 Resistor Pin8-Pin5: 2K Short Circuit Pin7-Pin5:2K or Broken C150/C151: ( SMD Capacitors CER MT 10nF 50V J NPO 103 (0805)) C150/C151 Capacitors 10nF Short Circuit or Broken
15 3.4 To Check AC Charging Circuit To Check Power Components Q20,Q21,Q22: ( Plug-in Transistor TSB/2SK3878 9A 900V N TUBE TO-3PN) Q20 Q21 Q22 E C G Q20,Q21,Q22 Diode EC: 0.4V CE: OL Short Circuit or Broken Note: If there is one or more than one components broken, please replace them all Drivers R259,R261,R263: ( SMD Resistor CHIP TF 1/4W 10 F(1206)) R258,R260,R262: ( SMD Resistor CHIP TF 1/4W 100 F (1206)) D56/D57/D58: ( SMD Diode PANJIT/1N4148W 0.15A 75V SOD123)
16 R259,R261,R263 Resistor 10 ohm Open Circuit or R258,R260,R262 Resistor 100 ohm other value D56/D57/D58 Diode EC: 0.6V CE: OL Short Circuit or Broken Note: When test diodes, please remove R259, R261, R263, otherwise the test result is not right. UC3843: U28 U28: (Plug-in IC LINEAR ON/UC3843BNG) U28 Resistor Pin7-Pin5: 42K ; Pin6-Pin5: 30K Short Circuit or Broken
17 3.5 To Check Rectifier Circuit Charging Circuit D21/D22/D23: (Plug-in Diode ON/MBR20200CT 20A 200V SCKY RAD BULK) D22 D22 D23 P N P D23 D22 D22 REC1: ( Plug-in Diode HY/GBU8M 8A1000V ) + ~ ~
18 D21/D22/D23 Diode P to N: 0.44V ; N to P: OL Short Circuit REC1 Diode ~ to +: 0.47V ; + to ~: OL or Broken - to ~: 0.47; ~ to -: OL 3.6 To Check Power Circuit Q1: ( Plug-in Transistor MOSFET IR/IRF640NPBF18A 200V) R1: ( Plug-in Resistor 3WS 0.15 J Rack F4) U2: (IC PWM ON/UC3845BD1R2G L-1 SMD SOP-8)
19 Q1 ZD4 D1 G D S R1 O R31 I CE6 8 1 U2 U11 G CE6: (Electrolytic Capacitor 470uF35V M 5mm *16mm Tape) If the capacitor appears burst, please replace it. R31: ( SMD Resistor CHIP TF 1/4W 2.2 F (1206) ) D1: (Plug-in Diode PAJIT/UF204 2A 400V ULTRAFAST AXI) ZD4: ( SMD Zen-er Diode PAN JIT 1SMA V 1W SMD ) U11: (IC ON/MC78M05CDTG DPAK-3 SMD) R90 R94 ZD12 R94: ( SMD Resistor CHIP TF 1/4W 4.7 F (1206)) R90: (SMD Resistor CHIP TF 1/4W 20 F(1206)) ZD12: ( SMD Diode ON/1SMA5931BT3G DO214AC1.5W 18V SMD)
20 R99: ( SMD Resistor CHIP TF 1W 2.2 F (0207) ) D34: (SMD Diode ON/MURA120T3 1A 200V 403D SMD) Q1 Diode SD: 0.5V ; DS: OL Short Circuit D1 Diode + to -: 0.47V ; - to +: OL or Broken ZD4 Diode + to -:0.4V ; - to +:OL ZD12 Diode + to -:0.4V ; - to +: OL D34 Diode + to -: 0.47V ; - to +: OL U11 Resistor I to O to G:OL R99 Resistor 2.2omh Open Circuit or R1 Resistor 0.15omh other Value R31 Resistor 2.2omh R94 Resistor 22 ohm R90 Resistor 4.7omh U2 Resistor Pin7-Pin5:42K;Pin6-Pin5: 30K Short Circuit or Broken
21 3.7 To Check MOSFETS for Reversed Protection on DC Terminal Please open the cover and measure as follows. PV - BAT - PV - to BAT - Resistor >10K Short Circuit If in Short Circuit, Please replace MOSFET in Main Board. Q12,Q13,Q14,Q40: (MOSFET IR/IRFB3206PBF 210A 60V N TO-220AB) Q40 Q14 Q13 Q
22 3.8 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 NTC in position of HS3 plugs in position of SW1 on main board. SW1 SW1 SW1 SW1 After taking cover: SW1: ( Thermistor KI66-120B5 120 KW) SW1 Resistor 0.1 ohm Open Circuit If it is not possible to check functioning, please make NTC short-circuit and test the inverter again; if the fault disappears, it means the NTC is wrong NTC1 under Transformer NTC1: 100-A ( Thermistor NTC 47K 240mW SMD 0805)
23 NTC4 Resistor 5.7K ohm Short Circuit or Open Circuit NTC in HS4 NTC_HS4: (Thermistor NTC 15K 2.5mA KW) NTC4 NTC4-21 -
24 NTC_HS4 Resistor 5.5K ohm Short Circuit or other value If it is not possible to check functioning, please make NTC short-circuit and test the inverter again; if the fault disappears, it means the NTC is wrong. 3.9 To Check Fan Drive Circuit CN10 CN8-22 -
25 R319/R K ohm Short Circuit or R321/R325/R326/R331 Resistor 10K ohm Other Value R320/R ohm D62/D65 Diode + to -:0.6V ; - to +: OL Short Circuit or Q34/Q35 SD: 0.5V ; DS: OL Burst 4. Other Common Faulty Cases 4.1 MOSFET Burnt 4.2 Input Cable Disconnection
26 4.3 Dust-covered Control Board 5. Assembling Guidance 5.1 Unfix Upper Cover Unscrew four screws of the cover as following Pluck LCD disconnection cable and take the cover
27 5.2 Unfix Power Board To take the Air-duct Paper To take five plastic nails in heat sink and take out the air-duct paper To pluck AC input and output cable and fan connection cable
28 5.2.3 To Remove PV Connection Cable To Remove the two screws on the side and take out the middle clapboard Unscrew the two screws in control board and take the control board out
29 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
30 + - Afterwards, please Turn ON the unit. 6.2 To connect with AC Grid for testing
31 6.3 To connect PV for testing
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