Service Manual

PV18-2K/3K HM

Inverter/Charger
PV1800 2K/3K HM

Service Manual
 Service Manual
PV18-2K/3K HM

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. Steps to Repair .......................................................................................................... 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.............................................................................................................6
3.2 To Check BUS Module............................................................................................9
3.2.1 Rectifier Diode................................................................................................9
3.3 To Check Full Bridge Invert Circuit........................................................................10
3.3.1 Power Devices...............................................................................................10
3.3.2 Divers.............................................................................................................10
3.3.3 To Check Drivers............................................................................................12
3.4 To Check AC Charging Circuit................................................................................13
3.4.1 To Inspect Power Components as.................................................................13
3.4.2 To Check Drivers............................................................................................13
3.5 To Check Rectifier Circuit.......................................................................................15
3.5.1 Charging Circuit.............................................................................................15
3.6 To Check Power Circuit.........................................................................................16
3.7 To Check MOSFETS for Reversed Protection on DC Terminal.............................19
3.8 To Check NTC Circuit.............................................................................................20
3.8.1 NTC in position of HS3 plugs in position of SW1 on main board..................20
3.8.2 NTC1 under Transformer...............................................................................20
3.8.3 NTC in HS4...................................................................................................21
3.9 To Check Fan Driver Circuit ..................................................................................22
4. Other Common Faulty Cases......................................................................................23
4.1 MOSFET Burnt.......................................................................................................23
4.2 Input Cable Disconnection......................................................................................23
4.3 Dust-covered Control Board...................................................................................24
5. Assembling Guidance..................................................................................................24
6. Test Guidance after Repairing.....................................................................................26
 Service Manual
PV18-2K/3K HM

1. General Information

1.1 Brief Introduction

This manual is used as a tool of inspection and repairing guidance for
PV18-2K/3K HM, 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:

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1.3 Over review and Introduction of Inverter /charger Parts

Main Board
Solar Charge Controller
& Control 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 3.9
02 Please to check the main board and repair according to 3.8
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 3.3
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

F1-F6: 180-00001-00 (Fuse, F40A/32VDC UL)

Positioning Attribute Reference Value Failure Status

F1-F6 Resistor 0 ohm open

C19,C20,C39,C40: 140-00093-00 (Electrolytic Capacitor, 4200uF 35V M RAD 7.5mm

105℃)

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PV18-2K/3K HM
If the capacitors explode, they need to be replaced.

3.1.2 DC/DC Boost Module

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

G D S

Positioning Attribute Reference Value Failure Status

All MOSFET, 8pcs Diode SD:0.44V Short-circuit
DS:OL 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.

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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.

R373,R7,R8,R9,R10,R11,R12,R13,R14,R79,R257
All the resistors are 100-10010-00 (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.

Positioning Attribute Reference Value Failure Status

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.

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UC2 UC1

UC3
UC4

E C B

UC2,UC4:150-00005-00 (Plug-in Transistor TOSHIBA/2SC2655-Y 2A 50V)

UC1,UC3:150-00004-00 (Plug-in Transistor TOSHIBA/2SA1020-Y 2A 50V)

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Positioning Attribute Reference Value Failure Status
UC2,UC4 Diode BE:0.6V Short-circuit or burnt
BC:0.6V
CE:1V
UC1,UC3 Diode BE:0.6V Short-circuit or burnt
BC:1.3V
CE:0.2V

Pin16 Pin9
Pin16 Pin9

Pin1Pin1 Pin8
Pin8

U3: 160-00006-00 ( Plug-In : IC LINEAR FAIRCHILD/KA3525A)

Positioning Attribute Reference Value Failure Status

U3 Diode Pin11-Pin12:5.4M Short Circuit or Burnt
Pin13-Pin12: 60K
Pin14-Pin12: 5.4M

If unable to make sure which components, we would like to suggest to replace them all.

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3.2 To Check BUS Module

3.2.1 Rectifier Diode

Rectifier Diode: D17,D18,D19,D20

D20
D19
D18
D17

- +

D17,D18,D19,D20: 150-10042-00 (FAIR./RHRP1560_NL 15A 600V)

Positioning Attribute Reference Value Failure Status

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.

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3.3 To Check Full-Bridge Invert Circuit

3.3.1 Power Parts

Q16,Q17,Q18,Q19:150-30088-00 (IGBT IR/IRGP4063D-EPBF 48A 600V TO-247)

Q18
Q17
Q19
Q18
Q17
Q16

G
C
E
Positioning Attribute Reference Value Failure Status
Q16,Q17,Q18,Q19 Diode EC: 0.4V Short Circuit
CE: OL or Broken

3.3.2 Divers

INV IGBT: Q16,Q17,Q18,Q19

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PV18-2K/3K HM

D12 ZD3
R64 R63 R61 R60

R53,R55,R60,R63: 100-17047-00 (SMD Resistor CHIP TF 1/4W 4.7 F(1206))

R54,R56,R61,R64: 100-10100-00 (SMD Resistor CHIP TF 1/4W 100 F(1206))
ZD2,ZD3: 120-20072-00 (SMD Zen-er Diode PAN JIT 1SMA4745 16V 1W SMD)
D10,D12: 120-20007-00 (SMD Diode PANJIT/SS14 1A 40V SMD)

-
-
+ +
ZD3 R56 R55
R54 R53 D10

Positioning Attribute Reference Value Failure Status

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 Short Circuit
- to +: OL or Broken
D10,D12 Diode + to -: 0.6V
- to +: OL

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3.3.3 To Check Drivers

U24,U25,U26,U27: 120-10065-00 (IC Driver Chip FOD3120 SMT)

Positioning Attribute Reference Value Failure Status

U24,U25,U26,U27 Resistor Pin8-Pin5: 2K Short Circuit
Pin7-Pin5:2K or Broken

C150/C151: 110-10040-00 ( SMD Capacitors CER MT 10nF 50V J NPO 103 (0805))

Positioning Attribute Reference Value Failure Status

C150/C151 Capacitors 10nF Short Circuit
or Broken

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3.4 To Check AC Charging Circuit

3.4.1 To Check Power Components

Q20,Q21,Q22: 150-30032-00 ( Plug-in Transistor TSB/2SK3878 9A 900V N TUBE

TO-3PN)

Q20 Q21 Q22

E C G

Positioning Attribute Reference Value Failure Status

Q20,Q21,Q22 Diode EC: 0.4V Short Circuit
CE: OL or Broken
Note: If there is one or more than one components broken, please replace them all.

3.4.2 Drivers

R259,R261,R263: 100-10010-00 ( SMD Resistor CHIP TF 1/4W 10 F(1206))

R258,R260,R262: 100-10100-00 ( SMD Resistor CHIP TF 1/4W 100 F (1206))
D56/D57/D58: 120-20001-00 ( SMD Diode PANJIT/1N4148W 0.15A 75V SOD123)

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Positioning Attribute Reference Value Failure Status
R259,R261,R263 Resistor 10 ohm Open Circuit or
R258,R260,R262 Resistor 100 ohm other value
D56/D57/D58 Diode EC: 0.6V Short Circuit
CE: OL or Broken
Note: When test diodes, please remove R259, R261, R263, otherwise the test result is not
right.

UC3843: U28

U28: 160-00001-00(Plug-in IC LINEAR ON/UC3843BNG)

Positioning Attribute Reference Value Failure Status

U28 Resistor Pin7-Pin5: 42K ; Pin6-Pin5: 30K Short Circuit
or Broken

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3.5 To Check Rectifier Circuit

3.5.1 Charging Circuit

D21/D22/D23: 150-10061-00 (Plug-in Diode ON/MBR20200CT 20A 200V SCKY RAD

BULK)

D22
D22

D23

P N P
D23 D22
D22

REC1: 150-10066-00 ( Plug-in Diode HY/GBU8M 8A1000V )

+ ～ ～ -

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Positioning Attribute Reference Value Failure Status
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: 150-30005-00 ( Plug-in Transistor MOSFET IR/IRF640NPBF18A 200V)
R1: 130-00211-00 ( Plug-in Resistor 3WS 0.15 J Rack F4)
U2: 120-10052-00 (IC PWM ON/UC3845BD1R2G L-1 SMD SOP-8)

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D1
Q1 ZD4

G R31
S R1
D CE6
O I

8 U11
U2
G
1

CE6: 140-00044-00 (Electrolytic Capacitor 470uF35V M 5mm 105℃ 10*16mm Tape) If

the capacitor appears burst, please replace it.
R31: 100-17022-00 ( SMD Resistor CHIP TF 1/4W 2.2 F (1206) )
D1: 150-10009-00 (Plug-in Diode PAJIT/UF204 2A 400V ULTRAFAST AXI)
ZD4: 120-20072-00 ( SMD Zen-er Diode PAN JIT 1SMA4745 16V 1W SMD )
U11: 120-10037-00 (IC ON/MC78M05CDTG DPAK-3 SMD)

R90

R94 ZD12

R94: 100-17047-00 ( SMD Resistor CHIP TF 1/4W 4.7 F (1206))

R90: 100-10020-00 (SMD Resistor CHIP TF 1/4W 20 F(1206))
ZD12: 120-00060-00 ( SMD Diode ON/1SMA5931BT3G DO214AC1.5W 18V SMD)

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R99: 100-30022-00 ( SMD Resistor CHIP TF 1W 2.2 F (0207) )

D34: 120-20048-00 (SMD Diode ON/MURA120T3 1A 200V 403D SMD)

Positioning Attribute Reference Value Failure Status

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

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3.7 To Check MOSFETS for Reversed Protection on DC Terminal

Please open the cover and measure as follows.

PV -

BAT -

Positioning Attribute Reference Value Failure Status

PV - to BAT - Resistor >10K Short Circuit

If in Short Circuit, Please replace MOSFET in Main Board.

Q12,Q13,Q14,Q40: 150-30060-00 (MOSFET IR/IRFB3206PBF 210A 60V N TO-220AB)

Q40 Q14 Q13 Q12

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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.

3.8.1 NTC in position of HS3 plugs in position of SW1 on main board.

SW1
SW1

SW1
SW1

After taking cover:

SW1: 130-20034-01 ( Thermistor KI66-120B5 120℃ KW)

Positioning Attribute Reference Value Failure Status

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.

3.8.2 NTC1 under Transformer

NTC1: 100-A0002-00 ( Thermistor NTC 47K 240mW SMD 0805)

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Positioning Attribute Reference Value Failure Status

NTC4 Resistor 5.7K ohm Short Circuit or Open Circuit

3.8.3 NTC in HS4

NTC_HS4: 130-20005-00 (Thermistor NTC 15K 2.5mA KW)

NTC4
NTC4

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Positioning Attribute Reference Value Failure Status

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

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Positioning Attribute Reference Value Failure Status
R319/R329 100K ohm
Short Circuit or
R321/R325/R326/R331 Resistor 10K ohm
Other Value
R320/R330 100 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

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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

5.1.2 Pluck LCD disconnection cable and take the cover

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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

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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