Hybrid 10KW Service Manual 201910A
Hybrid 10KW Service Manual 201910A
Service manual
1
Hybrid 10KW Service manual
Table of contents
1. General information ........................................................................................................................................................ 3
1.1 Getting start ......................................................................................................................................................... 3
1.2 Important safety instructions ............................................................................................................................. 3
2. Introduction of the inverter ............................................................................................................................................. 4
2.1 Basic information ................................................................................................................................................ 4
2.2 Functional topology ............................................................................................................................................ 4
2.3 Main board ........................................................................................................................................................... 5
2.4 DC-DC board ....................................................................................................................................................... 6
2.5 SPS board ............................................................................................................................................................ 7
2.6 PV EMI board ...................................................................................................................................................... 7
2.7 CNTL board ......................................................................................................................................................... 7
2.8 Relay board.......................................................................................................................................................... 8
2.9 Grid board ............................................................................................................................................................ 8
2.10 OP board .............................................................................................................................................................. 8
3. Trouble shooting ............................................................................................................................................................. 9
3.1 Check the fault information ................................................................................................................................ 9
3.2 Check the PCBs ................................................................................................................................................ 17
4. Appendix ........................................................................................................................................................................ 35
4.1 PCBs replacement guideline ........................................................................................................................... 35
4.2 Signal cables connection guideline ................................................................................................................ 44
2
Hybrid 10KW Service manual
1. General information
This manual is for Hybrid 10k, it can help service personal perform the basic maintenance and repair service.
This manual focus on the service, so you should get the basic operation of the inverter from the user manual, and
make sure you had read and understood user manual before you use this service manual.
3
Hybrid 10KW Service manual
This chapter will introduce the topology and each board of the inverter; it will give us the basic impression of the
inverter.
Load relay
OP board
LOAD
+ Three L1/L2/L3
PV1 +
EMI1 Boost1 Bridge INV EMI AC EMI GRID
- - INV/REC N
Relay Cntl
Grid board Grid Voltage&Frequecny
+
PV2 EMI2 Boost2
Relay
DC-DC DC-DC board board
DC-DC Cntl
PV
BAT
SPS
GRID
-
+
BAT
SPS board
COM
INV Current
MASTER SLAVE
COMM
Load Current
DSP DSP INV Voltage&Frequecny
I/P Voltage&Frequecny
Insulation dectec
GFCI COMM board
PV Voltage
Control board
There are four factors of the inverter: PV, battery, grid and load. PV and load is the single direction, PV only uses
for input, and load for output. Batter and grid is the bi-direction, cause the battery can be charged and also can
discharge, grid can be input and output. With these factors, we can make several combinations to meet every
application, maximum the availability of the power system.
4
Hybrid 10KW Service manual
The main board contains the Boost1, Boost2 and INV/REC module. Boost module takes in charge of MPPT from
solar. It transfers the energy from the solar to the BUS. INV/REC module, just as its name implies, it can invert the
energy from the BUS to grid or load; also it can convert the energy from the grid to the BUS.
The figure shows as below, and relevant modules are marked in red box.
5
Hybrid 10KW Service manual
DC-DC board only contains DC-DC module, the energy flows through this module between BUS and battery.
When the battery discharges, the energy flows from battery to BUS. When the battery is being charged, the
energy flows from BUS to battery. On the board, there are two symmetrical DC-DC module, each one supports
5KW.
The figure shows as below, and relevant modules are marked in red box.
DC-DC1 DC-DC2
BUCK-BOOST2
BUCK-BOOST1
6
Hybrid 10KW Service manual
7
Hybrid 10KW Service manual
IP board includes the input relay and EMI solution at grid input.
2.10 OP board
OP board includes the output relay and EMI solution at load side.
8
Hybrid 10KW Service manual
3. Trouble shooting
This section describes how to find the trouble when the system is abnormal. We suggest you can follow the
service procedure:
a. Check the system status by LCD display.
b. Observe the failure board, static checking.
c. Replace the failure board.
e. Power up checking.
f. Test after repair.
Following these sections will help service person to solve most of problem.
Note: The numbers with means fault code; with means warning code. Please clarify them.
9
Hybrid 10KW Service manual
Error 01
Error 01 means BUS voltage is overt the limitation. Please disconnect the load, and restart the inverter to
have a check.
If the inverter can work normally after the restarting, error 01 is usually caused by the surge from the utility
input or the energy feedback from the load.
If the error persists, please check:
If the error 01 happens immediately when the LCD is on, usually this is the control board problem, you can
change the control board to have a check.
If the error 01 happens when the output is available or charging, the possible cause is the DC-DC or main
board, please contact with us to do the diagnose together.
Error 02
Error 02 means BUS voltage is under the limitation. Please disconnect the load, and restart the inverter to
have a check.
If the inverter can work normally after the restarting, error 02 is usually caused by the solar or load
fluctuation.
If the error persists, the possible cause is the DC-DC board or control board.
Error 03
Error 03 means BUS soft start is failed.
Before the inverter turns on the output or starts charging, the SPS board will charge the BUS capacitors to
700~800V, and then the DC-DC board will be activated, to keep the BUS voltage at 700~800V. If everything
is OK, then the inverter will turn on the inverting module. If the voltage couldn’t reach 700~800V or stay at
this level, the error 03 will come out.
Error 03 is related to the main board, DC-DC board, SPS board and control board.
If you have the multimeter, it will help you to find out which board causes the error 03.
First, please find the BUS+, neutral and BUS- on the main board or DC-DC board, and follow the table as
below to do the measurement.
Table 3.1
Red probe Black probe Test value Reference values Failure status
BUS+ Neutral Diode voltage OL Less than 3V
Neutral BUS+ Diode voltage 0.4~0.7V Open or short
Neutral BUS- Diode voltage OL Less than 3V
BUS- Neutral Diode voltage 0.4~0.7V Open or short
10
Hybrid 10KW Service manual
If the reading is right, and still error 03, it’s usually the control board problem; you can change it and check
again.
If the reading is not right, it means that the issue is among the main board, DC-DC board and SPS board.
First, you can unplug this cable on the SPS board,
And then measure the diode voltage on the terminal CN7 of the SPS board by following table 3.1.
11
Hybrid 10KW Service manual
Error 04
Error 04 means inverting soft start is failed.
After bus soft start is finished, and DC-DC board is turned on. The controller will turn on the inverting module,
it will output the voltage from 0V to 230V (phase to neutral). If the voltage couldn’t reach 230V after a time,
the inverter will give error 04.
Error 04 is related to the main board, and control board.
Please replace the control board and main board both, it will solve error 04.
Error 05
Error 05 means inverting current is overt the limitation. Please disconnect the load, and restart the inverter to
have a check.
If the inverter can work normally after the restarting, error 05 is usually caused by the surge from the utility
input or the energy feedback from the load.
If the error persists, please check:
If the error 05 happens immediately when the LCD is on, the problem is related with SPS board, control
board, HCT board and parallel board.
If the error 05 happens when the output is available or charging, the problem is related with the main board,
please replace it to have a check.
Error 06
Error 06 means over temperature. Please disconnect the load, and restart the inverter to have a check.
If the error still persists even the inverter has cooled down, it means the temperature sensors are wrong.
We have the sensors on main board and DC-DC board. Please contact with us, we will provide a special
firmware for you to diagnose which sensor is wrong.
Error 07
Error 07 means relay checking fail. This error is usually caused by the rusting on the board which it is due to
the dust and moisture.
This error is related to the grid board, HCT board, and relay board. Please change these boards, this error
will be solved.
Error 08
Error 08 means DC current sensors are wrong. We have DC current sensors on main and DC-DC boards.
You can contact with us for the special firmware, it will help to identify which sensor is wrong. Or you can
follow as below to check which sensor is wrong.
Please find the terminals as below on the control board:
12
Hybrid 10KW Service manual
Unplug them, and put the jumper (Or use something to short them) on the terminal like as below:
13
Hybrid 10KW Service manual
Error 09
Error 09 means solar input power is not normal. Please restart the inverter to check.
This error is very rare to see, if you face this error, please contact with us.
Error 11
Error 11 means solar input is over current. This error is very rare to see, if you face this error, please contact
with us.
Error 12
Error 12 means leakage current is over the limitation.
For our inverter is the transformerless type, it means there is no galvanic isolation between the solar and
grid.
The loop of the leakage current will be like as below:
Generally the photovoltaic cells are isolated with the ground, but sometimes, it may have the isolation
problem, like the cable is broken or sinking in the water, the glass of the panels has something wrong. These
factors may cause leakage current from solar panels to ground.
By following the safety standard, the inverter needs to cut off the utility input if the current is over the
limitation.
Please check the installation of the solar panels to solve this error.
If the error persists without solar panels connected, the senor of the leakage current is failed; you can change
the PV EMI board to solve it.
Error 13
Error 13 means the isolated resistance of the solar panels is too low. If the error persists after you choose
“Grid tie with backup” or “Off-grid mode”, please contact with us.
Error 14
Error 14 means the DC component of the output current is over the limitation when the grid is connected in.
This error only happens when the grid is connected in.
If the error persists when you restart the inverter, the error is related to the main board or HCT board. You can
change these boards to have a check.
14
Hybrid 10KW Service manual
Error 16
Error 16 means the self-checking of the leakage current sensor is failed. Please replace the PV EMI board to
solve the issue.
Error 22
Error 22 means the battery voltage is too high. Please check the real voltage and the voltage showed in the
LCD display.
If the voltage is higher than 60V, this error will happen.
Error 23
Error 23 means the overload is activated.
Please check if some loads are too heavy for the inverter. Like air conditioner, pump and motors, this kind of
loads demand large inrush current when they start up. The recommended rating of these loads is less than
1/3 rating of the inverter.
Error 26
Error 26 means the output is shorted. It is usually caused by the load output connection is shorted.
Please check if the wire connection of the load is shorted, or the load is shorted by itself.
Error 27
Error 27 means the fans are blocked. When this error happens, please check if there is any fan stop working.
Usually this error is caused by fans stop working. In few cases, it is caused by SPS board.
Error 32
Error 32 means the DC component of the output voltage is over the limitation. This error only happens when
the inverter is in battery mode.
Some loads like drier, they are half waveform consumer, and they will create the DC component on the
voltage.
The recommended rating of these loads is less than 1/2 rating of the inverter.
Error 33
Error 33 means the output voltage is lower than limitation. This error is similar with error 23.
Error 34
Error 34 means the output voltage is too high. This error is similar with error 04.
Error 35
Error 35 means the wire connection is not well. Please check the cables if they are
tighten connected on the control board and the other boards connected with
control board.
The cable shown in the figure will cause error 35.
Error 36
This error has been canceled, if you have this error, please contact with us.
15
Hybrid 10KW Service manual
Error 37
Error 37 means the current is over limitation on the input neutral.
If the error persists without any loads, please replace the relay board.
Error 60
Error 60 means the power is not balance between each inverter which is working in parallel with each other.
Please disconnect the grid input, and check if the load percentage is the same in the LCD display of each
inverter.
This error is usually caused by the parallel board.
Error 61 and 62
Error 61 and 62 means relay board is failed, please change it to check.
Error 72
Error 72 means the current sharing control is failed.
This error is related with parallel board, sometimes control board also.
When do parallel installation, please make sure that the output neutral of each inverter should be connected
always, or it may cause error 72.
16
Hybrid 10KW Service manual
In most situations, we need to take the PCBs out of the inverter and do some static measurement, then we can
realize which part is damaged, and replace the relevant boards or components.
Most fault conditions are due to the damaged of the power board, including main board, DC-DC board, and
sometimes SPS board.
17
Hybrid 10KW Service manual
All of the IGBTs are 11-330086-00G( IGBT FC/FGH40T120SMD 40A 1200V NPT BULK TO-247)
All of the Diode are 11-200039-00G(D FAIRCHILD/RHRG75120 75A 1200V SFST RAD BULK)
18
Hybrid 10KW Service manual
Reference
Parts Attribute Failure status
values
GE: 16.7k
Resistor GC: 176k
Q3/Q4/Q5 /Q11/Q12/Q13 CE: 1M Short or explosion
CE: 0.4V
Diode
EC: OL
+ to -: 0.4V
D4/D6/D31/D12/D13/D40 Diode Short or explosion
- to +: OL
19
Hybrid 10KW Service manual
R-phase INV/REC:IGBT1/IGBT2/IGBT3/IGBT4/D5/D11/D16/D17
S-phase INV/REC: IGBT5/IGBT6/IGBT7/IGBT8/D21/D25/D26/D27
T-phase INV/REC: IGBT18/IGBT19/IGBT21/IGBT23/D24/D28/D32/D33
Reference Failure
Parts component Attribute
values status
GE: 44k
IGBT1/IGBT4/IGBT5/IGBT8/IGBT18/I
FC/FGL40N120AND GC: 200k
GBT23
CE: 1M
Resistor
GE: 44k
GC: 260k Short or
IGBT2/IGBT3/IGBT6/IGBT7IGBT19/IG explosion
IR/IRGP4266DPBF CE: OL
BT21
EC: 0.4V
Diode
CE: OL
20
Hybrid 10KW Service manual
21
Hybrid 10KW Service manual
DC-DC2 MOSFET:
Q49/Q50/Q51/Q52/Q53/Q54/Q55/Q56/Q57/Q58/Q59/Q60/Q61/Q62/Q63/Q64/Q65/Q66/Q67/Q68
22
Hybrid 10KW Service manual
ALL of the mosfets are 11-320117-00G (MOSFET IR/IRFB3077 210A 75V N BULK TO-220)
Parts Attribute Reference values Failure status
All: IRFB3077 Resistor1 GS: 9.4k
GD: 230k
DS: 2.4M Short or explosion
Diode SD: 0.41V
DS: OL
Note1: When you use the multimeter to measure the resistor of the transistor, because of the capacitor in the
circuit, it will cause the changing of the values when you measure the DS and GD. So we recommend you
measure the diode forward voltage of SD, and the resistor of GS. These two values can reflect the situation of the
transistor more correctly.
23
Hybrid 10KW Service manual
ALL of the IGBTs are 11-330087-00G (IGBT IR/IRGP4266DPBF 90A 650V N BULK TO-247)
24
Hybrid 10KW Service manual
25
Hybrid 10KW Service manual
ALL of the IGBTs are 11-330087-00G (IGBT IR/IRGP4266DPBF 90A 650V N BULK TO-247)
Parts Attribute Reference values Failure status
Q21/Q22/Q25/Q26 Resistor1 GE: 23.5k Short or explosion
Q71/Q72/Q73/Q76 GC: 215k
CE: OL
Diode EC: 0.38V
CE: OL
26
Hybrid 10KW Service manual
27
Hybrid 10KW Service manual
DS: OL
Diode SD: 0.5V
DS: OL
R251 Resistor 0.1ohm Open or other values
D66/D67 Resistor + to -: 230k Short or explosion
- to +: OL
Diode + to -: 0.44V
- to +: OL
U16 Resistor PIN7 TO PIN5: 1.5k Short or explosion
PIN6 TO PIN5: 1.2k
TX2 PIN7&PIN9 and PIN9&PIN12 need to be measured. The reference value is about 1.5ohm. If it is not, please
replace the TX2 also.
TX2: 41-070250-00G (TX 120:13:120 FER ER28/28)
Step 2: Check the battery switching power supply circuit:
28
Hybrid 10KW Service manual
29
Hybrid 10KW Service manual
+ to -: 91ohm
Resistor
- to +: 350k
D24 Short or explosion
+ to -: 0.09V
Diode
- to +: 2.0V
+ to -: 272ohm
Resistor
- to +: 1.5k
D27 Short or explosion
+ to -: 0.27V
Diode
- to +: 1.1V
PIN7 TO PIN5: 2k
U7 Resistor Short or explosion
PIN6 TO PIN5: 16k
30
Hybrid 10KW Service manual
+ to -: 0.46V
Diode
- to +: OL
+ to -: 227k
Resistor
- to +: OL
D5/D41 Short or explosion
+ to -: 0.44
Diode
- to +: OL
GS: 21ohm
Resistor GD: 227.3k
Q14/Q18 DS: OL Short or explosion
SD: 0.44V
Diode
DS: OL
32
Hybrid 10KW Service manual
+ to -: 0.44V
Diode
- to +: OL
GS: 21ohm
Resistor GD: 227.3k
Q7/Q8 DS: OL Short or explosion
SD: 0.44V
Diode
DS: OL
After checking, please provide the information to the supplier or local service.
34
Hybrid 10KW Service manual
4. Appendix
35
Hybrid 10KW Service manual
36
Hybrid 10KW Service manual
WARNING! The screws marked in YELLOW should be screwed tightly. Or when inverter works, it will
cause the electrical hazard.
WARNING! The connector marked in YELLOW should be connected tightly. Or when inverter works, it will
cause the electrical hazard.
37
Hybrid 10KW Service manual
WARNING! The screws marked in YELLOW should be screwed tightly. Or when inverter works, it will
cause the electrical hazard.
38
Hybrid 10KW Service manual
WARNING! The connector marked in YELLOW should be connected tightly. Or when inverter works, it will
cause the electrical hazard.
39
Hybrid 10KW Service manual
40
Hybrid 10KW Service manual
41
Hybrid 10KW Service manual
42
Hybrid 10KW Service manual
43
Hybrid 10KW Service manual
Single unit:
44
Hybrid 10KW Service manual
Parallel unit:
45