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SERVICE MANUAL 3KVA/5KVA-230V
3KVA/5KVA-230V
Service manual
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SERVICE MANUAL 3KVA/5KVA-230V
Table of contents
1. General information .............................................................................................................................................. 3
1.1 Getting start ................................................................................................................................................. 3
1.2 Basic topology introduction ....................................................................................................................... 3
1.3 Inverter family.............................................................................................................................................. 4
1.4 Overview the inverter ................................................................................................................................. 4
1.5 PCB overview.............................................................................................................................................. 5
2. Troubleshooting .................................................................................................................................................... 6
2.1 How to do..................................................................................................................................................... 6
2.2 Check the fault information ....................................................................................................................... 6
2.3 Fault condition............................................................................................................................................. 7
2.4 Test step....................................................................................................................................................... 8
3. Checking and measuring guide .......................................................................................................................... 9
3.1 Check the battery side components ........................................................................................................ 9
3.2 Check the bus side components ............................................................................................................ 16
3.3 Check the buck circuit.............................................................................................................................. 18
3.4 Check the INV full bridge ........................................................................................................................ 20
3.5 Check the MPPT board ........................................................................................................................... 22
4. Disassembling guide .......................................................................................................................................... 23
4.1 Remove the REMOTE BOX ................................................................................................................... 23
4.2 Open the case........................................................................................................................................... 23
4.3 Remove all boards.................................................................................................. !
5. Cables connection .............................................................................................................................................. 27
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1. General information
1.1 Getting start
This manual is used as a checking and repairing guide for 3KVA/5KVA-230V model. Before read this
manual, it's better to have some electrical or electronic background knowledge. With this guide, you can
fix the inverter by yourself firstly.
There are five main parts of this guide:
General information: This part is the basic information of the inverter; you can start to know the inverter
from this chapter.
Troubleshooting: This part will tell you how to do when you face a problem.
Checking and measuring guide: This part will teach you how to check or repair the inverter by
measuring the critical components.
Assembling guide: This part teaches you how to take the board outside and fix the new one.
Cables connection: This part is a reference for cable connection.
1.2 Basic topology introduction
The topology of the inverter shows as below:
Utility PFC Control
Solar Solar Charger INV Load
Charger
Discharger
Discharger
Battery
Compare with UPS or normal inverter, INVERTER combines a solar charger inside. Solar charger can be
a supplement for battery when there is not grid or for saving energy purpose. And with the solar charger,
the inverter can have more working modes than UPS. For detail information please refer to our user
manual.
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1.3 Inverter family
This service manual includes different models of the inverter, the table as below contains some important
parameters with different models.
These models names are only neutral names; please match the real model name of your inverter to the model
name in the table by comparing the typical characteristics.
Model name Power rating Solar charger Solar charger Off-grid/Hybrid
type number
3KVA 3KVA/3KW MPPT 1 Off-grid
5KVA 5KVA/5KW MPPT 1 Off-grid
Note: Main board of 3KVA model is 16-501021-XXG, main board of 5KVA model is 16-501016-XXG.
1.4 Overview the inverter
MPPT board
16-500689-XXG
IND board
16-501058-XXG
16-501021-XXG
Main board
16-501015-XXG
CNTL board
16-000259-XXG
CAP board
COMM board
16-501026-XXG
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1.5 PCB overview
Main board:
Power
supply
Connect
BUS soft start
power supply
MPPT
battery TX1
connection
cables
Battery
ISO BAT-
PFC BUCK
Inductance BAT+
Inductance
location
PFC Grid
Inductance Output terminer
terminer terminer
Inverter
Inductance Control board terminer
FAN terminer
Control board:
To communication board
(71-501026-00G)
To PAR communication board To MPPT board
(31-550170-00G) (31-550295-00G)
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MPPT board:
Battery connction Solar connection
2. Trouble shooting
2.1 How to do
When the inverter was faulty, normally there are two main symptoms:
No display at all;
Fault code or warning code on the LCD;
When the fault occurred, please help to record the fault information and follow "How to check" of part 2.3
to check the inverter, then feedback the checking result to the service center. It will be very helpful for
solving the problem as soon as possible.
2.2 Check the fault information
Please follow the steps as below to find the issues!
Make sure that you can finish all the steps and feedback us the results. Or we may not be able to
give you the right solution.
Step 1: Test the battery working mode.
Before turning on the inverter, only connect the battery with the inverter which means no solar input and
grid input. Turn on the switch, the LCD will light up and wait for the battery connecting to load.
If the connection is failed, please record the fault code.
Step 2: Test the grid charging mode.
Before turning on the inverter, only connect the utility and battery with the inverter. Without press any
buttons, the LCD will light up. And wait for the utility connecting to battery.
If the connection is failed, please record the fault code.
Step 3: Test the solar charging mode.
Before turning on the inverter, only connect the solar and battery with the inverter. Without press any
buttons, the LCD will light up. And wait for the solar connecting to battery.
If the connection is failed, please record the fault code.
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2.3 Fault condition
Note:
When open the top cover, please have a look first, are there any obviously damaged parts?
When take the main board out, please have a look around, are there any obviously damaged
parts?
2.2.1. Not working at all/ No display
Description The inverter couldn't startup completely.
Possible reason 1. SPS module damaged.
How to check 1. Firstly, please measure the resistor between BAT+ and BAT-. If it is not shorted,
only connect the inverter with battery, and press "ON" button, could the inverter
startup? If not, please check the fan.
2. If the LCD couldn't light up and fan doesn't work, please disconnect all the wires
and open the top cover, and then take the main board outside by following part 4.
How to solve Replace the main board.
2.2.2. 09 fault
Description Bus soft start fails.
Possible reason DC-DC module was damaged.
How to check Check the main board by following "3.1~3.4";
How to solve Repair the main board or replace it directly.
2.2.3. 56 fault
Description Battery couldn't be detected.
Possible reason Wire connection or fuse was burnt.
How to check 1. Check the wire connection, the priority of the battery cable;
2. Check the main board by following "3.1".
How to solve Repair the main board or replace it directly.
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2.4 Test step
After replacing all defected components, testing steps can be used to confirm the repair result and the
reliability of the Inverter.
Set up the testing system as below:
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3. Checking and measuring guide
3.1 Check the battery side components
Fuse and capacitors
F3
Parts Attribute Reference values Failure status
F3 Resistor 0 ohm Open
C9/C13/C8/C12
If the capacitors explode as below, they need to be replaced.
Power devices
DC/DC MOSFET: Q13/Q18/Q23 & Q11/Q17/Q20 & Q21/Q22/Q12 & Q26/Q25/Q14
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Q19 Q13 Q18 Q23 Q24 Q11 Q17 Q20 Q38 Q21 Q22 Q12 Q40 Q26 Q25 Q14
Parts Attribute Reference values Failure status
All: Resistor1 GS: 11.7K Short or explosion
GD: 250K
DS: 0.55M
Diode SD: 0.42V
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.
Note: If one or more of them were damaged, please replace all of them.
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3.1.1. Drivers (This part is only used for repair checking)
Note: Drivers usually need to be checked when users want to repair the boards. Because when power
devices were damaged, the high voltage will rush to driver circuit through the gates of power devices.
The reference of the resistors list as below:
R41/R59/R70/R76/R80/R78/R75/R42/R52/R62/R81/R64/R93/R92/R87/R53
TVS1/ TVS2/ TVS3/ TVS4/ TVS6/ TVS7/ TVS8/ TVS10/ TVS11/ TVS12/ TVS14/ TVS15/ TVS16
TVS16
TVS15
TVS14
TVS13
TVS12
TVS11
TVS10
TVS9
TVS8 TVS7 TVS6 TVS5 TVS4 TVS3 TVS2 TVS1
Use multimeter to measure each resistor, find the burnt resistors and replace them; don't need to replace
them all.
model Parts Attribute Reference values Failure status
3KVA All: 33ohm Resistor 33 ohm Open or other values
TVS1-16 Diode + To - : 0.42V Short or explosion
5KVA All: 22ohm Resistor 22 ohm Open or other values
TVS1-16 Diode + To - : 0.42V Short or explosion
If the resistors need to be replaced, please also check the driver transistors and control IC.
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Q46
Q47
Q48 Q49
The Q46and Q48 are 11-300012-00G (TR 2A 50V NPN TO-92)
The Q47and Q49 are 11-300005-00G (TR 2A 50V PNP TO-92NL)
Q15
Q41
Q16
Q43
The Q41 and Q43 are 11-300012-00G (TR 2A 50V NPN TO-92)
The Q15 and Q16 are 11-300005-00G (TR 2A 50V PNP TO-92NL)
Parts Attribute Reference values Failure status
Q46/Q48/Q41/Q43 Resistor BE: 434.2k Short or explosion
BC: 429.3k
CE: 19.52k
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Diode BE: 0.656V
BC: 0.655V
CE: 1.3V
Q47/Q49/Q15/Q16 Resistor BE: 433.5k Short or explosion
BC: 432.1k
CE: 8.1k
Diode BE: 0.656V
BC: 1.741V
CE: 0.2V
Q55 Q54 Q56 Q57
B E C
The Q54and Q56 are 11-400011-00G (TR 2A 50V NPN SOT-89)
The Q55and Q57 are 11-400010-00G (TR 3A 50V PNP SOT-89)
Q53 Q52 Q51 Q50
B E C
The Q51and Q52 are 11-400011-00G (TR 2A 50V NPN SOT-89)
The Q50and Q53 are 11-400010-00G (TR 3A 50V PNP SOT-89)
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Parts Attribute Reference values Failure status
Q54/Q56/Q51/Q52 Resistor BE: 12k Short or explosion
BC: 263.5K
CE: OL
Diode BE: 0.632V
BC: 0.631V
CE: OL
Q55/Q57/Q50/Q53 Resistor BE: 12k Short or explosion
BC: OL
CE: 277.3k
Diode BE: 0.632V
BC: OL
CE: 1.107V
Q60 Q61
S G
D
The Q60 and Q61 are 11-420007-00G (MOSFET 5.8A 30V SOT-23)
Parts Attribute Reference values Failure status
Q60/Q61 Resistor GS: 4.185k Short or explosion
GD: 12.08k
DS: 90k
Diode SD: 0.207V
DS: 1.389V
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U9
Parts Attribute Reference values Failure status
U9 Resistor Pin13TOPin12:100~300k Short or explosion
Pin11 TO Pin12: 438k
Pin14 TO PIN12: 438k
Note: If you are not sure about these components, we recommend you replacing them all.
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3.2 Check the bus side components
Power devices
DC/DC IGBT: Q30/Q29/Q27/Q28
QB2 QD2 QA1 QC1 QD4 QD3 Q32 D13 Q30 Q29 Q27 Q28
Parts Attribute Reference values Failure status
Q27/Q28/Q29/Q30 Resistor1 GE: 47.8 ohm Short or explosion
GC: 178.5K
CE:35M
Diode EC: 0.37V
CE: 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 CE and GE. So we recommend
you measure the diode forward voltage of EC, and the resistor of GE. These two values can reflect the
situation of the transistor more correctly.
Note: If one or more of them were damaged, please replace all of them.
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Drivers (This part is only used for repair checking)
Meanwhile, we also need to check the driver tubes of these power tubes.
Parts Attribute Reference values Failure status
R96/R91/R101/R102 Resistor 47 ohm Open or other values
Note2: When test the diode; please remove the R90/R99/R94/R97 from the board, or the test result is not
right.
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3.3 Check the buck circuit
Power devices
BUCK MOSFET and Diode: Q32 / D13
QB2 QD2 QA1 QC1 QD4 QD3 Q32 D13 Q30 Q29 Q27 Q28
Parts Attribute Reference values Failure status
Q32 Resistor GE: 22.7 K Short or explosion
GC: 225.3K
CE: 1.25M
Diode SD or CE: 0.37V
DS or EC: OL
D13 Resistor + to -: 178K
- to +: 15M
Diode + to -: 0.37V
- to +: OL
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Drivers (This part is only used for repair checking)
Parts Attribute Reference values Failure status
R125 Resistor 47 ohm Open or other values
Note: When test the diode; please remove the R124 from the board, ortherwise the test result is not right.
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3.4 Check the INV full bridge
Power devices
INV&PFC IGBT: QB2/QD2/QA1/QC1/QD4/QD3
QB2 QD2 QA1 QC1 QD4 QD3 Q32 D13 Q30 Q29 Q27 Q28
Parts Attribute Reference values Failure status
QB2/QD2 Resistor GE: 22.5K Short or explosion
QA1/QC1 GC: 250k
QD4/QD3 CE: 1.1M
Diode EC: 0.37V
CE: OL
Note1: If one or more of them were damaged, please replace all of them.
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Drivers
Parts Attribute Reference values Failure status
R144/R48/R140/R137 Resistor 47 ohm Open or other values
R151/R189 Resistor 22 ohm Open or other values
R153/R181 Resistor 10 ohm Open or other values
Optocoupler: U6/U12/U2/U4/U3/U1/U11
Pin1
Parts Attribute Reference values Failure status
U6/U12/U2/U4/U3/U1/U11 Resistor PIN8 TO PIN5: 0.94M Short or explosion
PIN7 TO PIN5: 0.97M
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3.5 Check the MPPT board
Power devices
Parts Attribute Reference values Failure status
Q2, Q3, Q4, Q10, Q11, Resistor GS: 4.964k Short or explosion
Q13 GD: 37.2k
DS: 260.0k
Diode SD: 0.45V
DS: OL
D8, D49, D48, D47, D24, Resistor + to -: 1.07k Short or explosion
D4 - to +: 1 Meg
Diode + to -: 0.167V
- to +: OL
TVS1, TVS2, TVS3 Resistor 223.3k ohm Short
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4. Disassembling guide
4.1 Remove the REMOTE BOX
Loosen the screw on
the two sides of
bottom case and push
up the case cover.
Then, remove screw
on the top of the
display panel. Now,
the display can be
removed from the
bottom case. Then,
pull out the cable from
the remote
communication port.
4.2 Open the case
Remove screws on
the top cover, and
then open the top
cover carefully.
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4.3 Remove all boards
Remove the two
screws and the signal
cables, then take out
the COMM board;
Remove the two
screws , then put the
COMM board on the
side;
Remove the two
copper pillars;
Remove the four
screws , you can take
the small board and
the fan paper off ;
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Remove the four
screws and two black
cables , you can take
the IND board off ;
Remove the two
screws and the signal
cables, you can take
the control board off ;
Remove all cables
here(AC In/Out
cablesGND cables
Signal cablesFAN
cables) .
Brown cable is line;
blue cable is neutral.
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Remove the screws,
and then you can
take the main board
out.
Note: There are ten
screws to fix the main
board.
Note: When you put the new control board on the main board, please make sure that the connection is
correct and tighten. Don't forget to put the screws and cables back.
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5. Cables connection
AXPERT KING 5KW With MPPT Model
16-501058-XXG
IND board MPPT board
16-500689-XXG
CN2
CN4
P1 P2
CN13
CN1
CN1
CN12
CN6
16-501015-XXG
CNTL board
16-501016-XXG
Main board
P6
P5
16-501026-XXG
COMM board
CN2
CN4
CN1
REMOTE&COMM board
16-501025-XXG
CN4
CN1 PAR communication board CN2
CN5 CN3
16-500243-XXG CN8
BAT+
BAT-
FAN2 FAN1
AXPERT KING 3KW With MPPT Model
16-501058-XXG
IND board MPPT board
16-500689-XXG
CN2
CN4
P1 P2
CN13
CN1
CN1
CN12
CN6
16-501015-XXG
CNTL board
16-501021-XXG
Main board
P5
P6
16-501026-XXG
COMM board
CN2
CN4
CN1
REMOTE&COMM board
16-501025-XXG
CN4
CN1 PAR communication board CN2
CN5 CN3
16-500243-XXG
CN8
BAT+
BAT-
FAN2 FAN1
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