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Easun IGrid SS 3KW Plus Service Manual

Solar power system
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SOLAR POWER SYSTEM
SERVICE MANUAL
IGrid SS 3KW Plus
1

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Summary of Contents for Easun IGrid SS 3KW Plus

  • Page 1 SOLAR POWER SYSTEM SERVICE MANUAL IGrid SS 3KW Plus...

  • Page 2: Table Of Contents

    Table of Contents 1. General Information ................... 3 1.1 Getting start ......................3 1.2 Important Safety Instructions.................. 3 2. Electric Specifications ................5 AC input data ......................5 PV input data ......................5 Grid Feeding data....................5 Battery mode output data ..................6 Overload capability ....................

  • Page 3: General Information

    1. General Information 1.1 Getting start This manual is for IGridSS3KWPlus . It can help service person perform the basic maintenance and repair service. This manual only focuses on the service section. The basic operation of the Inverter can be get from the user manual, and make sure you had read and understood the user manual before reading this manual.
  • Page 4 Verify input source (voltage and frequency) is within the maximum range before service. Don’t remove the battery or switch off the breaker of battery when the inverter is running, otherwise the inverter may change to error mode.

  • Page 5: Electric Specifications

    2. Electric Specifications Item Specification Comments AC input data AC start voltage 120~140Vac Auto restart voltage 194 Vac ±3% Tolerance 184~265 Vac (VDE) AC input voltage range 193.6~242Vac(Taibei) 194/255 Vac(VDE) AC input voltage comeback value 203.6/232 Vac(Taibei) 47.5 ~ 50.2 Hz (50Hz) AC input frequency range 59.3~ 60.5Hz(60Hz) 47.6/50.1 Hz(50Hz)

  • Page 6: Battery Mode Output Data

    184~265 Vac (VDE) Output voltage range 193.6~242Vac(Taibei) 194/255 Vac(VDE) Output voltage comeback value 203.6/232 Vac(Taibei) 47.5 ~ 50.2 Hz (50Hz) Operational frequency range 59.3~ 60.5Hz(60Hz) 47.6/50.1 Hz(50Hz) Output frequency comeback value 59.4/60.4Hz(60Hz) Max output current 13.6A Under the output voltage is 220VAC O/P current distortion <3% Under utility voltage THD<3%...

  • Page 7: Short Circuit

    Overload alarm for 30 sec, and then will switch to fault mode. > 150% If user decrease the load <100% rating, the overload alarm can release. > 200% Switch to fault mode immediately Short circuit Fuse Line Mode Can be re-start 3 cycles before power Battery Mode Software Detection shutdown.
  • Page 8 IUoU charging process...

  • Page 9: Functional Block

    3. Functional Block As a hybrid photovoltaic inverter, the product utilizes several power sources. Comprising functional blocks as shown in Figure 3.1 O/P Relay Load INV Relay Safety Relay PV EMI BOOST INV EMI INV/REC AC EMI RS232/USB GRID Parallel connection Figure 3.1 Function block Diagram The CNTL block provides control signals to control the action of the inverter.
  • Page 10 The SPS generates DC power supply needed for operation of the circuit of the inverter itself. The Discharger/Charger block converts battery voltage to high-BUS DC voltage or converts high-BUS DC voltage to low battery voltage. This block uses high frequency isolation technology.

  • Page 11: Working Principle Of The Major Functional Block

    4. Working Principle of the Major Functional Block 4.1 Switch Power Supply The Switch Power Supply (SPS) supplies DC power for Inverter operation including +5V,+12V,-12V and +15V. The SPS consists 3 parts: the battery SPS, the grid SPS and main SPS. The battery SPS generates a DC voltage at about 120Vdc(BATSPS) and the grid SPS generates a DC voltage about 150Vdc(ACSPS).

  • Page 12: Boost Circuit

    main SPS. They are all flyback converter. However, the grid SPS includes a rectifier to convert grid AC voltage to a DC voltage but the main SPS is multiple output circuits. Taking main SPS to explain the operation of flyback converter as a example. When Q13 is on, all rectifier diodes are on “open”...

  • Page 13: Charger/Discharger

    Figure 4.5 bridge inverter 4.4 Charger/Discharger The function of charger is to charge and maintain the batteries at fully charged condition. When the battery is working in charging mode, the control board will enable the charge control circuit and disable the discharge control circuit. As showed in figure 4.6, the charge control circuit provides PWM waves to regulate the cycle of Q8/Q9/Q10/Q11 on and off in this mode.
  • Page 14 EMI board is connected between the output of inverter and output terminal SWITCH block. Figure 4.8 Topology of the EMI...

  • Page 15: Function Explanations For Each Pcb

    5. Function explanations for each PCB Table 5.1 PCB information of InfiniSolar 3KW Item PCB Name PCB serial number Quantity CNTL 71-500083-XXG MAIN 71-500086-XXG 71-600021-XXG 71-000072-XXG PANEL 12-400030-XXG CHG CNTL 71-000074-XXG DISCHG CNTL 71-000076-XXG 71-500007-XXG Note: “XX” in the serial number is the version of the PCB. It may be modified according to releasing version in the future.

  • Page 16: Cntl Board

    5.2 CNTL board Figure 5.2 picture of CNTL board The CNTL board is the core of the Inverter system. It controls the actions of the semiconductors and other mechanical switches, LCD display, buzzer alarm, communication with the computer, and other important tasks. The inverter is controlled by two CPUs, DSP and MCU.

  • Page 17: Com Board

    5.4 COM board The COM board provides RS232 and USB interface to the users. 5.5 PANEL board The PANEL board is used to provide LCD interface.

  • Page 18: Chg Cntl Board

    5.6 CHG CNTL board It provides PWM waves to control the charging MOSFET when the battery is in charging mode. 5.7 DISCHG CNTL board It provides PWM waves to control the charging MOSFET when the battery is in discharging mode.

  • Page 19: Sps Board

    5.8 SPS board The Switch Power Supply (SPS) supplies DC power for Inverter operation including +5V, +12V, -12V and +15V. The input source of the SPS is from BUS voltage, the output of the battery SPS, or the output of the grid SPS.

  • Page 20: Interface

    6. Interface Figure 6.1 picture of the LCD panel This display is operated by four buttons. NOTICE: There is a battery inside of control board. It’s recommended to replace the battery every 5 years. 6.1 the display picture of LCD igure Table 6.1 LCD Information Define Display...
  • Page 21 Indicates solar panels. Indicates grid. Indicates battery. Indicates load. Indicates energy generated.

  • Page 22: Trouble Shooting

    7. Trouble Shooting This section describes how to find the troubles when Inverter is abnormal. We suggest you to follow the service procedure below: 1. Check the Inverter status via LCD display, the sound of the buzzer, or listen to the description of end users.

  • Page 23: Trouble Shooting For Fault Codes In Lcd Display

    7.1.2 Trouble shooting for fault codes in LCD display Code Fault Event Action Bus over voltage Bus under voltage Bus soft start time out Inverter soft start time out 1. Disconnect ALL PV(+), PV(-) and Grid 2. Wait for few seconds Inverter over current 3.

  • Page 24: Repair

    1.Check the connection between battery and Inverter. 2.restart the Inverter. Battery over charge 3.Make sure that don’t break connection between battery Inverter while the charging current is high. Remove the load, ensure that the load is Over load less than the maximum VA the Inverter can support.
  • Page 25 short Q13, Q14 MOSFET open Input and output Photo coupler short or open R136,R144,R143,R130,R129,R141,R145,R139,R137 Resistance Short or open ,R125,R126,R138, Diode Short or open D3, D4, D5, D6, D7, D8, D12, D13, D15, D16 R42, R43,R48, R54, R56, R60, R193, R194, R182, R210, R208, R209, R78, R83, R87, R95, R49, R55, Resistance Short or open...
  • Page 26 7.2.2.1 Major parameters of Booster section The most likely problems occur on the Booster section including: broken IGBT, broken Diode, and broken IGBT driver resistor. When checking Booster section, directly check the MOSFET with Resistance probe or the Diode Voltage Droop probe with multimeter. Referenc Checked components Instrument function...
  • Page 27 (B,E) Diode Voltage Droop Short or open 0.6V Q10,Q2,Q16,Q8 (B,C) Diode Voltage Droop Short or open 0.6V Note: 1.If MOS or RESISTOR is damaged, it means that the Optocoupler (U1&U2&U3&U4) may also be damaged extremely. So replace it at the same time. 2.Make sure the voltage of capacitor C22,C24 is less than 0.1Vdc when test QA1, QA2, QB1, QB2, QC1, QC2, QD1, QD2.
  • Page 28 7.2.2.5 Major parameters of CHARGE section The most likely problems occur on the CHARGE section including broken MOSFET, broken Diode, damaged relative driver resistor and driver IC with broken MOSFET. Reference Checked components Instrument function Failed Condition Value (S, D) Diode Voltage Droop Short or open 0.5V...

  • Page 29: Test Step

    8. Test Step After replacing all defected components, testing steps can be adopted to verify the repair result and the reliability of the Inverter. 1. Install all of boards/cable/ connector. 2. Check if wires are connected correctly. 3. Apply DC Power from power source with limited current (prefer 1A) to the PV terminal.

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