Growatt SPF 5000 ES User manual

SPF 5000 ES Service manual
1
Service manual
Table of contents
1. General information........................................................................................................................................................ 2
1.1 Getting start......................................................................................................................................................... 2
1.2 Important safety instructions............................................................................................................................. 2
2. Functional block.............................................................................................................................................................. 3
3. Working principle of the major functional block.......................................................................................................... 4
3.1 Switch Power Supply.......................................................................................................................................... 4
3.2 DC TO DC dual converter (Full bridge converter).......................................................................................... 5
3.3 Inverter (Full bridge)........................................................................................................................................... 5
3.4 Buck converter .................................................................................................................................................... 6
4. Functional explanations for each PCB ........................................................................................................................ 7
4.1 Main board........................................................................................................................................................... 7
4.2 CNTL board ......................................................................................................................................................... 8
4.3 MPPT board......................................................................................................................................................... 8
4.4 COMM board....................................................................................................................................................... 8
4.5 BMS board........................................................................................................................................................... 9
4.6 MOV board........................................................................................................................................................... 9
4.7 SWITCH board.................................................................................................................................................. 10
4.8 PARALLEL_COM board................................................................................................................................ 10
5. Troubleshooting............................................................................................................................................................. 12
5.1 Fault Reference Code...................................................................................................................................... 12
5.2 Warning Indicator.............................................................................................................................................. 13
5.3 Trouble shooting according to fault indication.............................................................................................. 15
5.4 Quick start.......................................................................................................................................................... 17
6. Test Step........................................................................................................................................................................ 20
7. Key components location ............................................................................................................................................ 21
7.1 Main board......................................................................................................................................................... 21
7.2 MPPT board....................................................................................................................................................... 24

SPF 5000 ES Service manual
2
1. General information
1.1 Getting start
This manual is for SPF 5000 ES series, 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/Charger from the user
manual, and make sure you had read and understood user manual before you use this service manual.
The manual include 7 sections, as follows
General Information, this section show you the general information of the service manual
Functional Block, this section show you the major functional block of the Inverter/Charger
Working Principle of the major Functional Block, this section show you the major functional block
Function explanations for each PCB, this section show you all the PCBs of the Inverter/Charger
Trouble shooting, this section will give you the way to find the trouble
Test step ,this section tell you how to test the Inverter/Charger after you repair the unit
Key components location, this section tell you where the key components are that you can easy find them out
and repair them
1.2 Important safety instructions
WARNING: This chapter contains important safety and operating instructions. Read and keep this
manual for future reference.
1. Before using the unit, read all instructions and cautionary markings on the unit, the batteries and all
appropriate sections of this manual.
2. Do not disassemble the unit. Take it to a qualified service center when service or repair is required.
Incorrect re-assembly may result in a risk of electric shock or fire.
3. To reduce risk of electric shock, disconnect all wirings before attempting any maintenance or cleaning.
Turning off the unit will not reduce this risk.
4. CAUTION –Only qualified personnel can install this device with battery.
5. NEVER charge a frozen battery.
6. For optimum operation of this inverter/charger, please follow required spec to select appropriate cable
size. It’s very important to correctly operate this inverter/charger.
7. Be very cautious when working with metal tools on or around batteries. A potential risk exists to drop a
tool to spark or short circuit batteries or other electrical parts and could cause an explosion.
8. Please strictly follow installation procedure when you want to disconnectAC or DC terminals. Please refer
to INSTALLATION section of this manual for the details.
9. Fuses with particular standard are provided as over-current protection for the battery supply.
10. GROUNDING INSTRUCTIONS -This inverter/charger should be connected to a permanent grounded
wiring system. Be sure to comply with local requirements and regulation to install this inverter.
11. NEVER cause AC output and DC input short circuited. Do NOT connect to the mains when DC input short
circuits.
12. Warning!! Only qualified service persons are able to service this device. If errors still persist after
following troubleshooting table, please send this inverter/charger back to local dealer or service center for
maintenance.

SPF 5000 ES Service manual
3
2. Functional block
The SPF 5000 ES series production employ a double conversion topology, comprise following functional blocks,
as shown in figure 2.1.
Figure 2.1 function block diagram

SPF 5000 ES Service manual
4
3. Working principle of the major functional block
3.1 Switch Power Supply
The switch power supply (SPS) supplies DC power for Inverter/Charger operation. The input voltage of the SPS is
the battery or AC/PV Charger output voltage.
Figure 3.1 basic circuit of power supply
This is the fly-back DC-DC converter, fly-back operation can be easily recognized from the position of the dots on
the transformer primary and secondary(these dots show starts of the winds). When Q40 is ON, the dot ends of all
winds are negative with respect to their no-dot ends. Output rectifier diodes D51, D52, D60 and D63 are
reverse-biased and all the output load currents are supplied from storage filter capacitors C78, C75, C79 and
C116.The primary coil of the transformer acts as an inductor and stored energy.
When Q40 is OFF, the stored energy in the primary coil is delivered to secondary filter capacitors C90, C94, C98
and C111.
As shown in figure 3.1, this circuit may generate several output voltage, such as +12V,-12V, +15V, +5V, HFPW+.

SPF 5000 ES Service manual
5
3.2 DC TO DC dual converter (Full bridge converter)
The full bridge topology is a transformer isolated forward-mode regulator. Unlike the Fly-back transformer, the
push-pull transformer does not store any energy and output current is drawn when either power switches (S1-S4
or S2-S3) is conducting. P1 is the battery, P2 is the BUS
This is dual converter, it means that battery can feed power to BUS and also BUS can charge the battery. And it is
an open loop control: the transformer N1:N2 is 1:8, when the battery voltage is transformed through the converter
to more than the BUS voltage, the battery discharge power to the BUS, or the BUS can charge the battery.
Figure 3.2 DC TO DC dual converter
3.3 Inverter (Full bridge)
The Inverter circuit (Figure 3.3) and PWM control are can both active under battery mode and line mode. In line
mode, the inverter can convert power from gird to BUS for charging .The Inverter circuit of SPF 5000 ES series is
based on a full-bridge circuitry and its output is driven by photo-couplers. The photo-couplers are capable to drive
high energy and high speed power of MOSFET and IGBT with independent high and low referenced output
channels.
To construct a high frequency PWM inverter, the drivers receive switching signals from PWM generation circuit
through a pair of photo-couplers to trigger the upper IGBT and the lower IGBT alternately. The output of IGBT's is
filtered by an LC circuit to reduce the o/p voltage harmonics distortion.
Figure 3.3 Full-bridge topology

SPF 5000 ES Service manual
6
3.4 Buck converter
The Buck circuit (Figure 3.4) is active only when the line charging the battery. When the battery is discharging, S1
is ON, D1 is reversed cut off, L1 is used as a filter inductor.
Figure 3.4 Buck topology

SPF 5000 ES Service manual
7
4. Functional explanations for each PCB
Item
Series name
PCB name
PCB serial number
Quantity
Remark
1
SPF 5000 ES
Main
530.SK00008XX
1
2
CNTL
530.SK00009XX
1
3
MPPT
530.SK00010XX
1
4
COMM
530.SK00035XX
1
5
BMS
530.SK00042XX
1
6
MOV
530.00552XX
1
7
SWITCH
530.00555XX
1
8
PARALLEL_COM
530.SK00037XX
1
Note: “XX” in the serial number is the version of the PCB.
4.1 Main board
The main board consists of SPS, DC-DC converter, inverter. Many semiconductors and easy-failure components
on the board, so it should be play more attention when the system is abnormal.

SPF 5000 ES Service manual
8
4.2 CNTL board
The CNTL board consists of AD sample, MCU control and communication module. It control the other module work
orderly.
4.3 MPPT board
The Maximum Power Point Tracking (MPPT) board based on a PWM control mode .When the solar source is
presented, battery charged from solar source; MAX charge current is 100Aif solar panel with enough energy.
4.4 COMM board
This inverter/charger is equipped with a communication port to communicate with a PC with corresponding
software. Please use supplied communication cable to connect to communication port of this inverter and USB
port of the PC.

SPF 5000 ES Service manual
9
4.5 BMS board
The BMS board is designed for relays protection.
4.6 MOV board
The function of this board is to prevent lightning strikes.

SPF 5000 ES Service manual
10
4.7 SWITCH board
This board includes four functional keys.
4.8 PARALLEL_COM board
For parallel communication.

SPF 5000 ES Service manual
11

SPF 5000 ES Service manual
12
5. Troubleshooting
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 LED and LCD display, the sounds of buzzer.
b. Observe the failure board, static checking.
c. Replace the failure components.
d. Static checking.
e. Power up checking.
f. Test after repair.
Following section will help service person to solve most of problem.
5.1 Fault Reference Code
Fault Code
Fault Event
Icon on
01
Fan is locked
02
Over temperature
03
Battery voltage is too high
04
Battery voltage is too low
05
Output short circuited
06
Output voltage is too high.
07
Overload time out
08
Bus voltage is too high
09
Bus soft start failed
51
Over current or surge
52
Bus voltage is too low

SPF 5000 ES Service manual
13
53
Inverter soft start failed
55
Over DC voltage in AC output
56
Battery connection is open
57
Current sensor failed
58
Output voltage is too low
60
Negative power fault
61
PV voltage is too high
62
Internal communication error
80
CAN fault
81
Host loss
5.2 Warning Indicator
Warning
Code
Warning Event
Audible Alarm
Icon
flashing
01
Fan is locked when inverter is on.
Beep 3 times every second
02
Over temperature
Beep once every second
03
Battery is over-charged
Beep once every second
04
Low battery
Beep once every second
07
Overload
Beep once every 0.5 second
10
Output power derating
Beep twice every 3 seconds

SPF 5000 ES Service manual
14
12
Solar charger stops due to low
battery
Beep once every second
13
Solar charger stops due to high PV
voltage
Beep once every second
14
Solar charger stops due
to overload
Beep once every second
15
Parallel input utility grid different
Beep once every second
16
Parallel input phase error
Beep once every second
17
Parallel output phase loss
Beep once every second
18
Buck over current
Beep once every second
19
Battery disconnect
No beep
20
BMS communication error
Beep once every second
21
PV power insufficient
Beep once every second
22
Parallel forbidden without battery
Beep once every second
25
Parallel inverters’capacity different
Beep once every second
33
BMS communication loss
Beep once every second
34
Cell over voltage
Beep once every second
35
Cell under voltage
Beep once every second
36
Total over voltage
Beep once every second
37
Total under voltage
Beep once every second
38
Discharge over voltage
Beep once every second
39
Charge over voltage
Beep once every second
40
Discharge over temperature
Beep once every second
41
Charge over temperature
Beep once every second

SPF 5000 ES Service manual
15
42
Mosfet over temperature
Beep once every second
43
Battery over temperature
Beep once every second
44
Battery under temperature
Beep once every second
45
System shut down
Beep once every second
5.3 Trouble shooting according to fault indication
Problem
LCD/LED/Buzzer
Explanation / Possible cause
What to do
Unit shuts down
automatically
during startup
process.
LCD/LEDs and
buzzer will be active
for 3 seconds and
then complete off.
The battery voltage is too low
(<1.91V/Cell)
1. Re-charge battery.
2. Replace battery.
No response after
power on.
No indication.
1. The battery voltage is far too
low. (<1.4V/Cell)
2. Battery polarity is connected
reversed.
1. Check if batteries and the
wiring are connected well.
2. Re-charge battery.
3. Replace battery.
Mains exist but the
unit works in
battery mode.
Input voltage is
displayed as 0 on
the LCD and green
LED is flashing.
Input protector is tripped
Check if AC breaker is tripped
and AC wiring is connected
well.
Green LED is
flashing.
Insufficient quality of AC power
(Shore or Generator)
1. Check if AC wires are too
thin and/or too long.
2. Check if generator (if
applied) is working well, or
check if input voltage range
setting is correct (UPS or
Appliance)
Green LED is
flashing.
Set Solar power as the priority of
output source
Change output source priority
to Utility first.
When the unit is
turned on, internal
relay is switched
on and off
repeatedly.
LCD display and
LEDs are flashing.
Battery is disconnected.
Check if battery wires are
connected well.
Buzzer beeps
continuously and
red LED is on.
Fault code 07.
Overload error. The inverter is
loaded with more than 110%
load and time is up
Reduce the connected load
by switching off some
equipment.
Fault code 05.
Output short circuited.
Check if wiring is connected
well and remove abnormal
load.

SPF 5000 ES Service manual
16
Fault code 02.
Internal Inverter component over
100°C
Check whether the air flow of
the unit is blocked or whether
the ambient temperature is
too high.
Fault code 03.
Battery is over charged.
Return to repair center.
The battery voltage is too high.
Check if spec and quantity of
batteries are meet
requirements.
Fault code 01.
Fan fault
Replace the fan.
Fault code 58/06.
Output abnormal (Inverter
voltage below than 190Vac or is
higher than 260Vac)
1. Reduce the connected
load.
2. Return to repair center
Fault code 08.
Internal components may be
failed.
1. Restart the inverter again.
2. If the problem still exists,
please return to repair center.
Fault code 09.
Fault code 51
Fault code 52
Fault code 53
Fault code 55
Fault code 57
Fault code 56
Battery is disconnected.
1. Check if battery wires are
connected well.
2. If the problem still exists,
please return to repair center.
Fault code 60
Negative power fault
1. Check whether the AC
output connects to the Grid.
2. Check whether the output
voltage setting in program 8
of all the Inverters in parallel
are the same.
3. Check whether the current
sharing cables are
connected well in the same
parallel phases.
4. Check whether all the
neutral wires of each unit in a
parallel system are
connected together.
5. If the problem still exists,
please return to repair center.
Fault code 80
CAN fault
1. Check whether the parallel
communication cables are
connected well.
2. If the problem still exists,
please return to repair center.
Fault code 81
Host loss

SPF 5000 ES Service manual
17
5.4 Quick start
Before any detail check of the system, please check the components listed as follow table.
NOTE: It is important to check the capacitor’s voltage on the board lower than the safety voltage before any
check action.
Functional
block
Checked components
Instruction
function
Reference value
Failed status
DC-DC
Converter
Fuse
F1
Resistance
<0.5ohm
open
MOSFET
(CSD19505KCS)
Q45/Q46/Q47/Q48/Q49/
Q50/Q51/Q52/Q54/Q55/
Q56/Q57/Q58/Q58/Q60/
Q61
Resistance
Diode position
>20k DS
short or open
VSD=0.434V REF
0 or OL
240k GD
short or open
11.74k GS
short or open
Diode(1N4148SM)
D15/D17/D19/D20/D21/D
22/D25/D26
Resistance
>240K
short or open
Diode position
VPN=0.562V REF
0 or OL
Driver NPN /PNP
Q21/Q26/Q30/Q31
Resistance
11.9K PIN1-2
short or open
Q23/Q27/Q32/Q33
11.9K PIN1-3
short or open
Driver IC
KA3525
Resistance
>400K PIN14-PIN13/12
PIN12-PIN13/11
short or open
IGBT
(STGWT80H65DFB)
Q64/Q66/Q67/Q68
Resistance
Diode position
>60K CE
short or open
VEC=0.346V REF
0 or OL
100K GC
short or open
47ohm GE
short or open
Resistance
R221/R222/R223/R224/R
225/R226/R227/R228/R2
37/R238/R239/R240/R24
1/R242/R243/R244
Resistance
22 ohm
short or open
R229/R230/R231/R232/R
233/R234/R235/R236/R2
45/R246/R247/R248/R24
9/R250/R251/R252
Resistance
47K
short or open
R100/R104/R107/R117/R
118/R119/R122/R123
Resistance
10 ohm
short or open
R255/R256/R268/R269
Resistance
47 ohm
short or open
R257/R258/R268/R269
Resistance
49.9K
short or open

SPF 5000 ES Service manual
18
DC-AC
Inverter
IGBT
(STGWT80H65DFB)
Q5/Q6/Q8/Q10
Resistance
Diode position
>60K CE
short or open
VEC=0.346V REF
0 or OL
100K GC
short or open
49.9K GE
short or open
BUCK
(STGWT80H65DFB)
Q69
Resistance
Diode position
>60K CE
short or open
VEC=0.346V REF
0 or OL
100K GC
short or open
49.9K GE
short or open
Resistance
R33/R34/R55/R56
Resistance
47 ohm
short or open
Photo-coupler
U5/U6/U7/U8/U9
Resistance
64K PIN 8-7
>100K PIN 5-6
short or open
Main board
S.P.S
Control IC
UC2845
Resistance
2K PIN5-PIN7
short or open
Diode
D52/D56
Resistance
>1K
short or open
diode position
VPN=0.357V REF
0 or OL
MOSFET
(IRF640NPBF)
Q40
Resistance
Diode position
>400K DS
short or open
VSD=0.512V REF
0 or OL
0.7M GD
short or open
>14K GS
short or open
Resistance
R176/R180
Resistance
10 ohm
short or open
MPPT
IGBT
(FGH60N60SMD)
Q1/Q2
Resistance
Diode position
>20K CE
short or open
VEC=0.358V REF
0 or OL
180K GC
short or open
24.9K GE
short or open
Diode
(APT30DQ60BG)
D1
Resistance
>180K
short or open
Diode position
VPN=0.374 REF
0 or OL
Photo-coupler
U1
Resistance
>200K PIN5-PIN6 ，
PIN7-PIN8，
short or open
Diode position
PIN2-PIN3 ，V=1.27
REF
0 or OL
Driver NPN /PNP
Q3
Diode position
PIN1-2 V=0.56 REF
PIN1-3 V=0.56 REF
0 or OL
Q4
PIN1-3 V=0.56 REF
PIN2-3 V=0.88 REF
0 or OL
MPPT
board S.P.S
MOSFET
(IXTP3N100P)
Q7/Q9
Resistance
Diode position
>100K DS
short or open
VSD=0.526V REF
0 or OL

SPF 5000 ES Service manual
19
0.7M GD
short or open
>14K GS
short or open
Diode
(STTH310SSM)
D9/D18
Resistance
50K
short or open
Diode position
VPN=0.47 REF
0 or OL
Resistance
R48/R65
Resistance
22 ohm
short or open
Resistance
R51/R69
Resistance
0.33ohm
short or open

SPF 5000 ES Service manual
20
6. Test Step