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Photovoltaic Inverter Repair & Diagnostics

  • In-depth diagnostics of inverter failures — including internal explosions, burnt PCBs, and severe hardware faults
  • Root-cause analysis using oscilloscopes, logic analyzers, and load simulations
  • Detection and elimination of software-related faults: EEPROM corruption, firmware bugs, and error code resolution
  • Repair of MPPT modules, power stages, gate drivers, and signal path anomalies
  • Troubleshooting of grid synchronization, DC link stability, and AC waveform distortion
  • Detailed failure reports, waveform captures, and high-resolution photos of defective areas

Inverter Component Restoration & Upgrades

  • Replacement of IGBTs, MOSFETs, optocouplers, control ICs, and passive components
  • Micro-soldering and trace repair for severely damaged circuit boards
  • Custom replacement of rare or obsolete components using 3D-printed or CNC-machined parts
  • Rebuilding of cooling systems: fan units, thermal paste, and heat sink realignment
  • Reinforcement against future failures: conformal coating, transient suppression modules, and enhanced insulation paths
  • Optional firmware optimization for extended inverter lifespan and better grid behavior
  • Includes post-repair testing, load simulation, and full technical documentation with results

Advanced Inverter Diagnostics

  • Complete diagnostics using professional Fluke and Tektronix equipment
  • Electrical parameter analysis with 0.1% precision accuracy
  • Thermal imaging diagnostics to detect hidden defects
  • Insulation and grounding testing according to VDE standards
  • Detailed report with photographic documentation of all problem areas

Control Board Reprogramming

  • Factory firmware restoration for all inverter brands
  • EEPROM and Flash memory programming
  • Software adaptation for specific operating conditions
  • Firmware updates to latest versions
  • Original settings backup and recovery

PCB Board Restoration

  • Circuit trace restoration using micro-soldering techniques
  • BGA component replacement on professional rework stations
  • CPU and microchip reballing services
  • Contact pad restoration and repair
  • Protective coating application against corrosion

Final Quality Testing

  • Complete safety function verification
  • Overload condition testing
  • Calibration of all measurement circuits
  • Quality certificate with comprehensive test protocols

List of errors on the inverter KOSTAL


By Erik Zaikin
2 min read


- **Left Fan Blockage Warning**: Indicates the left fan is obstructed. To resolve, clean the fan, check for damage to the plug, connection cable, and the fan itself. If the cause remains unidentified, seek assistance from the support hotline. Note: Fan testing is only feasible in feed-in mode.
- **Right Fan Blockage Warning**: Suggests blockage in the right fan.
- **Left Fan Speed Warning**: Signals that the left fan is operating too slowly.
- **Right Fan Speed Warning**: Indicates the right fan is moving too slowly.

Network Failures:
- **N Conductor Failure (106)**: The N conductor is not correctly connected. Action required: Verify the connection of the neutral conductor N.
- **Network Frequency Failure (150)**: Indicates a network frequency error. Suggested action: Check the network frequency.
- **Network Voltage Failures (151 - 164)**: Errors occur during network feed due to incorrect voltage. Ensure all phases and the N relative to PE are checked.
- **Frequency Errors (165 - 178)**: Highlight frequency errors, making operation with an emergency group impossible. The network frequency should be verified.
- **AC Feed Phase Disturbance (240)**: A disturbance on the AC side during the feed phase. Persistent issues necessitate contact with technical support.
- **Network Voltage Too High/Low (250)**: Check the network voltage as it's outside acceptable limits.
- **Phase Errors (279 - 292)**: Suggests a phase error. If possible, check the phase angle.

Fault Current:
- **Fault Current Shutdown (300 - 399)**: Prompted by a fault current, indicating possible insulation errors in the electrical installation on both DC (PV module) and AC (network) sides. Insulation resistance should be checked (minimum 500 kOhm).

Insulation Errors:
- **Insulation Error (400 - 401)**: Insulation resistance is insufficient. Check for insulation defects on the module side, including faulty connectors or moisture. Insulation resistance check is required (minimum 500 kOhm).

Electric Arc Failures:
- **Parallel Electric Arcs (501-503)**: Indicate parallel electric arcs on strings 1 to 3. Comprehensive installation checks are advised to locate potential electric arc indicators.
- **Serial Electric Arcs (504-506)**: Denote serial electric arcs on strings 1 to 3, necessitating thorough inspection of the installation for damage indicative of electric arcs.

Overheating:
- **Device Overheating (601 - 615)**: The device has overheated, leading to a temporary shutdown or power reduction. Let the device cool down and ensure the installation site allows for adequate cooling. Avoid direct sunlight exposure and check the fan for dirt, cleaning as necessary.

System Failures:
- **Internal System Failure (800 - 999)**: Indicates a failure within the system. For sporadic short occurrences, no action is needed. For frequent short appearances or permanent issues, power down the inverter, restart after 5 minutes, and contact technical support if the problem continues.

Models: PIKO 4.2 5.5 7.0 8.3 10.1
MP Plus 5.0-2
3.0 4.2 4.6 5.5 7.0 8.5
30 50 60

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