In Balance Energy

Solar & Electrical | Services & Systems

Home Services Systems About Contact

 

Kostal Piko Solar Inverter Faults and Repairs

Kostal Solar Electric was established in 2006 and is part of the Kostal Group. A family owned business, the Kostal group have been industry pioneers in automotive components for over 100 years. Kostal Solar Electric's development and manufacturing is carried out in Germany and they launched their first single phase 3.0 and 3.6 Piko solar inverters in 2009.

Kostal Piko inverters have an LCD display on the front of the chassis, which providing it's working, will highlight any errors with the solar inverter or the solar PV system that it runs. We have listed and described common faults with Kostal Piko inverters and what action to take to resolve them below:

All Solar Inverter Fault Codes, Warnings and Troubleshooting

Solar PV System Repairs

Solar Inverter Replacement

Repair Kostal Piko Inverter

Kostal Piko Solar Inverter LED Indicators:

  • Red Light - The red 'fault' LED is illuminated or flashes when a fault has been detected, an accompanying message is displayed on the LCD screen.

  • Yellow Light - The yellow 'DC' LED is illuminated temporarily to indicate that the DC voltage is within range but the solar inverter is not yet activated, when the unit is starting up or shutting down.

  • Green Light - The green 'AC' LED is illuminated when the solar inverter is in operation and feeding electricity into the electrical system and grid.

Kostal Piko Inverter Faults and Warnings:

Some of the advice we give related to identifying, confirming and or resolving some of the faults detailed below, starts with safely shutting down and restarting the solar inverter and the solar PV system. This is something that nearly all solar PV systems installed in the UK would have been designed to be carried out safely by the solar PV system owner. However, paperwork, schematics and manuals are not always clear or available, so if you have any concerns about how to do this, Contact us and we will be pleased to talk you through the process over the telephone at no charge.

How to Restart Kostal Piko Solar Inverters:

Leave everything near the supply meters turned on. At the solar inverter there will be an AC isolator, this is used to isolate the mains/grid supply from the solar inverter and to prevent the solar inverter from feeding solar power into the electrical system. Switch the AC isolator 'off', if the solar inverter is running correctly you will hear a clunk inside the machine and after a while a 'no-grid', 'missing grid' warning or similar on the LCD display.

Restart Kostal Piko Solar Inverter

AC Isolator

Near to and or built into the solar inverter will be a method of isolating the solar (DC) supply from the solar inverter. Often these are black and grey and will be labelled 'DC isolator' or similar. There might be two or more of these if the system is fed by multiple strings. If there isn't a seperate DC isolation device, there will be a way to isolate the DC supply built-in to the solar inverter itself (often a rotary style switch underneath), turn this 'off'.

When all of the lights on the solar inverter have gone out, reintroduce the AC/mains power supply by turning the AC isolator 'on'. Introduce the DC supply by turning all DC isolators 'on'.

This will restart the solar inverter, on the display it might show you progress during it's startup procedure. During startup is when the solar inverter carries out all of the tests needed before being able to connect the solar supply to the electrical system. If errors are found during testing they will be displayed on the screen or an indication light might come on. Make a note of any warning messages, warning lights and fault codes.

If the restart is succesful a green light will come on, sometimes flashing at first but once connected to the mains/AC supply remaining permenantly on. The LCD display will show how much power the solar PV system is generating. The solar PV system can be verified as working at the solar generation / Feed in Tariff (FIT) meter which will count on the display, the red light will pulse as it counts.

Kostal Piko Solar Inverter: No lights, No Display

Kostal Piko solar inverters are powered by the solar panels (the DC supply) and will startup at sunrise each day and shutdown at night. If you find the solar inverter with no lights or display working during the day, there is either a problem with the solar panels or with the solar inverter. Follow the shutdown and restart procedure outlined above and if the problem persists Contact us to discuss the next steps.

If you have the correct tools and are comfortable in doing so, isolate the AC and DC power supplies from the solar inverter and confirm that the incoming DC voltages are as expected by measuring between the positive and negative incoming terminals in DC isolators (if avalable) and or at the DC solar inverter inputs. Light conditions and the type of solar panel will affect voltages but as a rule of thumb anywhere from 30V-60V per panel x the number of panels connected in series in the string would be a reasonable voltage estimate.

No or very low DC voltage would suggest a problem with the solar panels, measuring the expected voltage at the isolator terminals and or the DC inputs, although additional testing should be carried out, would suggest a problem with the solar inverter. Contact us to discuss the next steps.

Kostal Piko Solar Inverter Fault Codes and Explanations:

* 1 - Warning Fan blockage le - The solar inverter has picked up a problem with the left side cooling fan. If possible clear any blockages. Contact Usif the fault doesn't clear and you would like further assistance.

* 2 - Warning Fan blockage ri - The solar inverter has picked up a problem with the right side cooling fan. If possible clear any blockages. Contact Usif the fault doesn't clear and you would like further assistance.

* 3 - Warning Fan Speed le - The left side cooling fan is running slowly. If possible clear any blockages. Contact Usif the fault doesn't clear and you would like further assistance.

* 4 - Warning Fan Speed ri - The right side cooling fan is running slowly. If possible clear any blockages. Contact Usif the fault doesn't clear and you would like further assistance.

* 106 - Fault, Neutral conductor - The solar inverter has lost it's neutral connection to the grid (mains). Assuming that this is an existing installation that has been specified correctly, hasn't recently been changed or added to and has operated before without problems. This could mean either a problem with the mains, the solar inverter's supply circuit or with the solar inverter. We would advise that the AC side of the system is disconnected using either an isolator located near the solar inverter (if available) or at the solar inverter's circuit breaker and contact us to test the AC side of the system including and excluding the solar inverter.

* 150 - Fault, Mains fault - The solar inverter is measuring a grid (mains) frequency that is either too high or too low in relation to the parameters that the solar inverter has been set to safely operate within. If this fault persists contact us to arrange for a solar engineer to visit to establish whether the fault lies with the solar inverter or with the grid.

* 151-164 - Fault, Mains fault - The solar inverter is measuring a grid (mains) voltage or a grid impedence that is too low in relation to the parameters that the solar inverter has been set to safely operate within. If this fault persists and mains power is available to other local circuits then check that all isolators, MCBs and RCDs on the AC side of the solar PV system are 'On'.

Check fuses, isolators, Miniture Circuit Breakers (MCBs) and Residual Current Devices (RCDs) in and around consumer units, around the solar generation and mains/grid supply meters and see if anything marked 'solar PV' or you can see is related to the solar PV system is switched 'off'. The solar generation meter draws it's power from the mains so if this isn't on, this would be a strong indication that something heading toward the incoming grid/mains power supply has tripped off.

RCD

RCD

 

MCB

MCB

An RCD has a test button and is twice the width or a circuit breaker. An RCD that's switched itself 'off' is an indication that it has picked up an earth fault somewhere on the circuit that it protects, this fault could be anywhere on the circuit and might have been temporary.

- If an RCD has switched itself 'off' it's ok to try to turn it back 'on' again. If you meet with instant and strong resistance to closing the switch, leave it 'off'. If it stays on for a short while and switches off when the solar PV system has warmed up and begun to feed in power, there's most likely a problem with the solar PV system somewhere, leave the RCD turned 'off' and contact us to discuss the next steps.

If the RCD remains on for a few hours, weeks or days and then switches itself off, faults like these are often weather related. Damp cables and wet or windy conditions will often expose faults both physical and in design, with AC and DC cabling, connectors, solar panels and RCDs. Contact us to discuss the next steps.

If the RCD stays on, the solar inverter starts up and everything works fine in all conditions - all good.

- If a circuit breaker has switched 'off' this is an indication of either a short circuit, most likely a serious failure either within the solar inverter or with the solar inverter supply cable. Or for some other reason the circuit breaker has picked up a fault and isolated the circuit to prevent the solar inverter supply cable from becoming overloaded.

Turn on circuit breakers at your own risk, there is the potential to cause damage and only do so when you are able to access and inspect the solar inverter and all isolation equipment whilst it's in operation. If you meet instant and strong resistance, leave the circuit breaker 'off' and turn everything to do with the solar PV system 'off' remembering to also safely isolate the DC circuits.

If the circuit breakers stays on and then switches itself off after a few minutes, this is reasonably strong indication that the solar inverter has a serious internal fault. Turn off everything to do with the solar PV system including the DC isolators and contact us to discuss the next steps.

If the circuit breaker stays on, the solar PV inverter starts up and feeds power into the electrical system through the circuit breaker; although the circuit breaker will continue to protect the circuit, ideally a physical inspection and electrical test of the supply circuit including all isolators, circuit breakers, RCDs and electrical connections would also be carried out.

- Everything's 'on' but the error remains and the solar inverter won't start. If everything on the grid/mains power supply side including the solar generation meter is switched 'on', this would be an indication that there is either an internal fault within the solar inverter or there's a problem with the grid/mains power supply. Contact us to discuss the next steps.

* 165-178 - Fault, Frequency - The solar inverter is measuring a grid (mains) frequency that is either too high or too low in relation to the parameters that the solar inverter has been set to safely operate within. If this fault persists contact us to arrange for a solar engineer to visit to establish whether the fault lies with the solar inverter or with the grid.

* 240-241 - Fault, Mains fault - The solar inverter is measuring an AC current peak on the grid/mains power supply. The solar inverter will monitor the grid and reconnect when the current is within range. If this fault persists then contact us to arrange for a solar engineer to visit to establish whether the fault lies with the solar inverter or with the grid.

* 250-278 - Fault, Mains Voltage - The solar inverter is measuring a grid (mains) voltage or a grid impedence that is too low in relation to the parameters that the solar inverter has been set to safely operate within. If this fault persists and mains power is available to other local circuits then check that all isolators, MCBs and RCDs on the AC side of the solar PV system are 'On' and carry out the procedures outlined for * 151-164 - Fault, Mains fault above. If everything on the grid/mains power supply side including the solar generation meter is switched 'on', this would be an indication that there is either an internal fault within the solar inverter or there's a problem with the grid/mains power supply. Contact us to arrange for a solar engineer to visit to establish whether the fault lies with the solar inverter or with the grid/mains power supply.

* 300-399 - System Residual current - This error is generated either due to a leakage current to ground/earth on the DC side of the system or an internal fault within the solar inverter. See ( * 400-401 - System Insulation error) below. If after the system has been safely shutdown and restarted this condition persists then contact us.

* 400-401 - System Insulation error - This error is generated when during normal operation of the solar inverter, a leakage current to ground/earth is detected on the DC side of the system. Although it is also possible that the solar inverter generates this alarm message due to AC leakage currents connected to the capacitive nature of the solar panels compared to ground/earth or there could be a problem with the solar inverter itself.

Cable

For as long as the situation persits then the solar inverter will not startup. Earth / Ground Faults (also called Insulation or Isolation Faults) often present themselves when it is raining or at times of high humidity when moisture can enter the solar PV system through damaged solar panels, connectors or cabling. These faults often clear when weather conditions improve but they will not get better by themselves, most often degrading and becoming more dangerous over time.

We would advise that you book a solar repair engineer's visit in order to carry out a full solar system test, identify the source and rectify the fault. We've written more about how to identify and repair ground faults here: Ground Faults, Isolation (ISO) Faults, RISO Low Faults and Insulation Resistance Faults with Solar PV Systems

* 501 - System Arc - Parallel arc on string 1. This fault suggest that there could be a seriously damaged DC circuit where current is arcing between two conductors of different polarities. We would advise that you isolate the system and book a solar repair engineers visit in order to carry out a test and inspection of the DC circuits.

* 502 - System Arc - Parallel arc on string 2. This fault suggest that there could be a seriously damaged DC circuit where current is arcing between two conductors of different polarities. We would advise that you isolate the system and book a solar repair engineers visit in order to carry out a test and inspection of the DC circuits.

* 503 - System Arc - Parallel arc on string 3. This fault suggest that there could be a seriously damaged DC circuit where current is arcing between two conductors of different polarities. We would advise that you isolate the system and book a solar repair engineers visit in order to carry out a test and inspection of the DC circuits.

* 504 - System Arc - Serial arc on string 1. This fault suggest that there could be a seriously damaged DC circuit where current is arcing across a damaged or poorly installed circuit or connection. We would advise that you isolate the system and book a solar repair engineers visit in order to carry out a test and inspection of the DC circuits.

* 505 - System Arc - Serial arc on string 2. This fault suggest that there could be a seriously damaged DC circuit where current is arcing across a damaged or poorly installed circuit or connection. We would advise that you isolate the system and book a solar repair engineers visit in order to carry out a test and inspection of the DC circuits.

* 506 - System Arc - Serial arc on string 3. This fault suggest that there could be a seriously damaged DC circuit where current is arcing across a damaged or poorly installed circuit or connection. We would advise that you isolate the system and book a solar repair engineers visit in order to carry out a test and inspection of the DC circuits.

* 601-615 - Fault Excess Temperature - The solar inverter is too hot. This could be due to a number of factors, for example 1) If the solar inverter is exposed to direct sunlight 2) If the solar inverter has been installed without adequate ventilation around the chassis which would allow excess heat to dissipate 3) The solar inverter's components are getting too hot due to an internal component fault. If the unit isn't running hot and if after the system has been safely shutdown and restarted this condition persists then contact us.

* 800-999 - Fault System fault - If after the system has been safely shutdown and restarted this condition persists the inverter has a fatal error and should be replaced. There are a few ways that we can help with this: Solar Inverter Replacement

Solar PV System Repairs

Solar Inverter Replacement

Contact us

 

Solar Inverter Recycling: - Recycling Kostal Piko Inverters

Kostal Piko inverters contain valuable materials such as copper and aluminium, these materials are in high demand and recycling them is significantly less energy intensive than extracting them from ore.

If you find yourself with a damaged or faulty Kostal Piko solar inverter, we will be pleased to help you recycle it.

Solar PV System Repairs

All services

 

Solar Power System Testing, Servicing & Maintenance

Regular solar PV system testing, servicing and maintenance will extend the life of a solar PV system and ensure that solar panels are always operating safely and at their best, whilst maximising yields.

We offer complete safety and performance testing for solar PV power systems of any size. Includes solar panels, cables, solar inverters, isolators and mains connections.

We provide solar power system testing and maintenance services for residential, commercial, industrial and agricultural clients across Southern, South West England and the West Midlands, with specialist experience working with farmers, developers and commercial and industrial buildings owners.

Solar Power System Testing, Servicing & Maintenance

 

Solar PV Inverter Replacement

If you have a faulty solar inverter, we offer an efficient, value for money, hassle free solar inverter replacement service. We offer good advice and install quality equipment with comprehensive warranty and support options. We will test the rest of the system as part of the service, take care of all hardware deliveries, record the new unit's serial number and confirm the warranty details with the manufacturer.

Our solar electricians work cleanly and will dispose of any unwanted boxes, faulty equipment and packaging.

Many modern solar inverters can now use wireless home networks to transmit solar generation data to PCs, tablets and smartphones, so if you would like something like this, let us know and we will be happy to set it up as part of the installation.

Solar PV Inverter Replacement

 

Mains/Grid Isolation and Surge Protection

Mains/AC Surge Protection Solar PV Systems

A whole house surge protector is installed to provide protection from transient overvoltages originating from the mains/grid. A whole house surge protector is installed directly inline and as close as possible to the incoming mains/grid supply meter, this allows for surge protection for all circuits and equipment including solar inverters, routers, stereos and other sensitive electrical equipment within the network. The addition of a 100Amp lockable isolator also allows for safe and convenient isolation of all electrical equipment within the network including consumer units, solar inverters, battery storage units and EV chargers from the mains/grid in one place.

Surge protectors are in compliance with the recently updated 18th edition amendment 2 of BS7671.

Mains/Grid Isolation and Surge Protection

All services

Articles: Further Information, Calculators & Solar Inverter Fault Codes

Lots of articles, calculators and technical information including links for further reading. Covering a range of topics related to the installation and maintenance of solar photovoltaic and electrical systems in the UK.

/Solar PV Information Articles

How to provide power to a house using a portable generator

We look at changeover switches, the importance of earthing, generator loadings, isolating non essential loads. Where to locate the generator and how best to safely isolate the grid/mains power supply and switch to a generator supply.

Solar PV, Safety & The Building Regulations

Residential PV systems notifiable under Part P. Special consideration needed for Part A. A combination of serious risks for solar PV installers.

Ground Faults, Isolation (ISO) Faults, RISO Low Faults and Insulation Resistance Faults with Solar PV Systems

After a number of years exposed to wind, rain, snow, ice and sometimes animals; solar panel systems can start to develop faults. The most common faults we find related to exposure are ground faults, isolation (ISO) faults, RISO low faults and insulation resistance faults. In this article we take a look at what these faults are, the possible causes and what steps are taken to identify and resolve them.

All articles

 

What Our Customers Say:

"I spoke to Glen as my inverter was coming to its end of life (10 years). Glen quickly appraised me of the many different inverters that I could use. I selected a similar SMA type. The next week Alex replaced it with a new inverter with WiFi connectivity. Everything is working perfectly (thanks Alex) in-addition I can now view my information through the Sunny Portal. A BIG thanks to Glen and Alex, superb service, highly recommended!!!!!" - David Powell, Worcester

All testimonials

 

Case Studies

We've carried out Solar PV System design, installation, testing, repair and maintenance work on solar PV systems of all shapes and sizes all across the UK.

All case studies

Areas Served:

We are located in Wanborough, very close to Swindon in Wiltshire, Southern England, UK. From here we service clients within a 90 minute driving radius including the towns, cities and regions below:

Swindon: Abingdon, Aldbourne, Amesbury, Andover, Banbury, Basingstoke, Bath, Berkshire, Bicester, Blunsdon, Box, Bracknell, Bradford on Avon, Bridgwater, Bristol, Buckingham, Burford, Burnham on Sea, Calne, Camberley, Cardiff, Carterton, Cheltenham, Chippenham, Chipping Norton, Chipping Sodbury, Cirencester, Corsham, Cricklade, Devizes, Didcot, Evesham, Eynsham, Faringdon, Frome, Fleet, Glastonbury, Gloucester, Gloucestershire, Hampshire, Henley-on-Thames, Highclere, Highworth, Hook, Hungerford, Keynsham, Kingsclere, Lambourn, Lechlade, Ledbury, Ludgershall, Lyneham, Maidenhead, Malmesbury, Marlborough, Marshfield, Melksham, Minety, Newbury, Newport, Oxford, Oxfordshire, Pewsey, Purton, Ramsbury, Reading, Ross on Wye, Royal Wootton Bassett, Salisbury, Shaftesbury, Shalbourne, Slough, Southampton, Stow, Stratford upon Avon, Stroud, Swindon, Tewkesbury, Thatcham, Tidworth, Trowbridge, Wanborough, Wantage, Warminster, Weston Super Mare, Wiltshire, Winchester, Windsor, Witney, Wokingham, Worcester, Wroughton and Yate.

Contact us

Top of page

Privacy: None of your data will be collected and nothing will be installed on your device.

We do not use cookies, trackers, fingerprinting or embedded scripts on this website.

©2007-2024 - In Balance Energy