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22kWp Solar Installation: Solis 20kW Inverter OV-G-V04 Fault, YKY 5x10mm2 Cable Issues

jedras64 4473 13
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  • #1 19234166
    jedras64
    Level 4  
    Hello forum members.
    I have a question:
    I have had a 22kWp solar installation for a year. I used a YKY 5x10mm2 cable as the AC connection. There are about 80 meters to the box with the meter.
    Solis 20kW inverter.
    The installation has not been operating for several days, because a message appears on the inverter screen suggesting to use a connection with a larger cross-section.
    Allegedly, the cable resistance is too high and the message OV-G-V04 appears on the inverter screen.
    Is it possible that the wire in the ground is damaged? It looks as if it has lost its conductivity ..
    I am asking for a logical answer, best regards.
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  • #2 19239731
    kosmos99
    Level 38  
    Was there anything being done around the cable that might have been damaged?
    Connection clamps on both sides checked for play, carbon deposit, etc?
    It would also be good to measure the value of the AC voltage coming to the inverter.
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  • #3 19240046
    jedras64
    Level 4  
    Hello
    I would like to say that nothing was done around the cable and the terminals were checked several times too.
    To clear all my doubts, I went to a friend who also has a Solis inverter. We disassembled his inverter and plugged in mine and ... OV-G-V04 again, I have no doubt it's the inverter's fault.
    I'm talking to the service tomorrow.
    best regards
  • #4 19240527
    Merio186
    Level 17  
    During the inverter spacer, you did not notice any suspicious discoloration in the vicinity of the power connection? Perhaps that's where the problem lies.
  • #5 19240584
    jedras64
    Level 4  
    Hello..
    There are no disturbing changes ...
    I need to change something in the settings, but this is the responsibility of the website.
    My installation will be on 02/25. year as it was launched ..
    Thanks greetings.
  • #6 19241042
    studniarz
    Level 20  
    jedras64 wrote:
    OV-G-V04 appears on the inverter screen

    Hello friend.
    This message rather says that the network voltage is too high.
    best regards
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  • #7 19241238
    jedras64
    Level 4  
    Hello
    Regarding the OV-G-V04 message, it says that the voltage in the network is too high, but this is not true, because it is 236-240V.
    The AC cable is also ok. It was checked with a meter each wire separately and one to the other.
    As I mentioned earlier in a friend, it also shows the same (it has the same inverter). The indications are evident that it is an inverter.
    best regards
  • #8 19241330
    theo33
    Level 27  
    The inverter may be damaged, the measurement of this circuit would have to be done with a short circuit loop meter, but 22kW at a distance of 80m is a drop above 2% and it is surprising that the inverter did not turn off, maybe you have a decent network there and you are not too far from the destination
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  • #9 19242439
    prose
    Level 36  
    jedras64 wrote:
    Regarding the OV-G-V04 message, it says that the voltage in the network is too high, but this is not true, because it is 236-240V.

    And where is it measured?
  • #10 19242459
    noja102
    Level 24  
    For me, at a distance of 80m there should be at least 5x25mm2 in copper or 5x35mm2 in aluminum, the cable is buried and peace of mind, it would be
  • #11 19258015
    retrofood
    VIP Meritorious for electroda.pl  
    noja102 wrote:
    For me, at a distance of 80m there should be at least 5x25mm2 in copper or 5x35mm2 in aluminum, the cable is buried and peace of mind, it would be

    Get that copper out of your thinking. It is expensive, heavy and completely unnecessary. All normal power industry (without special applications) works on aluminum cables. And it works without any problems.
  • #12 19258048
    lukaszd82
    Level 31  
    It is probably a power plant that is not power industry, because you will not find alu cables with us, those that were exchanged for copper a long time ago, in new installations alu is unacceptable on the premises of the plant.
    If after transferring the inverter to a friend the same symptoms, it is known that something is wrong with the equipment of the author of the topic.
    I understand that you did not change anything in the inverter settings and did not play with the service technician? :)
  • #13 19258064
    trojan 12
    Level 40  
    Colleagues, let's not get crazy. About 32 A flows in the cables in the summer in the sun from PV, which is a small value even on aluminum.

    At the moment, the production from PV reaches 10% of the maximum power, it does not matter the conductor cross-section (0.32 A / mm2 ;) .
  • #14 19258292
    retrofood
    VIP Meritorious for electroda.pl  
    lukaszd82 wrote:
    It is probably a power plant is not energy because you will not experience any cables with us

    Read to the end and understand. The power plant is not a network, not an installation. And I mentioned explicitly about special applications (that they exist). For example in mines too. However, by far over 90% of the applications are aluminum.
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Topic summary

✨ The discussion revolves around a 22kWp solar installation utilizing a Solis 20kW inverter and YKY 5x10mm2 cable for AC connection. The inverter displays an OV-G-V04 fault, indicating potential issues with cable resistance or conductivity. Users suggest checking for physical damage to the cable and terminals, measuring AC voltage, and considering the inverter's functionality. Despite confirming the cable's integrity and voltage levels, the author suspects the inverter is faulty, as similar issues arise when tested with another inverter of the same model. Recommendations include using larger cable sizes for long distances and verifying inverter settings. The conversation highlights the debate over using aluminum versus copper cables in solar installations.
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FAQ

TL;DR: On 22 kWp with ~80 m of 5×10 mm², expect a voltage drop above 2%; "The inverter may be damaged." For Solis OV-G-V04, verify supply with a loop-impedance test before concluding a bad unit. [Elektroda, theo33, post #19241330]

Why it matters: Grid-trip faults stop production; this FAQ helps Solis 20 kW owners diagnose OV-G-V04 and right-size cabling to avoid downtime.

Quick Facts

What does Solis fault OV-G-V04 actually mean?

OV-G-V04 indicates the inverter detects the grid voltage as too high and disconnects for protection. “This message rather says that the network voltage is too high.” Address the cause before restarting generation. [Elektroda, studniarz, post #19241042]

Could my 80 m YKY 5×10 mm² AC cable cause OV-G-V04?

Yes. Long 10 mm² runs increase line impedance and voltage rise during export. For 22 kW over about 80 m, expect a voltage drop above 2%, which narrows protection margins and can trigger trips on OV-G-V04. [Elektroda, theo33, post #19241330]

How do I quickly diagnose OV-G-V04?

  1. Check if any work occurred along the cable route that could cause damage.
  2. Inspect connection clamps on both ends for looseness or carbon deposits.
  3. Measure the AC voltage arriving at the inverter during operation. [Elektroda, kosmos99, post #19239731]

The grid at my inverter reads 236–240 V. Why do I still get OV-G-V04?

A user measured 236–240 V and still saw OV-G-V04. The same inverter produced the fault on another system, indicating an internal inverter issue rather than the grid. When voltage is normal yet the fault persists, suspect the device. [Elektroda, jedras64, post #19241238]

Should I try swapping inverters to confirm the fault?

Yes. Move your Solis to a known‑good installation and observe. In the thread, swapping the inverter to a friend’s plant reproduced OV-G-V04 immediately, confirming an inverter fault rather than site wiring or cable. [Elektroda, jedras64, post #19240046]

What instrument can check if supply impedance is too high?

Use a short‑circuit loop‑impedance meter on the AC feed. It verifies whether supply impedance is acceptable. If readings are good and OV-G-V04 persists, “The inverter may be damaged.” [Elektroda, theo33, post #19241330]

Is aluminum cable acceptable for long PV AC runs?

Yes, where appropriate terminations and rules permit. “All normal power industry … works on aluminum cables. And it works without any problems.” Aluminum helps manage cost and weight on long runs. [Elektroda, retrofood, post #19258015]

What cable size do users recommend for an ~80 m AC run?

One practitioner recommended 5×25 mm² copper or 5×35 mm² aluminum for about 80 m between inverter and meter. This increases headroom by reducing voltage rise under export. [Elektroda, noja102, post #19242459]

How much current does a 20 kW three‑phase inverter export?

Around 32 A under strong sun. “About 32 A flows in the cables in the summer in the sun from PV.” On 10 mm², that is roughly 0.32 A/mm², within typical thermal limits. [Elektroda, trojan 12, post #19258064]

Who should adjust inverter grid‑protection settings?

Leave grid parameters to authorized service or installer. As the owner stated, “I need to change something in the settings, but this is the responsibility of the website.” Unauthorized changes can violate local grid codes. [Elektroda, jedras64, post #19240584]

What should I look for at the inverter AC terminals?

Inspect around the AC power connection for suspicious discoloration. Heat marks or darkening can signal poor contact or arcing that increases local impedance and trips protection. [Elektroda, Merio186, post #19240527]

Could recent digging or ground works cause OV-G-V04?

Yes. Damage along the buried cable can increase resistance or cause intermittent faults. Confirm whether any work happened near the cable and inspect the route before deeper tests. [Elektroda, kosmos99, post #19239731]

When does conductor cross‑section matter less?

During low generation, conductor size has limited impact. “At the moment, the production from PV reaches 10% of the maximum power, it does not matter the conductor cross-section (0.32 A/mm²).” Expect fewer voltage‑rise issues in such conditions. [Elektroda, trojan 12, post #19258064]

Is copper always better than aluminum for PV AC runs?

Not always. One expert noted that, outside special cases, aluminum dominates. “By far over 90% of the applications are aluminum.” Use proper terminations and follow site‑specific requirements. [Elektroda, retrofood, post #19258292]
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