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KACO Powador 5300 Inverter User manual

1. Fault message shown on the display Description of the fault Did you notice anything unusual What has already been done to analyse the fault e Module type and string circuit e Date of installation Start up report e Consignment identification Delivery address Contact person with telephone number You can find our warranty conditions on our website http kaco newenergy de de site service garantie From there you can easily navigate to our international websites by clicking on the appropriate flag Please use our website to register your unit within 24 months http kaco newenergy de en site service registrieren You can also select the appropriate flag on this page to access the website for your own country In this manner you can assist us in providing you with the quickest service possible In return you receive two additional years of warranty coverage for your unit Note The maximum length of the warranty is based on the currently applicable national warranty conditions We have prepared a template for complaints It is located at http www kaco newenergy de en site service kundendienst index xml Hotlines Technical troubleshooting Technical consultation Inverters 49 0 7132 3818 660 49 0 7132 3818 670 Data logging and accessories 49 0 7132 3818 680 49 0 7132 3818 690 Construction site emergency 49 0 7132 3818 630 Customer help desk Monday to Friday from 7 30 a m to 5 30 p m CET Al
2. Figure 9 Instructions for wall mounting Figure 10 Drill stencil for wall mounting with minimum clearances inmm CAUTION Use suitable mounting parts Use only the supplied mounting parts Mount the inverter upright on a vertical wall only Page 20 Operating Instructions Powador 3200 6600_EN Mounting the Inverter K D C 0 Q new energy Authorised electrician Clearance from the ceiling 500 mm Clearance from any other inverter 700 mm Safety catch open Safety catch closed Duo NS y Sy j 5 qn 5 m Clearance from the floor 500 mm a fcd x Clearance from any other inverter 700 mm NN Figure 11 Minimum clearances mounting plate Key 1 Fixings for mounting 4 Suspension bracket 2 Mounting plate 5 Safety catch 3 Screws for mounting 61 Installing and securing the inverter Mounting the Inverter 1 Markthe positions of the drill holes using the cut outs in the mounting plate NOTE The minimum clearances between two inverters or the inverter and the ceiling floor have already been taken into account in the diagram see Figure 10 on page 20 2 Fixmounting plate to the wall with the supplied mounting fixtures Make sure that the mounting plate is oriented correctly 3 Hangthe inverter on the mounting plate using the suspension brackets on the back of the housing Secure the inverter with safety catch The mounting of the inverter is complete Continue with the installation Operatin
3. KACO new energy Powador 3200 4200 4400 5300 5300 supreme 5500 6600 Operating Instructions E English translation of German original Contents 1 General NOES wisssisccssssecsccsscccasdssasscescsssscinss 4 11 About this documentation 4 12 Layout of Instructions esee 4 2 Safety sessccncs ses secucsdccasansieravensunersiosdscceseteesenss 6 2 1 dis c 6 22 Protection features see 7 23 Standards and directives 7 3 Description siccis oci 8 31 Mode of Operation eese 8 3 2 Description of the unit esses 8 4 Technical Data oinnes eno n o eoa ao ossa sa ses aso 15 4 1 Electrical Data ruinn 15 4 2 Mechanical data ss 17 5 Transportation and Delivery 18 51 Delivery M TN 18 5 2 Transportation eese eterne 18 6 Mounting the Inverter 19 6 1 Installing and securing the inverter 21 7 Installing the Inverter 22 7 1 Opening the connection area 22 72 Making the electrical connection 22 73 Connecting the interfaces s 27 74 Limiting during asymmetric feed to the ORC ences naeirco tiet 29 75 Sealing the connection area 34 7
4. Noise emission Particular ambient from the inverter conditions In spite of high The device is too radiation levels the hot and the system inverter does not limits the power feed the maximum power into the grid Table6 Troubleshooting Page 48 Kaco m new energy Explanation remedy By The PV generator voltage or power is not sufficient for feed in solar radiation is too low e The inverter checks the grid parameters before the feed in process begins The length of time it takes to switch back on again differs from country to country depending on applicable standards and regulations and may be several minutes The starting voltage may have been set incorrectly Adjust starting voltage in the Parameter menu if K required When there are certain ambient conditions the units may emit audible noises Grid interference or grid failure caused by particular loads motors machines etc which are either connected to the same point on the grid or located in the vicinity of the inverter n cases of volatile weather conditions frequent switching between sunny and cloudy conditions or strong solar radiation a light hum may be audible due to the increased power e Under certain grid conditions resonances may form between the unit s input filter and the grid which may be audible even when the inverter is switched off These noise emissions do not affect the operation of the inverter They do
5. ok or measured values The green Grid feed LED is illuminated after the country specific waiting period The inverter is internally power reduced and ready to feed in i e is on the grid in accordance with VDE application rule AR N 4105 2010 8 Alternatives V A oh 1 Internal external power limiting or start up limiting 7 s is active 2 The inverter is operating in standalone mode The waiting period ensures that the generator voltage continuously remains above the power delivery limit of 200 V For country specific waiting periods see out web site at http www kaco newenergy de Operating Instructions Powador 3200 6600_EN Page 35 Configuration and Operation K A C 0 Q new energy Non grid feed Status message The display shows the corresponding message mode 9 ok O Qs Fault D Fault message The display shows the corresponding message The red Fault LED is illuminated The inverter is not ready for grid feed i e no longer on the grid Fault pub Fault message The display shows a SYM bus parameter error ila 8 1 2 Display The display shows measured values and data and allows the configuration of the inverter In normal operation the backlighting is switched off As soon as you press one of the control buttons the backlighting is activated If no button is pressed for a minute it switches off again You can also activate or deactivate the backlighting permanently NOTE Depending on the
6. Grid side connection for systems with multiple inverters with three phase grid monitoring 3 2 2 3 Electrical connection G o o Pose aN Ele aN tle NOTE Note the grid type specific connection conditions see section 7 2 1 on page 23 Operating Instructions Powador 3200 6600_EN Page 9 Description K D C 0 Q new energy 3 2 3 Summary of the components PV generator The PV generator i e the PV modules converts the radiant energy of sunlight into electrical energy DC terminal point Options for parallel connections of several generator strings To a DC terminal point between the DC generator and inverter Directly to the inverter terminals for 3 strings are provided on the inverter e Directly to the PV generator with a positive and negative lead to the inverter DC disconnect Use the DC disconnect to disconnect the inverter from all power sources on the PV generator side Grid fuses gL fuses are suitable Feed in meter The feed in meter is to be specified and installed by the power supply company Some power supply companies also allow the installation of your own calibrated meters Selective main switch If you have questions about the selective main switch contact your power supply company 3 2 4 Inverter diagram Figure 4 Inverter diagram Key 1 Display 6 Cable fitting for DC connection 2 LED indicators 7 Cable fitting for interface cable 3 Control buttons 8 Cable fitting for AC connecti
7. EN 61000 6 2 2005 2004 108 EC Emitted interference Directive relating to electromagnetic EN 61000 6 3 2007 compatibility EN 61000 6 4 2007 Secondary effects on the grid EN 61000 3 2 2006 EN 61000 3 12 2005 EN 61000 3 3 1995 A1 2001 A2 2005 EN 61000 3 11 2000 The types mentioned above are therefore labelled with the CE mark Unauthorised modifications to the supplied units and or any use of the units that is contrary to their proper use shall render this Declaration of Conformity null and void Neckarsulm 17 10 2011 KACO new energy GmbH p p Matthias Haag CTO Operating Instructions Powador 3200 6600 EN Page 55 VLOOTL SO SELLOOLE peide xe suolssiwo pue s10413 sebueup ed UYyIa 0 Palqns Hulud jo aun eui 3e IS 2ED UYIA 3u24n2 ay Palas seunfy pue xa eu e CE x new energy 74172 Neckarsulm Germany Tel 49 7132 3818 0 Fax 49 7132 3818 703 info kaco newenergy de www kaco newenergy com Carl Zeiss StraBe 1
8. ON Figure 6 DC disconnect 3 2 6 2 Night start button The unit switches off in the evening as nightfall approaches At this point nothing is shown on the display In order to retrieve the values from the current day daily yield daily hours of operation and max feed in power after the display switches off the unit can also be activated during the night by pressing the night start up key on the underside of the inverter mmmn Figure 7 Night start interface on the inverter 3 2 7 Interfaces The inverter has the following interfaces for communication and remote monitoring e RS232 port e RS485 interface e SO interface You configure the interfaces in the Settings menu see section 8 3 on page 39 3 2 7 1 RS232 port Use this monitoring variant if you wish to manage operating data directly on a computer The data can be processed with standard spreadsheet programs The inverter and computer are connected with a serial 1 1 interface cable The cable length should not exceed 20 metres The data from the inverter is sent unidirectionally as pure ASCII text over the serial interface The data is not checked for errors The RS232 interface has the following parameters ssobes s ww none Table 1 on page 14 shows an example of a few lines of data transmitted over the RS232 interface Operating Instructions Powador 3200 6600 EN Page 13 Descrip
9. Press key 2 for 15 seconds S The LCD is showing the country specific parameters Press key 1 repeatedly or press and hold The display runs through menu level 3 To return to menu level 1 press keys 1 and 2 simultaneously or wait for one minute without pressing a key S Key 1 selection of items 1 4 The LCD shows the selected digits by underlining them Press key 2 to set the value 0 9 A F The LCD shows the set digits or letters D Press 1 to check password If the password is correct the unlocked menu item is displayed Press keys 1 and 2 simultaneously to save settings or wait one minute after setting The LCD jumps back to menu level 1 D Initial start up When started for the first time the inverter displays the configuration assistant It takes you through the settings necessary for the initial start up NOTE After configuration is completed the configuration assistant does not appear again when the inverter is restarted You can then change the country setting only in the password protected parameter menu NOTE The sequence of the settings required for initial start up is preset in the configuration assistant Initial configuration You are in the parameter menu Select the country of operation Select the required grid type Press keys 1 and 2 simultaneously to save the selection You have completed the initial configuration The inverte
10. failure O e The voltage of a grid phase is too high Notify your E overvoltage the grid cannot be fed into authorised L1 The phase experiencing failure is electrician displayed FS 48 Line failure O e Grid frequency is too low Notify your E Underfrequency This fault may be grid related authorised electrician FS 49 Line failure O Grid frequency is too high Notify your E Overfrequency This fault may be grid related authorised electrician FS 50 Line failure O e The grid voltage measurement Notify your E average voltage according to EN 50160 has exceeded authorised the maximum permitted limit value electrician This fault may be grid related FS 50 Line failure O e String voltage L1 is above the set Notify your E overvoltage L1 maximum permissible string voltage authorised electrician FS 51 Grid fault medium O e String voltage L1 is above the set Notify your E overvoltage L1 maximum permissible string voltage authorised electrician FS 52 Grid fault medium O e String voltage L1 is below the set Notify your E overvoltage L1 minimum permissible string voltage authorised electrician FS 53 Grid fault medium O e String voltage L2 is above the set Notify your E overvoltage L2 maximum permissible string voltage authorised electrician FS 54 Grid fault medium O String voltage L2 is below the set Notify your E overvoltage L2 minimum permissible string voltage authorised electrician FS 55 Fault O e Volta
11. new energy 7 3 3 Connecting the RS485 bus NOTE Gi Ensure that the A and B wires are properly connected Communication is not possible if the wires are reversed 73 31 Wiring diagram RS485 RS485 B A RSABS SYM Bus RJ45 Patch Cable Figure 18 RS485 interface wiring diagram with CAN RJ45 connection Properties of the RS485 data line Maximum length of the RS485 The maximum allowed length of the RS485 bus is 1200 m bus line This length can be reached only under optimum conditions Lengths exceeding 500 m generally require a repeater of a hub Maximum number of 31 inverters 1 data monitoring unit connected bus devices Data line Twisted shielded Recommendations LIZYCYv twisted pair black for laying cable outside and in the ground 2 x 2 x 0 5 LI2YCY twisted pair grey for dry and moist indoor spaces 2x 2 x 0 5 NOTE Different manufacturers do not always interpret the standard on which the RS485 protocol is based in the same way Note that the wire designations and for wires A and B can vary between manufacturers NOTE Calculating efficiency by measuring the current and voltage values leads to unusable results due to the tolerances of the measurement devices The sole purpose of these measured values is to monitor the basic operation of the system Page 28 Operating Instructions Powador 3200 6600_EN Installing the Inverter K D C 0 Q new energy Connecting the
12. not lead to loss of efficiency failure damage or to a shortening of the unit s service life People with very sensitive hearing particularly children are able to hear the high frequency hum caused by the inverter s operating frequency of approximately 17 kHz No action Because the temperatures inside the unit are too high the inverter reduces its power to prevent damage to the unit Note the technical data Ensure that the convection cooling is not impeded from the exterior Do not cover the cooling fins Provide for sufficient cooling of the unit B E Do not cover the cooling fins Operating Instructions Powador 3200 6600 EN Maintenance Troubleshooting K D C 0 Q new energy Authorised electrician Fault Cause of fault Explanation remedy By Additional devices The potential free If the priwatt function is not activated the potential that are connected contactconnects free contact functions as a fault signal relay and therefore via the potential to indicate an indicates errors However if additional devices that are free contact error provided for the priwatt function are connected to suddenly start up the inverter via the contact they can still start up when even though the the inverter experiences an error because the contact priwatt function is is connected at that point in time If you deactivate the deactivated and the priwatt function we recommend that you disconnect inverter indicates
13. of the cables to the DC connections Check that all connected cables are tightly seated Tighten the cable fittings The requirements of protection rating IP54 are met by closing the unused cable fittings with blind caps ONAN RWHN gt The inverter is connected to the PV generator 7 2 2 3 Connection of the PV generator with solar plug connector Connecting the PV generator 1 Screw the cable fittings from the base plate 2 Insert the solar plug connector through the opening from the outside and lock from the inside with black plastic nuts Remove the outer cladding of the DC cables Insert the DC leads into the connection area through the solar connectors Strip the insulation from the DC cables 3 4 5 6 Connectthe ends of the cables to the DC connections 7 Checkthat all connected cables are tightly seated 8 Tighten the cable fittings 9 Therequirements of protection rating IP54 are met by closing the unused cable fittings with blind caps The inverter is connected to the PV generator Figure 15 Assembling the solar plug connection Page 26 Operating Instructions Powador 3200 6600 EN Installing the Inverter K D C 0 Q new energy 7 3 Connecting the interfaces All interfaces are connected on the communications board located on the inner side of the doors Risk of fatal injury due to electric shock Severe injury or death from improper use of the interface connections and non observance of
14. the inverter A Pack the inverter securely for transport Carefully transport the inverter using the the carrying handles of the boxes Do not subject the inverter to shocks For safe transportation of the inverter use the holding openings in the carton Figure 8 Transportation of the inverter Page 18 Operating Instructions Powador 3200 6600_EN Mounting the Inverter K A C 0 Q new energy 6 Mounting the Inverter Risk of fatal injury from fire or explosions Fire caused by flammable or explosive materials in the vicinity of the inverter can lead to serious injuries gt Do not mount the inverter in an area at risk of explosion or in the vicinity of highly flammable materials Risk of burns from hot housing components Coming into contact with the housing can cause burns gt Mount the inverter so that it cannot be touched unintentionally Installation space As dry as possible climate controlled with the waste heat dissipated away from the inverter Unobstructed air circulation When installing the unit in a control cabinet provide forced ventilation so that the heat is sufficiently dissipated Easily accessible from the front and sides Protected from direct sunlight and moisture rain in outdoor areas For easy operation ensure during installation that the display is slightly below eye level Installation location e Free standing installation or wall mounting possible Consisti
15. the total yield back to the last reset Press 2 to clear the yield meter Displays the yield of the current day up to now Displays the total yield up to now The total yield value can be set in menu level 2 Displays the calculated CO savings in kg Menu item is displayed with SYM bus test activated Shows the phase allocation and total phase power selected on the unit Shows the total operating time back to the last reset The yield hour meter can be cleared in menu level 2 Grid feed meter Displays the duration of operation on the current day Displays the total operating time If the function is enabled the last five grid errors in 1000 operating hours are displayed The fault messages are displayed by pressing 1 After displaying the grid errors the menu level is run through again and when key 1 id pressed again the unit name is displayed Press keys 1 and 2 to run through the following menu level 2 Displays the installed software version Displays the installed configuration version Displays the serial number of the inverter Displays the selected country setting Optional Displays the grid type if a grid type has been selected Select the desired menu language Allows the grid feed meter to be cleared Yield meter and Operating hours meter f yes is selected the password is requested Setting required password number 2 If the code number is valid th
16. 1 Remove the inverter fastening 2 Securely pack up the inverter if it is to be used later or or have the inverter disposed of professionally see section 12 on page 54 12 Disposal For the most part both the inverter and the corresponding transport packaging are made from recyclable raw materials Do not dispose of faulty inverters or accessories together with household waste Ensure that the old unit and any accessories are disposed of in a proper manner 121 Packaging Ensure that the transport packaging is disposed of properly Page 54 Operating Instructions Powador 3200 6600_EN Documents K D C 0 Q new energy 13 Documents 131 EU Declaration of Conformity Manufacturer s name KACO new energy GmbH and address Carl Zeiss Straf3e 1 74172 Neckarsulm Germany Product description Photovoltaic feed in inverter Type designation Powador 3200 4200 4400 5300 5300 supreme 5500 6600 This is to confirm that the units listed above comply with the protection requirements set forth in the Directive of the Council of the European Union of 15 December 2004 on the harmonisation of the laws of the member states relating to electromagnetic compatibility 2004 108 EC and the Low Voltage Directive 2006 95 EC The units conform to the following standards 2006 95 EC Safety of the unit Directive relating to electrical EN 50178 1997 equipment designed for use within specific voltage limits Interference immunity
17. 4200 4400 5300 Max recommended PV generator power W 3 200 4 200 4 400 5 300 DC MPP range from V to V 350 600 Operating range from V to V 370 to 500 Starting voltage V 410 Open circuit voltage V 800 Max rated current A 8 6 11 5 12 14 5 Max power per tracker W 3 200 4 200 4 400 5 250 Number of strings 3 Number of MPP controls 1 Polarity safeguard Short circuit diode Output levels Rated power VA 2 600 3 450 3 600 4 400 Max rated power VA 2 850 3 800 4 000 4 800 Grid voltage V 184 264 Rated current A 11 3 15 15 6 19 1 Max rated current A 12 4 16 5 17 5 20 9 Rated frequency Hz 50 60 cos phi 0 80 over excited 0 80 under excited Number of feed in phases 1 General electrical data Max efficiency 96 6 96 6 96 5 96 4 European efficiency 95 8 95 8 95 9 95 8 Internal consumption night W 0 Feed in starts at W Approx 35 Circuit design Transformerless Transformer unit No Grid monitoring Country specific CE conformity yes Operating Instructions Powador 3200 6600_EN Page 15 Technical Data K D C 0 Q new energy Input levels 5300 supreme 5500 6600 Max recommended PV generator power W 5 300 5 500 6 600 DC MPP range from V to V 350 510 350 600 350 600 Operating range from V to V 370 to 500 Starting voltage V 410 Open circuit voltage V 600 800 800 Max rated current A 14 5 15 2 18 Max power per tracker W 5 250 6 000 6 800 Number of strings 3 Number of MPP contr
18. 6 Starting up the inverter sss 34 Kacoe Operating Instructions for Installers and Operators Powador 3200 4200 4400 5300 5300 supreme 5500 6600 8 Configuration and Operation SI CONTOS ohatead cence A 8 Initial start up eese 9 3 Venu SUCU G icono rie tipos 9 Maintenance Troubleshooting 91 Visual inspection esses 92 Cleaning the inverter externally 93 Shutting down for maintenance and troubleshooting sss OF cec 9 5 Messages on the display and the Fault LED sss 10 X SerVICe icones ivi veas eiae viet ia 11 Shutdown Disassembly 111 Shutting down the inverter 11 2 Deinstalling the inverter 1 3 Dismantling the inverter 12 PILTprt eer 124 PackagllGoaseeeiieaertordcer the iine iis 13 DOCUnDniells ssscssssscsssvssasccctevassssasercseansis 131 EU Declaration of Conformity new energy Operating Instructions Powador 3200 6600 EN Page 3 General Notes K D C 0 Q new energy 1 General Notes 1 1 About this documentation Improper handling of the inverter can be hazardous A You must read and understand the operating instructions before you can install and use the inverter safely 1 1 1 Other applicable documents During installati
19. 85 conductors RS485 conductors Figure 20 SYM bus wiring diagram in group of three Operating Instructions Powador 3200 6600 EN Page 29 Installing the Inverter K D C 0 Q new energy Authorised electrician NOTE Gi When a patch cable with an RJ45 plug is used an RS485 connection which is required for a proLOG connection is established at the same time Figure 20 on page 29 7 4 1 2 Wiring diagram for park operation NOTE Gi One of the three connection options must be used when connecting multiple inverters gt 3 The termination for the CAN bus must be performed in groups of three Option 1 The maximum patch cable length for each group of three is 100 m total length of the inverter chain max 1200 m N 13 L2 L1 i xx ee patch cable kx CAN RS485 E group of pF e three a patch cable aes CAN RS485 ee i d _ vane eee eee ce ee RSABS NN Ra xXx z xx Th patch cable T CAN RS485 EE aem n pT x three Ii a patch cable a CAN R5485 pe uy ox BY RS485 aa UE S P D Ra RS485 o patch cable CAN RS485 group of three patch cable CAN RS485 Page 30 Operating Instructions Powador 3200 6600_EN Installing the Inverter K D C 0 Q new energy Option 2 The maximum length of the CAN twisted pair without RS485 conductors for every group of three is 500 m total length of the inverter chain
20. AN twisted pair without three an conductors RS485 sb a J R 2 DAS On OONA OORA SOOS RMBS T CAN twisted pair without RS485 conductors RS485 group of CAN twisted pair without gt three i RS485 conductors RS485 NOTE The terminator must be activated via the DIP switch in the unit Cables must be appropriately fuse protected Page 32 Operating Instructions Powador 3200 6600_EN Installing the Inverter K D C 0 Q new energy Connecting CAN bus 1 2 3 4 Unscrew the cable fitting Thread the connection cables through the cable fitting Connect the connection cable to the corresponding connection terminals Connect the following to all inverters CAN H with CAN H and CANL with CAN L and e GND with GND see Figure 20 on page 29 5 Tighten the cable fitting For correct signal transmission the first and last devices in the group of three must have the Term CAN terminating switch set to ON The terminating switch Term CAN must be set to OFF on the middle inverter This termination does not depend on the manner of cabling that is used The switch is found on the board next to the terminal block See Figure 17 on page 28 All inverters of a group must be assigned a unique SYM bus address within the range of 1 to 32 Enter feed in phase for every inverter into which the inverter feeds The red LED flashes until a feed in phase or SYM bus address has been ente
21. H offers the following units Powador proLOG S to XL optional Powador proLOG allows you to monitor up to 31 inverters simultaneously Depending on the product model Powador proLOG sends yield and operating data by SMS or e mail Powador link RS485 optional Use the Powador link RS485 to bridge long distances between several inverters or between an inverter and the Powador proLOG by means of wireless radio transmission 3 2 7 4 SOinterface The SO interface transmits pulses between a pulsing counter and a tariff metering unit It is a galvanically isolated transistor output It is designed according to DIN EN 62053 31 1999 04 pulse output devices for electromechanical and electronic meters NOTE The SO interface pulse rate can be chosen in three unit intervals 500 1 000 and 2 000 pulses kWh 3 2 7 5 Digital input If a Powador protect is installed as external grid and system protection the fail safe disconnection of suitable Powador inverters from the public grid can be initiated by a digital signal instead of by tie circuit breakers This requires the inverters in the photovoltaic system to be connected to the Powador protect For information on the installation and use see this manual the Powador protect manual and the instructions for use of the Powador protect on the web site Page 14 Operating Instructions Powador 3200 6600_EN Technical Data K D C 0 Q new energy 4 Technical Data 41 Electrical Data Input levels 3200
22. RS485 bus i x a lt To prevent interference during data transmission EE EE Observe the wire pairing when connecting DATA and DATA see Figure O Q e e 19 Do not install RS485 bus lines in the vicinity of live DC AC cables 1 Unscrew the cable fitting 2 Thread the connection cables through the cable fitting Connect the connection cables to the corresponding connection terminals see Figure 16 on page 27 4 Connect the following to all inverters and to the data monitor unit as follows Wire A with wire A and Wire B with wire B see Figure 17 on page 28 5 Tighten the cable fitting Figure 19 RS485 bus Assignment of twisted pair wires o o Activate the terminating resistor on the terminal unit NOTE When using the RS485 bus system assign a unique address to every bus device inverter sensor and terminate the terminal units see the Settings menu 7 4 Limiting during asymmetric feed to the grid 7 4 1 Connecting CAN bus NOTE Gi The inverters communicate information on the symmetrisation of the phase feed over the CAN communications interface Every inverter calculate the maximum allowable feed in power for its phase from the total and with reference to the asymmetry 7 4 1 1 Wiring diagram OFF CANCAN ON CANCAN CAR ON JHL patch cable patch cable CAN CAN CAN ON HLL CAN twisted pair without CAN twisted pair without RS4
23. age are being checked OS 2 Generator voltage O Insufficient generator voltage and too low power status before the transition to night shutdown OS 8 Self test Checks the shutdown of the power O O electronics as well as the grid relay before feed in mode Table 7 Operating statuses and fault messages on the display Operating Instructions Powador 3200 6600_EN Page 49 Maintenance Troubleshooting Authorised electrician Status FS 10 OS 17 OS 29 FS 30 FS 32 FS 33 FS 34 FS 35 FS 36 FS 38 FS 41 Table 7 Display Temperature in unit too high Powador Protect shutdown Ground fault Check fuse Instrument transformer fault Fault Self test Fault DC feed in Communication error Protect shutdown SW Protect shutdown HW Error PV overvoltage Line failure undervoltage L1 nih O O O O O O O O O O O Explanation In case of overheating the inverter switches off Possible causes e Ambient temperature too high Fans covered e Inverter defect The activated grid and system protection has been tripped A ground fault was detected on the DC side The current and voltage measurements in the inverter are not plausible The internal grid separation relay test has failed The direct component of the line current has exceeded the permitted value This DC feed in can be adopted from the grid onto the inverter so that
24. an devices from the inverter that were connected for this error function Table6 Troubleshooting 9 5 Messages on the display and the Fault LED Many fault signals indicate a fault in the grid They are not operational faults of the inverter The triggering levels are defined in standards e g VDE0126 1 1 The inverter shuts down if the values exceed or fall below the approved levels 9 5 1 Display of status and fault messages Display Fault LED red Fault signal relay has switched FS fault stat ON Habeat e Feed in was ended due to a fault The fault signal relay releases again OS operating status O OFF The inverter feeds back into the grid again after a country specific time period Details regarding the fault or operating status can be found either on the display or in the data that was recorded through the RS485 interface 9 5 2 Status and fault signals The following table lists the possible status and fault signals that the inverter shows on the LCD and the LEDs For the status consult the data that is logged via the RS485 interface BS operating status FS fault status B Action of the operator E The indicated work may only be carried out by an authorised electrician K The indicated work may only be carried out by a service employee of KACO new energy GmbH Status Display sk o Explanation Action By OS Waiting for feed in Self test The grid parameters and O O generator volt
25. control procedure cos phi P Pn offers the option of defining up to 10 nodes minimum of 2 for shift factor cos phi A node is defined by the relevant pair of values Specification of an active power in based on a nominal power of the device and an associated cos phi value In factory status cos phi is activated with a predefined characteristic This characteristic which consists of three individual nodes depends on the rated AC power of the inverter COS p 0 9 o overexcited P Pn Characteristic with 2 nodes Characteristic with 3 nodes Figure 5 Control procedure as per cos phi P pn PAc hom 13 8 kVA Istnode 0 P py cos phi 1000 2nd Node 50 P py cos phi 1 000 3rd node 100 P py cos phi 0 950 under excited u To meet the requirements for reactive power feed even at system level the inverters must be adjustable in the range from cos phi 0 8 over excited o and 0 8 under excited u Page 12 Operating Instructions Powador 3200 6600 EN Description K D C 0 Q new energy 3 2 6 Mechanical components 3 2 6 1 DC disconnect There is one DC disconnect inside the inverter housing The DC disconnect is used to disconnect the inverter from the PV generator in order to carry out service Disconnecting the inverter from the PV generator Switch the DC disconnects from 1 ON to 0 OFF Connecting the inverter to the PV generator Switch the DC disconnects from 0 OFF to 1
26. d off This requires an external power supply max 30 V DC and an external load relay Both can be obtained as part of the Powador priwatt switch from your specialist retailer Country specific function 3 2 5 3 Power limitation power control Since 1 January 2009 the German Renewable Energies Act EEG requires power limitation for systems with an output of more than 100 kW This limit value can be exceeded when using a unit group of several inverters Therefore each inverter must have an option for limiting power even if this is not needed in a system that is smaller than 100 kW The power reduction is achieved using a ripple control receiver in KACO new energy GmbH inverters If necessary the power supply company can reduce the power of the system remotely using an additional device from the Powador proLOG family The Powador proLOG activates this function which is already integrated in the inverter After a specified period of time without any signal from the power supply company the inverter returns to normal operation For information about Powador proLOG contact your specialist retailer Levels of AC power reduction Inverter action 100 Normal feed in mode 60 Limitation of power to 60 30 Limitation of power to 30 0 Disconnection from the grid Operating Instructions Powador 3200 6600_EN Page 11 Description K D C 0 Q new energy Country specific function 3 2 5 4 Control procedure cos phi P Pn The
27. e grid feed meter is cleared and a confirmation is displayed Grid feed meter cleared Page 40 Operating Instructions Powador 3200 6600_EN Configuration and Operation Country spec setting All countries All countries Menu level B Display settings Defining total yield Interface Inverter address SO interface Activate priwatt Set priwatt Power Boost Quick start oc oco oco oco Kacoe new energy Action in this menu meaning You can set the total yield to any value for example when you have received a replacement unit and want to continue the recording from the present value Select yes to set the total yield A selection is possible only if both RS232 and RS485 interfaces are installed The interface is changed by pressing 2 Every inverter must have a unique address The interface is used to communicate with the Powador proLog By pressing key 2 the RS485 address can be set consecutively from 1 to 32 Selection of pulse rate for the SO interface 500 1000 and 2000 pulses kWh Set pulse rate Releases the use of the fault signal relay for the Powador priwatt internal consumption control relay 1 Enterthe password See Section 8 1 4 on page 37 2 Confirm what you have entered using key 1 3 Activate or deactivate the home grid feed function NOTE Activating this option enables the menu item Set priwatt Define the switch on po
28. e protection of NYM cables for fixed wiring according to VDE 0100 part 430 For cable lengths up to 20 m use the conductor cross sections named in table 6 Longer cable lengths require larger conductor cross sections Model Conductor cross section Fuse protection gL safety fuses Powador 3200 2 5 mm 20 A for 2 5 mm conductor cross section Powador 4200 2 5 mm 20 A for 2 5 mm conductor cross section Powador 4400 2 5 mm 20 A for 2 5 mm conductor cross section Powador 5300 supreme 4 0 mm 25 A for 4 0 mm conductor cross section Powador 5500 4 0 mm 25 A for 4 0 mm conductor cross section Powador 6600 6 0 mm 35 A for 6 0 mm conductor cross section Table4 Recommended conductor cross sections and fuse protection of NYM cables NOTE When the line resistance is high i e long grid side cables the voltage at the grid terminals of the inverter will increase during feed in to the grid The inverter monitors this voltage If it exceeds the country specific grid overvoltage limit value the inverter switches off Ensure that the conductor cross sections are sufficiently large or that the cable lengths are sufficiently short Operating Instructions Powador 3200 6600 EN Page 23 Installing the Inverter K D C 0 Q new energy Authorised electrician NOTE In order to avoid asymmetries in the grid systems with multiple inverters should be designed so that the inverters feed into the grid in differing phases z T
29. eaker is necessary due to the installation specification a type A AC DC sensitive residual current circuit breaker must be used 7 2 2 Connecting the PV generator Connect the PV generator on the right of the connection area see Figure 12 on page 23 Use the provided cable fittings Solar plug connectors can be delivered as an option with the inverter Page 24 Operating Instructions Powador 3200 6600_EN Installing the Inverter K D C 0 Q Authorised electrician new energy Risk of fatal injury due to contact voltages earth PE Removing the plug connection without previously disconnecting the inverter from the PV generator may result in a hazard to health and damage to the inverter gt During installation Electrically disconnect the DC positive and DC negative from the protective Disconnect the inverter from the PV generator using the integrated DC disconnect Remove the plug connector NOTE Connected PV modules must be dimensioned for the DC system voltage in accordance with IEC 61730 Class A but at least for the value of the AC grid voltage 7 2 2 1 Before connecting Ensure that there is no ground fault 1 Determine the DC voltage between the protective earth PE and the positive cable of the PV generator protective earth PE and the negative cable of the PV generator If stable voltages can be measured there is a ground fault in the DC generator or its wiring The ratio between the m
30. easured voltages gives an indication as to the location of this fault 2 Rectify any faults before taking further measurements 3 Determine the electrical resistance between the protective earth PE and the positive cable of the PV generator protective earth PE and the negative cable of the PV generator In addition make sure that the PV generator has a total insulation resistance of more than 2 0 megohms since the inverter will otherwise not feed in if the insulation resistance is too low 4 Rectify any faults before connecting the DC generator 7 2 2 2 Connecting the DC generator using cable fittings Risk of fatal injury due to electric shock Severe injury or death will result if the live connections are touched When there is solar radiation DC voltage will be present at the open ends of the DC leads Do not touch the exposed ends of the cables Avoid short circuits V D833 w TP21 sci CON2 OK881 JO gt Lj EAEN 2 7 PV PV PV PV PV PV Figure 14 DC connection of the Powador 3200 6600 Operating Instructions Powador 3200 6600_EN Page 25 Installing the Inverter K D C 0 Q new energy Authorised electrician Connecting the PV generator Unscrew the cable fittings Remove the outer cladding of the DC cables Insert the DC leads through the cable fittings into the connection area Strip the insulation from the DC cables Connect the ends
31. g Instructions Powador 3200 6600 EN Page 21 Installing the Inverter K D C 0 Q new energy Authorised electrician 7 Installing the Inverter Lethal voltages are still present in the terminals and cables of the inverter even after the inverter has been switched off and disconnected Severe injuries or death will occur if the cables and terminals in the inverter are touched Only authorised electricians who are approved by the supply grid operator may open and install the inverter A The inverter must be mounted in a fixed position before being connected electrically Observe the safety regulations and current technical connection specifications of the responsible power supply company Disconnect the AC and DC sides Secure both sides against being inadvertently switched back on Ensure that the AC and DC sides are completely voltage free Connect the inverter only after the aforementioned steps have been taken 7 1 Opening the connection area Opening the connection area O You have mounted the inverter 1 Unscrew the two Philips screws on the right hand side of the housing 2 Open the housing door Make the electrical connection 72 Making the electrical connection Make the connection to the PV generator as well as the grid connection via the PCB terminals in the connection area of the inverter Note the following conductor cross sections AC connection DC connection Max conductor cr
32. ge at the DC link is too high or Notify your E DC link the DC link cannot be charged IGBT authorised damage electrician FS 57 Waiting for O e Waiting time of the inverter after a Inverter does not reactivation fault switch on again until a country specific time has elapsed FS 58 Control board The temperature inside the unit was Provide for E O too high Thei itches off ffici prevent damage to the hardware ventilation FS 59 Self test error O e An error occurred during the buffer Notify your E inspection authorised electrician OS 60 Waiting for PV TR The inverter does not begin feeding 9 into the grid until the PV voltage fall voltage lt 550V AN into the grid until the PV voltage falls below a specified value OS 61 External S The external Power Control limit was limit 96 a O activated by the grid operator The inverter limits its power Table 7 Operating statuses and fault messages on the display Operating Instructions Powador 3200 6600_EN Page 51 Maintenance Troubleshooting Authorised electrician Status OS 63 OS 64 FS 66 FS Table 7 Display Measured values Measured values Instrument transformer fault Config error Invalid CRC Az o e o O e O e Explanation P f frequency dependent power reduction Frequency dependent power reduction will be activated when the BDEW German Association of Energy and Water Industries Medium Voltage Directive goes i
33. he Powador protect in the Figure 21 Digital input parameter menu under the Powador protect menu item Operating Instructions Powador 3200 6600 EN Page 33 Installing the Inverter K D C 0 Q new energy 75 Sealing the connection area 1 Therequirements of protection rating IP54 are met by closing the unused cable fittings with blind caps Put on the lid for the connection area Close and lock the housing door The inverter has been mounted and installed Starting up the inverter 76 Starting up the inverter Lethal voltages are still present in the terminals and cables of the inverter even after the A inverter has been switched off and disconnected Severe injuries or death will occur if the cables and terminals in the inverter are touched Only authorised electricians who are approved by the supply grid operator may start up the inverter Attachment of safety label in accordance with UTE C 15 712 1 The code of practice UTE C 15 712 1 requires that upon connection to the French low voltage distribution network a safety sticker showing a warning to isolate both power sources when working on the device must attached to each inverter Attach the provided safety sticker visibly to the outside of the enclosure avant toute intervention 763 Switching on the inverter O Theinverter has been mounted and electrically installed O The cover for the connection area is grounded and closed O The PV generator is suppl
34. he cables and terminals in the inverter are touched Only authorised electricians who are approved by the supply grid operator may open and maintain the inverter Observe all safety regulations and the currently applicable technical connection specifications of the responsible power supply company Disconnect the AC and DC sides Secure the AC and DC sides from being inadvertently switched back on Do not open the inverter until after these two steps are complete After shutdown wait at least 30 minutes before working on the inverter CAUTION Destruction of the DC connection The connection terminals can be destroyed by arcing if disconnected while still live Itis absolutely necessary that the shutdown sequence be carried out in the correct order Shutting down the inverter 1 Switch off the grid voltage by turning off the external circuit breakers 2 Disconnect the PV generator using the DC disconnect DANGER The DC cables are still live Ensure that there is no voltage present on grid connection terminals 9 4 Faults 9 41 Procedure A Lethal voltages are still present in the terminals and cables of the inverter even after the inverter has been switched off and disconnected Severe injuries or death may occur if the cables and terminals in the inverter are touched When a fault occurs notify an authorised electrician approved by the supply grid operator or KACO new energy GmbH Service The
35. he dynamic grid support FRT is functional with a three phase grid connection only gt Observe the following grid type specific connection requirements and the schematic view in section 3 2 2 on page 9 Country and Grid monitoring Required max asymmetry between grid type monitoring phases L1 L2 L3 CDE NSp Three phase or phase unbalanced load 4 6 kVA Single phase CIT Single phase phase unbalanced load 6kVA Three phase or other countries single phase Ask your grid operator Table 5 Grid type specific connection conditions Making the grid connection Use wires with 3 conductors L1 N PE or 5 conductors L1 L2 L3 N PE 3 phase grid monitoring Unscrew the cable fitting Remove the outer cladding of the AC cables Insert the AC leads through the cable fitting into the connection area Strip the insulation from the AC cables Open the locks for the PCB terminals O Uu BwNMc Connect wires in accordance with the labels on the PCB terminals Figure 13 Close the locks for the PCB terminals Check that all connected cables are tightly seated GY BK BN BU GNYE Tighten the cable fitting O o N The inverter is now connected to the power grid Figure 13 AC connection terminals NOTE An AC side disconnection unit must be provided in the final installation This disconnection unit must installed in such a manner that it can be accessed at any time without hindrance If a residual current circuit br
36. he parameter menu You arein menu level 1 O The unit name is displayed Press 2 for at least 15 seconds to open menu level 3 The default setting is used if no is selected 1 Enter the four digit password using key 2 The password is unit specific 2 Confirm what you have entered using key 1 3 Set the desired country setting Select the type of grid applicable to the use of the inverter NOTE This option influences the country specific operating settings of the inverter Please consult KACO service for further information The overvoltage switch off can be optionally password protected Specify the switch off threshold for overvoltage shutdown The 10 minute average for the measured voltage as per EN50160 is used The grid voltage is averaged over ten minutes If the defined value is exceeded the inverter is disconnected from the grid Set voltage threshold The voltage drop between the inverter and the grid feed meter is added to the limit value that was set for grid shutdown according to EN 50160 The limit value can be set from 0 to 11 Vin 1 V increments Specify the switch off value for the voltage drop 0 to 11 V If the grid frequency exceeds or drops below the configured values the inverter switches off The minimum switch off threshold can be set in 1 V increments Configure the switch off values for undervoltage and overvoltage Shows the minimum maximum al
37. lowable grid frequency Shows the minimum maximum allowable grid frequency Set limit values for underfrequency and overfrequency switch off in 0 1 Hz increments Set connect time for grid monitoring after fault or device start in 10 sec increments Page 42 Operating Instructions Powador 3200 6600_EN Configuration and Operation Authorised electrician Country Menu Display spec setting level settings HE Starting voltage H8 Grid monitoring All countries Activating SYM bus 3 Activation P f Internal power limiting All countries Activate Powador protect Reactive power setting oco oco oco oco oco oco oco oco oco oco oco oco Kacoe new energy Action in this menu meaning The inverter begins grid feed as soon as this PV voltage is present Set the starting voltage Offers the option of activating three phase grid monitoring During this process single phase grid monitoring is deactivated Set grid monitoring The SYM bus must be activated in order to symmetrise a group of inverters Enter SYM bus CAN address 1 32 Set SYM bus phase none L1 L2 L3 Enter SYM bus asymmetry lt 4600 W IT lt 6000 W up to 100 W setting in 100 W increments Activate SYM bus test check settings for plausibility Offers the option of activating active power reduction in case of overfrequency Activate P f The power reduction func
38. max 1200 m N L3 L2 L1 xA xx a xXx l CAN twisted pair without RS485 conductors Poke Se group of Oooo xx three l CAN twisted pair without RS485 conductors xXx aT xXx eT x C7TTb777Tt 777 p77717777777777777777777777777777777777777 Ros See xXx a t xXx CAN twisted pair without RS485 conductors xx Em group of E a LE 3 y MD Gree CAN twisted pair without RS485 conductors xXx O MEL xx ee E R TTL T p O_O be ee eee X fK x X l aaa XX PK a AX JJ C 1 CAN twisted pair without RS485 conductors group of three CAN twisted pair without RS485 conductors E Operating Instructions Powador 3200 6600 EN Page 31 Installing the Inverter K D C 0 Q new energy Option 3 for example for retrofitting to an existing system The maximum length of the CAN twisted pair without RS485 conductors with RS485 connection for every group of three is 500 m total length of the inverter chain max 1200 m N L3 L2 L1 Ra PROLOG CAN twisted pair a without RS485 conductors x kK PK jx PK x SS ES RS485 group of CAN twisted pair without three RS485 conductors i R5485 xx 354 1 aum J a m CAN twisted pair without xx RS485 conductors i RS485 group of be bk Ik _ __ TN C
39. ng of non cracked cement e With sufficient load bearing capacity Accessible for installation and maintenance e Made from heat resistant material up to 90 C e Flame resistant e Minimum clearances for assembly see Figure 9 and Figure 10 on page 20 and Figure 11 on page 21 CAUTION Property damage by gases that have an abrasive effect on surfaces in combination with humidity resulting from weather conditions The inverter housing may be severely damaged by gases ammonia sulphur etc when they come into contact with ambient humidity caused by weather conditions If the inverter is exposed to gases it must be mounted so that it can be seen at all times Perform regular visual inspections Immediately remove any moisture from the housing Take care to ensure sufficient ventilation of the inverter Immediately remove dirt especially on vents Failure to observe these warnings may lead to inverter damage which is not covered by the KACO new energy GmbH manufacturer warranty Operating Instructions Powador 3200 6600_EN Page 19 Mounting the Inverter K A C 0 Q new energy NOTE Power reduction due to heat accumulation If the recommended minimum clearances are not observed the inverter may go into power regulation mode due to insufficient ventilation and the resulting heat buildup Maintain minimum clearances Provide for sufficient heat dissipation jo Y
40. no fault occurs A communication error has occurred in the internal data transmission Protective shutdown of the software AC overvoltage AC overcurrent DC link overvoltage DC overvoltage Protection shutdown of the hardware AC overvoltage AC overcurrent DC link overvoltage The voltage of the DC generator is too high The PV generator is configured incorrectly The voltage of a grid phase is too low the grid cannot be fed into The phase experiencing failure is displayed Operating statuses and fault messages on the display KACO Action Cool off the area around the inverter Uncover the fans Notify your authorised electrician Notify your authorised electrician if the fault occurs several times Check the PV generator Notify your authorised electrician if the fault occurs several times Notify your authorised electrician if the fault occurs several times Notify your authorised electrician Not a fault Grid related shutdown the grid connects again automatically Not a fault Grid related shutdown the grid connects again automatically Notify your authorised electrician Notify your authorised electrician new energy lt Page 50 Operating Instructions Powador 3200 6600_EN Maintenance Troubleshooting KACO new energy Authorised electrician Status Display Azk p Explanation Action By FS 42 Line
41. nto effect Power reduction starts at a frequency of 50 2 Hz Output current limiting The AC current is limited once the specified maximum value has been reached Plausibility test of ADC test between ARM and DSP has failed The checksum of the loaded config file does not match the checksum in the EEPROM This means that the EEPROM data originate from a different config file Operating statuses and fault messages on the display Action B Kacoe new energy lt In case of E repeated occurrence Notify your authorised electrician Notify E K authorised electrician KACO Service Page 52 Operating Instructions Powador 3200 6600_EN Service K D C 0 Q new energy 10 Service We place special emphasis on the quality and longevity of our inverters starting with the product development phase More than 60 years of experience in the field of power converters support us in this philosophy However in spite of all quality assurance measures faults may occur in rare cases In such cases KACO new energy GmbH will provide you with the maximum possible support KACO new energy GmbH will make every effort to remedy faults quickly and without requiring a lot of paperwork If you need help solving a technical problem with one of our KACO products please contact our service hotline Please have the following information ready so that we can help you quickly and efficiently Inverter type serial number
42. nu item is displayed Press 2 to select the language Press 1 to change the language Menu level T is shown after the selection Selecting a menu item O The inverter is operating The inverter displays a selection menu item Press 2 to make a selection Press T to confirm a selection The next menu item is displayed Making settings The inverter is operating The LCD is showing a setting menu item Press 1 to navigate to the setting position Press key 2 repeatedly or press and hold until the setting value is correctly shown After running though all setting positions the value is saved and the next menu item is displayed Selecting menu level 2 The inverter is operating The LCD is showing the unit name Press keys 1 and 2 simultaneously The LCD is showing the software version Press key 1 repeatedly or press and hold The display runs through menu level 1 and returns to the start point To return to menu level 1 press keys 1 and 2 simultaneously or wait for one minute without pressing a key KACO new energy OI eg Operating Instructions Powador 3200 6600 EN Page 37 Configuration and Operation K D C 0 Q Selecting menu level 3 service technician Entering password or unlock code gt O cm O cm O Saving changed settings cm 8 2 new energy The inverter is operating The LCD is showing the unit name
43. ols 1 Polarity safeguard Short circuit diode Output levels Rated power VA 4 400 4 600 5 500 Max rated power VA 4 800 5 060 6 000 Grid voltage V 190 264 Rated current A 19 1 20 23 9 Max rated current A 20 9 22 26 Rated frequency Hz 50 60 cos phi 0 80 over excited 0 80 under excited Number of feed in phases 1 General electrical data 97 2 i 0 Max efficiency 97 6 9 kHz 96 3 96 3 European efficiency 97 1 are 95 7 95 8 Internal consumption night W 0 Feed in starts at W Approx 35 Circuit design Transformerless Transformer unit No Grid monitoring Country specific CE conformity yes Table2 Electrical data Page 16 Operating Instructions Powador 3200 6600 EN Technical Data K D C 0 Q new energy 4 2 Mechanical data 3200 4200 4400 5300 5300 5500 6600 supreme LEDs PV generator green supply green fault red Visual displays LCD 2 x 16 characters Controls 2 keys for operating display DC disconnect Integrated DC disconnect with rotary switch Interfaces RS232 RS485 SO Potential free NO contact max 30V 3A Fault signal relay 230V 1A AC connections i inside the uni ion 2 PCB terminal inside the unit max cross section 10 mm AC connections Cable connection via M32 cable fitting Cable connection DC connections Cable connection via M16 cable fitting AMIEN temperature 20 to 60 range C Humidity range non condensing 96 ne Ma
44. on 4 DC disconnect 9 Night start button 5 RS232 port Page 10 Operating Instructions Powador 3200 6600_EN Description K D C 0 Q new energy 3 2 5 Electrical functions 3 2 5 1 Fault signal relay A potential free relay contact is integrated in the inverter The contact closes as soon as there is a fault during operation For connection see section 7 3 1 on page 27 Country specific function 3 2 5 2 Fault signal relay Powador priwatt A potential free relay contact is integrated in the inverter Use this contact for one of the following functions Fault signal relay Powador priwatt Powador priwatt The energy that is provided by the PV system can be put to use directly by the appliances that are connected in your home In Powador priwatt mode the potential free contact takes care of this function The contact closes if sufficient PV energy is available over a period of 30 minutes When the contact closes a visual or acoustic signal is emitted e g from a signal lamp or siren optional Activating the function optional The Powador priwatt function is not active in the unit s factory default state You can obtain the password for the function from your specialist retailer The electrician then activates the function in the configuration menu see section 8 3 on page 39 Powador priwatt switch optional The potential free contact switches larger appliances e g air conditioning units on an
45. on observe all assembly and installation instructions for components and other parts of the system These instructions are delivered together with the respective components and other parts of the system 11 2 Storing the documents These instructions and other documents must be stored near the system and be available at all times 12 Layout of Instructions 1 2 1 Symbols used General hazard High voltage A Risk of burns AVES OEREN Only authorised electricians may carry out tasks indicated with this symbol Risk of fire or explosion 1 2 2 Safety warnings symbols guide A High risk Failure to observe this warning will lead directly to serious bodily injury or death AN Potential risk Failure to observe this warning may lead to serious bodily injury or death Low risk hazard A CAUTION Risk of damage to property Failure to observe this warning will lead to minor or moderate bodily injury Failure to observe this warning will lead to property damage Page 4 Operating Instructions Powador 3200 6600_EN General Notes K A C 0 Q new energy 1 2 3 Additional information symbols NOTE Useful information and notes Country specific function Functions restricted to one or more countries are labelled with country codes in accordance with ISO 3166 1 1 2 4 Instructions symbols guide a Single step instructions or instructions that can be carried out in any sequence Instructions O P
46. operator can only carry out actions marked with a B Incase of power failure wait for the system to automatically restart Notify your electrician if there is an extended power failure Page 46 Operating Instructions Powador 3200 6600 EN Maintenance Troubleshooting new energy Authorised electrician 9 4 2 Troubleshooting B Action of the operator E The indicated work may only be carried out by an authorised electrician K The indicated work may only be carried out by a service employee of KACO new energy GmbH Fault Cause of fault Explanation remedy By The display is blank Grid voltage not Check whether the DC and AC voltages are within the E and the LEDs donot available permitted limits see Technical Data light up Notify KACO Service E The inverter stops Faulty grid If the grid separation relay is defective the inverter will feeding into the separation relay in recognise this during the self test grid shortly after the inverter being switched on Ensure that there is sufficient PV generator power even though there is sunlight present Ifthe grid separation relay is defective have it replaced by KACO Service Notify KACO Service The inverter is Grid feed is Due to a grid fault over undervoltage over underfrequency active but does interrupted dueto the inverter stopped the feed in process and disconnected not feed into the a grid fault from the grid for safety reasons grid The display Change
47. oss section without wire sleeves 16 mm 10 mm Max conductor cross section with wire sleeves 10 mm 6mm Length of insulation to be stripped off 10 mm 15mm Tightening torque 4 4 5Nm A screwdriver slotted 3 5 mm is to be used for the terminals in the inverter Put the screwdriver into the cut out provided Press the screwdriver upwards slightly Feed the cable into the spring terminal Put the screwdriver back into the original position Remove the screwdriver The spring terminal is closed and the cable is held in place The power section has two internal circuit board fuses These are labelled F2 and F861 on the circuit board Page 22 Operating Instructions Powador 3200 6600_EN Installing the Inverter K D C 0 Q new energy NO eS Figure 12 Connection area Electrical AC and DC connection of the Powador 3200 6600 Key 1 AC connection terminals 2 DC connection terminals 7 2 1 Connecting the inverter to the power grid The power connection wires are connected on the right of the connection area Figure 12 on page 23 A Risk of fatal injury due to electric shock Severe injury or death will result if the live connections are touched Switch off all power sources to the inverter before you insert the grid power cable into the unit Make sure that the device is isolated from the public power supply and the system power supply before starting work Recommended conductor cross sections and fus
48. protection class Ill The SELV circuits SELV safety extra low voltage can only be connected to other SELV circuits with protection class Ill NOTE When laying the interface connection cable note that too little clearance to the DC or AC cables can cause interference during data transfer RS232 Err RS485 O gt max 250Vac 1A A B 2 O a Figure 16 Interface terminals 7 31 Connecting the fault signal relay The contact is designed as an N O contact and is labelled ERR on the circuit board Maximum contact load DC 30V 1A AC 250V 1A Connecting the fault signal relay 1 Unscrew the cable fitting 2 Thread the connection cables through the cable fitting 3 Connectthe connection cables to the connection terminals 4 Tighten the cable fitting 73 2 Connecting the SO output An SO pulse output is located on the communication board Use this output to control accessories such as a large display for example The pulse rate of the output is adjustable Connecting the SO output 1 Unscrew the cable fitting 2 Thread the connection cables through the cable fitting 3 Connect the connection cables to the connection terminals 4 Tighten the cable fitting NOTE Ensure that the wires are properly connected Communication is not possible if the wires are reversed Operating Instructions Powador 3200 6600 EN Page 27 Installing the Inverter K A C 0 Q
49. r begins to operate Page 38 Operating Instructions Powador 3200 6600_EN Configuration and Operation 8 3 Menu structure Icons used I Menu level 1 2 3 D Display menu Option menu Password protected menu item Country spec setting All countries o Bg All countries Menu level 1 s Display settings Display Display menu Unit name Generator voltage and current Grid voltage current and power Mode Ramping up limitation External limitation Remaining time for Powador priwatt Powador Protect Temperature inside unit La KACO amp new energy Submenu available Country specific setting Country and grid type specific setting cO cO Action in this menu meaning Press keys 1 or 2 Press key T to run through the following menu level 1 Displays the unit name of the inverter Displays the current voltage and current of the PV array that is connected to the inverter Shows the current grid parameters that the unit is feeding into the grid Nominal power W nominal voltage V grid frequency Hz and amperage A Menu item with default value is only displayed when grid operator is limiting power Display of one of the following control procedures cos phi P specific characteristic cos phi P standard characteristic cos phi 0 800 u constant Q stepping of effective power in 96 steps Q U stepping of ac
50. r third parties or may result in damage to the unit and other property Operate the inverter only with a permanent connection to the public power grid Any other or additional use of the device is deemed improper This includes e Mobile use Usein rooms where there is a risk of explosion Usein rooms where the humidity is higher than 9596 Operation outside of the specifications intended by the manufacturer e Standalone operation Page 6 Operating Instructions Powador 3200 6600_EN Safety KACO eC new energy 2 2 Protection features For your safety the following monitoring and protective functions are integrated into Powador inverters Overvoltage conductors varistors to protect the power semiconductors from high energy transients on the grid and generator side e Temperature monitoring of the heat sink e EMC filters to protect the inverter from high frequency grid interference e Grid side grounded varistors to protect the inverter against burst and surge pulses Islanding detection according to VDE 0126 1 1 2 3 Standards and directives NOTE aD The EU declaration of conformity can be found in the appendix For information on grid coupling grid protection and safety parameters along with more detailed instructions see our web site at http www kaco newenergy de Operating Instructions Powador 3200 6600 EN Page 7 Description K D C 0 Q new energy 3 Description 3 1 Mode of Operation The inver
51. racteristic Specify the target voltage Specify slope Specify change time Page 44 Operating Instructions Powador 3200 6600_EN Maintenance Troubleshooting K D C 0 Q new energy 9 Maintenance Troubleshooting 9 1 Visual inspection Inspect the inverter and the cables for visible damage and pay attention to the operating status display of the inverter In case of damage notify your installer Repairs may only be carried out by authorised electricians NOTE Have your installer check for proper operation of the inverter at regular intervals 9 2 Cleaning the inverter externally Lethal voltages in the inverter A Serious injuries or death may occur if moisture gets into the inverter Only use completely dry objects to clean the inverter Only the exterior of the inverter should be cleaned Cleaning the inverter Do not use compressed air Use a vacuum cleaner or a soft brush to remove dust from the bottom fan covers and from the top of the inverter on a regular basis Remove dust from the ventilation inlets if necessary Operating Instructions Powador 3200 6600 EN Page 45 Maintenance Troubleshooting K D C 0 Q new energy Authorised electrician 9 3 Shutting down for maintenance and troubleshooting Lethal voltages are still present in the terminals and cables of the inverter even after the inverter has been switched off and disconnected Severe injuries or death may occur if t
52. red See Section 9 5 on page 49 10 The maximum permitted asymmetry must still be entered so that symmetrisation can take place properly In some countries DE IT this value is preconfigured in accordance with the applicable directive and does not normally need to be changed Table 3 on page 24 NOTE A maximum of 30 inverters may be connected when using one phase inverters to be symmetrised Number of inverters divisible by 3 A new inverter group must then be formed 7 4 2 Connecting Inverter off digital input optional Connecting and activating Inverter off digital input O 1 2 NO wire A to wire A and wire B to wire B NOTE The Powador protect digital output can only be used with suitable KACO inverters When using devices from other manufacturers or in combination with KACO inverters bus coupler circuit breakers as a minimum must be used for shutting down devices from other manufacturers Can only be used with suitable KACO inverters Unscrew the cable fitting Thread the connection cables through the cable fitting Connect wire A to the terminal marked EVU on the first inverter via the DOT terminal of the Powador protect Connect wire B to the terminal marked EVU on the first inverter via the GND terminal of the Powador protect Connect the other inverters to one another as follows Tighten the cable fitting After commissioning Activate the support for t
53. rerequisite s for the step s optional Carry out the next step Additional steps if applicable Result of the step s optional b Multi step instructions that must be carried out in a fixed sequence Instructions O Prerequisite s for the steps optional 1 Carry out the next step 2 Carry out the next step 3 Additional steps if applicable Result of the steps optional 1 2 5 Abbreviations PV Photovoltaic EEG German Renewable Energies Act MPP Maximum power point point of the current voltage diagram of a PV generator at which the maximum amount of power can be drawn Colour codes in accordance with IEC 60757 BK Black BN Brown BU Blue GNYE Yellow green GY Grey Operating Instructions Powador 3200 6600_EN Page 5 Safety KACO eC new energy 2 Safety Lethal voltages are still present in the terminals and cables of the inverter even after the inverter has been switched off and disconnected Severe injuries or death will occur if the cables and terminals in the inverter are touched Only authorised electricians who are approved by the supply grid operator may open install or maintain the inverter Keep the inverter closed when the unit is in operation Do not touch the cables or terminals when switching the unit on and off Do not make any modifications to the inverter The electrician is responsible for observing all existing standards and regulations e Keep unautho
54. rised persons away from the inverter and PV system e Be sure to observe IEC 60364 7 712 2002 Requirements for special installations or locations solar photovoltaic PV power supply systems in particular Ensure operational safety by providing proper grounding conductor dimensioning and appropriate protection against short circuiting Observe the safety instructions on the inverter and in these operating instructions Switch off all voltage sources and secure them against being inadvertently switched back on before performing visual inspections and maintenance e When taking measurements while the inverter is live Do not touch the electrical connections Remove all jewellery from your wrists and fingers Ensure that the testing equipment is in safe operating condition Stand on an insulated surface when working on the inverter while it is switched on e Modifications to the surroundings of the inverter must comply with the applicable national and local standards e When working on the PV generator it is also necessary to switch off the DC voltage with the DC disconnect in addition to disconnecting the PV generator from the grid 2 1 Proper use The inverter converts the DC voltage generated by the PV modules into AC voltage and feeds it into the grid The inverter is built according to the latest technological standards and safety regulations Nevertheless improper use may cause lethal hazards for the operator o
55. ristic oco oco oco oco oco oco oco oco oco oco Kacoe new energy Action in this menu meaning Set the idle power Q in 96 of device nominal power to a fixed value Select the type of phase shift under excited u over excited 0 Configure power factor f a power factor not equal to 1 is selected Select the type of phase shift under excited u over excited 0 Press 2 to retain the following mode gt edit characteristic Offers the option of resetting or editing the nodes Press 1 to display all nodes in succession Press 1 to activate default characteristic and a confirmation message is shown By pressing 1 the individual nodes can be edited This option defines the number of nodes that can be defined in the subsequent menu Grid type for medium voltage and low voltage up to 10 nodes definable Increment P Pn in with key 2 and confirm with key 1 Increment cos phi with key 2 and confirm with key q fa power factor that is not equal to 1 is selected Select the type of phase shift under excited over excited After running through all selected nodes all values are saved by pressing 1 and then this characteristic is checked for consistency In the event of an error the characteristic that was previously active is restored and the error message Characteristic invalid appears You then have the option of correcting the cha
56. so on Saturdays from 8 00 a m to 2 00 p m CET Operating Instructions Powador 3200 6600_EN Page 53 Shutdown Disassembly K D C 0 Q new energy 11 Shutdown Disassembly 11 1 Shutting down the inverter Lethal voltages are still present in the terminals and cables of the inverter even after the inverter has been switched off and disconnected Severe injuries or death may occur if the cables and terminals in the inverter are touched After shutdown wait at least 11 minutes before working on the inverter Destruction of the DC plug A The DC plug may be destroyed by arcing if it is disconnected under load It is absolutely necessary that the shutdown sequence be carried out in the correct order Shutdown sequence 1 Switch off the grid voltage by turning off the external circuit breakers 2 Disconnect the PV generator using the DC disconnects DANGER The DC cables are still live Ensure that there is no voltage present on the grid connection terminals 1 2 Deinstalling the inverter Shut down the inverter Unlock and open the housing door Open the connection cover connection area Remove the interface cable Release the DC and AC cables from the connection terminals Open the cable fittings O Uu PWN gt Pull out the cables The deinstallation of the inverter is complete Continue with dismantling 11 3 Dismantling the inverter Shut down the inverter O Deinstall the inverter
57. ter converts the DC voltage generated by the PV modules into AC voltage and feeds it into the grid The feed in process begins when there is sufficient sunlight and a specific minimum voltage is present in the inverter If as it gets dark the voltage drops below the minimum voltage value feed in operation ends and the inverter switches off 3 2 Description of the unit 3 21 Powador inverter as part of a PV system 3 2 11 System layout PV generator PV generator LUN LUN ZN CE LUN Inverter with DC Inverter with DC disconnect disconnect Fuse Fuse Consumer Reference Feed in meter counter KWh KWh Main switch Selective main switch C Grid connection point Figure 1 Overview circuit diagram for a system with two inverters Page 8 Operating Instructions Powador 3200 6600_EN Description K D C 0 Q new energy 3 2 2 System with multiple inverters 3 2 2 1 Asymmetric feed in 9 o Ge IC generator 7 n u nu Fuse L1 2 po a a po L1 1 Figure 2 Grid side connection for systems with multiple inverters with single phase grid monitoring 3 2 2 2 Three phase grid monitoring PV generator Rn AN Inverters WR1 L3 L3 L2 L2 L1 L1 WR2 L3 L1 L2 L3 L1 L2 WR3 L3 L2 L2 L1 L1 L3 WR4 L3 L3 L2 L2 L1 L1 L1 2 LI Hl IU o LI o y o S Figure 3
58. the line parameters within the permitted E indicates a line operating limits see the Start Up section failure The grid fuse trips The grid fuse In cases of high solar radiation the inverter exceeds its rated capacity is too current for a short period depending on the PV generator low di Select the capacity of the inverter s pre fuse to be E somewhat higher than the maximum feed in current see the Installation section Contact the grid operator if the grid failure continuesto E occur The grid fuse trips Damage to If the line fuse trips immediately when the inverter goes the inverter s into feed in mode after the start up period is complete the hardware inverter s hardware is probably damaged Contact KACO Service to test the hardware E Daily yields do Tolerances of The measuring elements of the inverter have been selected not correspond to the yields on the feed in meter Table 6 the measuring elements in the inverter Troubleshooting KACO m to ensure maximum yields Due to these tolerances the daily yields shown may deviate from the values on the feed in meter by up to 15 Noaction Operating Instructions Powador 3200 6600 EN Page 47 Maintenance Troubleshooting Authorised electrician Fault Cause of fault The inverter is Generator active but does not voltage too low feed into the grid Grid voltage or Display Waiting for py generator feed in voltage unstable
59. tion K D C 0 Q new energy Spalte 1 2 00 00 0000 00 05 30 00 00 0000 00 05 40 00 00 0000 00 05 50 00 00 0000 00 06 00 00 00 0000 00 06 10 00 00 0000 00 06 20 00 00 0000 00 06 30 00 00 0000 00 06 40 Table 1 Excerpt from the RS232 interface transmission log Key Column Meaning Column Meaning 1 Placeholder 6 Generator power in W 2 Daily running time 7 Line voltage in V 3 Operating state see section 8 1 on page 35 8 Line current feed in current in A 4 Generator voltage in V 9 Power fed into the grid in W 5 Generator current in A 10 Temperature of the unit in C 3 2 7 2 Software for direct monitoring Together with the Powador inverter KACO viso takes over the role of a data logger It saves the data from the inverter and displays it in various diagram types as a daily or monthly representation The PC however must also run continuously Because of the amount of energy used this type of monitoring only makes sense over limited periods such as during a fault analysis For permanent system monitoring we recommend the optional accessories see page 14 Powador proLOG 3 2 7 3 RS485 interface Use this monitoring option if you cannot check the functioning of the system on site on a regular basis e g if your place of residence is located a great distance from the system To connect the RS485 interface contact your authorised electrician For monitoring your PV system using the RS485 interface KACO new energy Gmb
60. tion is password protected Power is reduced in 10 W steps and is limited to 50 of the nominal unit power Enter the four digit password using key 2 Set power limiting Password protection can be re activated Configures the support for grid shutdown by a Powador protect connected to the digital input of the inverter O For Auto On A Powador protect is operating in the photovoltaic system and is connected to the inverter at the digital input output Auto The inverter automatically detects a Powador protect integrated into the photovoltaic system On The digital signal of the Powador protect must be pending at the digital input of the inverter for the inverter to start with feed in Off The inverter does not check whether a Powador protect is integrated in the photovoltaic system The following control methods can be set At least one mode must be active cos phi specification cos phi P Pn Q U characteristic Characteristic Q f U activate 5 nodes from value pairs Q1 U1 Q5 U5 lt Characteristic Q f U activate two state controller with 4 fixed value pairs Q U Operating Instructions Powador 3200 6600 EN Page 43 Configuration and Operation Authorised electrician Country spec setting il Menu level a Display settings Q specification cos phi specification cos phi P Pn Nodes Number of nodes 1st node 2nd node Q U characte
61. tive power based on characteristic Q f U Specific characteristic with 5 nodes Q f U Specific characteristic with 2 State DDC Menu item is displayed with active ramp limitation power ramp up Menu item is displayed with external effective power limitation Shows the power control in 96 steps 096 3096 6090 In accordance with the requirements of the German renewable energy act EEG Menu item is displayed with active Powador priwatt function and potential free contact switched Shows the remaining runtime in hours and minutes Status display with installed Powador protect KACO accessories for grid and system protection Displays the temperature of the heat sink in C If the unit overheats the first response is automatic power reduction In the second step the unit shuts down Operating Instructions Powador 3200 6600 EN Page 39 Configuration and Operation Country spec setting Menu level hn E B E All countries 1 B m AAAA Display settings Yield meter Yield today Total yield CO2 savings SYM bus test mode Operating hours meter Operating hours today meter Operating hours total meter Displaying grid error Setting mode menu Software version Configuration version Serial no Country and grid type display Language Clearing the grid feed meter oco oco oco oco Kacoe new energy Action in this menu meaning Shows
62. tolerances of the measuring elements the measured and displayed values are not always the actual values However the measuring elements ensure maximum solar yield Due to these tolerances the daily yields shown on the display may deviate from the values on the grid operator s feed in meter by up to 15 After being switched on and after the initial start up is complete the inverter displays the unit name Figure 23 Display shows the unit name or menu item 8 1 3 Control buttons Operate the inverter with the two control buttons Figure 24 Control buttons Key 1 Shift button Opens menu 2 Set button Make settings or selection Page 36 Operating Instructions Powador 3200 6600_EN Configuration and Operation 8 1 4 Inverter menu Opening the menu oO O ER The inverter is in grid feed mode The LCD is showing the grid parameters 1 n Press the 1 key The power and configuration values are displayed in succession by pressing key 1 multiple times or by pressing and holding it Displaying the daily output The inverter is operating The LCD is showing the unit name Press key 1 repeatedly or press and hold until the display shows Yield today The LCD is showing the daily yield To return to the base display press key 1 repeatedly or press and hold or wait for one minute without pressing a key Setting display language O The LCD is showing menu level 2 The Language me
63. wer in kW that needs to be available on an uninterrupted basis for 30 minutes before the home feed in is activated Define the switch on time operating time of Powador priwatt after activation NOTE This menu item is only available if you have selected the On option for the Activate priwatt menu item in the Settings menu Offers the option of reducing the frequency of the IGBT bridge from 17 kHz to 9 kHz to improve efficiency Power Boost mode is activated by pressing 2 NOTE The change may cause operating noise Menu item is displayed only when waiting for grid feed and during ramp up limiting Offers the option of ramping up the inverter faster for inspection or testing If there is insufficient PV array power the inverter stops feeding into the grid after a short period of time Operating Instructions Powador 3200 6600_EN Page 41 Configuration and Operation Authorised electrician Country spec setting All countries jc S All countries Menu level Display settings Parameters menu Selecting country with grid type and directive Overvoltage Max line voltage EN 50160 Voltage drop between meter and inverter Voltage switch off Minimum maximum grid frequency Minimum maximum grid frequency Connect time oc oco D KACO amp Q new energy Action in this menu meaning Only service technicians are permitted to make changes in t
64. ximum installation elevation m 2 000 above sea level Temperature monitoring yes Cooling free convection K fan K L Protection rating IP54 according to EN 60529 Degree of contamination 2 Noise emission dB A lt 35 noiseless Housing Cast aluminium HxWxD Imm 500x340 550x340 550x340 550x340 550x340 600x340 600x340 x 200 x 200 x 220 x 220 x 220 x 220 x 220 Total weight kg 19 21 21 26 26 28 30 Table 3 Mechanical data Operating Instructions Powador 3200 6600 EN Page 17 Transportation and Delivery K D C 0 Q new energy 5 Transportation and Delivery 51 Delivery Every inverter leaves our factory in proper electrical and mechanical condition Special packaging ensures that the units are transported safely The shipping company is responsible for any transport damage that occurs 511 Scope of delivery e Powador inverter e Wall bracket e Installation kit e Documentation Checking your delivery 1 Inspect your inverter thoroughly 2 Immediately notify the shipping company in case of the following Damage to the packaging that indicates that the inverter may have been damaged Obvious damage to the inverter 3 Senda damage report to the shipping company immediately The damage report must be received by the shipping company in writing within six days following receipt of the inverter We will be glad to help you if necessary 5 2 Transportation Impact hazard risk of breakage to
65. ying a voltage 350 V 1 Connectthe grid voltage using the external circuit breakers 2 Connect the PV generator using the DC disconnect 0 1 Theinverter begins to operate During the initial start up Follow the instructions of the New Connection Wizard Page 34 Operating Instructions Powador 3200 6600 EN Configuration and Operation K A C 0 Q new energy 8 Configuration and Operation 8 1 Controls The inverter has a backlit LCD as well as three status LEDs The inverter is operated using two buttons Figure 22 LED indicators Key o Operating LED Grid feed LED Fault LED 811 LED indicators The three LEDs on the front of the inverter show the different operating statuses The LEDs can take on the following states e LED illuminated 20 LED flashing C LED not illuminated FPN I The LED indicators show the following operating statuses Operating LEDs Display Description status Start The green Operating LED is illuminated ok if an AC voltage is present independently of the DC voltage Grid feed start Power fed into the grid The green Operating LED is illuminated 9 ok or measured values The green Grid feed LED is illuminated after the country specific waiting period The inverter is ready to feed in i e is on the grid e AzA You can hear the grid relay switch on Grid feed start Power fed into the grid The green Operating LED is illuminated

KACO Powador 5300 Inverter User manual

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