Kaco Powador 2500xi Operating Instructions Manual Download Page 1

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Powador 2500xi
3600xi | 4000xi
4500xi | 5000xi

The next generation of transformerless inverters with
an integrated DC disconnector.

Operating instructions

Operator

Skilled and authorised electrician

Summary of Contents for Powador 2500xi

Page 1: ...Powador 2500xi 3600xi 4000xi 4500xi 5000xi The next generation of transformerless inverters with an integrated DC disconnector Operating instructions Operator Skilled and authorised electrician ...

Page 2: ...ations 5 3 Notes on Installation and Operation 5 3 1 Intended use 5 3 2 Factory warranty and liability 5 3 3 Service 6 4 Operation 6 4 1 Overview of controls and displays 6 4 2 LED displays 6 4 3 Keys 1 and 2 7 4 4 Level 1 menu Display menu 8 4 5 Level 2 menu Conﬁguration mode 9 4 6 DC disconnector 10 4 7 Night start up key 10 4 8 The serial RS232 interface 10 4 9 The RS485 interface 11 4 10 Displ...

Page 3: ...e instructions are delivered together with the respective components and additional parts of the system 1 1 Retention of documents Please pass these operating and installation instructions on to the plant operator These documents must be stored next to the system and must be available at all times 1 2 Symbols used in this document When installing the inverter observe the safety instructions provid...

Page 4: ...ltaic PV modules into AC voltage and feeds this into the power grid Powador inverters are built according to the state of the art and recognised safety rules However improper use may cause lethal hazards for the operator or third parties or may result in damage to the units and other property The inverter may only be operated with a permanent connec tion to the public power grid The inverter is no...

Page 5: ... of current inverters support us in this philosophy However despite all quality assurance measures faults may occur in exceptional 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 such faults in an expeditious manner and without a great deal of bureaucracy In such cases contact our service department d...

Page 6: ... to the temperature being too high Fault in the unit Leakage current is too high RCD type B Overfrequency or underfrequency Insulation fault Communication error Fault in the DC grid feed Fault in the voltage transformer Selftest fault Fault in the RCD type B module Wait approx 10 minutes to see if the fault is only temporary in nature If this is not the case notify your authorised electri cian If ...

Page 7: ...s all yields until it is reset again The customer can conﬁgure the time periods for this meter e g as a monthly meter The power that has been fed into the grid on the current day in watt hours Wh The power that has been fed into the grid since start up of the inverter Shows the CO2 savings of this PV installation compared to the German electricity mix The CO2 savings are calculated from the total ...

Page 8: ...t interface for transmitting pulses from a pulsing meter to a tariff metering device The S0 interface pulse rate can be chosen in three unit inter vals 500 1000 and 2000 pulses kWh Due to these toler ances the emitted pulse yield may deviate from the values on your supply grid operator s grid feed meter by up to 15 Immediate start The inverter can also be started up without any waiting period for ...

Page 9: ... isolated serial interface see ﬁgure 4 6 7 from where it can then be individually processed further using standard spreadsheet software A standard serial 1 1 interface cable is all that is required for connecting the inverter to the computer 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 ...

Page 10: ...lit LCD see ﬁgure 4 1 1 which displays measured values and data In normal mode the backlighting is switched off As soon as you press one of the keys the backlighting is activated If approx 1 minute elapses without a key being pressed it switches off once again Spalte 1 2 3 4 5 6 7 8 9 10 00 00 0000 00 05 30 4 363 8 0 37 134 226 1 0 53 103 23 00 00 0000 00 05 40 4 366 0 0 39 142 226 1 0 53 112 23 0...

Page 11: ...elays Testing line relays prior to beginning grid feed 10 Overtemperature shutdown If the inverter overheats heat sink temperature 85 C due to the ambient temperature being too high and inadequate air circulation the inverter switches off 11 Power limitation Protective function of the inverter when too much generator power is supplied or the heat sink of the unit exceeds 75 C 12 Overload shutdown ...

Page 12: ...gh grid feed power e g the inverter s maximum grid feed power Error RCD module An operational fault has occurred in the AC DC sensitive residual current circuit breaker Error Selftest The internal grid separation relay test has failed Error Measurement The current and voltage measurements in the inverter are not plausible This can be caused by very dynamic weather conditions if there are quick cha...

Page 13: ... into the grid once again If the fault is no longer present the Powador inverter begins feeding into the grid once again after a preset waiting period see Installation Instructions section 4 Technical Data Many of these fault signals point to a fault in the grid and are therefore not an operational fault on the part of the Powa dor inverter The minimum triggering levels are determined by applicabl...

Page 14: ... feed meter by up to 15 and even more in cases of low insolation The line fuse trips The line fuse capacity is too low Damage to the inverter s hardware In cases of high insolation the inverter can depending on the solar generator exceed its rated current for a short period For this reason the capacity of the inverter s pre fuse should be somewhat higher than the maximum grid feed current The line...

Page 15: ...f the inverter is deﬁnitely receiving suf ﬁcient generator power the grid separation relay is presumably faulty thus preventing the inverter from connecting Noise emission from the inverter Unusual ambient condi tions When there are unusual ambient conditions the units may emit audible noises The following reasons may be determining fac tors Line interference or a line failure caused by particular...

Page 16: ...oth the inverter and the corresponding transport packaging are made from recyclable raw materials Device Do not dispose of faulty inverters or accessories in the house hold waste Ensure that the old unit and where applicable any accessories are disposed of in a proper manner Packaging Ensure that the transport packaging is disposed of in a proper manner ...

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Page 18: ...iption 11 5 1 Scope of delivery 11 5 2 Dimensioning the PV generator 11 5 3 Protection concepts 12 6 Installation and Start up 12 6 1 Selecting an appropriate place for installation 12 6 2 Installing the inverter 13 6 3 Electrical connection 13 6 4 Connecting the fault signal relay 17 6 5 The S0 output connection 17 6 6 The RS485 interface connection 17 6 7 Starting up the inverter 17 6 8 Programm...

Page 19: ...rns from hot housing components Disconnect the inverter from all power sources 1 3 CE marking The CE marking is used to document that the Powador inverter shown on the name plate fulﬁlls the fundamental require ments of the following relevant directives Directive concerning electromagnetic compatibility Council Directive 2004 108 EC Low Voltage Directive Council Directive 2006 95 EC 1 4 Name plate...

Page 20: ... the testing equipment is in good and safe operating condition When working on the unit while it is switched on stand on an insulated surface thus ensuring that there is no earthed connection Follow the instructions contained in these operating and installation instructions exactly and observe all danger warning and caution information This list does not constitute a complete listing of all meas u...

Page 21: ...s Use of the units in ways not intended Improper installation and installation that does not comply with standards Improper operation Operation of units with defective protective equipment Unauthorised modiﬁcations to the units or repair attempts Inﬂuence of foreign objects and force majeure lightning overvoltage severe weather ﬁre Insufﬁcient ventilation of the unit Failure to observe the relevan...

Page 22: ... 15 2 A 18 0 A Polarity safeguard Short circuit diode Output Electrical data Model 2500xi 3600xi 4000xi 4500xi 5000xi AC rated power 2600 W 3600 W 4400 W 4600 W 5500 W Maximum power AC 2850 W 4000 W 4800 W 5060 W 6000 W Line voltage See section 4 Technical Data Country speciﬁc parameters page 9 Rated current 11 3 A 15 6 A 19 1 A 20 0 A 23 9 A Max current 12 4 A 17 5 A 20 9 A 22 0 A 26 0 A Power fa...

Page 23: ...Model 2500xi 3600xi 4000xi 4500xi 5000xi Visual displays LED PV generator green Grid feed green Fault red LCD 2 x 16 characters Controls 2 keys for operating display DC disconnector Integrated DC disconnector with continuous function Connections PCB terminals inside the unit Cable supply through cable ﬁttings Ambient temperature 20 60 C 40 C power derating at high ambient temperature Temperature m...

Page 24: ...30 Cyprus GR 208 252 49 5 50 5 180 180 180 Greece 190 264 49 5 50 5 180 180 180 South Korea 194 242 59 3 60 5 360 360 360 Czech Republic 196 252 253 V 49 5 50 5 60 180 30 Portugal 196 264 47 0 51 0 60 180 30 Bulgaria 196 264 47 0 51 0 60 180 30 The switch on times after a re start a fault or after insufficient grid feed power are approximate values Section 4 Technical Data Parameter Country L 1 L ...

Page 25: ... X Spain X Italy X France X Cyprus GR X Greece X South Korea X Czech Republic X Portugal X Bulgaria X Parameter menu A Max line voltage EN 50160 Voltage to metering Minimal line frequency Maximum line frequency Start at solar voltage 410 V Parameter menu B Minimal line voltage Maximum line voltage Minimal line frequency Maximum line frequency Start at solar voltage 410 V ...

Page 26: ...s from 25 C to 60 C the MPP voltage in 12 V modules decreases by approx 3 6 V per module 7 2 V for a 24 V module The MPP voltage of the entire string should be at least 350 V If the MPP voltage moves outside of the permitted input range the installation still functions properly In this situation the maximum possible amount of power is not fed into the grid instead a small amount less is fed Provid...

Page 27: ...on be sure that the units are installed in climate controlled areas in order to protect them from overheating This extends their service life When selecting the inverter s place of installation attention should be paid to the following items Ensure good access to the unit for installation or any service work that may later be required Maintain the following minimum clearances around the unit 200 m...

Page 28: ...al information After the inverter has been installed in its ﬁxed location the electrical connection to the unit can be established Section 6 Installation and Start up Anchor Notches for mounting the Powador M5 screw IMPORTANT Due to the high system voltage the current that ﬂows on the DC side is lower than that ﬂowing on the AC side If the cable cross sections are the same losses on the AC side le...

Page 29: ...500xi 3600xi 2 5 mm Powador 4000xi 4 0 mm Powador 4500xi 5000xi 6 0 mm Larger cross sections should be used for longer leads In accordance with VDE 0100 part 430 Protection of cables and cords against overcurrent when NYM cables are per manently laid with an ambient temperature in the B2 laying system multi conductor lead in the pipe or duct either on or in walls or ﬂush mounted of 25 C the cables...

Page 30: ...e and the negative leads must be strictly isolated electrically from the earth potential PE ATTENTION Risk of damage Ensure that the polarity is correct when connecting the unit ACTION Before connecting the PV generator to the Powador check that the PV generator is not earthed Measure the DC voltage between the protective earth PE and the positive lead and between the protec tive earth PE and the ...

Page 31: ...rs Section 6 Installation and Start up ATTENTION To achieve protection class IP54 unused cable ﬁttings must be closed off by using the included blind caps ACTION To do this unscrew the cable ﬁttings until you can insert the cables through the ﬁtting and screw the ends of the cables into place in the connection terminals labelled PV and PV When doing this ensure that the polarity is correct Tighten...

Page 32: ...e 6 7 Connections 6 5 The S0 output connection The inverter is equipped with an S0 pulse output Items such as a large display can be connected to it The pulse rate is adjustable see section 6 8 Parameter programming 6 6 The RS485 interface connection On the inverter s control card rear panel of the door there are four terminals labelled RS485 A and B see ﬁgure 6 7 To connect several Powadors termi...

Page 33: ...very starts This is signalled by the green LED 2 The display now shows the power being fed to the grid Key 1 can now be used to display the various measured values see Operating Instructions If the inverter stops feeding into the grid because the power is too low it waits a country speciﬁc length of time before resuming power delivery see section 4 Technical Data Quick start The inverter can also ...

Page 34: ...ring unfavourable weather condi tions At a high generator voltage the starting voltage may be increased to ensure that the inverter does not switch itself on and off too often with low power The starting voltage may be set within a range from 370 V to 500 V in increments of 10 V factory setting 410 V 7 Switching the Inverter Off The inverter must be switched off to adjust settings and for maintena...

Page 35: ...ection 8 Powador as Part of a PV Installation Selektiver Hauptleitungs Schutzschalter HA Kabel 8 8 8 8 Neozed Rücklieferzähler HAK Bezugszähler 8 8 8 8 Powador PV Generator zur UV DC Klemmenstelle PV Generator clamping point redelever meter selective circuit breaker Neozed reference meter to UV HA cable Netzeinspeise Wechselrichter Hauptschalter Bezugszähler NEOZED selektiver Hauptschalter Rücklie...

Page 36: ... DC disconnector As a result the installation of an external DC disconnector is not required Line fuses In order to protect the lead the inverter s power supply lead should be secured with NEOZED fuses The fuses that are used should be appropriate to the length and cross section of the leads and fulﬁl applicable standards and directives Grid feed meter The required grid feed meter is speciﬁed and ...

Page 37: ...with 3 phase monitoring but it only feeds in on one phase In order to avoid asymmetries in the grid instal lations with multiple inverters should be designed so that the inverters feed into the grid in differing phases The inverter feeds into the phase that is labelled L1 on the inverter s terminals If you have multiple inverters connect the actual phase L1 to terminal L1 on the ﬁrst unit On the s...

Page 38: ...or 5000xi L2 Powador 4000xi L3 Powador 4000xi Asymmetry 0 8 kW L1 Powador 5000xi L2 Powador 4000xi L3 Powador 4500xi Asymmetry 0 6 kW Section 8 Powador as Part of a PV Installation NOTE The Powador 5000xi is designed for installations with sev eral inverters and at 5 5 kW is above the limit for single phase feed into the grid It therefore may be operated only together with at least two additional ...

Page 39: ...006 95 EC The devices are compliant with the following standards 2006 95 EC Directive concerning electrical equipment designed for use within certain voltage limits Safety of the device EN 60950 1 2006 EN 50178 1997 regarding clearance and creepage distances 2004 108 EC Directive concerning electromagnetic compatibility Interference immunity EN 61000 6 1 2007 EN 61000 6 2 2005 Emitted interference...

Page 40: ...l coupling via an inverter in the public mains supply The automatic disconnection device is an integral part of the aforementioned inverter This serves as a replacement for the disconnection device with insulating function which the distribution network provider can access at any time Applied rules and standards DIN V VDE V 0126 1 1 VDE V 0126 1 1 2006 02 and Generator at the public low voltage gr...

Page 41: ...Notice ...

Page 42: ... Neckarsulm Germany Phone 49 7132 3818 0 Fax 49 7132 3818 703 info kaco newenergy de www kaco newenergy de The text and ﬁ gures reﬂ ect the current technical state at the time of printing Subject to technical changes Errors and omissions excepted ...

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