Kaco Powador 7700 Operating Instructions Manual Download

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Maintenance/Troubleshooting

Page 42

Operating Instructions for Powador 7700-9600_EN

Maintenance/Troubleshooting

9.1

Visual inspection

Inspect the inverter and the cables for visible damage and note the operating status display of the inverter. In case

of damage, notify your installer. Repairs may only be carried out by authorised electricians.

NOTE

The inverter should be checked for proper operation by a qualified electrician at regular intervals.

9.2

External cleaning

DANGER

Lethal voltages in the inverter

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.

Remove loose dust on the vents regularly using a vacuum cleaner or soft brush.

9.3

Shutting down for maintenance and troubleshooting

DANGER

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.
Only appropriately qualified and authorised electricians may open and maintain the inverter.

›

Observe all safety regulations and the current technical connection specifications from the relevant

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 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.

›

It is absolutely essential 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 isolator switch.

DANGER! The DC cables are still live.

Ensure that there is no voltage present on the grid connection terminals.

Summary of Contents for Powador 7700

Page 1: ...Operating Instructions n English translation of German original Powador 7700 7900 8600 9600 ...

Page 2: ......

Page 3: ...2 Setting up the inverter 15 7 Installing the inverter 17 7 1 Opening the connection area 17 7 2 Making the electrical connection 17 7 3 Connecting the interfaces 23 7 4 Limiting during asymmetric feed to the grid 25 7 5 Sealing the connection area 28 7 6 Starting up the inverter 29 8 Configuration and Operation 30 8 1 Controls 30 8 2 Initial start up 33 8 3 Menu structure 34 9 Maintenance Trouble...

Page 4: ... documents These instructions and other documents must be stored near the system and be available at all times 1 2 Layout of Instructions 1 2 1 Symbols used General hazard Risk of fire or explosion High voltage Risk of burns Authorised electrician Only authorised electricians may carry out tasks indicated with this symbol 1 2 2 Safety warnings symbols guide DANGER High risk Failure to observe this...

Page 5: ... that can be carried out in any sequence Instructions Prerequisites before carrying out the following instructions Carry out 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 Prerequisite s for the steps optional 1 Carry out step 2 Carry out step 3 Additional steps if applicable Result of the steps ...

Page 6: ...ctions 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 Modifications to the surroundings of the inverter must comply with the applicable national and local standards When working on the PV generator it is also necessary to switch off the DC voltage with the DC isolator swit...

Page 7: ...oltage is present in the inverter If as it gets dark the voltage drops below the minimum voltage value the feed in mode ends and the inverter switches off 3 2 Description of the unit 3 2 1 Powador inverter as part of a PV system Main switch Selective main switch Reference counter Feed in meter Consumer Fuse Fuse Inverter with DC isolator switch Inverter with DC isolator switch PV generator PV gene...

Page 8: ...ters with single phase grid monitoring 3 2 2 2 Three phase grid monitoring L1 L1 L2 L3 N N PE 1 2 3 4 n L2 L3 N PE L3 L2 L1 N PE L3 L1 L2 L3 N PE L2 L1 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 Safety fuse Inverter PV generator Figure 3 Grid side connection for systems with multiple inverters with three phase grid monitoring 3 2 2 3 electrical connecti...

Page 9: ...ch to disconnect the inverter from all power sources on the PV generator side Grid fuses Use only specific PV rated fuses Feed in meter The feed in meter is 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 any questions about the selective main switch contact your power supply...

Page 10: ... page 34 3 2 6 1 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 ...

Page 11: ...e 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 4 Technical Data 4 1 Electrical Data Powador input levels 7700 7900 8600 9600 Max recommended PV generator power W 7 700 7 900 8 600 9 600 DC MPP range from V to V 350...

Page 12: ...s Interfaces RS485 S0 SYM bus Fault signal relay Potential free NO contact max 30 V 3 A AC connections PCB terminal inside the unit max cross section 10 mm AC connections Cable connection AC M32 screw connection DC connections DC M16 screw connection Optional DC connection 1x plus 1x minus without string fuse Ambient temperature range C 20 60 Humidity range non condensing 0 95 Maximum installation...

Page 13: ...shipping company is responsible for any transport damage that occurs 5 1 1 Scope of delivery Powador inverter Wall bracket Installation kit Documentation 5 2 Transportation WARNING Impact hazard risk of breakage to the inverter 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 transpo...

Page 14: ...n and wind in outdoor areas For easy operation ensure during installation that the display is slightly below eye level Wall With sufficient load bearing capacity Protected against high winds Accessible for installation and maintenance Made from heat resistant material up to 90 C Flame resistant Minimum clearances for installation see Figure 10 and Figure 11 on page 16 and Figure 13 on page 17 CAUT...

Page 15: ...ng the inverter Figure 9 Setting up the inverter Key 1 Carton 3 Inverters 2 Protective packaging Unpacking the inverter 1 Open carton at the front 2 Remove installation material and documentation 3 Slide inverter carefully out of the carton with the protective packaging 4 Place the protective packaging back into the carton during mounting Continue setting up the inverter 6 2 Setting up the inverte...

Page 16: ...mum clearances between two inverters or the inverter and the ceiling floor have already been taken into account in the diagram see Figure 11 on page 16 6 Fix wall holder to the wall with the mounting fixtures Make sure that the wall holder is oriented correctly A B C B C A A 1 2 3 4 5 Safety catch open Safety catch closed Figure 12 Minimum distances of inverter Key A horizontal distance between th...

Page 17: ... AC and DC sides Secure both sides against being inadvertently switched back on Ensure that the AC and DC sides are completely isolated and voltage free Connect the inverter only after the aforementioned steps have been taken 7 1 Opening the connection area Opening the connection area You have completed assembly 1 Unscrew the two Philips screws on the right hand side of the housing 2 Open the hous...

Page 18: ...ctions and fuse 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 specified in Table 3 Longer cable lengths require larger conductor cross sections Model Conductor cross section Fuse protection gL safety fuses Powador 7700 Powador 7900 Powador 8600 Powador 9600 10 mm flexible 16 mm The largest fusing allowed is a ...

Page 19: ...ned at regular intervals using the necessary tightening torque see chapter 7 2 on page 17 Making the grid connection Use wires with 3 conductors L1 N PE or 5 conductors L1 L2 L3 N PE 3 phase grid monitoring 1 Unscrew the cable fitting 2 Remove the outer cladding of the AC cables 3 Insert the AC leads through the cable fitting into the connection area 4 Strip the insulation from the AC cables 5 Ope...

Page 20: ...ages can be measured there is a ground fault in the DC generator or its wiring The ratio between the measured 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 and between the protective earth PE and the negative cable ...

Page 21: ...se two leads to the terminals labelled PV and PV on the fuse board Figure 16 7 2 2 4 DC Plus string fuses 1 2 3 4 PV PV Strang 1 Strang 2 Strang 3 Strang 4 U_PV U_Start PV PV F2 F4 R4 R3 TP6 TP5 TP3 TP1 TP4 TP2 TP9 R5 R6 D2 TP8 TP7 TP10 CON6 CON7 CON1 CON2 CON3 CON4 CON5 LBL1 F1 F3 Order no Designation dimensions 22800169 PV fuse 8A 1000VDC Type 10x38mm 22800170 PV fuse 10A 1000V DC Type 10x38mm 2...

Page 22: ... Determining fuse size per string 1 6 x Isc fuse value Determining number of parallel mod ules strings N parallel modules strings Does the defined fuse value exceed the maximum Isc range Max Isc range N 1 x Isc PV string fuse In 1 6 x Isc Select the equivalent or next higher PV string fuse Vn max system voltage Insert string fuses no PV string fuse required Selection diagram for PV fuse No Isc sho...

Page 23: ... CAN 5V OC out CAN L H 10 1 2 40 1 2 ON 1 2 40 1 2 Figure 17 Interface terminals 7 3 1 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 30 V 3 A Connecting the fault signal relay 1 Unscrew the cable fitting 2 Thread the connection cables through the cable fitting 3 Attach the connection cables to the connectio...

Page 24: ... Maximum number of connected bus devices 31 inverters 1 data monitoring unit Data line Twisted shielded Recommendations LI2YCYv 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 2 x 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 ...

Page 25: ...m 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 The inverters communicate information on the symmetry of the phase feed over the CAN communi cations interface Every inverter calculates the maximum permitted feed in power for its phase both in total and ...

Page 26: ...here on the terminal unit of the inverter chain Up to version 4 91 one of the three connection options must be used The termination for the CAN bus must be performed in groups of three 1 option The maximum patch cable length for each group of three is 100 m total length of the inverter chain max 1200 m Group of 3 Patch cable CAN RS485 Group of 3 Group of 3 2 option The maximum length of the CAN tw...

Page 27: ...rrect 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 7 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 23 8 All inverters of a group must be assign...

Page 28: ...screw the cable fitting 2 Thread the connection cables through the cable fitting 3 Connect wire A to the terminal marked EVU on the first inverter via the DO1 terminal of the Powador protect 4 Connect wire B to the terminal marked EVU on the first inverter via the GND terminal of the Powador protect 5 Connect the other inverters to one another as follows wire A to wire A and wire B to wire B 6 Tig...

Page 29: ...ribution network a safety sticker showing a warning to isolate both power sources when working on the device must be attached to each inverter Attach the provided safety sticker visibly to the outside of the inverter housing ATTENTION Présence de deux sources de tension Réseau de distribution Panneux photovoltaïques Isoler les deux sources avant toute intervention 7 6 1 Switching on the inverter T...

Page 30: ...in start ok Power fed into the grid or measured values The green Operating LED is lit The green Feed in LED is illuminated after the coun try specific waiting period The inverter is ready to feed in i e is on the grid You can hear the grid relay switch on Feed in start ok Power fed into the grid or measured values The green Operating LED is lit The green Grid feed LED is illuminated after the coun...

Page 31: ...tches off again In sleep mode the inverter deactivates the display regardless of the selected setting NOTE Depending on the 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 yield shown on the display may deviate from the values on the grid operator s fe...

Page 32: ...o select the language Press 1 to change the language Menu level 1 is shown after the selection Selecting a menu option The inverter is operating The inverter displays a selection menu option Press 2 to make a selection Press 1 to confirm a selection The next menu option is displayed Making settings The inverter is operating The LCD is showing a setting menu option Press 1 to navigate to the settin...

Page 33: ... displayed Saving changed settings Press keys 1 and 2 simultaneously to save settings or wait one minute after setting The LCD jumps back to menu level 1 8 2 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...

Page 34: ...pecific characteristic cos phi P standard characteristic cos phi x xxx u under excited o over excited const Q xx x u under excited o over excited const Q f U standard characteristic IT CEI021 Additional modes Q f U specific characteristic with 5 nodes Q f U specific characteristic with two state controller All countries 1 2 3 1 External limitation power control Menu option is displayed with extern...

Page 35: ...nit 1 2 3 1 Hours counter Shows the total operating time since the last reset Press 2 to reset the yield meter 1 2 3 1 Operating hours today meter Displays the duration of operation on the current day 1 2 3 1 Operating hours total meter Displays the total operating time 1 2 3 1 Date Time With an additional PCB installed real time module RTC displays the current time and the date 1 2 3 1 Displaying...

Page 36: ...3 2 Inverter address A unique address must be defined for every inverter with an active RS485 interface The interface is used to com municate with the Powador proLog By pressing key 2 the RS485 address can be set con secutively from 1 to 32 1 2 3 2 S0 interface Selection of pulse rate for the S0 interface 500 1000 and 2000 pulses kWh Set pulse rate 1 2 3 2 Activate priwatt Enables the use of the f...

Page 37: ... required grid parameters in the next menu If No is selected the defined country specific parameters will be used DE MSP ES GB FR HTA IT CEI021 UD IL Undervoltage shutdown Specify the shutdown threshold for fast and slow undervoltage shutdown Set period from occurrence of the fault to shutdown of the inverter DE MSP ES GB FR HTA IT CEI021 UD IL Overvoltage shutdown Specify the shutdown threshold f...

Page 38: ...nder over frequency shutdown Shows the minimum maximum allowable grid fre quency Set limit values for underfrequency and overfre quency switch off in 0 1 Hz increments All countries not GB G83 2 Minimum maximum connection voltage Set the threshold for the minimum and maximum connection voltage NOTE The limit values cannot be edited for DE NSP DE VDN and BE All coun tries not GB G83 2 Minimum maxim...

Page 39: ... voltage The inverter begins feed in as soon as this PV voltage is present Set the starting voltage All countries 1 2 3 3 Activate SYM bus The SYM bus must be activated in order to synchronise a group of inverters Enter SYM bus CAN address 1 32 Set SYM bus phase none L1 L2 L3 Enter SYM bus asymmetry 4600 W IT 6000 W up to 100 W setting in 100 W increments Activate SYM bus test check settings for p...

Page 40: ...os phi specification active Configure power factor If a power factor not equal to 1 is selected Select the type of phase shift under excited u over excited o 1 2 3 3 cos phi P Pn active The selection enables display resetting or editing the nodes min 2 max 10 Displays All nodes are displayed in succession Reset Press 1 to activate default characteristic and a confirmation message is shown Edit Spe...

Page 41: ...es the support for grid shutdown by a Powador protect connected to the digital input of the inverter 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 Pow ador protect integrated into the photovoltaic system On The digital signal of the Powador protect must be present to the d...

Page 42: ... 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 Only appropriately qualified and authorised electricians may open and maintain the inverter Observe all safety regulations and the current technical connection specifications from the relevant power supply co...

Page 43: ...of KACO new energy GmbH Fault Cause of fault Explanation remedy By The display is blank and the LEDs do not light up Grid voltage not available Check whether the DC and AC voltages are within the permitted limits see Technical Data E Notify KACO Service E The inverter stops feeding into the grid shortly after being switched on even though there is sun light present Faulty grid sepa ration relay in...

Page 44: ...espond to the yields on the feed in meter Tolerances of the measuring elements in the inverter The measuring elements of the inverter have been selected 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 No action The inverter is active but is not feeding into the grid Display Waiting for feed in Generator volt age t...

Page 45: ...he potential free contact connects to indicate an error If the priwatt function is not activated the potential free contact functions as a fault signal relay and therefore indi cates errors However if additional devices that are provided for the priwatt function are connected to the inverter via the contact they can still start up when the inverter expe riences an error because the contact is conn...

Page 46: ...rter defect Cool off the area around the inverter Clean vents Notify your author ised electrician B B E OS 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 OS 17 Powador protect disconnection The activated grid and system pro tection has been tripped Notify your author ised electrician if the fault occurs se...

Page 47: ... electrician E FS 48 Line failure underfrequency Grid frequency is too low This fault may be grid related Notify your author ised electrician E FS 49 Line failure overfrequency Grid frequency is too high This fault may be grid related Notify your author ised electrician E FS 50 Line failure average voltage The grid voltage measurement according to EN 50160 has exceeded the maximum permitted limit ...

Page 48: ... mode PAC W The inverter was switched to island ing operation by the Powador Grid Save The inverter is disconnected from the public low voltage grid The power indicator percentage refers to the maximum AC power OS 63 Measured values P f frequency dependent power reduction Frequency dependent power reduction will be activated when the BDEW German Associa tion of Energy and Water Industries Medium V...

Page 49: ...odule type and string circuit Date of installation Start up report Consignment identification Delivery address Contact person with telephone number Information about the accessibility of the installation site Any additional costs arising from unfavourable structural or mounting conditions shall be billed to the customer You can find the following items and other information at our web site http ww...

Page 50: ... DC cables are still live Ensure that there is no voltage present on the grid connection terminals 11 2 Uninstalling the inverter Shut down the inverter 1 Unlock and open the housing door 2 Open the connection cover connection area 3 Remove the interface cable 4 Release the DC and AC cables from the connection terminals 5 Open the cable fittings 6 Pull out the cables The uninstallation of the inve...

Page 51: ...irective 2006 95 EC The units conform to the following standards 2006 95 EC Directive relating to electrical equipment designed for use within specific voltage limits Safety of the unit EN 62109 1 2010 EN 62109 2 2011 2004 108 EC Directive relating to electromagnetic compatibility Interference immunity EN 61000 6 2 2005 Emitted interference EN 61000 6 3 2007 A1 2011 EN 61000 6 4 2007 A1 2011 Secon...

Page 52: ...y Fon 49 7132 3818 0 Fax 49 7132 3818 703 info kaco newenergy de www kaco newenergy de The text and figures reflect the current technical state at the time of printing Subject to technical changes Errors and omissions excepted 31001123 05 140311 ...

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