Omron KP100G Technical Manual
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Omron KP100G Technical Manual

Omron KP100G Technical Manual

Grid connect photovoltaic inverter
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KP100G
Technical manual
Grid Connect Photovoltaic Inverter
Part number 1868180-8 A

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Summary of Contents for Omron KP100G

  • Page 1 KP100G Technical manual Grid Connect Photovoltaic Inverter Part number 1868180-8 A...
  • Page 2 The software and the protective functions are not accessible and/or changeable to the user. Please read this manual carefully and make sure that you understand it well to ensure that you are using the KP100G correctly. Keep this manual in a safe location so that it is available for reference when required.

  • Page 3: Meanings Of Alert Symbols

    Safety Precautions · Definition of Precautionary Information The following notation is used in this manual to provide precautions required to ensure safe usage of the KP100G Gridconnect Photovoltaic Inverter (hereafter called the KP100G). Always read and heed the information provided in all safety precautions.
  • Page 4 KP100G Important Safety Descriptions Observe the following warnings and cautions when using the KP100G. Important user information: WARNING CAUTION Injury due to electric shock, or fire, may possibly Burn injury will occur. Do not touch the upper part occur. Do not open the front cover or of the product cabinet during operation or disassemble, modify, or repair.
  • Page 5 KP100G Important installer information: WARNING CAUTION Injury due to electric shock, or fire, may possibly Burn injury will occur. Do not touch the upper part occur. Do not open the front cover or disassemble, of the product cabinet during operation or modify, or repair.
  • Page 6 KP100G WARNING Death may possibly result due to injury because the PV module operates at a high voltage. Be extremely careful when handling the MC connector. Electric shock will occur. Doing AC wiring work during Turn OFF the AC breaker before connecting the MC connector.

  • Page 7: Precautions For Safe Use

    (5) Leave space of 20 cm minimum between the Unit and the ceiling or eave, 20 cm minimum between the Unit and the floor or ground, and 20 cm minimum between the Unit and right or left wall. (6) When installing multiple KP100G Inverters, leave a space of 20cm minimum to the side of each Inverter. Do not install multiple Inverters vertically.

  • Page 8: Precautions For Correct Use

    Narrow places where the ventilation would be obstructed or the ambient temperature conditions would be exceeded. (3) Omron KP100G PV Inverter shall be installed and used properly in a way to keep away from the following incidents a) altered or repaired, maintained or overhauled except by OMRON or any person expressly authorized by OMRON, without prior...
  • Page 9 KP100G 2. Model Name The following KP100G models are available. Table 2-1 Model Name Model ENS Availability Country KP100G-OD-DE With ENS Germany KP100G-OD-ES Without ENS Spain KP100G-OD-IT Without ENS Italy...

  • Page 10: System Description

    KP100G 3. System Description The KP100G converts DC power obtained from solar modules into the AC power that is used in homes and businesses, and enables interconnection with the utility grid. This makes it possible to purchase power from the utility during periods when the load is high, and to sell power to the utility during periods when the load is low.
  • Page 11 KP100G searches for the operating voltage that will produce the maximum output while it converts the DC input voltage. The KP100G has three MPP trackers. The topology of the MPP Trackers is mainly a boost converter. Each boost converter steps up the DC input voltage to a higher DC BUS voltage.

  • Page 12: Grid Voltage

    (relays) operate properly, always do an operational check before starting up the KP100G. If the test results are negative, the KP100G will repeat the self-diagnostics. If the problem remains, it will be necessary to have a specialist diagnose it. Malfunctions are indicated by the...

  • Page 13: Parts Names

    KP100G 4. Parts Names Data Logger 3-pairs of DC input RS-485 communication port Heat sink AC Output 3 Fans RS-232C connector Fig, 4-1 Parts names (1) Air Cooling Fan: 3 force air cooling fans to dissipate heat produced by the inverter. When temperature reaches 50 °C, air cooling fans will switch on automatically by inverter and three fans will start operating simultaneously.
  • Page 14 KP100G (3) AC Output and GND: Delivering AC to the Public Utility. AC output plug GND plug Fig, 4-4 AC output terminals (4) RS-485 communication interface: Interface allows communication with computer via RS-485. The port is protected by a water-proof cover.

  • Page 15: Installation Procedure

    Mounting Package Contents The following items are included in the KP100G package. Check that all of the items shown in the following are included in the package before you start the installation. KP100G, Mounting base plate, Technical Manual...

  • Page 16: Mounting Dimensions

    KP100G Rubber Bushing For connection of AC cable For connection of RS-485 cable Fig, 5-3 Rubber Bushing Securing plate and screws for removable data logger Securing plate screws Fig, 5-4 Securing plate and screws MC caps (-), MC caps (+)
  • Page 17 KP100G Mounting Procedure Safety Precautions (1) Do not install the Unit on ocean-going vessels or in places near the seacoast that are subject to saltwater spray. (2) When installing outdoors, be sure to provide an awning or eave of some kind to prevent direct sunlight or rain from striking the Unit.
  • Page 18 KP100G (6) Omron KP100G PV Inverter shall be installed and used properly in a way to keep away from the following incidents; a) altered or repaired, maintained or overhauled except by OMRON or any person expressly authorized by OMRON, without prior...
  • Page 19 KP100G (1) Mark the positions of the 4 outer mounting holes onto the wall with the bracket as illustrated in Fig, 5-10. To install the device to a narrow upright, mark the 4 central holes at the back of the bracket as illustrated in Fig, 5-11.
  • Page 20 Fig, 5-12 Mounting the base plate (3) Mount the PV-Inverter onto the base plate as illustrated: Safety-lock screw Safety-lock screw Fig, 5-13 Mount the KP100G onto the base plate (4) Insert the Safety Lock screws to fix the PV-Inverter in place.
  • Page 21 KP100G Install the Data Logger independently The data logger can be easily detached and be installed in the wall. (1) To detach the data logger, push the side of it and pull out. Push and pull out Fig, 5-14 Detach the securing plate (2) Insert 2 screws and tighten to attach the securing plate to data logger.

  • Page 22: Connecting The Ac Output Cable

    GND cable breaker, fuse, (10mm or AWG 8) terminals etc.) Fig, 5-17 Wiring the KP100G to the grid (1) Open the AC output cover with a screw driver. AC output cover Cable glands Fig, 5-18 Open the AC output cover...
  • Page 23 KP100G (2) Unscrew the cable gland and prepare AC and Ground(GND) cable. Remove the rubber bushing from inside the AC connector socket. Rubber bushing (no hole) Fig, 5-19 Remove the rubber plug (3) Insert the provided rubber bushing into the AC connector socket.
  • Page 24 KP100G (5) After checking the 5 wires are fixed properly, push the AC output connection set back in to the Connection Panel. Drive 5 screws back to fix the set. Fig, 5-22 Set the AC output cover (6) Now screw on the cable glands to lock the bushing and cable together.
  • Page 25 RS-485 KP100G has RS-485 as a standard interface. The RS-485 card enables the multi-inverter connection solution. The card is a half-duplex with 2-wires, one for each inverter connection. The steps for processing the RS-485 are as follows. When the RS-485 card is inserted, the RS-232C port is not available.
  • Page 26 KP100G Terminal of RS-485 card R- R+ T- T+ R- R+ T- T+ N.C. N.C. N.C. N.C. Connect to RS-485 interface of another inverter Connect to RS-485 interface of another inverter N.C. means “No Connection Fig, 5-27 Instruction of for wiring of terminal of RS-485 card 3.
  • Page 27 Fig, 5-31 RS-232C interface Fig, 5-32 Socket available for RS-232C connection KP100G uses a DB9 socket for the RS-232C interface. Remove the DB9 socket cover before use. The pin assignment of this DB9 socket is listed In.Table 5-2. Table 5-2 Pin assignment Signal Assignment N.C.

  • Page 28: Connecting To The Grid

    Refer to the installation manual for the solar modules. KP100G installation condition Visual confirmation: Make sure none of the mounting screws are loose. Make sure that the KP100G and the mounting base plate are securely fixed with the main body mounting screw. Wiring, connection, and Visual confirmation: conductivity Inspect for looseness in plugs and screws, proper wire connection, and conductivity.
  • Page 29 (-) terminal. KP100G has 3 MPPT trackers. Usually PV-Panels are connected to 3 DC terminals as illustrated in Fig, 5-35(a). Each set of PV-Inverter DC terminals takes a maximum DC input of 13A. As a result, 3 pairs of PV-Inverter DC terminals can take a combined input of up to 39A.
  • Page 30 Note 1 : The power -ON delay time is the time that it takes for the KP100G to resume operation after the power supply of the supply side has been restored following an error, such as a power interruption. The remaining seconds are counted down on the display during the power-ON delay time.
  • Page 31 KP100G 6. The setting in the case of particular countries The setting in Italy (KP100G-OD-IT) Auto Test The inverter is supplied with an auto-test function which enables the user to verify the correct operation of the protection interface. In order to select this function press the “ / ” button until the message "AUTO TEST" appears on the display panel. Press and hold the “OK” button for at least 5 second, to initiate the auto-test procedure.
  • Page 32 KP100G By pressing the “OK” button again the display panel will show the lower frequency threshold check. The display will show a message similar to “f↓ 49.7Hz ≤ 0.06s”, which is the value set for the lower frequency threshold and the maximum delay admitted before the protection intervenes (in reality the display would not show this value, as the 0.06s step (3 cycles) has only been shown as the protection is not sensitive to the frequency variations less...
  • Page 33 KP100G 7. Display KP100G shows the status, measured values, graphs of generated power, etc. on LCD (Data Logger). Using the LCD (Data Logger) Operation Keys . “ ”: To lower layer (1st to 2nd) or moving cursor right . “ ” : To higher layer (2nd to 1st) or moving cursor left .
  • Page 34 V e r 0 1 . 0 5 If DC voltage of the PV-Panel is greater than 260VDC, KP100G power on. After power on of the KP100G, the LCD should show the brand and f/w information. The screen lasts for 5 seconds and switch to text display.
  • Page 35 P r e s s O K t o C l e a r 12/05/06 16:13 4. Shutdown If DC voltage decreases than 200VDC at the moment of reduced sunlight, the KP100G automatically shuts down. The display is not shown and the operation keys are inactive. Daily graph By pressing “...
  • Page 36 KP100G Weekly graph By pressing up “ ” key from previous at any time, the weekly display shows. The principles are: Time-axis: 7 days from Sunday of a week. The left most point is the data of Sunday. Accumulated kWh (Y-axis): The amount is kWh of that day. From 0 to 100kWh Week change: By pressing “...
  • Page 37 Baud rate:19200bps Protocol: “TYPE1” or “TYPE2”, to select protocol of communication To communicate by OMRON protocol, select TYPE1. Node No.: Node number setting of the inverter. Only valid whenTYPE1 protocol is selected Baud rate: Baud rate setting of communication. Only valid when TYPE1 protocol is selected Baud rate is 9600bps or 19200bps.

  • Page 38: System Monitoring

    Example converter: K3SC (RS-232C-RS-485 Interface Converter) RS-485 Communications To communicate with multiple KP100G Units, you can connect them to a personal computer via RS-485 ports. The maximum cable length is 500 m. RS-485 allows communication with up to 31 Units.
  • Page 39 Fig, 8-2Fig, 8-1Fig, 8-2 shows the wiring diagram. Use an RS-232C/RS-485 Interface Converter for connection with the personal computer. Connect a terminator plug to the communications cable for the last KP100G Unit in the series. 0.3 mm shielded twisted pair cable is recommended for RS-485 connection.

  • Page 40: Data Logger

    Data download User can download and manage the stored data by another computer. For KP100G, user can take out the data logger and access its internal data via USB without providing external power. The power in this case is provided by USB port of computer.
  • Page 41 KP100G LCD(Data Logger) Messages Operating In English In German In Spanish In Italian Description conditions Normal Working Status Shown in “Status” row on the display PV inverter is totally shutdown, Power off BUS voltage < 200V IPV <200V & 600V< BUS...
  • Page 42 KP100G System Fault and Inverter Fault Shown in “Status” row on the text display and Error display No utility E1-0:No Utility E1-0:Kein Netz E1-0:SIN RED E1-0:Assenza rete Utility is not available Grid failure Grid measured data is beyond E1-1:Grid OV...
  • Page 43 KP100G Audible alarm AUDIO ALARM: ALARMA Allarme Sonoro: Alarm:An/Aus Set up audible alarm setting on/off ON/OFF SONORA:ON/OFF ON/OFF LANGUAGE:XXX Sprache: XXX IDIOMA:XXX Lingua:XXX XXX:ENG XXX:Englisch XXX:ENG XXX:ENG Setting Language Set up of the display language Deutsch Warning Message Shown in warning row...

  • Page 44: Technical Data

    Tolerable relative humidity: 0 to 95%, non-condensing, Efficiency Max efficiency: 96.5% Euro efficiency: Ppv(W) = 13 x Vpv Example: V is 400VDC, the maximum power could take by inverter in one string is 5200W. Fig, 9-1 Load Graph of KP100G...

  • Page 45: Maintenance

    Fig, 10-1 Additional tightening of the tightening cap Others Please keep the original carton box and use it for transportation of the Omron KP100G PV Inverter when it has to be transported as such for a repair service. Troubleshooting When You Suspect a Problem Operation does not start immediately even though the connectors are correctly connected.
  • Page 46 KP100G 12. Meanings of Error Messages and Their Remedies Troubleshooting Your PV-Inverter requires very little maintenance. When unexpected situation occurs, please refer to the following table should further assistance be required before calling your local dealer. The following table lists common fault messages that display when the fault LED is lit, and their solutions.
  • Page 47 The main ground-fault the insulation resistance of the breaker trips frequently. KP100G and the solar modules. Also describe the circumstances under which the problem happens (for example, the problem occurs on the morning after a rainy day,...

  • Page 48: Other Information

    Other applications requiring a high level of safety, corresponding to points i) to iv), above. c) When OMRON Products are used in an application that could pose significant risk to human life or property, the overall system must be designed so that the required safety can be ensured by providing notice of the danger and incorporating redundancy into the design.
  • Page 49 KP100G 14. Appendix Certificates for the KP100G ･CE mark, self-declaration of conformity ･VDE0126-1-1 test report by TUV ･RD1663/2000 self-declaration ･DK5940...
  • Page 50 KP100G EC DECLARATION OF CONFORMITY...

  • Page 51: Technical Report

    KP100G Technical Report...
  • Page 52 KP100G Declaration of Conformity RD1663/2000...
  • Page 53 KP100G Declaration of Conformity DK5940...

  • Page 54: After-Sales Service

    After-sales service When requesting service… In situations such as the following, stop the KP100G operation and contact the store from which you purchased the product. • The KP100G is operating, but nothing is displayed. • When the malfunction massage show •...

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