Kaco Powador 2002 Operating Instructions Manual
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Kaco Powador 2002 Operating Instructions Manual

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Operating Instructions
 English translation of German
original
Powador
2002 | 3002
4202 | 5002
6002

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Summary of Contents for Kaco Powador 2002

  • Page 1 Powador 2002 | 3002 4202 | 5002 6002 Operating Instructions  English translation of German original...

  • Page 3: Table Of Contents

    EU Declaration of Conformity ......51 Opening the connection area ......18 Making the electrical connection ....18 Generator grounding (optional) .....22 Connecting the interfaces.........24 Sealing the connection area ......28 Starting up the inverter........28 Operating Instructions for Powador 2002-6002_EN Page 3...

  • Page 4: General Information

    Failure to observe this warning may lead to serious bodily injury or death. CAUTION Low-risk hazard Failure to observe this warning will lead to minor or moderate bodily injury. CAUTION Risk of damage to property Failure to observe this warning will lead to property damage. Page 4 Operating Instructions for Powador 2002-6002_EN...

  • Page 5: Standards And Directives

    NOTE 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 for Powador 2002-6002_EN Page 5...

  • Page 6: Safety

    Temperature monitoring of the heat sink, • EMC fi lters to protect the inverter from high-frequency grid interference, • Grid-side grounded varistors to protect the inverter against burst and surge pulses, • Islanding detection according to VDE 0126-1-1. Page 6 Operating Instructions for Powador 2002-6002_EN...

  • Page 7: Description

    Inverter with DC isolator switch isolator switch Fuse Fuse Consumer Reference Feed-in meter counter Main switch Selective main switch Grid connection point Figure 1: Overview circuit diagram for a system with two inverters Operating Instructions for Powador 2002-6002_EN Page 7...

  • Page 8: Electrical Connection

    N PE N PE Fuse Figure 2: Grid-side connection for systems with multiple inverters with single-phase grid monitoring 3.2.3 Electrical connection NOTE Note the grid-type-specifi c connection conditions (see section 7.2 on page 18). Page 8 Operating Instructions for Powador 2002-6002_EN...
  • Page 9 Inverter diagram Figure 3: Inverter diagram Display Cable fi tting for interface cable LED indicators Connection board Control buttons RS232 port Fuse for generator grounding (optional) Night start button DC isolator switch Mounting plate Operating Instructions for Powador 2002-6002_EN Page 9...
  • Page 10 The table below shows an example of a few lines of data transmitted over the RS232 interface. Spalte 1 00.00.0000 00:05:30 3 363.8 0.37 226.1 0.53 00.00.0000 00:05:40 3 366.0 0.39 226.1 0.53 00.00.0000 00:05:50 3 359.5 0.41 226.1 0.53 Table 1: Excerpt from the RS232 interface transmission log Page 10 Operating Instructions for Powador 2002-6002_EN...
  • Page 11 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.

  • Page 12: Technical Data

    Circuit design Galvanically isolating high-frequency DC/DC converter with down- stream self-commutated inverter Clock frequency 17 kHz Grid monitoring Automatic disconnection device in accordance with DIN VDE 0126- 1-1:2006-02 CE conformity Table 2: Electrical data Page 12 Operating Instructions for Powador 2002-6002_EN...

  • Page 13: Mechanical Data

    DC connections 6 (2 x 3) MC-4 compatible solar plug connections Ambient temperature -20 °C to +60 °C (Powador 2002 / 3002) -25 °C to +60 °C (Powador 4202 / 6002) (> +40 °C Power derating at high ambient temperatures) Temperature monitoring >...

  • Page 14: Transportation And Delivery

    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 6: Transportation of the inverter Page 14 Operating Instructions for Powador 2002-6002_EN...

  • Page 15: Mounting The Inverter

    Take care to ensure suffi cient 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 for Powador 2002-6002_EN Page 15...

  • Page 16: Unpacking The Inverter

    If the recommended minimum clearances are not observed, the inverter may go into power regula- tion mode due to insuffi cient ventilation and the resulting heat build-up. › Maintain minimum clearances. › Ensure suffi cient heat dissipation. Page 16 Operating Instructions for Powador 2002-6002_EN...
  • Page 17 Make sure that the wall holder is oriented correctly. Safety catch Safety catch (closed) (open) Figure 11: Minimum distances of inverter • horizontal distance between the two inverters / 25 cm inverter and the wall • Distance in front Operating Instructions for Powador 2002-6002_EN Page 17...

  • Page 18: Installing The Inverter

    6 mm² sleeves MC4 solar plug connection Max. conductor cross-section with wire sleeves 4 mm² Length of insulation to be stripped off 12 mm Tightening torque (Powador 4202-6002 only) 1.2 Nm - 1.5 Nm Page 18 Operating Instructions for Powador 2002-6002_EN...
  • Page 19 Recommended conductor cross-sections and fuse protection of NYM cables for fi xed wiring according to VDE 0100 part 430 For cable lengths up to 20 m, use the conductor cross-sections specifi ed in Table 4. Longer cable lengths require larger conductor cross-sections. Operating Instructions for Powador 2002-6002_EN Page 19...
  • Page 20 4. Strip the insulation from the AC cables. 5. Guide the AC leads through the ferrite cores. 6. Wrap the AC leads once around the ferrite cores. (See Figure 14 on page 20) Page 20 Operating Instructions for Powador 2002-6002_EN...
  • Page 21 Installing the inverter Authorised electrician Variants: Spring terminal (Powador 2002-3002) Insert screwdriver into the spring terminal and press it lightly upwards. 8. Insert AC lines completely into the spring terminal as specifi ed by the labels. (Figure 15 on page 21) 9.
  • Page 22 2. Connect PV generator to the DC plug connectors on the underside of the housing. 3. Meet the requirements of protection rating IP65 by closing the unused plug connectors with protective caps. » The inverter is connected to the PV generator. Page 22 Operating Instructions for Powador 2002-6002_EN...

  • Page 23: Generator Grounding (Optional)

    GN/YE GN/YE GN/YE BK BU GN/YE GN/YE GN/YE Figure 17: Powador 2002-3002 with generator grounding kit Figure 18: Powador 4202-5002-6002 with generator grounding kit (via PE terminal) GN/YE GN/YE BU BK GN/YE GN/YE Figure 19: Positive grounding on the Powador 2002-3002...

  • Page 24: Connecting The Interfaces

    GN/YE BU GN/YE GN/YE BK GN/YE Figure 21: Negative grounding on the Powador 2002-3002 Figure 22: Negative grounding on the Powador 4202- 6002 (via PE terminal) NOTE The fuse is triggered in the event of a ground fault in the PV system. The inverter interrupts the grid feed-in until the fuse has been replaced.
  • Page 25 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 / 1 A 250 V / 1 A Operating Instructions for Powador 2002-6002_EN Page 25...
  • Page 26 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 Page 26 Operating Instructions for Powador 2002-6002_EN...
  • Page 27 The requirements of protection rating IP54 are met by closing the unused cable fi ttings with blind caps. 2. Put on the lid for the connection area. 3. Close and lock the housing door. » The inverter has been mounted and installed. » Start up the inverter. Operating Instructions for Powador 2002-6002_EN Page 27...

  • Page 28: Sealing The Connection Area

    Connect the grid voltage using the external circuit breakers. 2. Connect the PV generator using the DC isolator switch (0 → 1). » The inverter begins to operate. » During the initial start-up: Follow the instructions of the New Connection Wizard. Page 28 Operating Instructions for Powador 2002-6002_EN...

  • Page 29: Confi Guration And Operation

    1. Internal/external power limiting or start-up limiting 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. Operating Instructions for Powador 2002-6002_EN Page 29...

  • Page 30: Control Buttons

    Figure 28: Display (shows the unit name or menu item) 8.1.3 Control buttons Operate the inverter with the two control buttons Figure 29: Control buttons Shift button Navigation to the next menu item Setting key Make settings or selection Page 30 Operating Instructions for Powador 2002-6002_EN...

  • Page 31: Inverter Menu

    The display runs through menu level "2" 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. Operating Instructions for Powador 2002-6002_EN Page 31...

  • Page 32: Starting Up For The Fi Rst Time

     Select the country of operation with grid type.  Press key 1 and confi rm with "Yes" that you want to permanently save the country set. » You have completed the initial confi guration. The inverter begins to operate. Page 32 Operating Instructions for Powador 2002-6002_EN...

  • Page 33: Menu Structure

    Display menu Country-specifi c setting Option menu DE-NSP Country and grid type-specifi c setting Password protected menu (password can be requested from KACO Service) Enter the four-digit password using key "2". The password is unit-specifi c. Coun- Menu Display/ Action in this menu/meaning try-spec.
  • Page 34  If "yes" is selected the password is requested. Clear grid-feed meter  Setting required password number "2" If the code number is valid, the grid-feed meter is cleared and a confi rmation is displayed with "Grid meter cleared!". Page 34 Operating Instructions for Powador 2002-6002_EN...
  • Page 35  If the function is disabled, the display runs through the menu level and when key "1" is pressed again it shows the software version. Operating Instructions for Powador 2002-6002_EN Page 35...
  • Page 36 Set the desired country setting. Select country NOTE: This option infl uences the country-specifi c oper- ating settings of the inverter. Please consult KACO service for further information.  Provides the option to set the grid parameters. Confi rm "Yes" input using "1" key.
  • Page 37 NOTE: Set gradients for power limitation with rising and falling mains frequency in %/Hz. This percentage relates to the nominal frequency of 50 Hz  Set f_act. NOTE: Set the current shutdown frequency. Operating Instructions for Powador 2002-6002_EN Page 37...
  • Page 38  Set internal fall-back time to set default power if external power reduction is not pending. With an active self-test and feed-in operation, the switch- IT-CEI021 Activate self-test off values for grid voltage and grid frequency are dis- played. Page 38 Operating Instructions for Powador 2002-6002_EN...
  • Page 39  U_Lock In and U_Lock Out power range set as ‰ of rated power, in which the network support process is active.  Specify the target voltage.  Specify gradient. DE-NSP, BE Q(U) characteristic  Specify change time. Operating Instructions for Powador 2002-6002_EN Page 39...
  • Page 40 On activation the specifi ed parameters for the selected country are reset to the default values. Set default  Reset default parameters. All countries parameters NOTE: When password protection is activated, only the grid operator can make a change. Page 40 Operating Instructions for Powador 2002-6002_EN...

  • Page 41: Maintenance/Troubleshooting

    If the fan is only covered with loose dust, it can be cleaned with the help of a vacuum cleaner or a soft brush. If the fan is very dirty, or if it is defective, it can be removed. Figure 30: Plug for fan Figure 31: Fan cover Operating Instructions for Powador 2002-6002_EN Page 41...

  • Page 42: Shutting Down For Maintenance And Troubleshooting

    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. Page 42 Operating Instructions for Powador 2002-6002_EN...

  • Page 43: Faults

    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...
  • Page 44 (after the start-up period is complete), the invert- ware. er’s hardware is probably damaged.  Contact KACO Service to test the hardware. Daily yields do Tolerances of The measuring elements of the inverter have been selected...

  • Page 45: Messages On The Display And The "Fault" Led

    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...
  • Page 46 The voltage of a grid phase is too low; the grid cannot be fed into. The phase authorised elec- undervoltage L1 experiencing failure is displayed. trician. Table 6: Operating status and fault messages on the display Page 46 Operating Instructions for Powador 2002-6002_EN...
  • Page 47 OS 61 External The external „Power Control“ limit was limit (%) activated by the grid operator. The inverter limits its power. Table 6: Operating status and fault messages on the display Operating Instructions for Powador 2002-6002_EN Page 47...
  • Page 48 Invalid CRC in the EEPROM. This means that the KACO Service EEPROM data originate from a diff er- ent confi g. fi le. Table 6: Operating status and fault messages on the display Page 48 Operating Instructions for Powador 2002-6002_EN...

  • Page 49: Service

    More than 60 years of experience in the fi eld 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 eff ort to remedy faults quickly and without requiring a lot of paperwork.

  • Page 50: Shutdown/Disassembly

    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. 12.1 Packaging Ensure that the transport packaging is disposed of properly. Page 50 Operating Instructions for Powador 2002-6002_EN...
  • Page 52 Carl-Zeiss-Straße 1 · 74172 Neckarsulm · Germany · Fon +49 7132 3818-0 · Fax +49 7132 3818-703 · info@kaco-newenergy.de · www.kaco-newenergy.de...

This manual is also suitable for:

Powador 3002Powador 4202Powador 5002Powador 6002

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