Badger Power Electronics BPE600 Instruction Manual

Installation / User Manual
Rev 1.3
©All Rights Reserved
Models BPE600 & BPE1300
Photovoltaic Grid-connected Microinverter

Installation/User Manual
1
Table of Contents

Installation/User Manual
2
This manual contains important instructions for the proper installation and maintenance of the
Photovoltaic Grid-connected Inverter (Microinverter). To reduce the risk of electrical shock, and
ensure safe installation and operation of the Microinverter, the followingsymbols appear
throughout this document to indicate dangerous conditions and important safety considerations.
Specifications are subject to change without notice - please ensure you are using the most recent update
found at the manufacturer website.
WARNING SYMBOL: Indicates a situation where failure to follow instructions
appropriately may cause a serious hardware failure or personal injury. Use extreme
caution when performing this task.
WARNING
SYMBOL
NOTE SYMBOL: Displays information that is important for optimized microinverter
operation. Follow these instructions closely.
Safety Instructions
Do NOT disconnect the PV module from the Microinverter without
first disconnecting the AC power.
NOTE
SYMBOL
Only qualified professionals should install and/or replace the Microinverters.
Perform all electrical installations in accordance with local electrical codes.
Before installing or using the Microinverter, please read
all instructions and cautionary markings in the technical documents and on the Microinverter
system and the solar-array.
Be aware that the body of the Microinverter is a heat-sink, and can reach temperatures
close to 80°C. To reduce risk of burns, do not touch the body of the Microinverter.
DO NOT attempt to repair the Microinverter. If it fails, contact Customer Support to obtain an
RMA number and start the replacement process. Damaging or opening the Microinverter will
void the warranty.
Caution!
The external protective grounding conductor is connected to the inverter grounding
terminal through AC connector.
For connection: Connect the AC connector first to ensure inverter grounding, then
perform the DC connections.
When disconnecting: First disconnect the AC connector by opening the branch circuit breaker,
with the protective grounding conductor still connected. Disconnect the DC inputs afterwards.
In any circumstance, do not connect DC input when the AC connector is unplugged.
Please install isolation switching devices on the AC side of the inverter.
Important Safety Instructions

Installation/User Manual
3
Radio Interference Statement
CE EMC Compliance：The equipment complies with CE EMC, which is designed to protect against
harmful interference in residential installations. The equipment could emit radio frequencies
which might cause harmful interference with radio communications, if the following
installation instructions are not adhered to. There is no guarantee that interference will not
occur in a particular installation. If this equipment causes hindering interference to radio
or television reception, the following measures might resolve the issue:
a) Relocate the receiving antenna, and keep it well away from the equipment.
b) Consult the dealer or an experienced radio / TV technician for further assistance.
Changes or modifications not approved by the party responsible for compliance may void the user’s
authority to operate the equipment.
Communication Statement
The Energy Monitoring system and Analysis (EMA) software analyses and reports the performance
of each module using real-time data, which is collected through the Data Monitoring Unit (DMU)
gateway. The EMA promptly detects any performance issues in the array, pinpointing the
location and nature of the problem and providing precise guidance for maintenance, all within a
user-friendly graphic interface.
Communication between inverters and the DMU may be affected by signal “noise” from nearby
electrical equipment, the distance between inverters and the DMU, the number of inverters
supported, as well as other factors. If the DMU experiences a random loss of signal or data, an error
or problem did not occur. If the DMU does not communicate with the EMA database at all, contact
support.
Important Safety Instructions

Installation/User Manual
4
Symbol Definitions
Trademark.
Caution, risk of electric shock.
Caution, hot surface.
Symbol indicating electrical and electronics device disposal according to Directive
2002/96/EC. Indicates that the device, accessories and the packaging must not be
disposed as unsorted municipal waste. Waste electrical equipment should be
collected and disposed separately. Please follow your local ordinances/regulations
for disposal, or contact an authorized representative of the manufacturer for
information concerning the decommissioning of equipment.
The CE mark is attached to the solar inverter to verify that the unit follows the
provisions of the European Low Voltage and EMC Directives.
Refer to the operating instructions.
Person requires supervision by an adequately trained person, in order to
avoid the risks and hazards associated with electricity. For the purposes of
the safety information contained in this manual, "an adequately trained
person" is someone who is familiar with requirements for safety,
refrigeration system and EMC, and is authorized to energize, ground, and
tag equipment, systems, and circuits in accordance with established safety
procedures. The inverter and end user system may only be commissioned
and operated by qualified personnel
Qualified
personnel
Important Safety Instructions

Installation/User Manual
5
The microinverter is used in utility-interactive grid-tied applications, comprised of three key elements:
Microinverter
Data Monitoring Unit (DMU) & Radio Transmission Unit (RTU)
Energy Monitor and Analysis (EMA) web-based monitoring and analysis system
Microinverter System Introduction
DMU
Microinverter
BPE 600
Microinverter
BPE1300

Installation/User Manual
6
Microinverter System Introduction
This integrated system improves safety, maximizes solar energy harvest, and increases system
reliability. It also simplifies solar system design, installation, maintenance, and management.
Microinverters maximize PV energy production
Each PV module has individual Maximum Peak Power Tracking (MPPT) controls, which ensures that
the maximum power is transmitted to the utility grid regardless of the performance of the other PV
modules in the array. When PV modules in the array are affected by shade, dust, orientation, or
any situation in which one module under performs compared with the other units, the
microinverter ensures peak performance from the array by maximizing the performance of each
module.
More reliable than centralised or string inverters
The distributed microinverter system ensures that no single point of failure exists across the PV
system. Microinverters are designed-to operate at maximum power within ambient outdoor
temperatures, including up to 149°F (65°C). The inverter housing is designed for outdoor installation
and complies with the IP65 environmental enclosure rating.
Simple to install
Individual PV modules can be installed in any combination of Module quantity, orientation,
different type and power rate. The ground wire (PE) of the AC cable is connected to the chassis
inside the microinverter. This may potentially eliminate the installation of a grounding wire (check
this with local regulation).
Smart system performance monitoring and analysis
The Data Monitoring Unit (DMU) is installed by simply plugging it into any wall outlet, and providing
an Ethernet connection to a broadband router or modem. After installing and setting-up the DMU
(see DMU manual), the full network of microinverters automatically reports to the Energy Monitor
and Analysis (EMA) web server. The EMA software displays performance trends, alerts the user to
abnormal events, and controls system shutdown when required (See DMU manual for instructions.)
Microinverter System Introduction

Installation/User Manual
7
Microinverter Introduction
The microinverters connect with the single-phase grid. A three-phase grid can also be achieved
through the use of multiple microinverters, which operates with most 60 and 72 cell PV modules.
For more information, please see the Technical Data page (p.18) of this manual.
Model AC grid PV Module
Number
Max. #
Per branch
Module Connector
BPE600 50/60Hz,127/240V 60, 72 Cell
8 for 25A
breaker
MC-4 Type or Customize
BPE1300 50/60Hz,240V 60, 72 Cell
4 for 25A
breaker
MC-4 Type or Customize
Microinverter Introduction

Installation/User Manual
8
Microinverter System Installation
Setting up microinverters for a PV system is simple. Each microinverter easily mounts on the PV
racking, directly beneath the PV module(s). Low voltage DC wires connect from the PV module
directly to the microinverter, eliminating the risks associated with high DC voltage. Installation
MUST comply with local regulations and technical rules.
Special Statement! An AC GFCI device should not be used to protect the dedicated circuit to the
microinverter, even though it is an outside circuit. None of the small GFCI devices (5mA-30 mA)
are designed for back feeding, and will be damaged. In a similar manner, AC AFCIs have not been
evaluated for back feeding and may be damaged if back feed with the output of a PV inverter.
WARNING: Perform all electrical installations in accordance with local
electrical codes.
WARNING: Be aware that only qualified professionals should install
and/or replace microinverters.
WARNING: Before installing or using a microinverter, please read all instructions
and warnings in the technical documents, on the microinverter system itself, as
well as on the PV array.
WARNING: Be aware that installation of this equipment includes the
risk of electric shock.
WARNING: Do not touch any live parts in the system, including the
PV array while the system is connected to the electrical grid.
NOTE: It is strongly recommend to install surge protection devices in the
dedicated meter box.
Additional Installation components
AC male and female connectors (sold separately)
Sealing end caps (sold separately)
Required Parts and Tools
In addition to your PV array and its associated hardware, the following items are
required:
An AC connection junction box
Mounting hardware suitable for module racking
Sockets and wrenches for mounting hardware
Continuous grounding conductor and washers
A cross head screwdriver
A torque wrench
Microinverter System Introduction

Installation Procedures
Installation/User Manual
9
Step 1 - Install the AC branch circuit junction box
a) Install an appropriate junction box at a suitable location on the PV
racking system (typically at the end of a branch of modules).
b) Connect the open wire end of the AC cable into the junction box
using an appropriate gland or strain relief fitting.
c) Wire the conductors of the AC: L - RED; N - BLACK ;
PE - YELLOW GREEN.
d) Connect the AC branch circuit junction box to the point of utility
interconnection.
WARNING: The wiring colour code can be different according local regulation. Check
that all of the installed wire colours match regulation before connecting the AC cable.
Wrong cabling can irreparably damage the microinverters. This error is not covered by
the warranty.
Step 2 - Attach the Microinverters to the racking or the PV
module frame
a) Mark the location of the microinverter on the rack,with respect to the
PV module junction box, or any other obstructions.
b) Mount one microinverter at each of these locations, using the
hardware recommended by your module racking vendor.
600W Mounting 1300W Mounting
Installation Procedures

Installation Procedures
Installation/User Manual
10
WARNING: Prior to installing any of the microinverters, verify that the
utility voltage at the point of common connection matches the voltage
rating on the microinverter label.
WARNING: Do not place the inverters (including DC and AC
connectors) where they can be exposed to the sun, rain or snow. Allow a
minimum of 3/4’’(1.5 cm.) between the roof and the bottom of the
microinverter to allow proper air flow.
Step 3 - Connect themicroinverters in parallel
600w connect in parallel 1300w connect in parallel
Check the microinverter technical data page (p.18) for the maximum allowable
number of microinverters on each AC branch circuit.
Plug the male AC connector of the microinverter into the female
counterpart.
AC connector interface as follows.
WARNING: Do NOT exceed maximum number of microinverters in an AC
branch circuit, as displayed on the page 7 of this manual.
Installation Procedures

Installation Procedures
Installation/User Manual
11
Step 4 - Install a AC cable protective end cap at the end of AC cable
Step 5 - Connect Microinverters to the PV Modules
NOTE: When the DC cables are plugging in, the microinverter LED should immediately
blink red once, followed by three short green blinks. This will happen as soon as the
cables are plugged in, indicating that the microinverter is functioning correctly. This
entire function will occur within 5 seconds of plugging in the unit, so pay careful
attention to the LED when connecting the DC cables.
WARNING: Double-check to make sure all of the AC and DC wiring has been correctly
installed. Ensure that none of the AC and/or DC wires are pinched or damaged. Make
sure that all of the junction boxes are properly closed.
Installation Procedures

Installation/User Manual
12
Microinverter PV System Operation:
1. Turn ON the AC circuit breaker on each microinverter AC branch circuit.
2. Turn ON the main utility-grid AC circuit breaker. Your system will start producing power after a
one-minute waiting time.
3. The unit LEDs should start blinking red, one minute after turning on the AC circuit breaker. The
LED should then blink blue. This indicates that the units are functioning normally, the faster the
LED blinks blue, the more power is generated.
4. Plug in the DMU and follow the instructions according to its manual.
5. The microinverters will send performance data through the power line to the DMU. The time
required for all the microinverters in the system to report to the DMU will vary on the number of
microinverters in the system. You can verify proper operation of the microinverters via the DMU.
See the DMU Installation and Operation Manual for more information.
NOTE: Once AC power is supplied, about 0.1A current and 25VA(W) power for each
microinverter may be measured with a meter. The current and power are reactive.
The inverters ARE NOT operating. After an over 60s waiting time, the inverters will
start operation.
Microinverter system operating instructions

Installation/User Manual
13
Troubleshooting
Qualified personnel should use the following troubleshooting steps if the PV system is inoperative:
Status Indications and Error Reporting
Start up LED
One minute after DC power is first applied to the microinverter, one short red blink indicates a
successful microinverter startup sequence. If two or more short red blinks occur after DC
power is first applied to the microinverter, a failure during microinverter setup has occured.
Operation LED
•Flashing Slow Blue - a small amount of power is produced.
•Flashing Fast Blue - large amounts of power are produced.
•Flashing Red - Not producing power
•Red blinking twice - AC low-voltage or high-voltage
•Red blinking three times - Grid malfunction
GFDI Error
If the LED blinks four times, it indicates that the Microinverter has detected a Ground Fault
Detector Interrupter (GFDI) error in the PV system. Unless the GFDI error has been cleared, the
LED will continue to blink 4 times in sequence.
Other Errors
All other errors are reported to the DMU. Refer to the DMU Installation and Operation Manual
for a list of additional errors and troubleshooting procedures.
WARNING: Only qualified personnel should directly handle the
microinverter.
WARNING: Never disconnect the DC wire connectors under load. Ensure that no
current is flowing in the DC wires prior to disconnection. An opaque covering may be
used to protect the module prior to disconnecting the module.
WARNING: Always disconnect the AC power before disconnecting the PV module
wires from the microinverter. Either disconnect through the appropriate AC circuit
breaker, or unplugging the AC connector to the first microinverter of a branch
circuit. Both are suitable as a means of
disconnection.
WARNING: The microinverter is powered by the PV module DC power. AFTER
disconnecting the DC power, when reconnecting the PV modules to the
microinverter, pay attention for the three short LED flashes.
Troubleshooting

Troubleshooting
Installation/User Manual
14
Troubleshooting an Inoperative Microinverter
There are two malfunction possibilties:
a) The microinverter itself may be experiencing problems.
b) The microinverter is working, but it is having trouble communicating with the
DMU. The items below refer to microinverter issues, which exclude communication
issues (addressed in the DMU installation and user manual).
Quick ways to tell whether the issue is inside the microinverter or a
communication problem with the DMU include:
1. Diagnosing the Microinverter: A red LED light –either blinkingor solid, or no light
at all. No light, or red light indicates a malfunction within the microinverter.
2. Diagnosing from the DMU:
•No-Data-Display: This is probably a communication issue- not a
microinverter problem.
•Problems with erratic display: Data is displayed for randomperiods of time:
most likely a communication issue.
•0 W, or 2 W: Possibly a microinverter problem
•Erratic data display: Poor coordination with data displays fromother units
indicates a likely a microinverter malfunction.
To troubleshoot an inoperative microinverter, follow
the instructions below:
1. Verify that the utility AC voltage and frequency are within the ranges
indicated in the Technical Data section of this manual.
2. Check the connection to the utility grid. Verify utility power is present at the
inverter in question by removing AC, then DC power. Never disconnect the DC
wires while the microinverteris transmitting power. Re-connect the DC module
connectors andwatch for three short LED flashes.
3. Check the AC branch circuit interconnection between all the microinverters. Verify
each inverter is energized by the utility grid as described in the previous step.
4. Make sure that the AC breakers are functioning properly and are closed.
5. Check the DC connections between the microinverter and the PV module.
6. Verify that the PV module DC voltage is within the allowable
range indicated in the Technical Data of this manual.
7. If the problem persists, please call Customer Support.
WARNING: Do not attempt to repair the microinverter. If troubleshooting methods
fail, please call for Technical Support
Maintenance
Maintenance is not required.
Troubleshooting

Installation/User Manual
15
Follow the procedure to replace a failed microinverter:
a) Disconnect the microinverter from the PV module, in the order shown below:
i) Disconnect the AC by turning off the branch circuit breaker.
ii) Disconnect the AC connector of the microinverter.
iii) Cover the module with an opaque casing.
iv) Disconnect the PV module DC wire connectors from the microinverter.
v) Remove the microinverter from the PV array racking.
b) Remove the opaque cover, then install a replacement microinverter to the
rack. Remember to consider the flashing LED light as soon as the new
microinverter is plugged into the DC cables.
c) Connect the AC cable of the replacement microinverter.
d) Close the branch circuit breaker, and verify proper operation of the
replacement microinverter.
Replace a Microinverter

Installation/User Manual
16
WARNING: Be sure to verify that the voltage and current specifications of your PV
module match with those of the Microinverter. Please refer to the datasheet or user
manual.
WARNING: You must match the DC operating voltage range of the PV
module with the allowable input voltage range of the Microinverter.
WARNING: The maximum open circuit voltage of the PV module must not
exceed the specified maximum input voltage of the inverter.
Technical Data

Installation/User Manual
17
Model BPE600-127V BPE600-240V
Input Data (DC)
Operation Voltage Range 20V-55V
Startup Voltage 20V
Maximum DC Short Circuit Current
Output Data (AC)
Nominal Output Voltage 127/240V
Nominal Output Current 2.5A/4A
Default/Protect Output Voltage Range 184-265V
Extended/Reconnect Output VoltageRange 95-155V 184-265V
Nominal Output Frequency
Extended/Reconnect Output FrequencyRange 50Hz/45-55,60Hz/59.3-60.5
Total Harmonic Distortion <3%
Efficiency
Night Power Consumption 50mW
Mechanical Data
Storage Temperature Range -40 °C to +85 °C
Weight 2.2kg
Enclosure Rating IP65
Wet Locations Classification For Wet Locations
Relative Humidity Ratings 0-95%
Certificates UL1741,VDE0126,VDE4105,IEC62109,CE
© All Rights Reserved
Pollution Degree Classification PD3
Communication
Powerline
Operating Ambient Temperature Range -40 °C to +65 °C
Max. Inverter Efficiency 96.5%
Power Factor >0.99
Default/Protect Output Frequency Range 50Hz/45-55,60Hz/59.3-60.5
Maximum Output Power 600W
Maximum Input Voltage 60V
BPE600 Microinverter Datasheet
MPPT Voltage Range 25V-55V
Maximum Input Current 10.4A x 2
Dimensions (W x H x D)
187mm X 163mm X 29mm
Cooling
Natural Convection - NoFans
Maximum Altitude Rating All Data At This Technical Specifications Has Been Tested Under<2000m
50Hz/60Hz Auto Sense
13A
95-155V

Installation/User Manual
18
.
Model BPE1300-240V
Input Data (DC)
Operation Voltage Range 20V-55V
Startup Voltage 20V
Maximum DC Short Circuit Current
Output Data (AC)
Nominal Output Voltage 240V
Nominal Output Current 5.416A
Default/Protect Output Voltage Range
Nominal Output Frequency
Extended/Reconnect Output FrequencyRange 50Hz/45-55,60Hz/59.3-60.5
Total Harmonic Distortion <3%
Efficiency
Night Power Consumption 50mW
Mechanical Data
Storage Temperature Range -40 °C to +85 °C
Weight 6.5kg
Enclosure Rating IP65
Wet Locations Classification For Wet Locations
Relative Humidity Ratings 0-95%
Certificates UL1741,VDE0126,VDE4105,IEC62109,CE
© All Rights Reserved
Pollution Degree Classification PD3
Communication
Powerline
Operating Ambient Temperature Range -40 °C to +65 °C
Max. Inverter Efficiency 96.5%
Power Factor >0.99
Default/Protect Output Frequency Range 50Hz/45-55,60Hz/59.3-60.5
Maximum Output Power 1300W
Maximum Input Current 10.4A x4
MPPT Voltage Range 25V-55V
BPE1300 Microinverter Datasheet
Maximum Input Voltage 60V
Extended/Reconnect Output Voltage Range
184-265V
Dimensions (W x H x D)
450mm X 455mm X 35mm
Cooling Natural Convection - NoFans
Maximum Altitude Rating All Data At This Technical Specifications Has Been Tested Under<2000m
13A
184-265V
50Hz/60Hz Auto Sense

Installation/User Manual
19
Wiring Diagram
Sample Wiring Diagram Three Phase
Sample Wiring Diagram BPE600
MAX 9 BPE600
MAX 9 BPE600
MAX 9 BPE600
BLACK L2 RED L1 YELLOW NEUTRAL
JUNCTION BOX
METER
ETHERNET CABLE
TO BROADBAND ROUTER
26
GROUND