Kaco blueplanet hy-switch User manual

hy-switch for
KACO
blueplanet
Operating Instructions English
translation of German original
Important safety instructions
These instructions form part of the product and must be carefully read, observed
and stored in a place which is freely accessible at all times.
blueplanet
hy-switch
Accessories
for blueplanet
hybrid inverters

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hy-switch for KACO blueplanet hybrid inverters
Legal provisions
The information contained in this document is the property of KACO
new energy GmbH. Publication, in whole or in part, requires the
written permission of KACO new energy GmbH.
KACO warranty
For current warranty conditions, contact your system
integrator.
You can download the current warranty conditions on the
Internet at http://www.kaco-newenergy.com .
Definitions on product designations
In these operating instructions, the product "hy-switch” is
referred to as component for ease of reading.
Trademarks
All trademarks are recognised, even if not explicitly identified as such. A
lack of identification does not mean that a product or designation/logo
is free of trademarks.

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1. Contents
2. General information .........................................................................................5
2.1. About this document ................................................................................ 5
2.2. Design features ......................................................................................... 6
2.3. Target group ............................................................................................. 7
2.4. Identification............................................................................................. 8
3. Safety ...............................................................................................................9
3.1. Proper use............................................................................................... 10
4. Component description ..................................................................................11
4.1. Functionality ........................................................................................... 11
4.2. Available accessories .............................................................................. 11
4.3. Structure of the component ................................................................... 12
5. Technical data ................................................................................................13
5.1. Electrical data.......................................................................................... 13
5.2. Environmental data ................................................................................ 13
6. Delivery and transport....................................................................................14
6.1. Scope of delivery..................................................................................... 14
6.2. Transporting the component.................................................................. 14
6.3. Installation tool....................................................................................... 15
7. Assembly and preparation..............................................................................16
7.1. Unpacking the component ..................................................................... 16
7.2. Installing the component........................................................................ 16
8. Installation and start-up .................................................................................18
8.1. General information ............................................................................... 18
8.2. Integration possibilities........................................................................... 19
8.3. Connection to the mains......................................................................... 22
8.4. Communication to the inverter .............................................................. 25
8.5. Start-up ................................................................................................... 26
9. Operation .......................................................................................................27
9.1. General information ............................................................................... 27
9.2. Selecting the current sensors ................................................................. 27
9.3. Firmware updates ................................................................................... 27
10. Maintenance and troubleshooting .................................................................28
10.1. Visual inspection ..................................................................................... 28
10.2. Cleaning .................................................................................................. 28
10.3. Fault displays .......................................................................................... 29
10.4. Shutting down for troubleshooting ........................................................ 30
10.5. Manual reset of the mains relay ............................................................. 30

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hy-switch for KACO blueplanet hybrid inverters
11. Decommissioning and dismantling ................................................................ 32
11.1. Shutting down the component................................................................32
11.2. Uninstalling the component ....................................................................32
11.3. Disassembling the component ................................................................33
11.4. Packaging the component .......................................................................33
11.5. Storing the component............................................................................33
12. Disposal ......................................................................................................... 34
13. Service and warranty ..................................................................................... 34

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2. General information
2.1. About this document
WARNING
Improper handling of the component can be hazardous!
You must read and understand the operating instructions
in order to install and use the component safely.
Other applicable documents
During installation, observe all assembly and installation instructions for
components and other parts of the system. These instructions also apply to the
equipment, related components and other parts of the system.
Storing the documents
These instructions and other documents must be stored near the system and be
available at all times.
English translation of German original
This document has been produced in several languages. The German-language
version is the original version. All other language versions are translations of the
original version.
WARNING
Improper handling of the component can be hazardous!
You must read and understand the operating instructions in
order to install and use the component safely.

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hy-switch for KACO blueplanet hybrid inverters
2.2. Layout of Instructions
2.2.1. Symbols used
General hazard
Earthing – protective conductor
Electrical voltage
Protect from moisture
The tasks indicated with this symbol may only be
carried out by an authorised electrician.
DANGER
High risk
Failure to observe this warning will lead directly to serious bodily
injury or death.
WARNING
Potential risk
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.

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2.2.2. Additional information symbols
NOTE
Useful information and notes
Information that is important for a specific topic or objective,
but that is not safety-relevant.
2.2.3. Symbols for instructions
↻Prerequisite for action note
1Carry out the next step
1. Additional action sequence
Interim result of the action
» End result
2.3. Target group
All activities described in the document may only be carried out by
specially trained personnel with the following qualifications:
–Knowledge about how an inverter functions and operates.
–Training in dealing with hazards and risks when installing and
operating electrical components, devices and systems.
–Education concerning the installation and start-up of electrical devices and
systems.
–Knowledge of applicable standards and directives.
–Knowledge and adherence to this document with all safety notices.

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hy-switch for KACO blueplanet hybrid inverters
2.4. Identification
For the service and other setup-specific
requirements, you will find the name plate with the following data on
the left side panel of the product:
- Product name
- Part no.
- Serial number
- Date of manufacture
- Technical data
- Disposal information
- Certification marking, CE marking Fig. 1 Name plate

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3. Safety
NOTE
Before using the product for the first time, please read
through the safety instructions carefully.
DANGER
Lethal voltages are still present in the connections and cables
of the housing even after the component has been switched
off and disconnected!
Severe injuries or death may occur if the cables and/or
terminals/busbars in the component are touched.
>Comply with all safety regulations and current
technical connection specifications of the responsible
power supply company.
>The component is only permitted to be opened or
serviced by a qualified electrician.
>Switch off the grid voltage by turning off the
external circuit breakers.
>Check that no voltage is present using suitable
voltage tester.
>Keep the component closed when in operation.
The electrician is responsible for observing all existing standards
and regulations. The following applies:
–Keep unauthorised persons away from the component and/or system.
–Ensure operational safety by providing proper grounding, conductor
dimensioning and appropriate protection against short circuiting.
–Observe all safety instructions on the product and in these operating instructions.
–Switch off all voltage sources and secure them against being inadvertently
switched back on before performing visual inspections and maintenance.
–When taking measurements on the live component:
-Do not touch the electrical connections
-Remove all jewellery from wrists and fingers
-Ensure that the testing equipment is in safe operating condition.
–Modifications to the surroundings of the component must
comply with the applicable national standards.

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hy-switch for KACO blueplanet hybrid inverters
3.1. Proper use
The component is intended for indoor applications and may only be used in
countries for which it has been approved or for which it has been released by
KACO new energy and the grid operator.
Operate the component only with a permanent connection to the public power grid.
The country and grid type selection must be commensurate with the respective
location and grid type.
The requirements of the grid operator must be met for grid connection to take
place. The permission of the relevant authorities may also be required in order
to secure authorisation to connection to the grid.
The enclosed documentation is an integral part of the component. The
documentation must be read, observed and stored in a place which is freely
accessible at all times.
The name plate must be permanently attached to the component.
Any other or additional use of the device shall be regarded as
improper.
This includes:
–Use without a blueplanet hybrid inverter
–Mobile use
–Use in rooms where there is a risk of explosion
–Outdoor use
–Operation outside the specification intended by the manufacturer
–Modification of the component

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4. Component description
4.1. Mode of operation
The blueplanet hy-switch is a complementary component to the blueplanet
hybrid inverter series. It is not functional without the blueplanet hybrid inverter.
The blueplanet hy-switch serves as a measuring point and all-pole disconnection
point for the local network. It is connected to the three phases, the neutral
conductor and the earth (PE).
The measuring point is required to record and compensate the consumption of the
local installation in connection with the blueplanet hybrid inverter. This includes all
loads installed behind the blueplanet hy-switch. Therefore, the installation location
depends on the structure of the subnetwork to be compensated; in single-family
houses, it is typically located at the grid connection point.
In addition, the measuring point enables no electricity from the batteries connected
to the blueplanet hybrid to be exported to the public grid (flow direction sensor).
The all-pole disconnection point offers the possibility of disconnecting the local
installation from the public power supply. This makes it possible to temporarily set
up a stand-alone grid with the blueplanet hybrid inverter, e.g., if the public power
supply is disrupted. This function must be enabled on the inverter. Activation is
subject to a fee.
4.2. Available accessories
External current sensors are offered as accessories. These enable the measurement
of higher powers, as well as a separation of measuring and switching point. The
current sensors are designed with jack plugs, which are connected to the side of
the component.

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hy-switch for KACO blueplanet hybrid inverters
4.3. Structure of the component
Fig. 2: Structure of the component with external connections
Grid connection
Building
ti
Ground PE
external current sensor L3
external current sensor L2
external current sensor L1
Communication RS485

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5. Technical data
5.1. Electrical data
isolator switch
hy-switch
Max. isolation voltage
264 V
Max. load current
50 A
Max. continuous power
30 000 W
Grid failure detection
200 ms
Switchover time from grid to standalone mode
< 3 s (depending on test sequence)
Current counter
Measuring range of internal current sensors
35 A RMS
Measuring range of external current sensors
70 A RMS
Measuring accuracy of AC power (internal)
3%
Measuring accuracy of AC power (external)
5%
Measuring speed
Real-time
Installation
Max. cable length to the blueplanet hy-switch
20 m
AC cable cross-section max.
35 mm²
Communications connection
1 x RJ45 (RS485)
Connection for external current sensors
3 x 3.5 mm jack
General data
Protection rating (IEC 60529)
IP20
Protection class (IEC 62109-1)
I
Certificates
VDE 0126, VDE AR-N 4105
Warranty
2 years
Dimensions (W x H x D)
170 x 280 x 92 mm
Weight
1.2 kg
Supported devices
Inverter
blueplanet hybrid 10.0 TL3
Max. number of inverters
3
Tab. 1 Technical data
5.2. Environmental data
blueplanet hy-switch
Ambient temperature +5°C + 40°C
Protection rating (KACO installation location)
IP20
Humidity range (non-condensing) [%]
0 to 90 %
Tab. 2 Environmental data

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hy-switch for KACO blueplanet hybrid inverters
6. Transportation and Delivery
Every product leaves our factory in perfect electrical and mechanical condition.
Special packaging ensures that the devices are transported safely. The shipping
company is responsible for any transport damage that occurs.
6.1. Scope of delivery
Check the equipment included
1. Inspect the component thoroughly.
2. Immediately notify the shipping company in case of the following:
–Damage to the packaging that indicates that the component may have been
damaged.
–Obvious damage to the component.
3. Send a damage report to the shipping company immediately.
4. The damage report must be received by the shipping company in
writing within six days following receipt of the component.
We will be glad to help you if necessary.
Scope of delivery
1x component in closed housing 1x
mounting kit, consisting of
4x fixings
4x screws 1x
operating instructions
6.2. Transporting the component
For safe transport of the product, please use the
original packaging (cardboard box).
Packaging:
Folding cardboard box
Packaging size:
400 x 245 x 100 mm
Total weight
approx. 1.5 kg

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CAUTION
Hazard due to impact; risk of breakage to the component!
>Pack the component securely for transport.
>
Do not subject the component to any shocks.
6.3. Installation tool
The codes given in the table below are used in all usage instructions for
assembly/installation/maintenance and disassembly for the tools and tightening
torques being used.
Code (s) Shape of the
connector
W External hexagon
A Internal hexagon
D Torx
S Slot
Outer contour
Tightening torque
Spanner size or number

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hy-switch for KACO blueplanet hybrid inverters
7. Assembly and preparation
7.1. Unpacking the component
CAUTION
Property damage as a result of condensation!
Faulty storage can form condensate in the component and impair
its function (e.g., storage outside the ambient conditions or
a brief change of location from a cold to a hot environment).
1. Open the packaging carefully. Be careful not to damage the component
when using sharp objects.
2. Remove the operating instructions and installation bag
3. Remove the component from the packaging.
4. Place the protective packaging back into the carton.
» Continue installing the component.
7.2. Install the component
Choosing the installation location
Place the blueplanet hy-switch near the control cabinet or energy sub-distributor.
Observe the environmental data under 5.2.
When mounting, keep a distance of at least 15 cm to all sides. The additional space
required for the connection area of the AC cables below the hy-switch must be
provided. Observe the permissible bending radii of the cables.
NOTE
Access by maintenance personnel for service
Any additional costs arising from unfavourable structural or
mounting conditions shall be billed to the customer.

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Securing the component
1. Insert the screwdriver [ S_1.0] into the central recess between the
cover plate and the plastic hinge and carefully separate the two.
2. Store the cover plate carefully until installation is complete.
3. Attach the four dowels with the hole dimensions 153 mm x
247 mm to the mounting wall (cf Fig. 3)
» Component is mounted next to the switch box/control cabinet on the wall.
CAUTION
Avoid damage due to hard striking!
Hard strikes or an uneven surface can damage the
component.
Fig. 3: Hole spacing for mounting

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hy-switch for KACO blueplanet hybrid inverters
8. Installation and start-up
8.1. General information
DANGER
Serious injury or death may occur from touching the cables,
busbars or terminals of the component or the control cabinet.
>Comply with all safety regulations and current
technical connection specifications of the responsible
power supply company.
>The component is only permitted to be opened or
serviced by a qualified electrician.
>Switch off the grid voltage by turning off the
external circuit breakers.
>Do not touch the cables and/or terminals/busbars when
switching the device on and off.
>Keep the component closed when in operation.
WARNING
To prevent the risk of fire,
Never cover the component completely or partially when it is
in operation.
NOTE
Select conductor cross-section, safety type and safety value in
accordance with the following basic conditions:
Country-specific installation standards; power rating of the
component; cable length; type of cable installation; local
temperatures.
Install the blueplanet hy-switch near the building connection or
energy sub-distributor.

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8.2. Integration options
The component has two different options for current measurement. The internal
current sensors may be loaded with a maximum of 50 A. The external current
sensors (optional) may be loaded up to a maximum of 100 A. Compensation
control and feed-in limitation in connection with external feeders is possible up to
a maximum of 35 A for internal current sensors and 70 A for external current
sensors.
Only consumers that are installed downstream of the component on the grid
connection side and in the same area of the local installation as the blueplanet
hybrid inverter can be entitled to replacement power (if enabled, see 4.1).
No. Description
1Power supply company counter (bidirectional meter)
2blueplanet hy-switch
3Switchable line protection (4p 20A)
4EVU counter for generation (optional)
5RCD type B, 30 mA (required for backup power operation)
6blueplanet hybrid inverter
7Load

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hy-switch for KACO blueplanet hybrid inverters
Installation of grid parallel and standby power operation (standard)
Fig. 4: Installation of grid parallel and standby power operation
Installation Grid parallel operation
Fig. 5: Installation of grid parallel operation
Load
Load
Grid connection point
Grid connection point
PE
PE
RCD
type B