Kaco Powador 2002 User manual

Operating Manual
English translation of German
original
Powador
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 | 
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Operating Instructions Powador -_EN Page 
 General Notes............................................
. About this documentation .................................
. Layout of Instructions...........................................
 Safety .........................................................
. Proper use.................................................................
. Protection features ................................................ 
. Standards and directives..................................... 
 Description ................................................
. Mode of Operation ................................................
. Description of the unit .........................................
 Technical Data ..........................................
. Electrical Data........................................................ 
. Mechanical data.................................................... 
 Transportation and Delivery ...................
. Delivery.....................................................................
. Transportation........................................................
 Mounting the Inverter ............................ 
. Unpacking the inverter ..................................... 
. Setting up the inverter....................................... 
 Installing the inverter ..............................
. Opening the connection area...........................
. Making the electrical connection....................
. Generator grounding (optional).....................
. Connecting the interfaces.................................
. Sealing the connection area .............................
. Starting up the inverter.......................................
 Conguration and Operation................. 
. Controls....................................................................
. Starting up for the rst time.............................
. Menu structure......................................................
 Maintenance/Troubleshooting .............. 
. Visual inspection...................................................
. External cleaning..................................................
. Shutting down for maintenance and
troubleshooting................................................... 
. Faults.........................................................................
. Messages on the display and the "Fault"
LED............................................................................ 
 Service...................................................... 
 Shutdown/Disassembly.......................... 
. Shutting down the inverter..............................
. Uninstalling the inverter....................................
. Dismantling the inverter....................................
 Disposal ................................................... 
. Packaging................................................................
 Documents .............................................. 
. EU Declaration of Conformity .........................
Operating Manual
for Installation Engineers and Operators
Powador
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 | 
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Contents

General Notes
Page  Operating Instructions for Powador -_EN
 General Notes
. About this documentation
WARNING
Improper handling of the inverter can be hazardous
›You must read and understand the operating instructions before you can install and use the
inverter safely.
.. Other applicable documents
During installation, observe all assembly and installation instructions for components and other parts of the system.
These instructions are delivered together with the respective 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.
. Layout of Instructions
.. Symbols used
General hazard Risk of re or explosion
High voltage! Risk of burns
Authorised electrician Only authorised electricians may carry out tasks indicated with this symbol.
.. Safety warnings symbols guide
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.

General Notes
Operating Instructions for Powador -_EN Page 
ACTIVITY
Risk of damage to property
Failure to observe this warning will lead to property damage.
.. Additional information symbols
NOTE
Useful information and notes
DE Country-specic function
Functions restricted to one or more countries are labelled with country codes in accordance with
ISO-.
.. Instructions symbols guide
a) Single step instructions or instructions that can be carried out in any sequence:
Instructions
↻Prerequisite(s) for the step(s) (optional)
Carry out step.
(Additional steps, if applicable)
» Result of the step(s) (optional)
b) Multi-step instructions that must be carried out in a xed sequence:
Instructions
↻Prerequisite(s) for the steps (optional)
. Carry out step.
. Carry out step.
. (Additional steps, if applicable)
» Result of the steps (optional)
.. Abbreviations
PV Photovoltaic
EEG German Renewable Energies Act
MPP Maximum power point (point on the current-voltage diagram for a PV generator at which the maximum
amount of power can be drawn)
Colour codes (in accordance
with IEC 60757)
BK Black BN Brown
BU Blue GNYE Yellow-green
GY Grey

Safety
Page  Operating Instructions for Powador -_EN
 Safety
DANGER
Lethal voltages are still present in the terminals and cables of the inverter even after the
inverter has been switched o and disconnected.
Severe injuries or death may occur if the cables and terminals in the inverter are touched.
Only authorised electricians who are approved by the supply grid operator may open, install or
maintain the inverter.
›Keep the inverter closed when the unit is in operation.
›Do not touch the cables or terminals when switching the unit on and o.
›Do not make any modications to the inverter.
The electrician is responsible for observing all existing standards and regulations.
• Keep unauthorised persons away from the inverter and PV system.
• In particular, be sure to observe IEC---: "Requirements for special types of business premises, rooms
and installations - Solar-Photovoltaic-(PV) Power Supply Systems.
• Ensure operational safety by providing proper grounding, conductor dimensioning and appropriate protection
against short circuiting.
• Observe the safety instructions on the inverter and in these operating instructions.
• Switch o all voltage sources and secure them against being inadvertently switched back on before performing
visual inspections and maintenance.
• When taking measurements while the inverter is live:
–Do not touch the electrical connections.
–Remove all jewellery from your wrists and ngers.
–Ensure that the testing equipment is in safe operating condition.
• Stand on an insulated surface when working on the inverter.
• Modications 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 o the DC voltage with the DC disconnect in
addition to disconnecting the PV generator from the grid.
. Proper use
The inverter converts the DC voltage generated by the PV modules into AC voltage and feeds it into the grid. The
inverter is built according to the latest technological standards and safety regulations. Nevertheless, improper use
may cause lethal hazards for the operator or third parties, or may result in damage to the unit and other property.
Operate the inverter only with a permanent connection to the public power grid.
Any other or additional use of the device shall be regarded as improper. This includes:
• Mobile use,
• Use in rooms where there is a risk of explosion,
• Use in rooms where the humidity is higher than %,
• Operation outside of the specications intended by the manufacturer,
• Standalone operation.

Safety
Operating Instructions for Powador -_EN Page 
. Protection features
For your safety, the following monitoring and protective functions are integrated into Powador inverters:
• Overvoltage conductors/varistors to protect the power semiconductors from high-energy transients on the grid
and generator side,
• Temperature monitoring of the heat sink,
• EMC 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 --.
. 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://kaco-newenergy.de/en/site/index.xml.

Description
Page  Operating Instructions for Powador -_EN
 Description
. Mode of Operation
The inverter converts the DC voltage generated by the PV modules into AC voltage and feeds it into the grid. The
feed-in process begins when there is sucient sunlight and a specic minimum voltage is present in the inverter.
If, as it gets dark, the voltage drops below the minimum voltage value, the feed-in operation ends and the inverter
switches o.
. Description of the unit
.. Powador inverter as part of a PV system
... System layout
KWhKWh
Figure : Overview circuit diagram for a system with two inverters
Grid connection point
Main switch Selective
main switch
Reference
counter Feed-in meter
Load
Fuse Fuse
Inverter with DC
disconnect
Inverter with DC
disconnect
PV generator PV generator

Description
Operating Instructions for Powador -_EN Page 
.. System with multiple inverters
... Asymmetric feed-in
L1
L1
L2
L3
N
N PE N PE L1 N PE L1 N PE L1
1234n
Figure : Grid-side connection for systems with multiple inverters with single-phase grid monitoring
.. Electrical connection
NOTE
Note the grid-type-specic connection conditions (see section .. on page )
PV generator
Inverters
Fuse

Description
Page  Operating Instructions for Powador -_EN
.. Summary of the components
PV generator
The PV generator, i.e. the PV modules, converts the radiant energy of sunlight into electrical energy.
DC terminal point
Options for parallel connections of several generator strings:
• To a DC terminal point between the DC generator and inverter,
• Directly to the inverter (terminals for  strings are provided on the inverter),
• Directly to the PV generator with a positive and negative lead to the inverter.
DC disconnect
Use the DC disconnect to disconnect the inverter from all power sources on the PV generator side.
Grid fuses
gL fuses are suitable.
Feed-in meter
The feed-in meter is to be specied 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 questions about the selective main switch, contact your power supply company.
.. Inverter diagram
12
5
8
9
3
4
7
6
10
Figure : Inverter diagram
Key
1 Display 6 Cable tting for interface cable
2 LED indicators 7 Connection board
3 Control buttons 8 RS232 port
4 Fuse for generator grounding (optional) 9 Night start button
5 DC disconnect 10 Mounting plate

Description
Operating Instructions for Powador -_EN Page 
.. Electrical functions
... Fault signal relay
A potential-free relay contact is integrated in the inverter. The contact closes as soon as there is a fault during opera-
tion.
For connection see section .. on page .
DE Country-specic function
... Fault signal relay/Powador-priwatt
A potential-free relay contact is integrated in the inverter. Use this contact for one of the following
functions:
• Fault signal relay
• Powador-priwatt
Powador-priwatt
The energy that is provided by the PV system can be put to use directly by the appliances that are
connected in your home. In“Powador-priwatt”mode, the potential-free contact takes care of this
function.
The contact closes if sucient PV energy is available over a period of  minutes. When the contact
closes, a visual or acoustic signal is emitted, e.g. from a signal lamp or siren (optional).
Activating the function (optional)
The“Powador-priwatt”function is not active in the unit’s factory default state. You can obtain the
password for the function from your specialist retailer. The electrician then activates the function in
the conguration menu (see section 8.3 on page 36).
Powador-priwatt switch (optional)
The potential-free contact switches larger appliances (e.g. air conditioning units) on and o. This
requires an external power supply (max.  V DC) and an external load relay.
Both can be obtained as part of the Powador-priwatt switch from your specialist retailer.
DE Country-specic function
... Power limitation (power control)
Since  January , the German Renewable Energies Act (EEG) requires power limitation for sys-
tems with an output of more than kW. This limit value can be exceeded when using a unit group
of several inverters. Therefore, each inverter must have an option for limiting power, even if this is not
needed in a system that is smaller than kW.
The power reduction is achieved using a ripple control receiver in KACO new energy GmbH inverters.
If necessary, the power supply company can reduce the power of the system remotely using an addi-
tional device from the Powador proLOG family. The Powador-proLOG activates this function, which is
already integrated in the inverter. After a specied period of time without any signal from the power
supply company, the inverter returns to normal operation. For information about Powador-proLOG,
contact your specialist retailer.
Levels of AC power reduction Inverter action
100% Normal feed-in mode
60 % Limitation of power to 60%
30 % Limitation of power to 30 %
0 % Disconnection from the grid

Description
Page  Operating Instructions for Powador -_EN
DE NSp. Country-specic function
... Control procedure cos phi (P/Pn)
The control procedure cos phi (P/Pn) oers the option of dening up to  nodes (minimum of ) for
shift factor cos phi. A node is dened by the relevant pair of values (Specication of an active power in
% based on a nominal power of the device and an associated cos phi value.)
In the delivery state cos phi is activated with a predened characteristic.
This characteristic, which consists of three individual nodes, depends on the rated AC power of the
inverter.
1
0.9
0.9
0,2 0,5
cos φ
P /Pn
1
Figure : Control procedure as per cos phi (P/pn)
PAC,nom < . kVA
. node  % P/PN - - cos phi .
. node  % P/PN - - cos phi .
. Node  % P/PN - - cos phi . under-excited (u)
To meet the requirements for reactive power feed even at system level, the inverters must be adjusta-
ble in the range from cos phi . over-excited (o) and . under-excited (u).
.. Mechanical components
... DC disconnect
There is one DC disconnect in the inverter housing. The DC disconnect is used to disconnect the inverter from the
PV generator in order to carry out service.
Disconnecting the inverter from the PV generator
Switch the DC disconnects from  (ON) to  (OFF).
Connecting the inverter to the PV generator
Switch the DC disconnects from  (OFF) to  (ON).
Figure : DC disconnect
overexcited (o)
underexcited (u)
Characteristic with  nodes
Characteristic with  nodes

Description
Operating Instructions for Powador -_EN Page 
... Night start button
The unit switches o in the evening as nightfall approaches. At this point, nothing is shown on the display. In order
to retrieve the values from the current day (daily yield, daily hours of operation and max. feed-in power) after the
display switches o, the unit can also be activated during the night by pressing the night start-up button on the
underside of the inverter.
Figure : Night-start interface on the inverter
.. Interfaces
The inverter has the following interfaces for communication and remote monitoring:
• RS port
• RS interface
• S interface
You congure the interfaces in the Settings mode (see section . on page ).
... RS port
Use this monitoring option if you wish to manage system operating data directly on a computer. The data can be
processed with standard spreadsheet programs.
The inverter and computer are connected with a serial : interface cable.
The cable length should not exceed  metres.
The data from the inverter is sent unidirectionally as pure ASCII text via the serial interface. The data is not checked
for errors.
The RS interface has the following parameters:
Baud rate Data bits Parity Stop bits Protocol
 baud  None  None
The table below shows an example of a few lines of data transmitted over the RS interface.
Column 1 2 3 4 5 6 7 8 9 10
00.00.0000 00:05:30 3 363.8 0.37 134 226.1 0.53 103 23
00.00.0000 00:05:40 3 366.0 0.39 142 226.1 0.53 112 23
00.00.0000 00:05:50 3 359.5 0.41 147 226.1 0.53 116 23
00.00.0000 00:06:00 3 369.8 0.42 155 226.1 0.58 118 23
00.00.0000 00:06:10 3 377.0 0.43 162 226.1 0.63 131 23
00.00.0000 00:06:20 3 373.6 0.45 168 226.1 0.63 133 23
00.00.0000 00:06:30 3 364.0 0.48 174 226.1 0.68 146 23
00.00.0000 00:06:40 3 364.3 0.49 178 226.1 0.68 146 23
Table 1: Excerpt from the RS232 interface transmission log
Key
Column Meaning Column Meaning
1 Placeholder 6 Generator power in W
2 Daily running time 7 Line voltage in V
3 Operating status (see section 8.1 on page 13) 8 Line current, feed-in current in A
4 Generator voltage in V 9 Power fed into the grid in W
5 Generator current in A 10 Temperature of the unit in °C

Description
Page  Operating Instructions for Powador -_EN
... 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. For permanent system monitoring, we recommend
the optional accessories. (Powador proLog)
... RS interface
Use this monitoring option if you cannot check the functioning of the system on-site on a regular basis, e.g. if your
place of residence is located a great distance from the system. To connect the RS interface, contact your author-
ised electrician.
For monitoring your PV system using the RS interface, KACO new energy GmbH oers the following data log-
gers:
Powador-proLOG S to XL (optional)
Powador-proLOG allows you to monitor up to  inverters simultaneously. Depending on the product model,
Powador-proLOG sends yield and operating data by SMS or e-mail.
Powador-piccoLOG (optional)
Powador-piccoLOG allows you to monitor up to  inverters up to  kWp simultaneously. With this self-learning data
logger, yield and operating data as well as error messages are transferred to monitoring devices via Ethernet. System
errors are also issued optically and acoustically. A ripple control receiver can be connected via the integrated digital
input.
Powador-link RS (optional)
Use the Powador-link RS to bridge long distances between several inverters or between an inverter and the
Powador-proLOG or Powador-piccoLOG by means of wireless radio transmission.
... S interface
The S interface transmits pulses between a pulsing counter and a tari metering unit. It is a galvanically isolated
transistor output. It is designed according to DIN EN -:- (pulse output devices for electromechanical
and electronic meters).
NOTE
The S interface pulse rate can be chosen in three unit intervals (, , and , pulses/kWh).

Technical Data
Operating Instructions for Powador -_EN Page 
 Technical Data
. Electrical Data
Input levels 2002 3002 4202 5002 6002
Max. recommended PV generator power [W] 2 000 3 000 4 200 5 000 6 000
DC MPP range from [V] to [V] 125 to 510 200 to 510
Operating range from [V] to [V] 125 to 295 200 to 300
Starting voltage [V] 125 200
Open circuit voltage [V]* 600
Max. rated current [A] 14.3 13.5 18.5 22.4 26.5
Number of strings 3
Number of MPP controls 1
Polarity safeguard Short-circuit diode
* To protect the electronic system, the grid-feed is made at < V.
Output levels
Rated power [VA] 1 650 2 500 3 500 4 200 4 600
Grid voltage [V]  to  V
Rated current [A] 7.2 10.9 15.2 18.3 20.0
Rated frequency [Hz] 50
cos phi 0.80 over-excited ... 0.80 under-excited
Number of feed-in phases 1
Distortion factor [%] <3
General electrical data
Maximum eciency 95.9 % 96.0 % 95.9 % 95.9 % 95.9 %
European eciency 95.3 % 95.4 % 95.1 % 95.3 % 95.3 %
Internal consumption: Standby [W] /
operation [W]
0.4 / < 5
Feed-in starts at [W] 10 15 25 25 25
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 yes
Table 2: Electrical data

Technical Data
Page  Operating Instructions for Powador -_EN
. Mechanical data
2002 3002 4202 5002 6002
Visual displays LEDs: PV generator (green), supply (green), fault (red)
LCD (2 x 16 characters)
Controls 2 keys for operating display
DC disconnect Integrated DC disconnect with rotary switch
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 > 75 °C
> 85 °C
> 70 °C (temperature-dep.
power matching)
> 80 °C (disconnection from the grid)
Max. humidity 95% (non-condensing)
Maximum installation elevation
[m above sea level]
2 000
Cooling Free convection (no fan)Fans
Protection class IP54 according to EN 60529
Noise emission < 35dB (noiseless) < 45dB (fan operation)
Housing Aluminium wall-mounted housing
H x W x D [mm] 450 x 340 x
200
500 x 340 x
200
600 x 340 x
240
600 x 340 x
240
600 x 340 x
240
Total weight [kg] 14.5 20 26 28 28
Table 3: Mechanical data

Transportation and Delivery
Operating Instructions for Powador -_EN Page 
 Transportation and Delivery
. Delivery
Every inverter leaves our factory in proper electrical and mechanical condition. Special packaging ensures that the
units are transported safely. The shipping company is responsible for any transport damage that occurs.
.. Scope of delivery
• Powador inverter
• Wall bracket
• Installation kit
• Documentation
. 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 transportation of the inverter, use the holding openings in the carton.
Figure : Transportation of the inverter

Mounting the Inverter
Page  Operating Instructions for Powador -_EN
Authorised electrician
 Mounting the Inverter
DANGER
Risk of fatal injury from re or explosions
Fire caused by ammable or explosive materials in the vicinity of the inverter can lead to serious
injuries.
›Do not mount the inverter in an area at risk of explosion or in the vicinity of highly ammable materials.
CAUTION
Risk of burns from hot housing components.
Coming into contact with the housing can cause burns.
›Mount the inverter so that it cannot be touched unintentionally.
Installation space
• As dry as possible, climate-controlled, with the waste heat dissipated away from the inverter,
• Unobstructed air circulation,
• When installing the unit in a control cabinet, provide forced ventilation so that the heat is suciently dissipated,
• Easily accessible from the front and sides,
• Protected from direct sunlight and moisture (rain) in outdoor areas,
• For easy operation, ensure during installation that the display is slightly below eye level.
Installation location
• Free-standing installation or wall mounting possible,
• Consisting of non-cracked cement,
• With sucient load-bearing capacity,
• Accessible for installation and maintenance,
• Made from heat-resistant material (up to  °C),
• Flame resistant,
• Minimum clearances to be observed during assembly: see Figure  and Figure  on page .
CAUTION
Property damage due to gases that have an abrasive eect on surfaces when they come into
contact with ambient humidity caused by weather conditions
The inverter housing may be severely damaged by gases (ammonia, sulphur, etc.) when they
come into contact with ambient humidity caused by weather conditions.
If the inverter is exposed to gases, it must be mounted so that it can be seen at all times.
›Perform regular visual inspections.
›Immediately remove any moisture from the housing.
›Take care to ensure su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.

Mounting the Inverter
Operating Instructions for Powador -_EN Page 
Authorised electrician
. Unpacking the inverter
CAUTION
Risk of injury due to high weight of the inverter (approx. .- kg) !
›Observe the weight of the inverter during transport.
›Select suitable mounting location and mounting base.
›Use mounting material corresponding to or included with the base for mounting the inverter.
›Only mount the inverter with the help of a second person.
1
2
3
Figure : Unpacking the inverter Figure : Setting up the inverter
Key
1 Carton 3 Inverters
2 Protective packaging
Unpacking the inverter
. Open carton at the front.
. Remove installation material and documentation.
. Slide inverter carefully out of the carton with the protective packaging.
. Place the protective packaging back into the carton during mounting.
» Continue setting up the inverter.
. Setting up the inverter
NOTE
Power reduction due to heat accumulation.
If the recommended minimum clearances are not observed, the inverter may go into power regula-
tion mode due to insucient ventilation and the resulting heat build-up.
› Maintain minimum clearances.
› Ensure sucient heat dissipation.

Mounting the Inverter
Page  Operating Instructions for Powador -_EN
Authorised electrician
1386
405
565
1120
328
Figure : Instructions for wall mounting Figure : Drill stencil for wall mounting with mini-
mum clearances (in mm)
Fasten wall holder to mounting location
. Mark the positions of the drill holes using the cut-outs in the wall holder.
NOTE: The minimum clearances between two inverters, or the inverter and the ceiling/oor have already been
taken into account in the diagram (see Figure  on page ).
. Fix wall holder to the wall with the mounting xtures.
Make sure that the wall holder is oriented correctly.
250mm 250mm
1
2
3
4
5
Figure : Minimum clearances/mounting plate
Key
1 Fixings for mounting 4 Suspension bracket
2 Mounting plate 5 Safety catch
3 Screws for mounting
Clearance from the ceiling: 500 mm
Clearance from any other inverter:
700mm
Clearance from the oor 500 mm
Clearance from any other inverter: 700 mm
Safety catch
(open)
Safety catch
(closed)