Kaco Powador 2002 User manual

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

EN
Page Operating Instructions for Powador -_EN
Operating Instructions
for Installation Engineers and Opera-
tors
Powador
2002 | 3002
4202 | 5002
6002
Contents
 General information .................................
. About this document............................................
. Layout of Instructions...........................................
. Standards and directives.....................................
 Safety .........................................................
. Proper use.................................................................
. Protection features ................................................
 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 ......................... 

ENEN
General information
Page  Operating Instructions for Powador -_EN
 General information
. About this document
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 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.
. 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.

EN
General information
Page Operating Instructions for Powador -_EN
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
↻Prerequisites before carrying out the following instructions
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)
. 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/

ENEN
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 if the cables and/or terminals in the inverter are touched. Only appropriately
qualied and authorised electricians may open, install or maintain the inverter.
› Keep the inverter closed when the unit is in operation.
› Do not touch the cables and/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 all 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 isolator switch in
addition to disconnecting the PV generator from the grid.
. Proper use
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 prop-
erty.
Operate the inverter only with a permanent connection to the public power grid.
Any other or additional use of the device is deemed improper. This includes:
• Mobile use
• Use in potentially explosive atmospheres,
• Use in rooms where the humidity is higher than %
• Operation outside of the specications intended by the manufacturer
• Islanding operation.
. 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 --.

EN
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 mode ends and the inverter
switches o.
. Description of the unit
.. Powador inverter as part of a PV system
KWhKWh
Figure : Overview circuit diagram for a system with two inverters
Grid connection point
Main switch Selective
main switch
Reference
counter Feed-in meter
Consumer
Fuse Fuse
Inverter with DC
isolator switch
Inverter with DC
isolator switch
PV generator PV generator

ENEN
Description
Page  Operating Instructions for Powador -_EN
.. 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
Inverter
Fuse

EN
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 isolator switch
Use the DC isolator switch to disconnect the inverter from all power sources on the PV generator side.
Grid fuses
Use only specic PV rated fuses.
Feed-in meter
The feed-in meter is 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 any 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 isolator switch 10 Mounting plate

ENEN
Description
Page  Operating Instructions for Powador -_EN
.. Mechanical components
... DC isolator switch
There is one DC isolator switch in the inverter housing. The DC isolator switch 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 isolator switches from  (ON) to 
(OFF).
Connecting the inverter to the PV generator
Switch the DC isolator switches from  (OFF) to 
(ON).
Figure : DC isolator switch
... 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 button 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.
Spalte 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
Table 1: Excerpt from the RS232 interface transmission log

EN
Description
Page Operating Instructions for Powador -_EN
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
... 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, Pow-
ador-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 Pow-
ador-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).

ENEN
Technical Data
Page  Operating Instructions for Powador -_EN
 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 ... 510 200 ... 510
Starting voltage [V] 125 200
Open circuit voltage [V]* 600
Max. input 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 (DE)
5 000 (INT)
Grid voltage [V]  ... 
Rated current [A] 7.2 10.9 15.2 18.3 20.0
Rated frequency [Hz] 50
Cos phi 0.80 inductive ... 0.80 capacitive
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:
Night [W] / Standby [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

EN
Technical Data
Page Operating Instructions for Powador -_EN
. Mechanical data
2002 3002 4202 5002 6002
Visual displays LCD (2 x 16 characters)
LEDs: PV generator (green), supply (green), fault (red)
Controls 2 keys for operating display
DC isolator switch Integrated DC isolator switch 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)Fan
Protection class IP54 according to EN 60529
Degree of contamination 2
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

ENEN
Transportation and Delivery
Page  Operating Instructions for Powador -_EN
 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

EN
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 mate-
rials.
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, well-ventilated, 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 and wind) in outdoor areas,
• For easy operation, ensure during installation that the display is slightly below eye level.
Wall
• With sucient load-bearing capacity
• Protected against high winds,
• 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 can be severely damaged by gases (ammonia, sulphur, etc.) if it comes
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.

ENEN
Mounting the inverter
Page  Operating Instructions for Powador -_EN
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.

EN
Mounting the inverter
Page Operating Instructions for Powador -_EN
Authorised electrician
1386
405
172
565
1120
328
Figure : Instructions for wall mounting Figure : Drill stencil for wall mounting with minimum
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 ).
. Fix wall holder to the wall with the mounting xtures.
Make sure that the wall holder is oriented correctly.
A
BC
B
C
A
A





Safety catch
(open)
Safety catch
(closed)
Figure : Minimum distances of inverter
Key
A• horizontal distance between the two inverters /
inverter and the wall
• Distance in front
25 cm

ENEN
Installing the inverter
Page  Operating Instructions for Powador -_EN
Authorised electrician
B Distance between the inverter and the ceiling / oor 50 cm
C vertical distance between the two inverters 70 cm
1 Fixings for mounting 4 Suspension bracket
2 Wall bracket 5 Safety catch
3 Screws for mounting
Securing the inverter
. Secure the inverter with a second person and with both hands on the housing side and base plate, and move
to the mounting location. (See Figure  on page )
. Hang the inverter on the wall holder using the suspension brackets on the back of the housing.
. Secure the inverter with safety catch. (See Figure  on page )
» The mounting of the inverter is complete. Continue with the installation.
 Installing the inverter
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 appropriately qualied and authorised electricians may open and install the inverter.
The inverter must be mounted in a xed position before being connected electrically.
› Observe all safety regulations and current technical connection specications of the responsible
power supply company.
› Disconnect the AC and DC sides.
› Secure both sides against being inadvertently switched back on.
› Ensure that the AC and DC sides are completely isolated and voltage free.
› Connect the inverter only after the aforementioned steps have been taken.
. Opening the connection area
Opening the connection area
↻You have completed assembly.
. Unscrew the two Philips screws on the right-hand side of the housing.
. Open the housing door.
» Make the electrical connection.
. Making the electrical connection
Make the connection to the PV generator as well as the grid connection via the PCB terminals in the connection area
of the inverter. Note the following cable cross-sections:
AC connection DC connection
Max. conductor cross-section without wire
sleeves
6 mm²
MC4 solar plug connection
Max. conductor cross-section with wire sleeves 4 mm²
Length of insulation to be stripped o 12 mm
Tightening torque (Powador 4202-6002 only) 1.2 Nm - 1.5 Nm

EN
Installing the inverter
Page Operating Instructions for Powador -_EN
Authorised electrician
The power section has two internal circuit board fuses. These are labelled F or F and F on the circuit board.
2002 / 3002 4202 / 5002 / 6002
Fuse F801 type 179120 5x20 slow-blow 250 V / 0.4 A
Vendor SIBA
Fuse F861 type TR5 fuse, series 372 slow-
blow 250 V/ 125 V / 1 A
F701 type 179200 5x20 slow-
blow 250 V / 0.4 A
Vendor Littelfuse/Wickmann SIBA
Overvoltage safety class DC: III, AC: III
Overvoltage safety category DC: II, AC: III
12
3
4
5
Figure : Connection area
Key
1 6 (2 x 3) MC4-compatible DC plug connectors for
PV generator
4 Cable tting (M40) for AC connection
2 DC isolator switch 5 AC connection terminals
3 Cable ttings (M16) for housing ground connec-
tion
.. Connecting the inverter to the power grid
The power connection wires are connected on the right of the connection area.
A screwdriver (slotted, .mm) is to be used for the terminals in the inverter.
DANGER
Risk of fatal injury due to electric shock
Severe injury or death will result if the live connections are touched.
› Switch o all power sources to the inverter before you insert the grid power cable into the unit.
› Make sure that the device is isolated from the public power supply and the system power supply
before starting work.
Recommended conductor cross-sections and fuse protection of NYM cables for xed wiring according to VDE
 part 
For cable lengths up to m, use the conductor cross-sections specied in Table . Longer cable lengths require
larger conductor cross-sections.

ENEN
Installing the inverter
Page  Operating Instructions for Powador -_EN
Authorised electrician
Model Conductor cross-sec-
tion
Fuse protection: gL safety fuses
Powador 2002 1.5 mm² 16 A for 1.5 mm² conductor cross-section
Powador 3002 2.5 mm² 20 A for 2.5 mm² conductor cross-section
Powador 4202 4.0 mm² 25 A for 4.0 mm² conductor cross-section
Powador 5002 4.0 mm² 25 A for 4.0 mm² conductor cross-section
Powador 6002 6.0 mm² 35 A for 6.0 mm² conductor cross-section
Table 4: Recommended conductor cross-sections and fuse protection of NYM cables
NOTE
When the line resistance is high (i.e. long grid-side cables), the voltage at the grid terminals of the
inverter will increase during feed-in to the grid. The inverter monitors this voltage. If it exceeds the
country-specic grid overvoltage limit value, the inverter switches o.
› Ensure that the conductor cross-sections are suciently large or that the cable lengths are su-
ciently short.
Figure : Insert AC leads into the connection area Figure : AC leads wound around the ferrite cores
Making the grid connection
↻Use cables with three wires (L, N, PE).
. Loosen cable tting for AC connection.
. Remove the outer cladding of the AC cables.
. Insert the AC leads through the cable tting into the connection area. (See Figure  on page )
. Strip the insulation from the AC cables.
. Guide the AC leads through the ferrite cores.
. Wrap the AC leads once around the ferrite cores. (See Figure  on page )