Kaco Powador 3200 User manual

Operating Instructions
English translation of German
original
Powador
3200 | 4200
4400 | 5300
5300 supreme
5500 | 6600

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.............................
. Installing and securing the inverter................
 Installing the Inverter............................. 
. Opening the connection area .........................
. Making the electrical connection ..................
. Connecting the interfaces ................................
. Limiting during asymmetric
feed to the grid .....................................................
. Sealing the connection area ............................
. Starting up the inverter......................................
 Conguration and Operation................ 
. Controls....................................................................
. Initial start-up ........................................................
. Menu structure......................................................
 Maintenance/Troubleshooting..............
. Visual inspection ..................................................
. Cleaning the inverter externally .....................
. Shutting down for maintenance and
troubleshooting................................................... 
. Faults........................................................................ 
. Messages on the display
and the “Fault” LED............................................. 
 Service...................................................... 
 Shutdown/Disassembly ......................... 
. Shutting down the inverter..............................
. Deinstalling the inverter....................................
. Dismantling the inverter....................................
 Disposal ...................................................
. Packaging................................................................
 Documents .............................................. 
. EU Declaration of Conformity .........................
Operating Instructions
for Installers and Operators
Powador
3200 | 4200
4400 | 5300
5300 supreme
5500 | 6600
Contents

General Notes
Page  Operating Instructions 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 Powador -_EN Page 
.. 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 the next 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 the next step.
. Carry out the next step.
. (Additional steps, if applicable)
» Result of the steps (optional)
.. Abbreviations
PV Photovoltaic
EEG German Renewable Energies Act
MPP Maximum power point (point of the current-voltage diagram of 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 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 will 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.
• Be sure to observe IEC --: “Requirements for special installations or locations – solar photovoltaic
(PV) power supply systems” in particular.
• 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 while it is switched on.
• 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 is deemed 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 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://www.kaco-newenergy.de/.

Description
Page  Operating Instructions 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, 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
Consumer
Fuse Fuse
Inverter with DC
disconnect
Inverter with DC
disconnect
PV generator PV generator

Description
Operating Instructions 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
... Three-phase grid monitoring
L1
L1
L2
L3
N
N PE
1234n
L2L3
N PE
L3 L2 L1
N PE
L3 L1L2 L3
N PE
L2 L1
WR1 : L3 - L3 / L2 - L2 / L1 - L1
WR2 : L3 - L1 / L2 - L3 / L1 - L2
WR3 : L3 - L2 / L2 - L1 / L1 - L3
W
R4 : L3 - L3
/
L2 - L2
/
L1 - L
1
.........
Figure : Grid-side connection for systems with multiple inverters with three-phase grid monitoring
... Electrical connection
NOTE
Note the grid type-specic connection conditions (see section .. on page ).
PV generator
Inverters
Fuse
PV generator
Inverters
Fuse

Description
Page  Operating Instructions 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
123
456
7
8
9
Figure : Inverter diagram
Key
1Display 6 Cabletting for DC connection
2 LED indicators 7 Cable tting for interface cable
3 Control buttons 8 Cable tting for AC connection
4 DC disconnect 9 Night start button
5RSport

Description
Operating Instructions 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
operation.
For connection see section 7.3.1 on page 27.
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 39).
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 systems
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
additional 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 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 factory status 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
st node % P/PN - - cos phi 
nd Node % P/PN - - cos phi .
rd node % P/PN - - cos phi . under-excited (u)
To meet the requirements for reactive power feed even at system level, the inverters must be
adjustable in the range from cos phi . over-excited (o) and . under-excited (u).
Characteristic with  nodes
Characteristic with  nodes
u (underexcited)
o (overexcited)

Description
Operating Instructions Powador -_EN Page 
.. Mechanical components
... DC disconnect
There is one DC disconnect inside 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
... 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 key 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 menu (see section . on page ).
... RS port
Use this monitoring variant if you wish to manage 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 over 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
Table  on page  shows an example of a few lines of data transmitted over the RS interface

Description
Page  Operating Instructions Powador -_EN
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
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 state (see section 8.1 on page 35) 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 (see page ). (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
authorised electrician.
For monitoring your PV system using the RS interface, KACO new energy GmbH oers the following units:
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-link RS (optional)
Use the Powador-link RS to bridge long distances between several inverters or between an inverter and the
Powador-proLOG 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).
... Digital input
If a Powador protect is installed as external grid and system protection, the fail-safe disconnection of suitable
Powador inverters from the public grid can be initiated by a digital signal instead of by tie circuit-breakers. This
requires the inverters in the photovoltaic system to be connected to the Powador protect. For information on
the installation and use see this manual, the Powador protect manual and the instructions for use of the Powador
protect on the web site.

Technical Data
Operating Instructions Powador -_EN Page 
 Technical Data
. Electrical Data
Input levels 3200 4200 4400 5300
Max. recommended PV generator power [W] 3 200 4 200 4 400 5 300
DC MPP range from [V] to [V] 350...600
Operating range from [V] to [V] 370 to 500
Starting voltage [V] 410
Open circuit voltage [V] 800
Max. rated current [A] 8.6 11.5 12 14.5
Max. power per tracker [W] 3 200 4 200 4 400 5 250
Number of strings 3
Number of MPP controls 1
Polarity safeguard Short-circuit diode
Output levels
Rated power [VA] 2 600 3 450 3 600 4 400
Max. rated power [VA] 2 850 3 800 4 000 4 800
Grid voltage [V] 184 - 264
Rated current [A] 11.3 15 15.6 19.1
Max. rated current [A] 12.4 16.5 17.5 20.9
Rated frequency [Hz] 50 / 60
cos phi 0.80 over-excited ... 0.80 under-excited
Number of feed-in phases 1
General electrical data
Max. eciency [%] 96.6 96.6 96.5 96.4
European eciency [%] 95.8 95.8 95.9 95.8
Internal consumption: night [W] 0
Feed-in starts at [W] Approx. 35
Circuit design Transformerless
Transformer unit No
Grid monitoring Country-specic
CE conformity yes

Technical Data
Page  Operating Instructions Powador -_EN
Input levels 5300 supreme 5500 6600
Max. recommended PV generator power [W] 5 300 5 500 6 600
DC MPP range from [V] to [V] 350...510 350...600 350...600
Operating range from [V] to [V] 370 to 500
Starting voltage [V] 410
Open circuit voltage [V] 600 800 800
Max. rated current [A] 14.5 15.2 18
Max. power per tracker [W] 5 250 6 000 6 800
Number of strings 3
Number of MPP controls 1
Polarity safeguard Short-circuit diode
Output levels
Rated power [VA] 4 400 4 600 5 500
Max. rated power [VA] 4 800 5 060 6 000
Grid voltage [V] 190 - 264
Rated current [A] 19.1 20 23.9
Max. rated current [A] 20.9 22 26
Rated frequency [Hz] 50 / 60
cos phi 0.80 over-excited ... 0.80 under-excited
Number of feed-in phases 1
General electrical data
Max. eciency [%] 97.2
(97.6 @ 9 kHz) 96.3 96.3
European eciency [%] 96.6
(97.1 @ 9 kHz) 95.7 95.8
Internal consumption: night [W] 0
Feed-in starts at [W] Approx. 35
Circuit design Transformerless
Transformer unit No
Grid monitoring Country-specic
CE conformity yes
Table 2: Electrical data

Technical Data
Operating Instructions Powador -_EN Page 
. Mechanical data
3200 4200 4400 5300 5300
supreme
5500 6600
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
Interfaces RS232, RS485, S0
Fault signal relay Potential-free NO contact max. 30V / 3A
230 V / 1 A
AC connections:
PCB terminal inside the unit (max. cross section: 10 mm²)
AC connections:
Cable connection Cable connection via M32 cable tting
DC connections Cable connection via M16 cable tting
Ambient temperature
range [°C] -20 to 60
Humidity range (non-
condensing) [%] 0 to 95
Maximum
installation elevation [m
above sea level]
2 000
Temperature monitoring yes
Cooling
(free convection (K) / fan
(L))
K
Protection rating
according to EN 60529 IP54
Degree of contamination 2
Noise emission [dB(A)] < 35 / noiseless
Housing Cast aluminium
H x W x D [mm] 500 x 340
x 200
550 x 340
x 200
550 x 340
x 220
550 x 340
x 220
550 x 340
x 220
600 x 340
x 220
600 x 340
x 220
Total weight [kg] 19 21 21 26 26 28 30
Table 3: Mechanical data

Transportation and Delivery
Page  Operating Instructions 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
Checking your delivery
. Inspect your inverter thoroughly.
. Immediately notify the shipping company in case of the following:
–Damage to the packaging that indicates that the inverter may have been damaged
–Obvious damage to the inverter
. Send a damage report to the shipping company immediately.
The damage report must be received by the shipping company in writing within six days following receipt of the
inverter. We will be glad to help you if necessary.
. 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
Operating Instructions Powador -_EN Page 
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 for assembly: see Figure  and Figure  on page  and Figure  on page .
CAUTION
Property damage by gases that have an abrasive eect on surfaces in combination with
humidity resulting from 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
Page  Operating Instructions Powador -_EN
Authorised electrician
NOTE
Power reduction due to heat accumulation.
If the recommended minimum clearances are not observed, the inverter may go into power
regulation mode due to insucient ventilation and the resulting heat buildup.
›Maintain minimum clearances.
›Provide for sucient heat dissipation.
1386
405
565
1120
328
Figure : Instructions for wall mounting Figure : Drill stencil for wall mounting with minimum clearances
(in mm)
CAUTION
Use suitable mounting parts.
›Use only the supplied mounting parts.
›Mount the inverter upright on a vertical wall only.