Kostal PIKO 1.5 MP User manual

PIKO 1.5 - 4.2 MP
Operating instructions

Legal notice
KOSTAL Solar Electric GmbH
Hanferstraße 6
79108 Freiburg i. Br.
Germany
Tel. [phone] - 100
Fax [phone] - 111
www.kostal-solar-electric.com
Exclusion of liability
All names, trademarks, product names or other designa-
tions given in this manual may be legally protected even if
this is not labelled as such (e.g.as a trademark). KOSTAL
Solar Electric GmbH accepts no liability and gives no
assurance that they can be freely used. The illustrations
and texts have been compiled with great care. However,
the possibility of errors cannot be ruled out. The compila-
tion is made without any guarantee.
General note on gender equality
KOSTAL Solar Electric GmbH is aware of the importance
of language with regard to the equality of women and
men and always makes an eort to reflect this in the
documentation. Nevertheless, for the sake of readability
we are unable to use non-gender-specific terms throug-
hout and use the masculine form instead.
© 2016 KOSTAL Solar Electric GmbH
All rights reserved by KOSTAL Solar Electric GmbH,
including those of reproduction by photocopy and sto-
rage in electronic media. Commercial use or distribution
of the texts, displayed models, diagrams and photo-
graphs appearing in this product is not permitted. This
manual may not be reproduced, stored, transmitted or
translated in any form or by means of any medium – in
whole or in part – without prior written permission.
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Table of contents
1 Preface................................................................................................ 5
2 General information............................................................................. 6
2.1 General safety instructions.......................................................... 6
2.2 Identification................................................................................ 7
2.3 Scope of delivery......................................................................... 8
2.4 Intended use................................................................................ 8
2.5 About this manual....................................................................... 9
3 Structure and function...................................................................... 11
3.1 Housing..................................................................................... 11
3.2 Operating buttons..................................................................... 12
3.3 Display....................................................................................... 12
3.4 Cooling...................................................................................... 20
3.5 Grid monitoring......................................................................... 20
3.6 Data communication................................................................. 21
4 Installation......................................................................................... 30
4.1 Safety measures during installation.......................................... 30
4.2 Mounting the inverter................................................................ 32
4.3 Prepare AC connection............................................................. 33
4.4 Prepare DC connections........................................................... 36
4.5 Preparing the data connection cable........................................ 36
4.6 Connecting the inverter and switching the AC on..................... 36
4.7 Initial commissioning of the inverter.......................................... 37
4.8 Feed-in management................................................................ 43
4.9 Switching the inverter on........................................................... 44
4.10 Switching the inverter o......................................................... 45
4.11 Deinstalling the inverter........................................................... 45
5 Operation.......................................................................................... 47
5.1 Overview of operating functions............................................... 47
5.2 General operating functions...................................................... 48
5.3 Important operating functions................................................... 48
5.4 PIKO Solar Portal....................................................................... 51
6 Self test............................................................................................. 52
7 Event messages................................................................................ 55
8 Maintenance and disposal................................................................ 62
8.1 Maintenance.............................................................................. 62
8.2 Disposal..................................................................................... 62
9 Technical data................................................................................... 63
9.1 Inverter...................................................................................... 63
Table of contents
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9.2 AC cables and line circuit breakers........................................... 73
10 Liability, commercial guarantee, legal guarantee.............................. 75
11 Contact.............................................................................................. 76
Appendix........................................................................................... 77
A Bore dimension drawing.............................................................. 78
Table of contents
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1 Preface
Thank you for purchasing a PIKO inverter from KOSTAL Solar Electric
GmbH. By using solar energy, you are making a significant contribution to
environmental protection; by reducing the amount of carbon dioxide (CO2)
and other harmful gases that burden the atmosphere of the earth.
The innovative inverter topology is based on a single-stage transformer-
less circuit concept. This unique technology allows peak eciencies of
98,0 % or 98,6 % to be achieved. Depending on the type, the European
eciency of the devices is also significantly greater than 98 % and sets
new standards in photovoltaic grid-feed systems.
A new, unique cooling concept in the interior of the inverter guarantees
uniform distribution of heat and thus a long service life.
For the first time, the very high eciency allows the use of a designer
housing made of plastic for the PIKO MP inverters. This oers many
advantages. The surface temperatures of the devices overall remains
extremely low. In addition, there are clear benefits for the installation.
The lightweight devices weigh only 9or 12 kg and can be easily and safely
mounted on a wall. The supplied wall bracket and practical recessed grips
for right and left handed installers make mounting of the device simple and
convenient. All connections and the DC circuit breaker are externally
accessible.
The devices have a graphic display, with which the energy load values,
actual capacities, and operating parameters of the photovoltaic system
can be visualized. Its innovative menu allows individual selection of the
various measurements.
For more information about our inverters, go to
www.kostal-solar-electric.com .
Maximum eciency with
a long service life
Designer casing and easy
installation
Visualisation
Preface
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2 General information
2.1 General safety instructions
nThis document is part of the product.
nInstall and use the device only after reading and understanding this
document.
nAlways perform the measures described in this document in the
sequence specified.
nKeep this document in a safe place for the entire service life of the
device. Pass the document on to subsequent owners and operators of
the device.
nThe yield of the system can be reduced through improper operation.
nIf the housing is damaged, do not connect the device to the DC or AC
lines.
nIf one of the following components is damaged, immediately take the
device out of operation and disconnect it from the mains grid and PV
generators.:
–Device (not functioning, visible damage, smoke, penetration of
liquid etc.)
–Lines
–PV generators
Do not switch the system on again before
–the device has been repaired by a dealer or the manufacturer,
–Damaged cables or PV generators have been repaired by a tech‐
nical specialist.
nNever cover the device
nDo not open the casing: Risk of death. Invalidation of the guarantee.
nFactory labels and markings must never be altered, removed or ren‐
dered unreadable.
nComply with the instructions of the respective manufacturer when you
connect an external component that is not described in this document
(e.g. external data loggers). Components that are incorrectly connected
can damage the device.
DANGER!
Dangerous voltages can remain present on the components
up to 10minutes after switching o the DC circuit breaker
and the line circuit breaker.
General information
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2.2 Identification
Feature Description
Types PIKO 1.5 MP, PIKO 2.0 MP, PIKO 2.5 MP, PIKO 3.0 MP, PIKO 3.6 MP,
PIKO 4.2 MP
Version status of the manual 11/2017
Manufacturer's address See
ÄChapter 11 „Contact“ on page 76
Certificates For the certificates, refer to our website under
www.kostal-solar-electric.com/Download/Zertifikate
①Bar code for internal use
②Protection class
③Technical data of the DC input
④Article number and product designation
⑤Manufacturer's address
⑥Cover the
Protection class II and CE mark
⑦Country of manufacture
⑧Technical data of the AC output
⑨Standard for grid monitoring
– For Australia only: Cover the Protection class IIsymbol on
the type plate, as described on Ä„ For Australia only:
Cover the Protection class II symbol on the type
plate. “ on page 32.
– For the serial number, see ÄChapter 2.5.3 „Designa‐
tions“ on page 9
– For the position of the type plate, see ÄChapter 3.1
„Housing“ on page 11.
The products described in this document comply with the applicable Euro‐
pean Directives. For the certificates for the products, refer to our website
under
www.kostal-solar-electric.com/Download/Zertifikate
Rating plate
཰ཱཱཱིིུུཷྲྀླྀ
EU Declaration of Confor‐
mity/Certificates
General information
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2.3 Scope of delivery
nInverter ①
nMounting plate ②
nAC plug ③
n1 pair SUNCLIX plug-in connectors ④
nShort Manual ⑤
Fig. 1: Scope of delivery
2.4 Intended use
nThe inverter must only be used in grid-coupled photovoltaic systems.
The inverter is suitable for all PV generator with connections that do not
need to be grounded.
nPV generator must be used that have an IEC 61730 class A rating
because the inverter does not have electrical isolation.
nIf the maximum AC operating voltage is higher than the maximum
system voltage of the PV generator, then PV generators must be used
that have a maximum system voltage that is higher than the AC grid
voltage.
General information
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2.5 About this manual
2.5.1 Contents
This manual describes the inverters of the types PIKO 1.5 - 4.2 MP. The
points at which the types dier are marked in the text.
This manual contains all information that a specialist needs to set up and
operate the inverters. Follow the instructions of the respective manufac‐
turers when installing other components (e.g. PV generator, cables).
2.5.2 Target group
Unless otherwise indicated, the target audiences of this manual are tech‐
nical professionals and system operators. Technical professionals are, for
example:
nPersons who have the knowledge of terminology and the skills neces‐
sary for setting up and operating photovoltaic systems.
nPersons who have the necessary training, knowledge and experience,
and knowledge of the applicable regulations in order to evaluate and
recognise the dangers inherent in the following work:
–Installation of electrical equipment
–Production and connection of data communication cables
–Production and connection of mains grid power supply cables
2.5.3 Designations
The following table contains the symbols used in this manual.
Warning signs Type of danger
Warning – high-voltage.
Warning – danger zone.
Tab. 1: The following table contains the symbols used on the device.
Cover the Description
Danger from electricity.
Read the manual before using the product.
Symbols
Symbols used on the
device
General information
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Cover the Description
Bar code with serial number.
Keywords used in conjunction with the symbols described:
Signal word Meaning
DANGER! This combination of symbol and
signal word indicates an immediate
dangerous situation that will result
in death or serious injury if it is not
avoided.
NOTICE! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in material and environmental
damage if it is not avoided.
Abbreviation Description
Derating Power reduction
DHCP DHCP automatically integrates the device in an existing network (acronym:
Dynamic Host Configuration Protocol)
MSD Internal grid monitoring of the inverter (English: Mains monitoring with allo‐
cated Switching Devices).
MPP Working point producing the most power (English: maximum power point)
MPP tracker Controls the power of the connected module strings to match the MPP
SELV, TBTS, MBTS Schutzkleinspannung (EN: Safety Extra Low Voltage; FR: Très Basse
Tension de Sécurité; ES: Muy Baja Tensión de Seguridad)
VPV The PV generator voltage present at the DC connection (photovoltaic
voltage)
Signal words
Abbreviations
General information
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3 Structure and function
3.1 Housing
①Hood
②Display (monochrome, 128 x 64 pixels)
③Rating plate, serial number, warnings
④Operating buttons: ESC, r, s, SET (from left to right)
⑤1x AC connection
⑥1x DC connection Minus(−) for PV generator (Phoenix Contact SUN‐
CLIX, touch protection)
⑦1x DC connection Plus(+) for PV generator (Phoenix Contact SUNCLIX,
touch protection)
⑧DC load-break switch (disconnects plus and minus input simultane‐
ously)
⑨2 x RJ45 sockets (RS485 bus)
⑩1 x RJ45 socket (TCP/IP Ethernet) for connection to an IP grid via LAN
⑪1 x RJ10 socket (Modbus RTU) for connection of an energy meter
The housing components are described in detail below.
11
2
3
14
16
8 7 15
11 10 9
Structure and function
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3.2 Operating buttons
The operating buttons ④in ÄChapter 3.1 „Housing“ on page 11 have the
following functions:
Button Action Function
General information Guided operation
ESC Press briefly Goes to the next higher menu
level
Navigates 1 step back
Discards any changes
Press longer
(≥ 1 second)
Goes to the status display Jumps to the start of the guided
configuration process
rPress briefly nMoves the marking bar or the display content upward
nIn a numeric setting, moves the marking 1 position to the left
nIncreases an adjustment value by 1 increment
sPress briefly nMoves the marking bar or the display content downward
nIn a numeric setting, moves the marking 1 position to the left
nIncreases an adjustment value by 1 increment
SET Press briefly Goes to the next lower menu
level
—
na selected numerical value starts flashing and can be changed
nApplies a change
nChanges the status of a control element (check box/option box)
Press longer
(≥ 1 second)
Answers a query dialog with Yes Goes 1 step back
3.3 Display
3.3.1 General information
For the presentation on the display ②in
ÄChapter 3.1
„Housing“ on page 11
, the following applies in general:
nSymbol : While the inverter is processing large volumes of data, it
cannot process any user inputs. The resulting waiting time is indicated
by the animated sun symbol.
nErrors are indicated by a red flashing backlighting. An event message is
also displayed at the same time.
Structure and function
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The display reacts slower at very low temperatures.
3.3.2 Information
The information shown on the display is described below using illustrative
examples.
The status display shows the following values:
①Measurement name
②Measurement with units
③Date is displayed alternatingly with IP address
④Cover the
Non-confirmed event messages ; for more information, see
ÄChapter 7 „Event messages“ on page 55 .
⑤Animated symbol
Connect symbol with 2‑digit inverter address; indi‐
cates data trac on the RS485 bus.
⑥Cover the
Power reduction (Derating)
⑦Cover the
Fixed voltage mode activated
⑧Time
⑨IP address of the device when a network connection has been estab‐
lished, display alternates with ③– ⑦
The following applies to the status display:
nThe measurements shown in the status display are defined under
Settings ▶Meas. values. Some measurements are always dis‐
played (default setting).
nCurrent values are not displayed at night (solar irradiation too low;
example in Fig. left).
Daily, monthly and annual yields can be displayed numerically in a list.
①Yield period (day/month/year)
②Individual yields with period and value (1 per row)
The yield periods contain the following numbers of individual entries:
nDay yield: last 31 days1)
nMonthly yield: last 13 months1)
nAnnual yield: last 30 years1)
1) A yield value of 0 is shown when the inverter was not yet installed at that
time.
Status display
34
2
2
7 8
9
5 6
1
F
Numeric yield (day,
month, year)
Structure and function
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Daily, monthly and annual yields can be displayed graphically in a chart.
①Period on an individual yield (here: day yield)
②Y axis 1) 2) 3)
③X axis: Time in hours/days/months/years
④Total of all individual yields shown in the diagram, in kWh
The graphical representation can show annual yields for the last 20 years.
1) Yield in kWh
2) With addition of
„M“ : : yield in MWh
3) The scaling changes depending on the maximum value.
ÄChapter 7 „Event messages“ on page 55
①X axis: input voltage in V
②Y axis: power in kW
③Peak = MPP
If the „Ch. Curve“ menu item is called, the inverter records the PV gener‐
ator characteristic curve and then displays it (Fig. upper left).
The following applies:
nThe inverter traverses the input voltage range and records the power
generated over this range. Duration: a few seconds; is displayed.
nThe MPP is at the peak of the PV generator characteristic curve.
nThis peak and the PV generator characteristic curve change with the
level of solar irradiation.
nMultiple peaks are a sign of partial shadowing (Fig. left).
nIf the top of the curve is flat, the inverter can possibly no longer feed
power into the grid.
Graphical yield (day,
month, year)
Event messages
PV generator character‐
istic curve
Structure and function
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The menu item Information contains the following sub-menu items.
nContact info
nSystem info: (see Fig. left)
–Product designation
–Serial number of the inverter
–Information concerning the software and hardware version of the
inverter (see sample ①in Fig. left)
–Inverter address
–Version of the manual that belongs with the inverter
nReactive power characteristic curve: Diagram of the reactive
power characteristic curve (only if prescribed for the set country)
nNetwork: Network parameters, partially configurable under Settings
▶Network
–Host name: Unique name in the network
–DHCP status: DHCP on/o
–Link status: Status of the network connection
–IP address: IP address of the inverter
–Subnet mask: Subnet mask of the inverter
–Gateway: IP address of the network gateway
–DNS address: IP address of the DNS server
–MAC address: Hardware address of the inverter
nResults of the last self-test (only if in the country setting Italy is set)
3.3.3 Settings
When performing numerical settings of remuneration and dates, the fol‐
lowing applies:
Remuneration
nPossible currencies: £ (Pounds), € (Euros), kr (Krones),
none.
nThe maximum value that can be set for remuneration is limited for tech‐
nical reasons. The remuneration must be set using dierent units as
required. Example: Dollars instead of Cents (set currency to
none ).
①Designation of the numerical setting
②Value to be set; the selected value to be set is highlighted in black.
Date
When setting the month/year, a check is performed to ensure that the
selected day is valid. If not, then the day is automatically corrected.
Example: 31.02.2011 is corrected to 28.02.2011.
Information
Numerical settings
Structure and function
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Selection of the measurements to be shown in the status display. The fol‐
lowing measurements can be selected:
nOutput power: Inverter output power1)
nCurrent day yield: Day yield since 0:00
nPV voltage: The voltage supplied by the PV generators
nPV current: The current supplied by the PV generators
nGrid voltage: Voltage at the inverter connection1)
nGrid current: The current fed into the mains grid
nGrid frequency: The frequency of the public grid
nInternal temperature: Internal temperature of the inverter
nDerating Reason for derating2)
nMax. daily power: The maximum power supplied in the current
day3)
nAbs. max. power: The maximum power ever fed into the grid3)
nMax. daily yield: The maximum daily yield achieved3)
nOperating hours: The operating hours during which the device has
been connected to the grid (including night-time hours).
nTotal yield: Yield since commissioning
nCO2savings: CO2savings achieved since commissioning
1) Measurement is always displayed (cannot be switched o)
2) Possible causes:
–Internal temperature too high
–User default
Power limiter
–Frequency too high
–Controlled by grid operator (feed-in management)
–Delayed increase in power after starting
3) Can be reset to 0 via Settings ▶Reset max. vals.
An acoustic alarm sounds (approx. 4.5 kHz) when an event message is
displayed.
n2 Sounds: Warning
n3 Sounds: Error
The acoustic alarm is switched o with the factory default settings.
Selection of the measure‐
ments
Acoustic alarm
Structure and function
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noff
nautomatic: Switches on for 30 seconds when a button is pushed
nGrid feed: (factory setting)
–
Not feeding : Switches on for 30 seconds when a button is pushed;
then switches o
– Feeding : Switches on for 30 seconds when a button is pushed; then
dims
– A prerequisite for this is that you know the parameters
required for setting up the TCP/IP network connection.
Consult (further) technical professionals if required.
– DHCP is activated in the device ex-works. This allows
automatic integration of the device in most networks.
Network settings, required for network communication, e. g. with an
Internet portal:
nDHCP: Switch DHCP on/o
nIP address: IP address of the inverter
nSubnet mask: Subnet mask of the inverter
nGateway: IP address of the network gateway
nDNS address: IP address of the DNS server
nweb-portal: Settings at the web portal
–Web portal setting: Disabling of data transmission and selec‐
tion of a web portal
–Connection check: Checks the internet connection and indicates
the result
3.3.4 Service menu
The service menu items are described below. Some items are password
protected; see ÄFurther information on page 47 (menu structure)
You can obtain the password from technical support; see
ÄChapter 11 „Contact“ on page 76 .
NOTICE!
Risk of reduced yields. In the service menu, inverter and grid
parameters can be changed. The service menu must only be
operated by a specialist, who ensures that the change does
not violate applicable regulations and standards!
Backlight
TCP/IP network
Structure and function
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The inverter output power can be manually limited to a minimum of 500 W.
When the power is manually limited, the Power reduction symbol is shown
in the status display and the „Derating“ / „Cause: User default“ measure‐
ment is displayed.
The device can regulate the input voltage to a manually adjustable value.
This switches o the automatic setting of the MPP (MPP tracking). The
input voltage can be adjusted over a range between the maximum and
minimum input voltage and the minimum input voltage in 1V steps.
Exemplary application: Hydroelectric installation
NOTICE!
Before setting a fixed input voltage, make sure that the PV
generator is suitable for this. Otherwise, this may result in
yield losses or damage to the system.
After the country setting has been deleted the device restarts anew and
displays the guided 1st commissioning menu.
Resetting the device to the factory setting deletes the following data:
nYield data
nEvent messages
nDate and time
nCountry setting
nDisplay language
nNetwork settings
After the factory setting has been deleted, the device restarts anew and
displays the guided 1st commissioning menu.
Power limiter
Fixed voltage
Delete country setting
Factory setting
Structure and function
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The following voltage limits can be changed:
nUpper disconnection value1)
nLower disconnection value1) (Fig. left)
1) The disconnection value relates to the peak value of the voltage.
The following frequency limits can be changed:
nUpper disconnection value
nLower disconnection value (Fig. left)
nDerating switch-on threshold (because frequency is too high)
nFrequency threshold when switching on again
The following voltage limits can be changed:
nUpper disconnection value1) (Fig. left)
nLower disconnection value1)
1) The disconnection value relates to the average value of the voltage.
Overview:
The reactive power characteristic curve must be set during 1st commis‐
sioning if this is prescribed for the previously selected country. The fol‐
lowing applies:
n3 characteristic curves are available for selection (Fig. left):
–Default. char. curve (pre-defined)
–Enter char. curve (manually adjustable)
–Char. curve cos φ = 1 (pre-defined)
nAfter configuration, the characteristic curve is displayed as a graph
(example in Fig. left).
①x-axis, output power P in %
②y-axis, phase shift cos φ
③Nodes (in example: 4 nodes)
④Arrow symbol Overexcitation
⑤Arrow symbol Underexcitation
Technical details
Voltage limits (peak value)
Frequency limits
Voltage limits ø (average
value)
Reactive power charac‐
teristic curve
Structure and function
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nEach characteristic curve is defined by 2 to 8 nodes.
nA node is defined by the output power P of the inverter (x-axis) and the
associated phase shift (y-axis).
nThe phase shift can be set over a range of 0.95 (overexcitation) through
1.00 (no phase shift) to 0.95 (underexcitation).
nThe type of phase shift is shown in the graph using arrow symbols
defined as follows (defined from the point of view of the inverter):
Overexcitation, inductive
Underexcitation, capacitive
nThe 3 characteristic curves available for selection have the following
properties:
Default char. curve: pre-defined according to the selected
country (example in Fig. left).
Char. curve φ = 1: pre-defined with cos φ = constantly 1.00. This
characteristic curve must be selected if no reactive power control is to
be performed on the device.
Enter char. curve: The number of nodes and their x/y values can
be configured. Exceptions: The first node is always at x (P %) = 0 %,
the last always at x (P %) = 100 %.
Service technicians can use this menu item for changing additional MSD
parameters.
3.4 Cooling
The internal temperature control system prevents excessive operating tem‐
peratures. When the internal temperature is too high, the inverter adjusts
the power consumption from the PV generators to reduce the heat dissipa‐
tion and operating temperature.
The inverter is convection cooled via fins on the front and rear side. A
maintenance-free fan circulates the heat within the closed housing evenly
over the entire surface of the housing.
3.5 Grid monitoring
The inverter constantly monitors the mains grid parameters while feeding
the grid. If the grid deviates from the legally prescribed specifications then
the inverter automatically switches o. When the grid conforms to the
legally prescribed specifications then the inverter automatically switches
on again.
All parameters
Structure and function
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