KStar KSG-10K User manual

201402 ︳ Ver 1.0
User Manual
Solar InverterSolar Inverter
KSG-10K/12K5/15K/17K/20KKSG-10K/12K5/15K/17K/20K

Installation and Opertion Manual 1
Table of Contents
1. Introduction for Signs .................................................................... 4
2. Introduction.................................................................................... 5
2.1 Preface..................................................................................... 5
2.2 PV Grid-connected Generating System .................................. 5
2.3 How to Use This Manual ........................................................ 5
3. Safety Instructions ......................................................................... 6
4. Overall Introduction....................................................................... 7
4.1 Circuit Structure ...................................................................... 7
4.2 Description for External Interface........................................... 8
5. System Operation........................................................................... 9
5.1 System Mode........................................................................... 9
5.2 Grid-connected Operation....................................................... 9
5.3 System Shutdown................................................................... 11
5.4 Error and Alarm...................................................................... 11
5.5 Type of system fault and trouble shooting ............................. 13
6. Human-machine Interface............................................................. 15
6.1 LCD controlled panel............................................................. 15
6.2 Networking for monitoring .................................................... 16
6.3 WLAN (optional) ................................................................... 17
6.4 Remote control ....................................................................... 17
7. LCD Operation Menu ................................................................... 18
7.1 Initialization ........................................................................... 18
7.2 Major cycle menu................................................................... 18
7.3 User interface ......................................................................... 20
7.4 Setting .................................................................................... 20

Installation and Opertion Manual 2
7.4.1 Input mode...................................................................... 21
7.4.2 Standard for electric network ......................................... 21
7.4.3 Remote CTRL................................................................. 21
7.4.4 Working parameters........................................................ 22
7.4.4.1 Starting-up voltage.................................................. 22
7.4.4.2 Starting-up timelag ................................................. 22
7.4.4.3 Low voltage of electric network ............................. 23
7.4.4.4 High voltage of electric network ............................ 23
7.4.4.5 Low frequency of electric network......................... 23
7.4.4.6 High frequency of electric network ........................ 24
7.4.4.7 Please starting-up again .......................................... 24
7.4.5 485 address ..................................................................... 24
7.4.6 485 baudrate ................................................................... 25
7.4.7 Display language ............................................................ 25
7.4.8 LCD backlight ................................................................ 25
7.4.9 Date/time ........................................................................ 26
7.4.10 History clearing ............................................................ 26
7.4.11 Password setting ........................................................... 27
7.5 Inquiry .................................................................................... 27
7.5.1 INV MODEL.................................................................. 28
7.5.2 MODEL SN.................................................................... 28
7.5.3 Firmware......................................................................... 28
7.5.4 RECORD........................................................................ 29
7.6 Statistics ................................................................................. 30
7.6.1 Time statistics ................................................................. 30
7.6.2 Times of paralleling in.................................................... 30
7.6.3 Power peak ..................................................................... 31

Installation and Opertion Manual 3
7.6.4 Generated energy of that day.......................................... 31
7.6.5 Generated energy of that week ....................................... 31
7.6.6 Generated energy of that month ..................................... 31
7.6.7 Generated energy of that year......................................... 32
7.6.8 Gross generation............................................................. 32
8. Installation..................................................................................... 33
8.1 Overview ................................................................................ 33
8.2 Mechanical installation .......................................................... 34
8.2.1 Installation introductions................................................ 34
8.2.2 Mechanical dimension.................................................... 34
8.2.3 Packing .......................................................................... 36
8.2.4 Installation of Inverter .................................................... 36
8.2.5 Installation Location....................................................... 37
8.2.6 Installation Procedure..................................................... 37
8.2.7 Ambient requirement...................................................... 39
8.3 Electric connection................................................................. 39
8.3.1 Requirement for electric installation .............................. 39
8.3.2 Wire for alternating current connection.......................... 40
8.3.3 Wire for direct current connection.................................. 41
8.3.4 Wire for communication connection .............................. 42
8.4 Starting and closing................................................................ 43
9. Technical Data............................................................................... 44
10. Appendix .................................................................................... 45
10.1 Quality assurance ................................................................. 45

Installation and Opertion Manual 4
1. Introduction for Signs
In order to make a better use of this manual, please read the following
sign explanation carefully.
Warning!
This sign indicates that it may cause danger to safety of
users and/or attentions or instructions for possible serious
damage to hardware.
Instruction!
This sign indicates important attentions required for good
operation of the system.

Installation and Opertion Manual 5
2. Introduction
2.1 Preface
Dear users, thank you for using photovoltaic grid-connected inverter
products manufactured by Kstar which is experienced in development
of photovoltaic grid-connected generating sets. We hope this product
can meet your demands and welcome you to put forward more
suggestions on performance and functions of this product.
2.2 PV Grid-connected Generating System
The photovoltaic grid-connected generating system is composed
of solar cell module, grid-connected inverter, metering devices and
power distribution system (as shown in Figure 1). The solar energy
is converted to DC electric power through solar cell module, which
is further converted to sine-wave current synchronous with grid
frequency and phase via grid-connected inverter. Such electric power
is then fed into power grid. The photovoltaic grid-connected inverter
is the key equipment in solar power system.
Figure 1: Application of Photovoltaic Grid-Connected Inverter in
Photovoltaic Generating System.
2.3 How to Use This Manual
This manual aims to provide detailed product information and
installation & use instructions for users of KSG-10K/12K5/15K/
17K/20K photovoltaic grid-connected inverter manufactured by this

Installation and Opertion Manual 6
company. Please read this manual carefully prior to use of this product
and store it properly in a place where it is convenient for installation,
operation and available for maintenance personnel.
3. Safety Instructions
Please read this manual carefully prior to installation. This►
company assumes no responsibility for quality assurance upon
equipment damage due to installation failing to follow instructions
in this manual.
All operations and wiring shall be conducted by professional►
electrical or mechanical engineer.
Do not move other parts inside the machine case except the►
binding post during installation.
All electrical installations must conform to local standards for►
electrical installation.
Please contact with local appointed personnel for system►
installation and maintenance if this equipment requires the
maintenance.
Use of this equipment for grid-connected power generation must►
be approved by local power supply departments.
When the photovoltaic array is installed in the day, it shall be►
covered with lightproof materials; otherwise the array end will
subject to high voltage under exposure of sunlight, thus causing
personal risk.
Warning! Ensure that the input DC voltage does not
exceed 900V since higher input voltage may damage
this equipment permanently and causing other losses,
under which circumstance, this company assumes no
responsibility for quality assurance and joint responsibility

Installation and Opertion Manual 7
4. Overall Introduction
4.1 Circuit Structure
Figure 2 shows main circuit of KSG-10K/12K5/15K/17K/20K
inverter by which the direct current is input via three-phase full-
bridge circuit and transformed into sine-wave current through filter
and output to power grid. To make the photovoltaic array generate
in maximum power, the new type power devices are adopted for this
machine and the advanced MPPT algorithm is used at the DC side.
Figure 2: Main Circuit of KSG-10K/12K5/15K/17K/20K Inverter

Installation and Opertion Manual 8
4.2 Description for External Interface
Figure 3: Interface of KSG-10K/12K5/15K/17K/20K Inverter
Instructions for Interface
■
1: DC Input: DC input terminal, connected to positive and negative►
electrode input of photovoltaic array respectively.
2: AC OUTPUT:AC output, spaced by three phases AC switch and►
connected to L1, L2, L3, N and GND of three-phase grid.
3: Communication Interface RS232: connected with PC via joint►
RS232.
4: Communication Interface RS485: wire RS485A/B is connected►
with PC via converter RS485/ RS232.(When two or more inverters
are in parallel communication, 2P DIP switch beside RJ45 of the
last one should be “ON”. Or else, it may cause communication
interruption.That 2P DIP switch is on, means connecting a 120Ω
communication terminal resistance between the R/T + and R/T - )
5. DC switch: can judge the►positive and negative electrode input
of photovoltaic array(option).
6. WIFI port.(option)►
The inverter is equipped with WIFI port. If you need to
use WIFI function, please choose to use the External WIFI
& Ethernet Box. WIFI communication can be single or
network used, 32 PCs at most.
5. DC-Switch
(Option)
1. DC Input 3. RS-232
6. WIFI port
4. RS-485
2. AC OUTPUT

Installation and Opertion Manual 9
5. System Operation
5.1 System Mode
The operation modes of KSG-10K/12K5/15K/17K/20K grid-
connected type inverter include the initialization, waiting, self-
checking, grid-connected operating and error modes.
Initialization mode: the internal data will be initialized upon►
power on of controller.
Waiting mode: the inverter will be under waiting mode if the►
output voltage of PV battery board is low and it has not detected
any fault.
Self-checking mode: self-checking will be conducted by inverter►
each time prior to grid-connected operation. The inspection items
include: inspection on insulation impedance at DC side, self-
checking for leakage current detection function and inspection on
AC output relay.
Grid-connected operating mode: the direct current of PV battery►
board is converted to alternating current by the inverter for grid-
connected operation. The advanced MPPT algorithm is adopted
for controller, making the inverter operating at the maximum
power point of PV arrays.
Error mode: the inverter will enter error mode when grid voltage/►
frequency is abnormal or fault arises during grid-connected
process. At this time, it will stop transformation of electric energy
and cut away from the grid.
5.2 Grid-connected Operation
Prior to grid connection of the inverter, please confirm if the wirings
among input side of inverter, PV arrays, output side and power grid
are all correct. Three kinds of modes are optional for connection
between DC input side of KSG-10K/12K5/15K/17K/20K grid-
connected inverter and PV arrays:

Installation and Opertion Manual 10
Independent input mode: three groups of different PV arrays may►
be connected to input end of inverter and independent MPPT
controller is available for each group of PV arrays to control grid-
connected operation.
Figure 4: Independent Input Mode
Parallel input mode: only one group of PV arrays is connected►
with input end of the inverter, which is then connected to input
side of inverter via three groups of parallel input terminals.
Figure 5: Parallel Input Mode
Mixed input mode: two groups of different PV arrays may be►
connected to input end of inverter, where one group of PV arrays
is required to lead out two lines of parallel input terminal and
connected to terminal PV1/PV2 at input side of inverter, while the
other group is connected to terminal PV3 at input side of inverter.
Figure 6: Mixed Input Mode

Installation and Opertion Manual 11
Users are required to set the item “Input Mode” under
LCD menu correctly based on actual conditions of
photovoltaic generating system and confirm that the mode
of connection at input side is consistent with setting (refer
to 7.4.1).
If both input and output wirings are correct and the power grid is free
of abnormal conditions, the inverter will enter waiting mode. The
grid connection of inverter will be started fully automatic. After PV
voltage is higher than Vpv, count down for grid connection will be
started automatically for controller and prepare for grid-connected
operation after delayed for Td. Manual setting is available for both
Vpv and Td through LCD panel.
5.3 System Shutdown
If grid-connected power of inverter is smaller than 100W
continuously, the alarm of “zero power” will emerge. After alarming
for one minute, the inverter will cut away from the grid and reenter
waiting mode.
The inverter will cut away from the grid upon discovery of any
abnormal condition during the grid-connected process.
5.4 Error and Alarm
The error and alarm information of KSG-10K/12K5/15K/17K/20K
photovoltaic grid-connected inverter refer to the following table:
Table 5.1 Working conditions and fault/alarm message
Working conditions Message display
in English Description
Normal working status
Inverter OFF No display PV voltage <180V,the inverter is
switched off
Inverter Stand-by Stand-by 210V< PV voltage <350V(adjustable)
Self-test Checking
PV voltage >350V(adjustable)，
the inverter get started and self-test
all modules

Installation and Opertion Manual 12
Normal Power Generation Normal
Generate AC power and feed to
municipal Grid after self-test is
completed
Monitoring parameter display
Instant Power Rate
& Volume Of Power
Generated
XXXX W/
XXXXX Kwh
Instant power rate & accumulated
power generated
Voltage And Current Of
PV1/PV2/PV3 Input
DC: XXX.X
VXXX.X A Voltage and current from PV arrays
Voltage And Current Of AC
output
AC: XXX.X V
XXX.X A Grid Voltage and current
System faulty display
AC Voltage Low F00 AC Voltage is too low.
AC Voltage High F01 AC Voltage is too high.
AC Frequency Low F02 AC frequency is too low.
AC Frequency High F03 AC frequency is too high.
Bus Voltage Low F04 Bus voltage is too low.
Bus Voltage High F05 Bus voltage is too high.
Bus Voltage Abnormal F06 Positive voltage or negative voltage
is too high or too low on bus.
Insulation Impedance Low F07 PV arrays Insulation impedance is
too low.
Input current high F08 PV Input current is too high.
Reserved F09 Reserved
Inverter Current High F10 Inverter current is too high.
Inverter DC Current High F11 Inverter DC current is too high.
Reserved F12 Reserved
Heatsink Temperature High F13 Heatsink temperature is too High.
AC Relay Abnormal F14 AC relay is abnormal.
PV Input Voltage Low F15 One of PV input is idle when
inverter is set on parallel mode.
Remote Off F16 Status of inverter is on remote off.
Reserved F17 Reserved
SPI Communication Fault F18 Communication fault on control
board.
Reserved F19 Reserved
Leakage Current High F20 Leakage current is too high.
Self-Checking Failure Of
Leakage Current F21 Self-checking Failure of Leakage Current.
Consistency Voltage Fault F22 Inconsistent voltage between
primary CPU and secondary CPU.
Consistency Frequency
Fault F23 Inconsistent frequency between primary CPU and secondary CPU.

Installation and Opertion Manual 13
DSP Operation Fault F24 DSP communication faulty on
control board.
DSP Communication Lost F32 DSP communication faulty on
control board.
Table 5.2 Alarm Information
Alarm message Alarm code Solutions
Speed Low Of Fan_A W00 Alarm message for speed low of Fan_
A.
Speed Low Of Fan_B W01 Alarm message for speed low of Fan_
B.
Speed Low Of Fan_C W02 Alarm message for speed low of Fan_
C.
Zero Power W03
It is only a reminding message to show
DC inputs very low and inverter is
about to shut down.
5.5 Type of system fault and trouble shooting
Table 5.3 Type of system fault and trouble shooting
Trouble Shooting
Alarm Message Solution
System
Faulty Or
Failure
Type
AC voltage &
frequency are too
high or too low.
(F00-F03)
(1)Pease check mains voltage whether it is complied with local
safety standard
(2)Please check the AC output line is properly connected. Make
sure its output voltage to see if it is normal.
(3)Disconnect PV input and restart the inverter and check whether
fault still exists.
(4)Contact with your local distributor if the fault still exists.
Bus voltage is too
high or too low
(F04-F05)
(1)Please check the setting of input mode.
(2)Disconnect PV input and restart the inverter and check whether
fault still exists.
(3)Contact with your local distributor if the fault still exists.
Bus Voltage
Abnormal
(F06)
(1)Please check the setting of input mode.
(2)Please try to restart inverter every few minutes for several times
and check whether fault still exists.
(3)Contact with your local distributor if the fault still exists.
Insulation
impedance
Fault(F07)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Please measure impedance of PV+/PV- to ground whether is over
than 500KΩ.
(3)Please contact your local distributor if impedance is less than
500KΩ.

Installation and Opertion Manual 14
Input Current High
(F08)
(1)Please check the setting of input mode
(2)Disconnect PV input and restart the inverter and check whether
fault still exists.
(3)Contact with your local distributor if the fault still exists.
Inverter Current
High (F10)
(1)Disconnect PV input and restart the inverter after few minutes
and check whether fault still exists.
(2)Contact with your local distributor if the fault still exists.
Inverter DC
Current high (F11)
(1)Disconnect PV input and restart the inverter after few minutes
and check whether fault still exists.
(2)Contact with your local distributor if the fault still exists.
Heatsink
Temperature
High(F13)
(1)Disconnect PV input and cool down the inverter then restart the
inverter to see if it is back to normal operation.
(2)Please check environmental temperature whether out of working
temperature.
(2)Contact with your local distributor if the fault still exists.
AC Relay Fault
(F14)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Contact with your local distributor if the fault still exists.
PV Input Voltage
Low
(F15)
(1)Please check the configuration of PV input, one of PV input is
idle when inverter is set on parallel mode.
(2)Disconnect the PV input and restart the inverter and check
whether fault still exists.
(3)Contact with your local distributor if the fault still exists.
Remote Off (F16) The inverter is on remote OFF status, the Inverter can be turned off/
on remotely by monitoring software.
SPI
communication
Fault (F18)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Contact with your local distributor if the fault still exists.
Leakage Current
High (F20)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Contact with your local distributor if the fault still exists.
Leakage Current
Self-Checking
Failure (F21)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Contact with your local distributor if the fault still exists.
Consistency
Voltage Fault (F22)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Contact with your local distributor if the fault still exists.
Consistency
Frequency Fault
(F23)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Contact with your local distributor if the fault still exists.
DSP Operation
Fault(F24)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Contact with your local distributor if the fault still exists.
DSP
communication
Lost (F32)
(1)Disconnect PV input and restart the inverter and check whether
fault still exists.
(2)Contact with your local distributor if the fault still exists.

Installation and Opertion Manual 15
6. Human-machine Interface
6.1 LCD controlled panel
There are 4 buttons and 4 LEDs installed on the panel of KSG-
10K/12K5/15K/17K/20K inverter, as shown in Figure 7.
Figure 7: LCD Controlled Panel
Table 6.1 Description for LED light
LED light Definition
WAIT Indicator light for waiting of paralleling in
NORMAL Indicator light for normal operation (generating electricity)
ALARM Indicator light for warning alarm
FAULT Indicator light for error (fault)
Table 6.2 Description for functions of buttons
Buttons Functions
ESC Return/Cancel/Exit
UP Upwards choice menu/increase value when setting parameters
DOWN Downwards choice menu/decrease value when setting parameters
ENTER Enter menu/confirm set value/move cursor
Note: press any button, backlight of LCD will last for a
certain period, specific time can be set in the menu.

Installation and Opertion Manual 16
6.2 Networking for monitoring
The inverter is provided with various kinds of communication
modes, when the user requires to monitor the running information of
photovoltaic power generation system, we will offer the following
design scheme for monitoring system.
The maximum distance of RS485 communication is about 1000m,
and device number should not be more than 32.
Intelligent cluster controller:
■
Figure 8: Data collector conducts monitoring through RS485
PC machine
■
■
Figure 9: PC machine conducts monitoring through RS485
Data collector+ PC machine
■
Figure 10: Data collector and PC machine conduct monitoring
through RS485

Installation and Opertion Manual 17
Inverter RJ45 Inverter RJ45
Pin NO. RS485 Pin NO. RS485
1 (A)T/R+ ►1 (A)T/R+
2 (B)T/R- ►2 (B)T/R-
3NC ►3NC
4NC ►4NC
5 GND ►5 GND
6NC ►6NC
7NC ►7NC
8NC ►8NC
Pin corresponding relationship between inverter and inverter unit.
6.3 WLAN (optional)
Equipped with WLAN/WIFI box, the inverter can realize Ethernet
wired/wireless multiple computer communication.
6.4 Remote control
The inverter can realize the remote SHUTDOWN and ON and power
limit regulatory function by the associated monitoring software.
Pin corresponding relationship
between inverter and GPRS/
Wifiunit.

Installation and Opertion Manual 18
7. LCD Operation Menu
7.1 Initialization
Interface Explanation
During initialization…
please wait!
After starting-up of inverter,
LCD will firstly enter this interface, and
deliver parameters required by operation
of the machine to DSP.
7.2 Major cycle menu
After initialization, LCD will enter a major cycle menu to display
running information of the inverter in a circulating mode, including
10 interfaces for network voltage, frequency of electric network, etc.
Time for automatic switch-over between interfaces is 3 seconds, also
the interfaces can be switched manually by pressing UP or DOWN
buttons, if you want to fix at a certain interface, press ENTER to
lock this interface, after successful locking, a lock icon will occur at
upper right corner of this interface, press ENTER button again, this
interface will be unlocked, and the menu will continue to display in a
circulating mode.

Installation and Opertion Manual 19
Figure 11: Interface of recycling display
When the menu is in an automatic cycling display mode, if error
(fault) or warning alarm occurs, it will skip into system interface
immediately and lock to it, and this will make convenience for the
user to determine its cause based on codes on the interface. After
disappearing of error (fault) or warning alarm, the menu will return
to automatic circulating mode. Press ESC button to exit major
circulating menu interface and enter user interface (refer to 7.3).
Display conversion
System
Mode: Initialization
Warning: XXX-X
Error: XXX-X
PV3 Input
Voltage: 550.0V
Current: 100.0A
Power: 10000W
PV2 Input
Voltage: 550.0V
Current: 100.0A
Power: 10000W
PV1 Input
Voltage: 550.0V
Current: 100.0A
Power: 10000W
Temperature
Fan: 50
Environment: 35
BUS Voltage
Positive BUS: 276.0V
Minus BUS: 274.0V
Network frequency
Grid-connected Current
Network voltage
Setting
Inquiry
Statistics Statistics
Inquiry
Setting
Power
PV input: 15002W
Paralleling in: 7002W