operating instructions - solar-go.co.uk

Powador XP500/550-HV-TL

Operating Instructionsn English Version

GM05201m

Operating Instructions Powador XP500/550-HV-TL

Operating Instructions- English Version -

Powador XP500/550-HV-TL

General Instructions for Installers and Operators

1 General Notes ........................................4

1.1 About this documentation ....................... 4

1.2 Name plate .............................................. 6

1.3 Intended use ............................................ 7

1.4 Safety instructions .................................... 7

2 Service ....................................................8

3 Unit Description ....................................9

3.1 Technical Data .......................................... 9

3.2 Dimensions ............................................ 11

3.3 Components inside the inverter .............. 13

4 Transportation and Delivery ..............15

4.1 Delivery .................................................. 15

4.2 Transportation ........................................ 15

5 Storage/Installation/Start-up .............16

5.1 Storage ................................................. 16

5.2 Transporting the unit to the installation location ................................................. 16

5.3 Selecting the installation location ........... 17

5.4 Electrical connection .............................. 18

5.5 Start-up ................................................. 26

5.6 Operation .............................................. 28

5.7 User interface ......................................... 31

5.8 MMI menu structure and details ............. 32

5.9 MMI main menu .................................... 33

5.10 MMI submenus ...................................... 35

6 Faults and Warnings ...........................45

6.1 Warning ................................................. 45

6.2 Fault .......................................................46

6.3 Solution for Error code ...........................48

7 Maintenance/Cleaning........................56

7.1 Maintenance intervals ............................ 57

7.2 Cleaning and replacing the fans ............. 58

8 Parameters ...........................................59

8.1 PV Array parameters .............................. 59

8.2 Inverter parameters ................................ 61

8.3 Grid parameters ..................................... 61

8.4 Time Parameters..................................... 70

8.5 Digital Parameters ................................. 70

8.6 Analog Parameters ................................ 71

8.7 Controller Parameters ............................ 72

9 User interface ......................................88

9.1 External TO AC Power supply ................ 89

9.2 Digital Input/output ............................... 89

9.3 RS485 Interface .................................... 93

9.4 Analog input .......................................... 95

10 Overview circuit Diagram ...................98

11 Decommissioning/Dismantling ..........99

12 Disposal .............................................100


General Notes

1 General Notes

1.1 About this documentation

WARNINGImproper handling of the inverter can be dangerous

› You must read and understand the operating instructions before you can install and use the inverter safely.

1.1.1 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. Some of the documents which are required to register your photovoltaic system and have it approved are included with the operating instructions.

1.1.2 Retention of documents

These instructions and other documents must be stored near the system and be available whenever they are needed.


General Notes

1.1.3 Description of safety instructions

DANGERImminent danger

Failure to observe this warning will lead directly to serious bodily injury or death.

WARNINGPotential danger

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.

ATTENTIONHazard with risk of property damage

Failure to observe this warning will lead to property damage.

NOTEUseful information and notes.


General Notes

1.1.4 Symbols used in this document

General danger symbol Information

High voltage Risk of burns

1.1.5 Description of actions

Action

" Perform this action

" (Possibly additional actions)

The result of your action(s)

1.1.6 Abbreviations

MMI Man Machine Interface RPC Remote Power Control

PEBB Power Electronics Building Block APS Anti –islanding method

PSI PEBB Signal Interface board ACI protocol

Advanced Communication Interface (KACO Communication protocol)

ASI Analog Signal Interface board PLL Phase Locked Loop

GUI Graphic User Interface XCU XP Control Unit (Inverter control system)

MPPT Maximum Power Point Tracking CAN Controller Area Network

MPP Maximum Power Point FPGA Field-Programmable Gate Array

Vdc PV Voltage DSP Digital Signal Processor

FRT Fault Ride Through ADC Analog to Digital Converter

CEI 0-21 Italia grid code NVSRAM Non-volatile Static RAM

1.2 Name plateThe name plate is located on the inside of the left door of the two housing components.


General Notes

1.3 Intended useThe inverter converts the DC voltage generated by the photovoltaic (PV) modules into AC voltage and feeds this into the power grid. The inverter is built according to the state of the art and recognized safety rules. Neverthe-less, improper use may cause lethal hazards for the operator or third parties, or may result in damage to the unit and other property. The inverter may be operated only with a permanent connection to the public power grid.

Any other or additional use is not considered the intended use. Examples of unintended use include:

•Mobile use

•Use in rooms where there is a risk of explosion

•Use in rooms where the humidity is higher than 95%

1.4 Safety instructions

DANGERLethal voltages are still present in the terminals and lines of the inverter even after the inverter has been switched off and disconnected!

Coming into contact with the lines and terminals in the inverter will cause serious injury or death.

Only authorised electricians who are approved by the supply grid operator are allowed to open, install and maintain the inverter.

› Keep all doors and covers closed when the unit is in operation.

› Do not touch the lines and terminals when switching the unit on and off!

The electrician is responsible for observing all existing standards and regulations.

•Above all, be sure to observe standard IEC 60364-7-712:2002, “Requirements for Special Installations or Locations – Solar Photovoltaic (PV) Power Supply Systems”.

•Ensure operational safety by providing for proper earthing, conductor dimensioning and appropriate protection against short circuiting.

•Observe the safety instructions located on the inner sides of the doors.

•Switch off all voltage sources and secure them against being inadvertently switched back on before per-forming visual inspections and maintenance.

•When taking measurements while the inverter is live:

– Do not touch the electrical connections.

– Remove jewelry from your wrists and fingers.

– Make sure that the testing equipment is in good and safe operating condition.

•Stand on an insulated surface when working on the inverter.

•Generally, the inverter may not be modified.

•Modifications to the surroundings of the inverter must comply with national and local standards.


Service

2 Service

If you need help solving a technical problem with one of our KACO products, please contact our service hotline. Please have the following information ready so that we can help you quickly and efficiently:

•Inverter type / serial number

•Fault message shown on the display / Description of the fault / Did you notice anything unusual? / What has already been done to analyse the fault?

•Module type and string circuit

•Date of installation / Start-up report

•Consignment identification / Delivery address / Contact person (with telephone number)

You can find our warranty conditions on our website:

http://kaco-newenergy.de/de/site/service/garantie

From there, you can easily navigate to our international websites by clicking on the appropriate flag. Please use our website to register your unit within 24 months:

http://kaco-newenergy.de/en/site/service/registrieren

You can also select the appropriate flag on this page to access the website for your own country.

In this manner, you can assist us in providing you with the quickest service possible. In return, you receive two additional years of warranty coverage for your unit.

Note: The maximum length of the warranty is based on the currently applicable national warranty conditions.

We have prepared a template for complaints. It is located at http://www.kaco-newenergy.de/en/site/service/kundendienst/index.xml.

Hotlines

Technical troubleshooting Technical consultation

Inverters (*) +49 (0) 7132/3818-660 +49 (0) 7132/3818-670

Data logging and accessories +49 (0) 7132/3818-680 +49 (0) 7132/3818-690

Construction site emergency (*) +49 (0) 7132/3818-630

Customer helpdesk Monday to Friday from 7:30 a.m. to 5:30 p.m. (CET)

(*) Also on Saturdays from 8:00 a.m. to 2:00 p.m. (CET)


Unit Descr ipt ion

3 Unit Description

3.1 Technical Data

Model XP500-HV-TL XP550-HV-TL

DC Input

PV Max. generator Power 600kW 660kW

MPP range 550V ~ 830V

Operating DC voltage range 550V ~ 1000V

Max. permissible DC voltage 1100V1*

Max. permissible DC current 1091A 1200A

Number of DC inputs 6

AC Output

Rated power 500kVA 550kVA

Grid voltage 3*370V (±10%)

Rated current 780A 858A

Grid frequency 50Hz / 60Hz

THD of grid current < 3% at rated power

power factor (cos θ) ≥ 0.99 at rated power

0.8 leading … 0.8 lagging (Adjustable)

Power Consumption

Internal consumption in operation < 1% of rated power (< 1650W)

Internal consumption in stand-by < Approx. 110W

External auxiliary supply voltage 208V ~ 240V, 50Hz / 60Hz

Efficiency

Max. efficiency 98.7% 98.7%

Euro efficiency 98.2% 98.2%

Environment

Operating temperature range -20°C ~ +50°C

Storage temperature range -20°C ~ +70°C

Relative humidity 0 ~ 95% (non condensing)

Max. altitude above mean sea level 2000m (as per IEC 62040/3)

Cooling Forced Fan

Audible noise < 70dB

Table 1: Electrical data of the inverter

1*1100Vdc is no-load voltage. And max. operating voltage is 1000Vdc


Unit Descr ipt ion

Model XP500-HV-TL XP550-HV-TL

Protection class IP21

indoor use only according IEC 62109-1:2010

Physical Parameters

Dimensions(H/W/D) in mm 2120 / 2400 / 870

Weight 1656Kg

Power Density 0.1130W/cm3 0.1242W/cm3

Standard

EMC EN61000-6-2, EN61000-6-4, EN61000-3-3, EN61000-3-12

Certificates CE, KTL

Grid monitoring In accordance with BDEW directive

ENEL 2010

RD1663

In accordance with BDEW directive

RD1663

Features

Display TFT- LCD with Touch screen

Ground fault detection Yes

Heating Yes

Emergency stop Yes

Overvoltage protection device AC / DC

Yes / Yes

Overvoltage protection for Ethernet Yes

Overvoltage protection device for auxiliary supply

Yes

Interfaces

Communication 2 × RS485 / Ethernet / USB

Analog input 4 × UAI2*

Argus box string-monitor RS485

User Digital Input / Output3* 1 / 1

S0 input / output4* 1 / 1

Table 1: Electrical data of the inverter

2*UAI: User Analog Input. 4 inputs are 1×irradiation input, 1×module temperature, 1×ambient temperature, 1×wind speed. (Option)3*UDIO: User Digital Input - 1×Start/Stop signal of the inverter. User Digital Output - 1×External fault signal.4* So-impulse signal for energy meter.


Unit Descr ipt ion

3.2 Dimensions

Figure 1: Dimension of the inverter [mm]

Figure 2: Dimension of the inverter base Bottom View (Cable Entry) [mm]


Unit Descr ipt ion

Figure 3: Dimension of the inverter base Bottom View (Anchor Bolt) [mm]


Unit Descr ipt ion

3.3 Components inside the inverter

Left side

18

19

1

2

3

45

6

7

89

15

14

17

16

13

1211

10

Figure 4: Components inside the inverter (left side)

Key

1 Ground fault detection (Voltage type) 11 Control power transformer

2 PSIM (Master control for interface) 12 DC connection

3 24V voltage supply EMC Filter for control power

13 DC fuses

4 24V voltage supply 14 Overvoltage protection (SP1 - DC side)

5 Control system 15 DC switch

6 Fuse protection for voltage supply circuit breaker for control power Overvoltage protection (SP3 - Control power side, SP4 - Ethernet side)

16 Heater

7 Terminals for user connection 17 DC current transformer

8 Earthing bar 18 PEBB (IGBT block)

9 FRT diode 19 Door sensor

10 FRT transformer


Unit Descr ipt ion

Right side

1011

1

2

3

4

9

8

7

6

5

Figure 5: Components inside the inverter (right side)

Key

1 EMC Filter (Grid side) 7 Circuit breaker for control power,

AC Overvoltage protection (SP2 - AC side)

2 AC switch 8 AC current transformer

3 LC filter (inductor) 9 AC contactor

4 AC(grid) connection to the External trans-former

10 AC fan

5 Earthing bar 11 Door sensor

6 LC filter (capacitor)


Transportat ion and Del ivery

4 Transportation and Delivery

4.1 DeliveryThe inverters leave our factory in proper electrical and mechanical condition. Special packaging ensures that they are transported safely. The shipping company is responsible for any damage that occurs during transporta-tion.

4.1.1 Scope of delivery

•Powador XP500/550-HV-TL

•Documentation

Check your delivery

" Inspect the inverter thoroughly.

" Notify the shipping company immediately if you discover any damage to the packaging which indicates that the inverter may have been damaged or if you discover any visible damage to the inverter.

" Send the damage report to the shipping company right away. It must be received by them within six days following receipt of the inverter. We will be glad to help you, if necessary.

4.2 TransportationThe inverter should be shipped using the original packaging to ensure that it is transported safely.

Each of the two inverter cabinets is delivered on a pallet.

CAUTION

Impact hazard, risk of breakage to the inverter

The centre of gravity is located in the upper part of the inverter.

› Transport the inverter in an upright position.


Storage/ Instal lat ion/Start-up

5 Storage/Installation/Start-up

5.1 StorageWhen inverters are in storage, the following conditions are required. If not, this may cause failures. The com-pany will not be responsible for the problems if following condition is not observed.

•The unit should be stored indoor in its original packaging when it’s being stored more than 6 months. If its original packaging is removed, it should be stored indoor in a cool, dry place.

•When the unit is stored outdoor, please keep the remained original packaging and do not leave the unit out-side more than 3 days.

•Storage temperature: -20°C ~ +70°C

•Relative humidity: 0% ~ 95% (Non-condensing)

•When inverter is stored under high humidity condition for long term period, it has to be dried out sufficiently more than 1 day before connecting to the power.

CAUTION

Inverter Storage Caution

Inverters need to be sotred at the correct temperature and correct humidity. If not, this may cause failures.

5.2 Transporting the unit to the installation location Once it has arrived at the installation location, the inverter may be transported using the designated eyebolts only. These are located on the top of the inverter housing.

CAUTION

Impact hazard, risk of breakage to the inverter

The centre of gravity is located in the upper part of the inverter.

› Transport the inverter in an upright position.

Transporting the inverter

" Transport the inverter in an upright position.

" Attach a rope (1) to the two eyebolts on the left.

" Attach a second rope (2) to the eyebolts on the right.

" Attach both ropes to a hook, making sure that the ropes do not cross each other.

" Position the hook at the middle of the unit.



(1)(2)

Figure 6: Transporting the unit at the installation location

5.3 Selecting the installation location

NOTEThe maximum flow rate of the cooling air is 6940m³ per hour. Please keep this value in mind when you select the installation location.

Floor•Must have adequate load-bearing capacity

•The building material must meet the requirements of building material class B1 (“Flame-resistant Building Materials”, in accordance with DIN EN 13501-1)

Room•Should be as dry as possible

•Must be indoors (IP21)

•The installation location must be climate-controlled in order to dissipate the waste heat

•Additional ventilation should be provided, if necessary

•Do not install in a room where there is a risk of explosion

Clearance between walls and ceiling•Must be accessible for installation and maintenance

•Air circulation may not be blocked

•You do not have to provide for clearance on the sides or to the rear of the unit

•Minimum clearance between unit and ceiling 60cm



Figure 7: Ventilation for the inverter [mm]

5.4 Electrical connection

DANGER

Lethal voltages are still present in the terminals and lines of the inverter even after the inverter has been switched off and disconnected!


Only authorised electricians who are approved by the supply grid operator may open, install and maintain the inverter.

› Use extreme caution when working on the unit.

› Disconnect the AC and DC sides.

› Secure them against being inadvertently switched back on.

› Connect the inverter only after the aforementioned steps have been taken.



5.4.1 Electrical connection between the inverter cabinets

An electrical connection must be made between the inverter cabinets. This applies to the controller as well as the bus bars. The bus bars are included with the inverter. They are placed in one of the cabinets.

Connecting the bus bars

" Slide the three bus bars through the upper opening in each of the housings.

" Use the screws that are supplied to screw down the bus bars on both sides (tightening torque: 25Nm).

Connecting the controller

" Pull the cables for the controller from the left cabinet through the lower opening in each of the hous-ings and into the right cabinet.

" Connect the cables for the controller in the right cabinet. The plug connectors are appropriately marked.

1

2

3

Figure 8: Electrical connection for the cabinets

Key

1 Bus bar connection on the left side 3 Controller connection on the right side

2 Bus bar connection on the right side



5.4.2 Protective earth connection

Connect the PE bus bars

The PE (protective earth) bus bars are located on the left and right sides of the inverter cabinets.

" Connect the wires for “both” PE bus bars.

Earth the inverter

" Determine the lay-out of the permanent wiring.

" Secure the protective earths (tightening torque for PE terminals: 25Nm). Do not use plug connections.

" Check whether all connected cables are securely attached and protected from mechanical forces.

" Attach the Plexiglas cover.

Figure 9: PE busbar



5.4.3 Connecting to the external transformer (AC connection)

The inverter is connected to the power grid using a 3-phase connection. The connection for the power grid is located in the right side of the housing, at the bottom.

Use the screws that are supplied to screw down the bus bars on both sides.

Connection data

Number of AC Cables (A,B,C) 6

Max. Cable diameter for each phase 300mm2 x 2

Tightening torque for AC terminal connections 43Nm

Cable lug hole size 12mm ~ 14mm

Connect the cables

Each cable corresponds to one phase.

" Guide the cables through the opening. Be sure to connect each of the cables to the correct terminal.

" Screw down the cables.

" Check to make sure that all of the cables are securely attached.

R S T

Figure 10: AC connection



5.4.4 Connection for the PV generator (DC connection)

The DC connection is located in the left side of the housing, at the bottom.

Connection data

DC input terminal +6, -6

Max. Cable diameter for each fuse 240mm2 x 2

Tightening torque for DC terminal connections 43Nm

Cable lug hole size 12mm ~ 14mm

DANGER

Lethal voltages in the PV system

Lethal voltages are present in the PV system.

› Make absolutely sure that the plus and minus poles are properly insulated.

Connect the cables

Each cable corresponds to a specific pole.

" Connect the cables to the poles. Make sure the polarity is correct.

" Screw down the cables.

" Check to make sure that all of the cables and seals are securely attached.

P PP PP P N N NN N N

Figure 11: DC connection

NOTEUse only the optional earthing kit to earth the PV generator.



5.4.5 Connection for the DC Cable

Figure 12: Bolt & NH Fuse

Item Description

A M12 Bolt Fuse Cover-1

B Flat Washer Fuse Cover-2

C Spring Washer Fuse

D M12 Nut Fuse Base

Table 2: Parameters of operating states



Single-cable Dual-cable

1 1

2 2

3 3

4 4

NOTEBolt Torque: 43Nm



5.4.6 Connecting the external voltage supply

The external voltage supply supplies the MMI, fans, measurement equipment, etc.

Connect the external voltage supply

The connection for the additional power supply is located in the left side of the inverter housing.

" Connect the additional power supply to the terminals marked “TO” using single-phase 230V.

1

2

Figure 13: Connecting the external voltage supply

Key

1 User interface

2 TO (connection for auxiliary power supply) 230VL, 230VN (Max. Cable diameter - 2.5mm2)



5.5 Start-upThe circuit breakers must be switched on to start up the inverter. The circuit breakers switch on the control cir-cuits.

DANGER






Switch on the circuit breakers or Fuse

Step Check Action

1. Fuse F30, 31, 34, 35 Circuit breakers CB32, 38, 39, 40

ON " Proceed to Step 2

OFF " Switch on, then proceed to Step 2

2. Circuit breakers MCB20, 21 ON " Proceed to Step 3

OFF " Switch on, then proceed to Step 3

3. Circuit breakers CB33 or CB37 " Switch on

" Start up the inverter

NOTEFor NG and PG type Inverter, please do not operate MCB20 arbitrarily.

It may cause failure of the unit.



21, 3

Figure 14: Cabinet (interior view)

Key

1 Fuse F30, 31, 34, 35

Circuit breakers CB32, 38, 39, 40

2 Circuit breakers MCB20, 21

3 Circuit breakers CB33 or CB37

When voltage is present at the inverter, it can be started up. Use the MMI interface screen (located in the left side of the housing) to start up the inverter.

The inverter begins operation in a specified sequence. For more information, see section 5.2 (“Transporting the unit to the installation location”)

If a fault occurs, the inverter cannot begin operation. For more information on faults, see section 6 (“Faults and Warnings”).

Start up the inverter

Display Check Action

Error message on the MMI screen NO " Select the ON button

YES " Reset using “Fault reset"

" Select the ON button

NOTEIf the fault cannot be reset using “Fault reset”, please contact our service depart-ment.



ON OFF

Fault History Statistics Setup

701.0V 380.0V

75.8kW79.0kW45.0°C

Date/Time

Figure 15: MMI screen

5.6 Operation

DANGER






5.6.1 Operating states

The Inverter has seven operating states. The explanations about each state are below.

Disconnected (default) Before operation has commenced the inverter is in the disconnected state. In this state, the inverter is totally isolated from the PV array and the utility grid.

Connecting to the PV array When the inverter is in the “Disconnected” state, the ‘Inverter On’ button on the GUI is selected and the PV voltage is kept above 400V for 5 seconds, the system turns on the PV Array side contactor (PV_MC).

Connecting to Grid When the inverter is in the “Connecting to PV Array” state and the PV volt-age is kept above the value of “MPPT V Start” parameter during the time set by “MPPT T start” parameter, the contactor on the grid side is turned on. The inverter keeps this state for 8 seconds.

Initializing MPP The inverter calculates the MPPT start voltage which is product of measure-ment of PV voltage and the parameter “MPP Factor”. After 5 seconds, the inverter system enters into the “MPP start” state.

Table 3: Operating states



MPP start In this state, the inverter controls the PV voltage. Reference of the PV voltage is determined by MPPT start voltage which is calculated at “Initializing MPP” state.

MPPT If the PV voltage approximates the MPP start voltage (value of “MPPT V Start” parameter), the MPPT will start. The inverter follows the MPP target value automatically, which is varied by irradiance values. If the MPP target value is out of the allowable MPPT range ([MPP start voltage - MPP Range lower] ~ [MPP start voltage + MPP range upper]), the system will return to the “Initializing MPP” state and will recalculate the MPPT start voltage.

System stop (Disconnected) When the “OFF” button in the GUI is selected, the PV Array side contactor and the Grid side contactor are turned off and the system stops. If the output power of inverter is kept below value of “MPPT P stop” parameter during time of “MPPT T stop” parameter, connection to the grid is terminated.

Fault If a fault occurs during operation, the system stops. The system resets the fault and tries to remove the fault. In the case that system removes a fault successfully, system restarts all by itself. The system tries to remove the fault at intervals of “MPPT Start” parameter since the last try until trial count reaches to the number set in an “Auto Fault Reset Count” parameter. After the number reaches to the “Auto Fault Reset Count” parameter, the system will log an error and the system will not try to restart.

Table 3: Operating states



5.6.2 Overview of operating states

Figure 16: Overview of operating states

Tag Parameter Default Value

TShift Time Shift (Grid tab) 0 sec

Vpv_start MPPT V Start (PV Array tab) 600V (above 500kVA: 700V)

Tstart MPPT T Start (PV Array tab) HV model: 300 sec, TL model: 900 sec

Vmpp_min MPPT V Minimum (PV Array tab) 410V (above 500kVA capacity: 505V)

Pstop MPPT P Stop (PV Array tab) 10kW (below 100kVA capacity: 1kW)

Tstop MPPT T Stop (PV Array tab) HV model: 30 sec, TL model: 60 sec

Table 4: Parameters of operating states



5.7 User interfaceThe MMI has a graphic interface which you use to monitor and control the inverter. The MMI has the follow-ing functional features:

•The LCD screen displays the operating states, along with voltages, currents, frequencies, temperatures, out-put powers, status of errors/warning messages, and events. Pressing the MMI touch screen switches on the LCD backlight. If the display is not activated within five minutes, the LCD backlight switches automatically off.

•Touch screen for navigating through the menus SD card: the MMI continually records data to the SD card. When recording once every 10 minutes (around the clock), the maximum amount of data per year is 360KB. When the SD card is full, the oldest data is overwritten.

•Configuration of country-specific settings (power grid standard, maximum/minimum voltage/frequency)

•Ethernet interface for monitoring and service, network connection for remote use

•RS485 interface for logging and transferring data

•USB interface for connecting external units (e.g. laptop computer)

2

3

145

6

7

8

Figure 17: Front of the MMI Figure 18: Rear of the MMI

Key

1 Protective cover 5 Ethernet interface

2 MMI touch screen, LCD 6 RS232 interface (internal interface)

3 USB interface 7 RS485 interface

4 Power connection 8 SD card



5.8 MMI menu structure and detailsThe MMI menu is structured hierarchically.

•The blue areas (rounded corners) are functions that are activated by pressing a button.

•The green areas (square corners) are windows with additional content, such as submenus, measured values and buttons. These functions are reserved for authorized electricians.

Fault Reset

Calendar

Delete All Statistics

Power Meter Clear

Setup RS485 Interface

MMI

C6x

SD card safe-remove

Stop speaker

Stop Inverter

Start Inverter

Yellow: special functional buttons

Grid

Inverter

PV Array String monitoring

Blue: functional screens

Information

Software Upgrade

Service

Network

User configuration

Language & Country

RS485

Recording

Analog

Digital

Date/Time

Year

Month

Day

Setup

Statistics

History

Grid

Inverter

PV array

Fault

Cos-phi

Main menue

Figure 19: MMI menu structure



5.9 MMI main menu

ON OFF

Circuit breaker CB10 Speaker

SD cardCircuit breakers MC21 + CB20

Fault History Statistics Setup

701.0V 380.0V

75.8kW79.0kW45.0°C

Date/Time

Displayed button colors

Colour Meaning

Green Normal operation

RedFault (not for switches CB10, MC21 and CB20)

Grey Not in use

Figure 20: Display when the MMI starts up

5.9.1 Changing the SD card, status display

DANGER






Insert the SD card

“No SD in slot” icon

" Open the inverter. The inverter shuts down.

" Slide the SD card into the slot until it locks into place.

" Close the inverter.

" Press the ON button. The inverter starts up.

“SD card in slot” icon

The inverter checks the card. If the SD card was detected, the “SD card in slot” icon appears in the lower right-hand corner of the display.

" Press the SD card icon.

" Wait until the SAFE icon is displayed.



SAFE

Remove the SD card

“Data was saved to the SD card” icon

You can remove the SD card. The icon is displayed for one minute.

" Open the inverter.

" Remove the SD card by gently pressing and then releasing it. The SD card will pop out slightly. You can now remove it.

" Close the inverter and start it up.

NOTEDo not remove the SD card until the SAFE icon is displayed so that it will be detected by the MMI when you reinsert it.

5.9.2 Status display for speaker

Audible signal when you press the LCD screen

No signal

5.9.3 Using the main menu

Press button Result / Function

PV Array The measured values for the PV generator are displayed.

Inverter The measured values for the inverter are displayed.

Power grid (AC connection) The measured values for the power grid are displayed.

ON Switches on the inverter.

OFF Switches off the inverter.

Speaker Switches speaker on/off.

Table 5: button function



5.10 MMI submenus

5.10.1 PV Array

String monitoring is activated

PV Array Strings

0.0 0.0 0.0

Power (kW) Voltage (V) Current (A)

Cell Temp. (°C)

N/A N/A N/A

Return to next higher level

Isolation R (kΩ)

0.0

Irr. (W/m2) Ambi.Temp. (°C) Wind (m/s)

N/A

Buttons

Display Meaning

Measured values

Current measured values for the PV Array

Strings String monitoring is activated

Figure 21: “PV Array” screen

5.10.2 String monitoring

Changes to the configuration for the current sensors first become effective after five minutes.

302520

Page :

1510500

2.4

4.8

7.2

9.6

12

Yellow bars: Average current values, faulty channel

Magenta dots: Actual current values

Green bars: Average current values, functioning channel

Light blue line: Average of all channels

Strings

Return to the previous level

Current

actual values

Only current actual values are displayed during the first five minutes after the function has been acti-vated.

Average current values of the channels

The actual values for the last five minutes are recorded (sampling period: every 30 seconds)

Average of all current values (channels)

Average of all current values (channels)

Figure 22: “String monitoring” screen

If the average of one channel deviates from the average of all channels by more than the specified range of tolerance and if this persists for longer than a specified delay period, this channel is assumed to be defective.



5.10.3 Inverter

Display of measured values for the inverter.

5.10.4 Power grid

Display of measured values for the power grid.

Inverter

Heatsink (°C)

Voltages (V)

Currents (A)

Frequency (Hz)

0.0

0.0 0.0 0.0

0.0 0.0 0.0

0.0

Grid

Power (kW)

Voltages (V)

Currents (A)

Frequency (Hz)

0.0

0.0 0.0 0.0

0.0 0.0 0.0

0.0

Figure 23: “Inverter” screen Figure 24: “(Power) Grid” screen

5.10.5 Faults and warnings

Display current faults and warnings.

23

Code Fault message

Arrows Scroll through several pages

Symbols for types of errors

Fault resetFault

F

W

L3

L3

L3

Correct current faults

" Press “Fault reset”.

The control unit is instructed to correct current faults. After a few seconds have passed, the fault list is empty.

Figure 25: “Fault” screen

Icon Fault type

F (red) Serious fault

W (yellow) Warning



5.10.6 History

This screen displays a list with a maximum of 100 faults, warnings and events that most recently occurred in the inverter.

23

Arrows Scroll through several pages

Symbols for types of events

History

E

F

W

L3

E

Date/Time Description

Icon Event type

E (purple) Event

F (red) Serious fault

W (yellow) Warning

Figure 26: “History” screen

5.10.7 Statistics

The statistics function displays the data that was recorded on the SD card as a diagram.

Day

Specific date

Statistics

Month Year

1. 1. 2010

Select time period

" Select one of the three combination fields. Day (daily statistics) Month (monthly statistics) Year (annual statistics)

" Select a specific date.

Figure 27: “Statistics” screen

Statistic display

Grid power x x x

19:0017:0015:0013:0011:0009:0007:000

20

40

60

80

100

Parameter selection

Grid power (kW)Day

Jun 13, 2009

Figure 28: “Day” screen with daily statistics

PV power x x x

PV voltage x - -

PV current x - -

PV temperature x - -

Insolation x - -

Line voltage x - -

Statistics are available as long as the relevant parameters were recorded. Recording is activated for all values by default. Monthly and annual statistics are recorded over the time period as cumulative values.



Monthly statistics Annual statistics

3025201510500

100

300

400

500

600

200

Parameter selection

PV power (kW)Month

Jan, 2009

1210864200

3000

9000

12000

15000

18000

6000

Parameter selection

Grid power (kW)Year

2009

Figure 29: “Month” screen with monthly statistics for the last nine months

Figure 30: “Year” screen with annual statistic

5.10.8 Settings

Change settings

" Use this menu to change the settings that influence how the inverter operates.

" Use the buttons in the upper right-hand corner to switch between the two screens.

Button for switching

DigitalDate/Time

Setup (1/2)

Analog Recording

Language & Country

RS485 User configuration

Network

Button for switching

Setup (2/2)

Software upgrade

Service Information

Figure 31: “Setup (1/2)” screen Figure 32: “Setup (2/2)” screen



Date/Time

NOTESet the current date and local time. This setting affects the logging functions (event log and statistics).

12

Date/Time

Year

Month

Day

Hour

Minute

0

0

0

0

0

Set

Set

Set

Set

Set

Figure 33: “Date/Time” screen

Change system time

" This is where you set the current date and local time.

After the values have been changed, it takes up to one minute for the time data that is displayed in the main menu to be updated.

Recording

Specify which values will be recorded

" Set the recording interval (in minutes).

" On pages 1 and 2 you specify which values are to be recorded.

12

Recording

Intervall (min)

Grid power

PV power

PV voltage

PV current

10

ON

ON

ON

ON

Set

Set

Set

Set

Set

Figure 34: “Recording” screen

You can use this menu item to delete all of the statistics data on the SD card (if necessary).

Recording settings

ID Name Unit Factory setting Min. Max.

0 Recording Interval minute 10 10 60

1 Grid Power - ON OFF ON

2 PV Power - ON - ON

Table 6: Recording settings



ID Name Unit Factory setting Min. Max.

3 PV Voltage - ON - ON

4 PV Current - ON - ON

5 PV Temperature - ON - ON

6 Irradiation - ON OFF ON

7 Grid Voltage - ON OFF ON

8 Delete All Statistics - N/A - -

Table 6: Recording settings

Language and country settings

NOTEImproper parameters will render the system inoperable. Make only the country-specific settings for your country.

Language & Country

English DE ES FR

IT KR GR

CZ CY CH

UK JP

Deutsch Español

Français Italiano

日本語

Figure 35: “Language & Country” screen

Set languages

" Press the appropriate button for your language. This sets the display language for the MMI.

Available languages: English, German, Spanish, Korean, French, Italian, Japanese.

Set country-specific parameters

" Press the button that shows the flag of your country.

The parameters for the country-specific power grids are stored.

Available country: Germany, Spain, France, Italy, Korea, Greece, Czech, Cyprus, China, United Kindom, Japan.



Network

Network

Config

IP

Netmask

Gateway

Web Port

Static

192.168.10.11

255.255.255.0

192.168.10.1

82

Set

Set

Set

Set

Set

Figure 36: “Network” screen

Configure the network for the MMI

" Select static and dynamic IP addresses via DHCP service requests.

" Change the web port used for monitoring the inverter via the web.

" Open the web monitoring service using the MMI`s IP address and web port (e.g. http://192.168.10.11:82).

Software upgradeIf an update is available (for example, when new functions are added), use the SD card to update the inverter software.

SAFE




Updating the software for the MMI

SAFE


Update the MMI software

Perform the following steps in the indicated sequence:

" Copy the software image file (*.img) to the SD card.

" Insert the SD card into the MMI.

" Select “Setup” → “Software upgrade”.

" Select “MMI” and press “Start”.

" A dialog box is then displayed.

" Confirm the message to indicate that you understand that this process cannot be undone. A dialog box for opening files is then displayed.

" Select the image file that you copied earlier.

" Press the “Open” button.

The MMI displays the progress of the upgrade. After a short period of time, the system is restarted.

NOTEIf the image file is faulty, an error message is displayed and normal operation is resumed.

Software upgrade

C6x

MMI

Start

MMI

/mnt/sdcardSearch in:

mmi_v107.img

mmi_v107.img

*.img

File name:

File type:

Open

Cancel

Figure 37: Software upgrade screen Figure 38: Dialog box for opening files



Software upgrade

MMI

Start

Synchronyzing flash system and SD-card controller

Software upgrade

MMI

Start

Software upgrade done! Auto reboot after 5 sec. ...

Figure 39: Upgrade process progress bar Figure 40: Restart dialog box

ATTENTION

Software damage due to an interruption of the synchronisation process

If the synchronising of the flash file system and the content of the SD card is interrupted (e.g. due to a power failure), the software can be damaged and the MMI may not be able to restart.

Update the C6x software

SAFE


Update the C6x software

Perform the following steps in the indicated sequence:

" Make sure that the RS232 cable between the MMI and the control unit is connected.

" Switch off the inverter. To do so, press the OFF button in the main menu.

" Copy the software file (*.hex) to the SD card.

" Insert the SD card into the MMI.

" Select “Setup” → “Software upgrade”.

" Select “C6x” and press “Start”.

A dialog box for opening files is then displayed.

" Select the file that you copied earlier.

" Press the “Open” button.

The MMI transfers the file to the control unit. If the file transfer was successful, the following message will appear:

“MMI has finished upgrading XCU.”

The control unit has now been successfully upgraded.

An error message indicates that the process was not successfully completed.

" Press the ON button in the main menu to activate system operation.



/mnt/sdcardSearch in:

dataxcu.hexxpconfxpdata

Computer

root

xcu.hex

*.hex *.HEX *.Hex

File name:

File type:

Open

Cancel

Communication between the MMI and the control unit (XCU) is interrupted during the upgrade process and automatically resumes once the download is complete.

Upgrade C6x

Connecting to XCU ...

Figure 41: Dialog box for opening files Figure 42: C6x upgrade screen

PRESS BS KEY TO DOWNLOAD FLASH LOCK OK! SYSTEM STARTUP! VERIFY FLASH CHECKSUM OK! PARAMETERS CHECKSUM OK! SYSTEM BOOT SUCCESS! >>>MMI has finished upgrading XCU.

Upgrade C6x

Figure 43: C6x upgrade screen (complete)

NOTECommunication between the MMI and the control unit (XCU) is interrupted during the upgrade process and automatically resumes once the download is complete.

5.10.9 Other menus and details

Some menus can only be accessed by service technicians from KACO new energy Inc., and are therefore not described in this manual.


Faults and Warnings

6 Faults and Warnings

When a problem occurs in the system, the Inverter will beep and inform the user on the GUI. The Inverter dis-plays two basic error messages. The first, the fault, is a serious problem that causes the inverter to stop running. The second, a warning, is a minor problem that does not cease the system operation. The GUI will indicate faults in red and warnings in yellow. The user can find a description of the different fault and warnings in the following Tables.

6.1 Warning

Message Code Description

SP1(PV SP) Failure 81 Failure of the PV side surge protector(SP1)

CB10(PV Contactor) Failure 82 PV side contactor(CB10) failure

PV Fuse Failure 83 PV side Fuse failure(option)

Ground Fault Warning 84 The insulation resistance of the PV falls short of the limit set in the ground fault monitoring for Alert1(option)

PV Over Voltage 85 PV voltage exceeds the parameter [DC over voltage Level]

PEBB Over Temp. Warning 100 The temperature of the PEBB(Power Electronics Building Block) over 85°C(185°F)

PEBB Fan Failure 101 Failure of a PEBB(Power Electronics Building Block) fan

PEBB Temperature Unbalance

102 The Difference of each PEBB temperature exceeds the operational parameter [PEBB Temperature Unbalance Level]

SP2(Grid SP) Failure 110 Failure of the grid side surge protector(SP2)

ASYNC Warning 111 The phase synchronous of inverter and grid failure

Test Mode 120 The system is working in test mode

Watchdog 121 Abnormalities detection in the DSP

Invalid Parameter 125 Parameter is invalid value

Reconnection Condition Warning

126 The grid voltage or frequency exceeds the reconnection condition when reconnection to grid during operational parameter [Reconnec-tion Condition Warning Delay] seconds

Cabinet Over Temp. Warning

130 The temperature of the cabinet over the parameter [Cabinet Tempera-ture Maximum]

Cabinet Under Temp. Warning

131 The temperature of the cabinet falls below the parameter [Cabinet Temperature Minimum]

SP3(Control Power SP) Failure

132 Failure of the control side surge protector(SP3)

CB32 Open 133 Failure of the top fan or power supply

SMPS Warning 134 Failure of the control SMPS(Switching Mode Power Supply)

CAN TX Failure 135 CAN bus communication transmission failure

Table 7: Warning


Faults and Warnings


CAN RX Failure 136 CAN bus communication reception failure

CAN EP Failure 137 CAN bus communication Error-Passive error

CAN Bus-Off 138 CAN bus communication Bus-off error

CAN Wrong Message 139 Reception of Wrong message in CAN bus communication

CAN Time Out 140 Time out in CAN bus communication

CAN Multiple Master 141 There are multiple Masters in CAN bus communication

Table 7: Warning

6.2 Fault


PV Over Voltage 1 PV voltage exceeds the parameter [DC over voltage Level]

PV Over Current 2 PV current exceeds the parameter [DC over current Level]

CB10(PV CB) Trip 4 PV side circuit breaker(CB10) tripped

PV Polarity Failure 5 Polarity(+, -) of PV side is reversed

Ground Fault 6 PV side ground fault

Inv. Over Voltage 10 Inverter side Voltage over the parameter [Grid Over Voltage Level 2]

Inv. Under Voltage 11 Inverter side Voltage under the parameter [Grid Under Voltage Level 2]

Inv. Over Frequency 12 Inverter side Frequency over the parameter [Grid over Frequency Level 2]

Inv. Under Frequency 13 Inverter side Frequency under the parameter [Grid under Frequency Level 2]

Inv. Over Current 14 Inverter side Current over the parameter [Inverter OverCurrent Level]

MC21(Inv. MC) Failure 15 Inverter side contactor(MC21) failure

Inv. Phase Order 16 Phase order failure on the inverter side, wrong phase rotation

Inductor or TR Over Temp. 18 Inductor or Transformer temperature over 150°C

Inv. Current Unbalance 19 The unbalanced current of inverter side

PEBB(1) IGBT Fault 20 PEBB 1 IGBT failure



PEBB Over Temp. Analog 24 The temperature of the heat-sink over the parameter [Heatsink OT Level] (Analog)

PEBB Over Temp. Digital 25 The temperature of the heat-sink over 100°C(Digital)

Grid Over Voltage 1 30 Grid side Voltage over the parameter [Grid Over Voltage Level 1]

Table 8: Fault


Faults and Warnings


Grid Under Voltage 1 31 Grid side Voltage under the parameter [Grid Under Voltage Level 1]

Grid Over Frequency 1 32 Grid side Frequency over the parameter [Grid Over Frequency Level 1]

Grid Under Frequency 1 33 Grid side Frequency under the parameter [Grid Under Frequency Level 1]

Grid CB Trip 34 CB20(AC Disconnect/Grid circuit breaker) was tripped during operation

Grid Over Voltage 2 35 Grid side Voltage over the parameter [Grid Over Voltage Level 2]

Grid Under Voltage 2 36 Grid side Voltage Under the parameter [Grid Under Voltage Level 2]

Grid Under Frequency 2 37 Grid side Frequency Under the parameter [Grid Under Frequency Level 2]

Grid Over Frequency 2 38 Grid side Frequency Over the parameter [Grid Over Frequency Level 2]

Parameters Version Error 40 Different version between the NVSRAM parameter table and the pro-gram parameter table

Flash Memory Failure 41 C6000 DSP program flash memory failure in XCU(main control) board

FPGA Failure 42 FPGA failure in XCU(main control) board

DSP28x Failure 43 F2000 DSP failure in XCU(main control) board

ADC Failure 44 ADC block failure in XCU(main control) board

NVSRAM Failure 45 NVSRAM Failure in XCU(main control) board or invalid parameter set-ting

Asynchronous 46 Synchronous fail of Grid and Inverter

CAN Failure 47 CAN bus communication failure

Emergency Stop 50 A door is open

MasterSlave Fault 52 Master Slave operation Failure

Grid Over Frequency Level3 57 Grid side Frequency over the parameter [Grid Over Frequency Level 3]

Grid Under Frequency Level3

58 Grid side Frequency under the parameter [Grid Under Frequency Level 3]

Grid Over Voltage Slow 59 Grid side Voltage over the parameter [Grid Over Voltage Level Slow] (RMS average value per 10 min)

MMI-XCU Communication Error

63 MMI-XCU communication Error

Table 8: Fault


Faults and Warnings

6.3 Solution for Error codeThe Inverter can detect faults during operation. The inverter will display the fault in the GUI. Faults are indicated in the GUI with an error code, and a plain text message with the error code and system plant name in the text line will be sent to the system operator (only available if purchased and configured during setup). This section describes how to recognize the types of faults and how to correct these faults.

Warning

Code Message Warning description Possible problem and Solution(s)

81 SP1(PV SP) Failure Failure of the PV side surge protector(SP1)

Possible problem

•LightningstrikeonornearthePVsystem wiring

Solution(s)

•Visualinspection

•ChangetheSPD

83 PV Fuse Failure PV side Fuse failure(option) Possible problem

•PVsystemwiringshort

•ShortcircuitintheIGBT

Solution(s)

•Checktheinputcurrent

•Checkmodulewiring

•ChangetheFUSE

100 PEBB Over Temp. Warning

The temperature of the PEBB(Power Electronics Building Block) over 85°C(185°F)

Possible problem

•PEBBFanFailure

Solution(s)

•CleanthefiltersorPEBBheat-sinkfins

•ChangethePEBBFan

101 PEBB Fan Failure Failure of a PEBB(Power Elec-tronics Building Block) fan

Possible problem

•PEBBFanFailure

Solution(s)

•ChangethePEBBFan

110 SP2(Grid SP) Failure Failure of the grid side surge protector(SP2)

Possible problem

•Lightningstrikeonornearthegrid system wiring

Solution(s)

•Visualinspection

•ChangetheSPD

120 Test Mode The system is working in test mode

Possible problem

•Thesystemisworkingintestmode

Solution(s)

•ChangetheparametersintheGUI

Table 9: Warning


Faults and Warnings

Code Message Warning description Possible problem and Solution(s)

130 Cabinet Over Temp. Warning

The temperature of the cabinet over the parameter [Cabinet Temperature Maximum]

Possible problem

•CabinetFanFailure

Solution(s)

•Cleantheairfilters

•Changethecabinetfan

131 Cabinet Under Temp. Warning

The temperature of the cabinet falls below operational param-eters [Cabinet Temperature Minimum]

Possible problem

•Ambienttemperatureistoolowfor operation

134 SMPS Warning Failure of the control SMPS Possible problem

•FailureofthecontrolSMPS

Solution(s)

•ChangethecontrolSMPS

135 CAN TX Failure CAN bus communication transmission failure

Possible problem

•CANbuscommunicationFailure

Solution(s)

•ChecktheCANbusConnection

•ChecktheCANbusterminalregisters

136 CAN RX Failure CAN bus communication reception failure

137 CAN EP Failure CAN bus communication Error-Passive error

138 CAN Bus-Off CAN bus communication Bus-off error

139 CAN Wrong Message Reception of Wrong message in CAN bus communication

140 CAN Time Out Time out in CAN bus communi-cation

141 CAN Multiple Master There are multiple Masters in CAN bus communication

Possible problem

•CANIDisduplicated

Solution(s)

•ChangetheparametersintheGUI

Table 9: Warning

Fault

Code Message Warning Description Possible problem and Solution(s)

1 PV Over Voltage PV voltage exceeds the param-eter [DC over voltage Level]

Possible problem

•Thevoltageofthesolargeneratoristoo high

Solution(s)

•Checktheinputvoltage

•Checkmodulewiringandsystem

Table 10: Fault


Faults and Warnings


2 PV Over Current PV current exceeds the parame-ter [DC over current Level]

Possible problem

•Thecurrentofthesolargeneratoristoo high

•PVsystemwiringshort

Solution(s)

•Checktheinputcurrent

•Checkmodulewiringandsystem

4 CB10(PV CB) Trip PV side circuit breaker(CB10) tripped

Possible problem

•CB10disconnectswitchisopen

•Auxiliaryswitchisinoperable,CB10 contactor failed closed

Solution(s)

•Checkthewiringconnection

•ChangetheCB10,replaceCB10 contactor

5 PV Polarity Failure Polarity(+, -) of PV side is reversed

Possible problem

•PolarityofPVsideisreversed Solution(s)

•Checkthewiringconnectionand change if necessary

6 Ground Fault PV side ground fault Possible problem

•TheGFDIfuseininverterisopened causing PV side grounding or short-cir cuit fault (DC side Grounding Type) •TheunbalanceofmeasuredPVvoltage in inverter causing PV side grounding or short-circuit fault (DC side Isolation Type)

Solution(s)

•Checkthesolargeneratorforaground ing or short-circuit fault and Replace the GFDI Fuse (DC side Grounding Type)

•Checkthesolargeneratorforaground ing or short-circuit fault (DC side Isolation Type)

10 Inv. Over Voltage Inverter side Voltage over the parameter [Grid Over Voltage Level 2]

Possible problem

•Theinvertervoltageistoohigh Solution(s)

•Checktheinvertervoltage

•Checktheinverterparameter

Table 10: Fault


Faults and Warnings


11 Inv. Under Voltage Inverter side Voltage under the parameter [Grid Under Voltage Level 2]

Possible problem

•Theinvertervoltageistoolow Solution(s)

•Checktheinvertervoltage

•Checktheinverterparameter

•ChecktheMC21

12 Inv. Over Frequency Inverter side Frequency over the parameter [Grid over Frequency Level 2]

Possible problem

•Thegridfrequencyisoutsidethe permitted range Solution(s)

•Checkthegridfrequency

13 Inv. Under Frequency Inverter side Frequency under the parameter [Grid under Frequency Level 2]

Possible problem

•Thegridfrequencyisoutsidethe permitted range Solution(s)


14 Inv. Over Current Inverter side Current over the parameter [Inverter OverCurrent Level]

Possible problem


•ShortcircuitintheGrid Solution(s)

•Checkthegridconnection

•Checktheinverterconnection

15 MC21(Inv. MC) Failure Inverter side contactor(MC21) failure

Possible problem

•MC21contactorisopen

•Auxiliaryswitchisinoperable Solution(s)


•ChangetheMC21

16 Inv. Phase Order Phase order failure on the inverter side

Possible problem

•Phaseorderfailureontheinverter

•Wrongphaserotation Solution(s)


•Reversetwophases

18 Inductor or TR Over Temp

Inductor or Transformer temper-ature over 150°C

Possible problem

•Cabinetfanfailure Solution(s)

•Cleaningthefilters

•ChangethecabinetFan

Table 10: Fault


Faults and Warnings


20 PEBB(1) IGBT Fault PEBB IGBT U failure Possible problem


Solution(s)

•Visualinspection

•ChangethePEBB

21 PEBB(2) IGBT Fault PEBB IGBT V failure

22 PEBB(3) IGBT Fault PEBB IGBT W failure

24 PEBB Over Temp. Analog

The temperature of the heat-sink over the parameter [Heat-sink OT Level] (Analog)

Possible problem

•PEBBfanfailure

Solution(s)

•Cleanthefilters

•Inspectandifnecessarycleanthe heat-sink fins

•ChangethePEBBFan

25 PEBB Over Temp. Digital

The temperature of the heat-sink over 100°C(Digital)

Possible problem

•PEBBFanFailure

Solution(s)

•Inspectandifnecessarycleanthe heat-sink fins Change the PEBB Fan

30 Grid Over Voltage level 1

Grid side Voltage over the parameter [Grid Over Voltage Level 1]

Possible problem

•Thegridvoltageistoohigh

Solution(s)

•Checkthegridvoltage

•Checkthegridparameter

31 Grid Under Voltage level 1

Grid side Voltage under the parameter [Grid Under Voltage Level 1]

Possible problem

•Thegridvoltageistoolow

Solution(s)



•ChecktheMCB24

32 Grid Over Frequency level 1

Grid side Frequency over the parameter [Grid Over Frequency Level 1]

Possible problem

•Thegridfrequencyisoutsidethe permitted rang

Solution(s)



Table 10: Fault


Faults and Warnings


33 Grid Under Frequency level 1

Grid side Frequency under the parameter [Grid Under Fre-quency Level 1]

Possible problem

•Thegridfrequencyisoutsidethe operation range

Solution(s)



34 Grid CB Trip CB20(AC Disconnect/Grid circuit breaker) was tripped during operation

Possible problem

•Shortcircuitinthegrid

Solution(s)

•Checkthewiringconnections

35 Grid Over Voltage Level 2

Grid side Voltage over the parameter [Grid Over Voltage Level 2]

Possible problem

•Thegridvoltageistoohigh

Solution(s)



36 Grid Under Voltage Level 2

Grid side Voltage Under the parameter [Grid Under Voltage Level 2]

Possible problem

•Thegridvoltageistoolow

Solution(s)



37 Grid Under Frequency Level 2

Grid side Frequency Under the parameter [Grid Under Fre-quency Level 2]

Possible problem


Solution(s)


38 Grid Over Frequency Level 2

Grid side Frequency Over the parameter [Grid Over Frequency Level 2]

Possible problem

•Thegridfrequencyisoutsidethe permitted range

Solution(s)


40 Parameters

Version Error

Different version between the NVSRAM parameter table and the program parameter table

Possible problem

•DifferentversionbetweentheNVSRAM parameter table and the program parameter table

Solution(s)

•Initializetheparametermenusettingin the GUI and reset faulted parameter

•ChangethePCBmodule

Table 10: Fault


Faults and Warnings


41 Flash Memory

Failure

C6000 DSP program flash memory failure in XCU(main control) board

Possible problem

•InternalC6000error

Solution(s)


42 FPGA Failure FPGA failure in XCU(main control) board

Possible problem

•InternalFPGAerror

Solution(s)


43 DSP28x Failure F2000 DSP failure in XCU(main control) board

Possible problem

•InternalF2000error

Solution(s)


44 ADC Failure ADC block failure in XCU(main control) board

Possible problem

•InternalAnalogtoDigitalconverter error

Solution(s)


45 NVSRAM Failure NVSRAM failure in XCU(main control) board or invalid param-eter

Possible problem

•InternalNVSRAMerror

•Invalidparameter

Solution(s)

•Initializetheparametermenusettingin the GUI


47 CAN Failure CAN bus communication failure Possible problem


Solution(s)



50 Emergency Stop The door is open Possible problem

•Frontdoorisopen

•Brokenoroutofalignmentdoorswitch

Solution(s)

•Closethedoor

•Alignorreplacedoorswitch

Table 10: Fault


Faults and Warnings


52 Master Slave Fault Master Slave operation Failure Possible problem

•WrongCANID


Solution(s)

•Checktheparameters



57 Grid Over Frequency Level 3

Grid side Frequency over the parameter [Grid Over Frequency Level 3]

Possible problem

•Thegridfrequencyisoutsidethe permitted range

Solution(s)



58 Grid Under Frequency Level 3

Grid side Frequency under the parameter [Grid Under Fre-quency Level 3]

Possible problem


Solution(s)



63 MMI-XCU Communi-cation Error

MMI-XCU communication Error Possible problem

•MMI-XCUCommunicationError

Solution(s)

•CheckMMI-XCUcommunication connectivity

Table 10: Fault


Maintenance/Cleaning

7 Maintenance/CleaningMaintenance must be performed on the inverter at regular intervals (Table 11 shows the maintenance schedule).






Switch off the inverter

" Press the MMI OFF button (Stop the inverter).

" Switch the CB20 to OFF.

" Switch the Power grid switch to OFF (disconnect the inverter from the grid).

" Switch the DC disconnector to OFF (disconnect the inverter from the PV generator).

" Make sure that the inverter is disconnected from all voltage sources.

" Please open the door, switch the CB33 to OFF.

" Wait at least ten minutes before working on the inverter.

Switch on the inverter

" Switch the CB33 to ON.

" Switch the Power grid switch to ON (connect the inverter to the grid).

" Switch the DC disconnector to ON (connect the inverter to the PV generator).

" Switch the CB20 to ON.

" Press the MMI ON button.



7.1 Maintenance intervals

DANGER



Only authorized electricians who are approved by the supply grid operator may open, install and maintain the inverter.

› Do not touch the lines and terminals when switching the unit on and off. Do not touch exposed contact connections.

› Always shut down the inverter prior to cleaning or maintenance.

NOTEEven between maintenance intervals, pay attention to any unusual behaviour that the inverter displays during operation, and fix the problem immediately.

Recommended Maintenance-inter-vals

Maintenance work

6 months* Cleaning or replacement Filter mats in the air intake filter

6 months Cleaning Inside of the cabinet

Fans

12 months* Function check Emergency stop (OFF)

12 months Cleaning Power section of the heat sink

12 months Visual inspection Contact connection

Fuses

Switches

Overvoltage protection

Redundant auxiliary power supplies

Check all parts in the cabinet for

– Heavy dust deposits and soiling

– Moisture (especially water that has permeated from the outside)

Visual inspection

(and replacement, if necessary)All warning labels

Function check Fans

Door contacts

Operating lights and fault lights

12 months Torque check Input, output, Check the status of the screws

*If heavy soiling is present at the installation location, you may need to shorten the maintenance interval.

Table 11: Maintenance intervals



7.2 Cleaning and replacing the fansThe inverter is equipped with eight fans. All of them are located at the top of the housing. Six of the fans are installed in the left side of the housing to provide ventilation for the power electronics building block. The fan in the right side of the housing is used to ventilate the housing. The fans must be cleaned on a regular basis to ensure maximum performance. If there are any problems with the fans, repair or replace them.

7.2.1 Accessing the fans


Clean the fans

" Remove the upper covers from the inverter.

" Clean the fans.

" Attach the upper covers.

Change the fans

" Remove the upper covers from the inverter.

" Disconnect the plug.

" Replace the fan.

" When you install a new fan, pay attention to the air flow direction (arrow on the fan housing).

" Attach the upper covers.

Switch on the inverter

Figure 44: Upper cover on the inverter

Figure 45: Fans used for the power electronics building block

Figure 46: Plug for the in the right side of the housing


Parameters

8 ParametersThe KACO XP-HV and XP-TL series parameters are pre-configured for operation. It is a good idea to adapt a number of the KACO XP series parameters to the solar generator.

The KACO XP-HV and XP-TL series parameters are subdivided into ten:

• PV Array

Setting values for MPPT control and startup of inverter

• Inverter

Setting values for inverter rate and cabinet temperature

• Grid

Setting values for abnormal and rated levels of grid

• Time

Setting values for the current time

• Digital

Setting values for digital interface

• Analog

Setting values for analog interface

• Controller

Setting values for inverter control

• Trace

Setting values for inverter fault analysis

• Offset

Setting values for sensing offset calibration

• Gain

Setting values for sensing gain calibration

8.1 PV Array Parameters

Parameters Min Max Unit Descriptions

MPPT Enable 0 1 - 1: MPPT is enabled

0: MPPT is disabled

MPPT V Maximum 0 830 Vdc Maximum voltage to run MPPT

MPPT V Start 200 800 Vdc MPPT wake-up voltage

MPPT T Start 0 3600 sec Time delay for MPPT wake-up

MPPT P Stop 0 10000 W Disconnect inverter from Grid when PV output power is lower than the setting value of MPPT P Stop.

MPPT T Stop 0 600 sec Time delay while inverter decides if PV output power is lower than the setting value of MPPT P Stop.

Table 12: PV Array Parameters


Parameters


MPPT V Minimum 200 800 Vdc Minimum voltage to run MPPT

Exception)

DC Over Voltage Level

300 1020 Vdc Upper limit for PV over voltage fault

DC Over Current Level

0 150 % Upper limit for PV over current fault

MPP Factor 0 1 - Maximum power point factor

MPP Range Upper 10 300 Vdc Upper limit of maximum power point

MPP Range Lower 10 300 Vdc Lower limit of maximum power point

PV Operation Level 900 1020 Vdc Maximum PV operation level

Table 12: PV Array Parameters

8.1.1 Operating DC voltage range

Figure 47: Operating DC voltage range

The range of possible operational input voltage is from [MPPT V Minimum] to [PV Operation Level]. The picture above shows that the output power decreases linearly where the input power is from [MPPT V Maximum] to [PV Operation Level].


Parameters

8.2 Inverter Parameters


Transformer & Type 0 8 N/A This parameter determines device specific informa-tion such as a switch type on DC side and whether the inverter has an internal transformer.

Inverter Capacity 100 550 kW Power Capacity of the inverter

Inverter Over Current Level

0 200 % Upper limit for inverter over current fault

Current Limit 0 150 % Limit of current which produces from the inverter

Cabinet Tempera-ture Maximum

30 70 °C Upper limit for cabinet over temperature warning

Cabinet Tempera-ture Minimum

-25 10 °C Lower limit for cabinet under temperature warning

PEBB Temperature Unbalance Level

5 30 °C Limit of Temperature gap between PEBBs

Table 13: Inverter Parameters

8.3 Grid Parameters


Rated Grid Voltage 208 400 V Rated value of the grid voltage

Rated Grid Fre-quency

50 60 Hz Rated value of the grid frequency

Grid Over Voltage Level 1

105 130 % Upper limit expressed as a percentage of the rated grid voltage for grid overvoltage level 1

Grid Under Voltage Level 1

75 100 % Lower limit expressed as a percentage of the rated grid voltage for grid under voltage Level 1

Grid Over Frequency Level 1

0 3 Hz Upper limit for grid over frequency level 1

Grid Under Frequency Level 1

0 3 Hz Lower limit for grid under frequency level 1

Frequency Depend-ant Power Reduc-tion Mode

0 2 - Power reduction function dependant on frequency rise

0: Disable

1: Enable

Table 14: Grid Parameters


Parameters


Power Gradient Mode

0 5 - Power gradient function when inverter start

0: Disable

1: Activated when connected to grid after fault (Germany Medium Voltage Requirements)

2: Activated according to VDE-AR-N 4105 (Ger-many Low Voltage Requirements)

3: Activated whenever connected to grid (Italy TERNA Grid Code)

Power Gradient Ramp

0 600 sec Ramp time for power gradient

Time Shift 0 6000 sec Delay time for inverter start

Gate-way Enable 0 1 - Reserved

Grid Level 2 Protec-tion Enable

0 1 - Grid level 2 protection function

0: Disable

1: Enable

Grid Over Voltage Level 2

105 130 % Upper limit expressed as a percentage of the rated grid voltage for grid overvoltage level 2



Grid Under Fre-quency Level 2

0 3.5 Hz Lower limit for grid under frequency level 2

Grid Over Voltage Level 1 Trip Time

100 10000 ms Time for grid over voltage level 1 trip

Grid Over Voltage Level 2 Trip Time

40 2000 ms Time for grid over voltage level 2 trip

Grid Under Voltage Level 1 Trip Time

100 10000 ms Time for grid under voltage level 1 trip



Grid Under Fre-quency Level 1 Trip Time

100 20000 ms Time for grid under frequency level 1 trip


40 3000 ms Time for grid under frequency level 2 trip

Grid Over Frequency Level 1 Trip Time

40 3000 ms Time for grid over frequency level 1 trip

FRT Enable 0 1 - FRT(Fault Ride Through) Function

0: Disable

1: Enable



Parameters


Grid Over Voltage FRT Enable

0 1 Over Voltage FRT Function

0: Disable

1: Enable

Power Reduction Gradient Level

0 100 %/Hz Gradient level for frequency dependant power reduction

Power Reduction Deactivation Frequency

0 0.3 Hz Frequency limit for frequency dependant power reduction deactivation




40 2000 ms Time for grid over frequency Level 2 trip

Reconnection Condition Mode

0 2 - Reconnection Condition Function

0: Disable

1: Checked before connected to grid (Germany Medium Voltage Requirements)

2: Checked according to VDE-AR-N 4105 (Germany Low Voltage Requirements)

Reconnection Condition Upper Voltage

-1 130 % This parameter represents the upper voltage in the range of “Reconnection condition” as a percent-age of the rated value.

The negative value represents that the relevant condition is not checked when an inverter decides “Reconnection condition”.

Reconnection Condition Lower Voltage

-1 100 % This parameter determines the lower voltage of “Reconnection condition” range as a percentage of the rated value.


Reconnection Condition Upper Frequency

-1 3 Hz This parameter determines the upper frequency of “Reconnection condition” range as an increment from the rated value.


Reconnection Condition Lower Frequency

-1 3 Hz This parameter determines the lower frequency of “Reconnection condition” range as a decrement from the rated value.




Parameters


Reconnection Condition Check Time Normal

0 1800 sec This parameter is used for time check during “Reconnection condition” for all the time except after fault.

Reconnection Condition Check Time After Fault

0 1800 sec This parameter is used for time check during “Reconnection condition” for after fault only.





Grid Over Voltage Level Slow

105 115 % This parameter represents Upper limit for the average RMS value of grid voltage as a percentage of the rated grid voltage.

If the average RMS value of grid voltage exceeds this parameter setting, fault will be occurred.

VDE-AR-N 4105(Germany Low Voltage Require-ments)

Grid Over Voltage Level Slow Shift Average Time

-1 3000 sec This parameter determines how long the average RMS value of grid voltage will be calculated.

(Low Voltage Requirements: 600 seconds duration)

Negative value means that the relevant function (Grid Over Voltage level slow) is disabled.

Reconnection Condition Warning Delay

0 600 sec Time delay for Reconnection Condition Warning

Grid Under Fre-quency Level 3

0 3 Hz Lower limit for grid over frequency level 3



Upper Deadband PPN

100 110 % Voltage Level for activation of P/Pn function when selected CEI 0-21 grid code

Lower Deadband PPN

90 100 % Voltage Level for deactivation of P/Pn function when selected CEI 0-21 grid code

Upper Deadband QV

10 100 % Active Power Level for activation of Q(V) function when selected CEI 0-21 grid code

Lower Deadband QV

1 20 % Active Power Level for deactivation of Q(V) function when selected CEI 0-21 grid code

QV Voltage 1 100 110 % Voltage upper dead band of Q(V) function when selected CEI 0-21 grid code

QV Voltage 2 90 100 % Voltage lower dead band of Q(V) function when selected CEI 0-21 grid code



Parameters


QV Voltage 3 100 110 % Voltage upper level to calculate ramp of Q(V) function when selected CEI 0-21 grid code

QV Voltage 4 90 100 % Voltage lower level to calculate ramp of Q(V) function when selected CEI 0-21 grid code

QV Inductive Max 0 48 % Reactive Power inductive maximum value of Q(V) function

QV Capacitive Max 0 48 % Reactive Power capacitive maximum value of Q(V) function


8.3.1 FRT Enable Off

If the function of FRT(Fault-ride through) is not active, XP series parameters for abnormal grid is as follows.

Grid Under Frequency

Figure 48: Grid under frequency

1. f < frated–2Hz, t > 10s → Grid Under Frequency Level 1 Fault

2. f < frated–2.5Hz, t > 100ms → Grid Under Frequency Level 2 Fault


Parameters

Grid Over Frequency

Figure 49: Grid over frequency

1. f > frated+0.2Hz, t > 100ms → Grid Over Frequency Fault

2. It disables Grid Over Frequency Level 2 and Grid Over Frequency Level 2.

Grid Under Voltage

Figure 50: Grid under voltage

1. U < 0.9*Urated, t > 5s → Grid Under Voltage Level 1 Fault

2. U < 0.8*Urated, t > 100ms → Grid Under Voltage Level 2 Fault


Parameters

Grid Over Voltage

Figure 51: Grid over voltage

1. U > 1.1*Urated, t > 5s → Grid Over Voltage Level 1 Fault

2. U > 1.2*Urated, t > 100ms → Grid Over Voltage Level 2 Fault

8.3.2 FRT Enable On

The parameter when FRT Enable is on is as follows.


FRT Enable 0 1 - FRT(Fault Ride Through) Function

0: Disable

1: Enable







MPP Range Upper 10 300 Vdc Upper limit of maximum power point

MPP Range Lower 10 300 Vdc Lower limit of maximum power point

Table 15: FRT Enable On


Parameters

Grid Under Voltage

Figure 52: Grid under voltage

1. U > 1.1*Urated, t > 2s → Grid Under Voltage Level 1 Fault

2. U > 1.2*Urated, t > 150ms → Grid Under Voltage Level 2 Fault

8.3.3 Frequency Dependant Power Reduction Enable On

Grid Over Frequency

Figure 53: Grid over frequency


Parameters

Figure 54: Power reduction gradient level

PM: Instantaneously Available Power

∆P: Power Reduction (Power Reduction Gradient Level)

This function controls active power which is proportional to Grid frequency increase. As you can see in the pic-ture, active power need to be restricted if grid frequency is over 50.2Hz. PM (Instantaneously available power) decreases with 40%/Hz slope and it can be restorable if grid frequency is less than 50.05Hz.

8.3.4 Power Gradient Enable On

Figure 55: PV gradient graph

This function is for PV inverter re-generation. Inverter need to generate active power slowly with specific slope when its operation stops due to various reasons. In this case, active power supply cannot be over 10% of rated active power per minute.


Parameters

8.4 Time Parameters

Parameters Min Max Descriptions

Year 2000 3000 The present year

Month 1 12 The present month

Day 1 31 The present date

Time 0 23 The present hour

Minute 0 59 The present minute

Second 0 59 The present second

Table 16: Time Parameters

8.5 Digital Parameters


DI1 Select 0 20 N/A DI1(Digital Input) selection

0: Disable DI1

1: Reserved

2: Reserved

3: Start/Stop operation of the inverter by DI1 (Recognition pattern: 1sec – Stop, 2sec – Start)

4: Start/Stop operation of the inverter by DI1 (Recognition pattern: 200msec – Stop, 400msec – Start)

5: Stop operation of the inverter by DI1 (Inverter turn off when DI1 signal over DI1 Check Period msec)

DO1 Select 0 20 N/A DO1(Digital output) selection

0: Fault state is output to DO1

RPC Mode Select 0 2 N/A The COSPHI control function of the XP-Series Inverter operates when this parameter is 2.

0: Disable

2: Enable

Power Meter 0 99999999 kWh PV generation amount check

RS485 Protocol 0 999 - RS485 communications’ protocol

0: ACI protocol

1: Communication with prolog

2: Communication with PVI-go

RS485 ID 0 999 - ID for RS485 communication

CAN ID 0 999 - ID for CAN communication

Table 17: Digital Parameters


Parameters


Argus Box 1 Address

0 99999 - Argus Box 1 address and type setup

Argus Box 2 Address


Argus Box 3 Address


Argus Box 4 Address


Argus Box 5 Address


Argus Box 6 Address


Argus Box 7 Address


Argus Box 8 Address


Prolog Positive Sequence Enable

0 1 - Provide positive sequence for grid voltage as prolog

Prolog Expanded Total Yield

0 1 - Provide expanded total yield to Prolog

DI1 Check Period 200 5000 msec Required time for inverter turn off when selecting DI1 Select parameter to ‘5’

Table 17: Digital Parameters

8.6 Analog Parameters

Parameters Min Max Descriptions

AI1 OffSet -300 300 AI (Analog Input) 1 offset

AI1 Gain -300 300 AI (Analog Input) 1 gain







Table 18: Analog Parameters


Parameters

8.7 Controller Parameters

Parameters Min Max Unit Parameters

VC P Gain 0 999.99 N/A PV voltage controller’s P Gain

VC I Gain 0 999.99 N/A PV voltage controller’s I Gain

Voltage Detection LPF

0 9999 Hz Grid Voltage and Inverter voltage filter of dq axis

CC P Gain 0 999.99 N/A Inverter output current controller’s P Gain

CC I Gain 0 999.99 N/A Inverter output current controller’s I Gain

CC di/dt 1 9999 p.u. Slope of inverter rated current generation

Ramp 0 99999 msec Slope of PV voltage generation(time for 100V change)

Li 0 99999 uH Inductance value of inverter output LC filter

Vdc Reference 0 999.9 Vdc DC voltage reference when it is not in MPPT range

CC Period 100 400 usec Inverter switching frequency

PLL P Gain 0 999.99 N/A Grid voltage PLL’s P Gain

PLL I Gain 0 999.99 N/A Grid voltage PLL’s I Gain

Auto Fault Reset Count

0 20 times The maximum count of auto reset function

Heatsink OT Level 50 150 °C The maximum value of PEBB temperature

Power Compensa-tion

0 1 - Power compensation for MPPT control

Test mode 0 99999 N/A The value for function test mode

Options 0 99999 N/A Outside option board setup

Deviation Tolerance Time

1 25 20msec Level 1 trip time use when level 2 protection disable

Reactive Power -30 30 % The control value for reactive power degree of accuracy

Variable MPP Vmin Enb

0 1 - The setup value for inverter operation rage maximization

T_CLOUD 0 3600 sec Time for declines of PV generation due to cloud

T_CLOUD_CNT 0 20 times Count for declines of PV generation due to cloud

Remote Power Control

0 100 % Inverter active power which can be controlled from outside device

PEBB2 Temperature 0 150 °C PEBB2 temperature(Read only)

PEBB3 Temperature 0 150 °C PEBB3 temperature(Read only)

Current Unbalance Limit

0 100 % Unbalanced current level

Table 19: Controller Parameters


Parameters


Cabinet FAN PWM 0 100 - Reserved

Remote Power Control Ramp

0 600 sec The slope of inverter output active poser when remote power is controlled

Total Yield 0 99999999 kWh Check total yield of generation(Read only)

Today Yield 0 99999999 kWh Check day yield of generation(Read only)

IIVCD P Gain 0 999.99 - Inverter output voltage controller’s D-axis P gain for Initial operation voltage

IIVCD I Gain 0 999.99 - Inverter output voltage controller’s D-axis I gain for initial operation voltage

IIVCQ P Gain 0 999.99 - Inverter output voltage controller’s Q-axis P gain for initial operation voltage

IIVCQ I Gain 0 999.99 - Inverter output voltage controller’s Q-axis I gain for Initial operation voltage

Anti-Islanding Enable

0 1 - The use of anti-islanding controller, Yes(1) NO(0)

APS Line Deadband 0 999.99 - The setup value for anti-islanding control

Reactive Power Limit

0 999.99 - The setup value for anti-islanding control

Wind Speed 0 9999.9 - Reserved

Power Derating Enable

0 1 - The use of power decline controller according to PEBB temperature, Yes(1) NO(0)

Power Derating Enable Temperature

50 100 - Temperature level which starts decreasing power according to PEBB temperature

Power Derating Disable Temperature

40 90 - Temperature level which stops decreasing power according to PEBB temperature

Power Derating Reference Tempera-ture

45 95 - PEBB temperature reference value

Power Derating P Gain

0 10 - Power declining controller’s P gain according to PEBB temperature

Grid IIR Filter Cutoff Frequency

0 10 Hz Filter cutoff frequency used for RMS value detec-tion of grid voltage

Asynchronous Fault Count

0 100 - Reserved

Asynchronous Fault Enable

0 1 - Reserved

Grid Positive Sequence

0 999.9 V Positive sequence value of grid



Parameters


COSPHI Control Mode

0 5 - Reactive power supply method in Internal mode and RPC mode

0: disabled

1: fixed P

2: fixed cosφ

3: fixed Q

4: Cosφ(P/Pn)

5: Q(U)

COSPHI Power Factor Internal

-1 1 - Power factor reference in internal mode

COSPHI Reactive Power Internal

-99.9 99.9 % Reactive power reference in internal mode(Percent for rated one)

COSPHI Power Factor Actual

-1 1 - The actual power factor value that is applied(Read only)

COSPHI Power Factor RPC

-1 1 - Power factor reference in RPC mode

COSPHI Reactive Power RPC

-99.9 99.9 % Reactive power reference in RPC mode(percent for rated one)

COSPHI Stray Ratio 0 2 The setup value for COSPHI control.

Positive Sequence PLL Enable

0 1 - The use of grid voltage of positive sequence at PLL

FRT K Factor 0 10 - The setup constant during FRT control

FRT IQ Ramp 0 99999 msec The slope of active power supply during FRT control

FRT IQ Ramp Time 0 99999 msec The time that use a slope changed by FRT IQ ramp parameter

Positive Sequence LPF

0 100 Hz The cutoff frequency for RMS value of positive sequence

PLL Freq LPF 0 100 Hz The cutoff frequency for frequency value detec-tion of PLL

Q(V) Control Target Voltage

208 440 V Value of Q(V) Control Target Voltage

Q(V) Control K Factor

0 50 - A setup constant for voltage control of BDEW

Q(V) Control Deadband

0 100 % Non-applicable voltage range during voltage control of BDEW

Q(V) Control Ramp Time

0 99999 sec The slope of reactive current increase during voltage control of BDEW



Parameters


FRT Asynchronous Level

0 100 V The voltage level in order to separate Asynchro-nous and synchronous. Inverter will recognize as Asynchronous if the difference between inverter sensing output voltage and RMS value of positive value is less then this parameter level

COSPHI (P/Pn) Ramp Time

0 99999 sec The slope setup value for PF’s answering time in Cosφ(P/Pn)

COSPHI_1 -1 1 - The variable power factor reference according to active power P_1

P1 0 100 % The active power setup conference for COSPHI_1











COSPHI_7 -1 1 - The variable power factor Reference according to active power P_7






COSPHI_10 -1 1 - The variable power factor Reference according to active power P_10




Parameters


IINV Voltage Build Up Time

0 9999 msec The sync of phase between inverter and grid voltage will be checked after this time, since “Initial voltage buildup” started(XP-TL does not apply)

IINV PLL Stabiliza-tion Time

0 9999 msec The phase between inverter and grid voltage checked and for this time(XP-TL does not apply)

IINV PLL P Gain 0 999.99 - Grid voltage PLL’s P Gain used for “Initial voltage buildup”(XP-TL does not apply)

IINV PLL I Gain 0 999.99 - Grid voltage PLL’s I Gain used for “Initial voltage buildup”(XP-TL does not apply)

IINV Synchroniza-tion Tolerance

1 20 degree This determines a tolerance limit when synchronize the inverter and the grid voltage in „Initial voltage buildup” state(XP-TL does not apply)

FRT Overcurrent Protection Time

0 5000 msec The power generation is stopped for this param-eter value after fault clear in FRT situation


8.7.1 Anti-Islanding Enable

With activation of Anti-Islanding function, XP-HV and XP-TL series will detect and disconnect itself from the grid within a few second. If the Anti-Islanding function is not activated, XP-HV and XP-TL cannot disconnect itself from the grid during grid failure, and generate power to load independently. For example, when inverter infuse 500kW power to gird with 500kW load connected to PCC (Point of Common Coupling), inverter can generate output voltage independently during grid failure, and operate itself with bearing 500kW load.

8.7.2 Power Derating

Figure 56: Block Diagram of Power Derating


Parameters

Figure 57: Decreasing rate

Figure 58: State Machine

Power derating is enabled or disabled by an output of state machine which is decided by 4 inputs. And while the output of state machine is 1, a decreasing rate affects an output power.

A decreasing rate is calculated by multiplying factor K(Power Derating P Gain) and a difference between refer-ence temperature(Power Derating Reference Temperature) and PEBB heatsink temperature.

An output of state machine depends on the state in which state machine is running. A transfer between states happens when defined conditions are satisfied. Basically, if Power Derating Enable is 0, the state is “Disable”. And If Power Derating Enable is 1, transfer is done according to PEBB heatsink temperature.

Following examples show power derating by default parameter.

Descriptions for sections of Example of Power Derating are:

T1: Inverter produces energy and PEBB temperature rises.

T2: When PEBB temperature is higher than 90°C, power derating is activated. And inverter controls output power according to expression, P(%) = 100-(TPEBB-80)x2 until power derating is deactivated.

T3: Output power decrease and PEBB temperature drops. When PEBB temperature is lower than 70°C, power derating is deactivated. And inverter doesn’t decrease output power.


Parameters

8.7.3 Example of Power Derating

Figure 59: Concept of XP series Power Derating


Parameters

8.7.4 Conceptual Relation between Output Power and Temperature

Below graph represents conceptual relation between inverter output power and heat sink temperature. The output power is reduced in proportion to heat sink temperature but keep in mind that the power derating is activated at 90°C and deactivated at 70°C (The activation/deactivation temperature can be tunable by param-eter).

Figure 60: Relation between output power and temperature

8.7.5 COSPHI Control

COSPHI Control function is for controlling active and reactive power which is infused from XP inverter to the grid with Prolog, MMI, and XCU at long distance.

Figure 61: COSPHI Control composition


Parameters

8.7.6 COSPHI Control Mode

COSPHI control operates with five reactive and active power control ways according to COSPHI Control Mode setting.

No. Power control Description Relative Parameters

1 Fixed P Control the maximum active power with Remote Power Control parameter value (% of max rated power).


2 Fixed COSPHI Control the maximum active power with Remote Power Control parameter value (% of max rated power). Control power factor with parameter value of COSPHI Internal Power Factor or COSPHI RPC Power Factor according to present RPC status.


COSPHI Internal Power Factor

COSPHI RPC Power Factor

3 Fixed Q Control the maximum active power with Remote Power Control parameter value (% of max rated power). Control reactive power with parameter value of COSPHI Internal Reactive Power or COSPHI RPC Reactive Power according to the present RPC status.


COSPHI Internal Reactive Power

COSPHI RPC Reactive Power

4 COSPHI (P/Pn) Control power factor to match the graph of maximum 10 continuous COSPHI_n and P_n pairs.

COSPHI_n, P_n

(n = 1~10)

COSPHI(P/Pn) Ramp Time

5 Q(V) Control reactive power infusion from inverter to grid when grid voltage is between rated range. The grid voltage range where Q(V) function is possible is determined by Q(V) Control Deadband and Q(V) Control K Factor.

Q(V) Control Deadband

Q(V) Control K Factor

Q(V) Control Ramp Time

Table 20: COSPHI Control Mode

8.7.7 Communication between Components

COSPHI Control enables remote control of reactive and active power by setting reference of reactive and active power by communication between Prolog, MMI, and XCU. Here are the communication methods between each component.

1. User activates COSPHI Control by Prolog.

2. Prolog sends a COSPHI Control massage at two-minute intervals.

3. MMI interprets the COSPHI Control message from Prolog to modify parameters of XCU.

4. XCU operates according to the modified parameter by MMI.

5. COSPHI (limited to Fixed COSPHI and Fixed Q) has two overlapping parameters for RPC and Internal modes, and MMI modifies the parameter for RPC mode only. If the relative RPC mode parameter is not modified longer than five minutes, XCU will operate according to the parameter for internal mode.


Parameters

Figure 62: The communication Sequence between COSPHI Components


Parameters

8.7.8 Operation Mode

COSPHI Control operates in RPC (Remote Power Control) and internal modes according to communication status to control power with Fixed COSPHI and Fixed Q.

Figure 63: Transition of RPC mode and Internal Mode

1. RPC mode

While MMI is modifying XCU’s Remote Power Control, COSPHI RPC Reactive Power and COSPHI RPC Power Factor parameters with two-minute interval, COSPHI Control operates in RPC mode. In RPC mode, it operates according to Remote Power Control, COSPHI RPC Reactive Power, and COSPHI RPC Power Factor modes.

2. Internal mode

If RPC mode parameter such as Remote Power Control, COSPHI RPC Reactive Power, and COSPHI RPC Power Factor is not be modified within five minutes, XCU will operate in Internal mode. In Internal mode, COSPHI control operates according to internal mode parameters such as COSPHI Internal Reactive Power and COSPHI Internal Power Factor, Remote Power Control parameter does not influence on the active power.

Figure 64: PQ Diagram of XP500-HV-TL


Parameters

Output power limit is based on apparent power which is 111% of the rated power. In other words, where the apparent power is over the rated power, active/reactive power is reduced at same rate respectively so that the final output power does not exceed 111% of the rated power.

PQ diagram above shows that the reactive power is from 0 to 242kVAR according to the power factor which is from 1 to 0.9, the active power is up to 500kW and active/reactive power is not limited because the final output apparent power is not over 555kVA(111% of the rated power). And because the apparent power is over 555kVA where power factor is less than 0.9 the active/reactive power is reduced.

Figure 65: PQ Diagram of XP550-HV-TL

Output power limit is based on apparent power which is 101% of the rated power. In other words, where the apparent power is over the rated power caused by reducing power factor, active/reactive power is reduced at same rate respectively so that the final output power does not exceed 101% of the rated power.

When changing the power factor from 1 to 0.9, the active power is down to 500kW and the reactive power will be up from 0 to 242kVAR since the final output apparent power should be remained at 555kVA (101% of rated power). In case of power factor is 1.0, the output power is 550kW (550kVA).


Parameters

8.7.9 The Relationship of Reactive Power and Active Power

While active and reactive power is set to exceed maximum complex power (1.11PRated) by parameter setting, COSPHI Control reduces active power, and control reactive power by parameter setting.

8.7.10 Cosφ (P/Pn)

The Cosφ (P/Pn) function allows inverter to send changeable PF (power factor) according to the active power to grid. The maximum setup point of both PF and active power is 10 points and the maximum required value of PF for Cosφ (P/Pn) is 0.9 in German market. XP-HV and XP-TL series can also operate with maximum PF, which is 0.9, and its transient time is 10sec.

Figure 66: Active Power - Power Factor Graph

8.7.11 FRT Control

Figure 67: Control Grid Voltage during Inverter Failure (FRT K Factor=2)


Parameters

Figure 68: 0% Drop of Grid Voltage 0%

Figure 69: Grid Voltage 60% Drop

The above graphs show the change of electrical values during FRT (Fault Ride Through) control, and the detailed description for each section is as follows.


Parameters

Section 1

• If Grid Voltage drops below standard FRT value (0.9P.U) set by parameter, inverter will convert its mode to FRT.

• The occurrence of Over Current is decided by the slope and depth, and if when over current occurs, inverter will stop PWM Modulation for one cycle.

• Inverter will infuse the reactive power to grid according to parameter setting.

• Since the reactive power value is proportional to the parameter setting value, you can infuse reactive power to grid as much as possible.

Section 2

• Infuse active power and reactive power to grid according to parameter setting.

Section 3

• The occurrence of Over Current is decided by the slope and depth, and if when over current occurs, inverter will stop PWM Modulation for one cycle.

• Infuse active power and reactive power to grid according to parameter setting.

Section 4

• If Grid voltage rises above standard FRT value (0.9P.U) set by parameter, inverter will convert its mode to normal and stop reactive current infusion.

The operation for FRT (Fault Ride Through) control is possible to set by parameter as follows.

• Grid Under Voltage Levels

- Grid Under Voltage Level 1 – Transfer to FRT mode.

- Grid Under Voltage Level 2 – Inverter stops its operation with ‘Grid Under Voltage Level 2 Fault’ when the grid voltage below ‘Grid Under Voltage Level 2’ sustains over “Grid Under Voltage Trip Time 2”.

- Grid Under Voltage Trip Time 1 – Permissible grid voltage under ‘Grid under Voltage Level 1’ time.

- Grid Under Voltage Trip Time 2 – Permissible grid voltage under ‘Grid Under Voltage Level 2’ time.

Figure 70: FRT Parameters


Parameters

8.7.12 Q(V) Control

Figure 71: Grid Voltage Control during Q(V) Control Enable

As you can see in the above picture, this Q(V) Control function is for the reactive power infusion even if grid is in normal range (90 ~ 110%). Dead band rage is UTarget±1%.

Here, you can calculate slope K Factor for Q(U) Control using an equation ΔQ/ΔU=K Factor, and the variables which are ΔQ=cos(Phi)=0.95, Phi=18.2° and sin(Phi)=0.31. ΔU is the voltage difference between the measured voltage and the specified parameter target voltage as a p.u. Therefore, you can decide slope k factor. For example, if you want to infuse ΔQ at UTarget±5% range and UTarget=UN, the K value would be calculated as 0.31/0.05=6.2. The rage of ΔU is calculated from the end of the dead band.


User interface

9 User interface

1

3, 42

5

6

7

8

9

Figure 72: Connecting the user interface

Key

1 User interface 6 RS485

2 TO (connection for external power supply) 7 UAI (User analog input)

3 L: 230V L 8 Ethernet

4 N: 230V N 9 CAN

5 UDIO (User digital input/output)


User interface

9.1 External TO AC power supply

2b

1b

1b

2b~230 V N

230 V L TO

AC1a

2a

Figure 73: TO AC connection Figure 74: Circuit diagram for TO AC connection

Terminal number Terminal designation Specification Wire cross- section

1b TO L 230V L AWG 14

(2.08mm2)2b TO N 230V N

Table 21: Connections for TO AC auxiliary supply

9.2 Digital input/output

9.2.1 Digital input

1d

3d

2d

4d

5d

1c

3c

2c

4c

5c

1c1d

UDIO

2d 2c

3d 3c

4d 4c

5d 5c

Figure 75: UDIO connection Figure 76: UDI1 connection


1c UDI1 PMax 27Vdc, 27mA

AWG 20 (0.518mm2)1d UDI1 N

Table 22: Connections for digital input


User interface

The system sends digital input signal in accordance with the setting of “DI1 Select” parameter in menu of MMI or parameter setup tool (CMT, AutoSetup).

DI1 Select Description Note

0 Disable DI1

1 Reserved

2 Reserved

3 Start/Stop operation of the inverter by DI1

Recognition pattern:

Stop: ∆t = 1sec

Start: ∆t = 2secRecognition pattern is checked whene-ver DI1 input signal is at rising edge(T0) then it is determined according to how long the DI1 input signal has been stayed in high state.

4 Start/Stop operation of the inverter by DI1


Stop: ∆t = 200msec

Start: ∆t = 400msec

5 Stop operation of the inverter by DI1


DI1 Check Period msec – Stop operation

Figure 77: DI1 input signal

NOTEThe DI1 Check Period is parameter in ‘8.5 Digital Parameters’ that mean recognition pattern period for inverter stop operation when selecting ‘DI1 Select’ to ‘5’.


User interface

9.2.2 S0 input

24Vdc

1c1d

UDIO

2d 2c

3d 3c

4d 4c

5d 5c0Vdc

4.7 kΩ

Input signal

Figure 78: Connection for S0 input


2c S0in PMax 27Vdc, 27mA

AWG 20 (0.518mm2)2d S0in N

Table 23: Connections for S0 input

9.2.3 S0 output

24Vdc

1c1d

UDIO

2d 2c

3d 3c

4d 4c

5d 5c0Vdc

4.7 kΩ

Output signal

Figure 79: Connection for S0 output


3c S0out PMax 27Vdc, 27mA

AWG 20 (0.518mm2)3d S0out N

Table 24: Connections for S0 output


User interface

9.2.4 Digital output

1c1d

UDIO

2d 2c

3d 3c

4d 4c

5d 5c

1c1d

UDIO

2d 2c

3d 3c

4d 4c

5d 5c

Figure 80: Connection for digital output (N/O contact)

Figure 81: Connection for digital output (N/C contact)

Terminal number Terminal designation Specification Wire cross-section

4c UDO1A Potential-free output

contact A

AWG 20 (0.518mm2)

4d UDO1B Potential-free output

contact B

5c UDIO1C Potential-free, common

output contact

5d UDIO1D -

Table 25: Connections for digital user output


User interface

9.3 RS485 interface

The inverter has two RS485 connections.

RS485-1 Interface for the Powador Argus

Interface for optional Powador-go

RS485-2 Interface for the MMI’s internal data logger, or for the external Powador proLOG data logger

9.3.1 RS485-1 Interface

1d

5d

2d

6d

3d

7d

4d

8d

1c

PE

5c

2c

6c

3c

7c

4c

8c

1c

PE

1d

PE

RS485

2d

5d

2c

5c

3d

6d

3c

6c

4d

7d

8d

4c

7c

8c

Signal transceiver

AB

GND

Figure 82: RS485-1 connection Figure 83: Circuit diagram for RS485-1 connection


1c RS485 A1 RS485 signal A1

AWG 20 (0.518mm2)

1d RS485 B1 RS485 signal B1

3c RS485 C1 Termination resistor terminal

3d RS485 G1 RS485 data transmission GND 1

" For termination disposal, you can use RS485 B1(1d) and RS485 C1(3c) with jumper because termination resistor is already installed inside of XCU of XP500/550-HV-TL.

Table 26: Connections for RS485-1


User interface

9.3.2 RS485-2 Interface

1d

5d

2d

6d

3d

7d

4d

8d

1c

PE

5c

2c

6c

3c

7c

4c

8c

1c

PE

1d

PE

RS485

2d

5d

2c

5c

3d

6d

3c

6c

4d

7d

8d

4c

7c

8c

Signal transceiver

AB

GND

Figure 84: RS485-2 connection Figure 85: Circuit diagram for RS485-2 connection


5c RS485 A2 RS485 signal A2

AWG 20 (0.518mm2)

5d RS485 B2 RS485 signal B2

7c RS485 C2 Termination resistor terminal

7d RS485 G2 RS485 data transmission GND 2

" For termination disposal, you can use RS485 B2(5d) and RS485 C2(7c) with jumper because termina-tion resistor is already installed inside of XCU of XP500/550-HV-TL.

Table 27: Connections for RS485-2

9.3.3 Settings for RS485 interfaces

ID Name Unit Default value Min. Max.

0 Activate Powador-proLOG - OFF OFF ON

1 MMI address - 0 0 31

2 Change Powador-go address - - - -

3 Activate Powador-go - OFF OFF ON

4 Diff. tolerance % 10 10 100

5 Fault trigger time minutes 120 10 240

6 Address 0 string number - 0 0 4

Table 28: RS485 interface settings


User interface

ID Name Unit Default value Min. Max.



.. .. - 0 0 4

.. .. - 0 0 4



Table 28: RS485 interface settings

9.4 Analog input

The inverter has four analogue connections.

1c, 1d, 2c, 2d Solar sensor

3c, 3d Ambient temperature sensor

4c, 4d Wind speed sensor

Input range 0 to 10V

1d

2d

3d

4d

1c

2c

3c

4c

1c

2c

3c

4c

1d

2d

3d

4d

An

alo

gu

e

inp

ut

Wind speed sensor

Solar sensor

Temperature sensor

Figure 86: Analogue user input Figure 87: Connection diagram of the analogue Interface


User interface

9.4.1 Solar sensor

Red (rd)Black (bk)Orange (og)Brown (bn)

VCC (12~24Vdc)

GNDIrradiation (0~10V)

Cell Temperature (0~10V)

1c1d

UAI

2d 2c

3d 3c

4d 4c

Si-12TC - T

og

bn

12 ... 24 Vdc

+ -rd

bk

Figure 88: Si-12TC - T Solar sensor Figure 89: Connection diagram for solar sensor


1c IVP0 to 10V

AWG 24 (0.205mm2)

1d IVN

2c CTP0 to 10V

2d CTN

Table 29: Connections for analogue user input - Solar sensor

9.4.2 Ambient temperature sensor

Red (rd)

Black (bk)

Brown (bn)

VCC (12~24 Vdc)

GND

Temperature (0~10V)

1c1d

UAI

2d 2c

3d 3c

4d 4c

PT 1000

bk

bn

12 ... 24 Vdc

+ -rd

Figure 90: PT 1000 Ambient temperature sensor Figure 91: Wiring of the ambient temperature sensor


User interface

9.4.3 Wind speed sensor

Black (bk)

Brown (bn)

GND

Wind speed (0~10V)

bkbn

1c1d

UAI

2d 2c

3d 3c

4d 4c

Figure 92: Wind speed sensor Figure 93: Configuration of the wind speed sensor


3c PTP0 to 10V

AWG 24 (0.205mm2)

3d PTN

4c RSVP0 to 10V

4d RSVN

Table 30: Connections for analogue user input-Ambient temperature sensor, Wind speed sensor

9.4.4 Parameter settings for analogue sensors

IIn order to determine measured values using the analogue sensors, you have to set the “Options” parameter.

The options are calculated and set by a service technician from KACO new energy Inc.,.

ATTENTIONBe careful not to destroy the sensor's measuring input!

Avoid using voltages > 10 V and make sure that the polarity is correct.


Overview Circuit Diagram

10 Overview Circuit Diagram

Figure 94: Configuration of the Powador XP500/550-HV-TL


Decommissioning/Dismantl ing

11 Decommissioning/Dismantling




› Always shut down the inverter (in the sequence described below) before dismantling the unit.

› Do not touch exposed contact connections.


" Switch the main ON/OFF switch to OFF (stop the inverter).

" Switch the power grid switch to OFF (disconnect the inverter from the grid).

" Switch the DC disconnector to OFF (disconnect the inverter from the PV generator).

" Make sure that the inverter is disconnected from all voltage sources.

" Attach locking devices to the circuit breaker of the power grid connection and to the AC and DC disconnectors.

" Wait at least six minutes before working on the inverter.

Decommission and dismantle the inverter

" Disconnect all terminals and cable fittings.

" Remove all DC and AC leads.

" Disconnect the connections and bus bars between the cabinets.


Disposal

12 Disposal

Dispose of the packaging materials

The packaging for the inverter consists of a wooden pallet, plastic foil made of polypropylene, and the shipping container.

" Dispose of the packaging materials in accordance with the applicable waste disposal regulations.

Dispose of the inverter

" After the inverter has reached the end of its service life, dispose of it in accordance with the applicable disposal regulations for electronic waste at your own expense or ask it to Kaco new energy Inc.,

Carl-Zeiss-Straße 1 · 74172 Neckarsulm · Germany · Tel. +49 7132 3818-0 · Fax +49 7132 3818-703 · [email protected] · www.kaco-newenergy.com

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operating instructions - solar-go.co.uk

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