Kaco xi Series Inverter User Manual
Contents
1. Tsing Labloralery is granted hy the 1 5 Oecugeilional Safety amd Healthy A diia ran OSH AS bo Eiberaberues which have heen to pier form D 17 5 Stands 207 Bae KACO Solar Inc 20 Installation Instructions US KACO R e CSA INTERNATIONAL Certificate 1779537 Master Contract _ 225346 Project 1779537 Date Issued 2006 1272 Maximum Operating Current DC 30 A Maximum Array Short Circuit Current 33 A Maximum Utility Backfeed Current AC U A Operating Voltage Range AC 211 264 Vac 240 Vac nominal Operating Frequency Range HZ 59 3 60 5 Hz Nominal Output Voltage AC 240 Vac Normal Output Frequency 60 Hz Maximum Continuous Output Current AC 15 Maximum Continuous Output Power ACh 3100 W i TC Maximum Output Fault Current 20 A Maximum Output Overcurrent Protection 20 A Enclosure Rating Type for Model Blue Planet 2901xi 1 for Model SUNstring 4000 Notes 1 Inverter Models Blue Planet 25811 and SUNstring 4000 have been evaluated for use in utility interactive applications CAN UCSA C22 2 No 0 M9 General Requirements Canadian Electrical Code Part I 4 04 Bonding of Electrical Equipment 07 1 01 General Use Power Supplies UL Std Mo 1731 First Edition Static Inverters and Charge Controllers for Use in Photovoltaic Power Systems Including Revisions through and including January 17 2001 S07 Rey D 30 KA2. 0 blueplanet 3601xi 100 95 175 se 85 iT 80 E 19 175 Vac 70 0 10 20 30 40 50 60 of Rated Output Power 70 80 90 100 peak efficiency curve Blue Planet 3601xi KACO Solar Inc 17 Installation Instructions US A LC KACO 10 UL listing confirmation letter H 10 1 UL Certificate of Compliance Certificate of Compliance Certificate 1624128 Master Contract 228346 Project 1790852 Date Issued 2006 06 01 Issued to KACO Geratetechnik GmbH Gottfried Leibniz Str 1 Neckarsulm 74172 Germany Attention Mr Matthias Haag The products listed below are eligible to bear the CSA Mark shown with adjacent indicators C and US Issued by Ernesto Lopez AScT US Authorized by Lindsay Clark Product Group Manager PRODUCTS CLASS 5311 09 POWER SUPPLIES Distributed Generation Power Systems Equipment CLASS 5311 89 POWER SUPPLIES Distributed Generation Power Systems Equipment Certified to U S Standards Utility Interactive Inverter Model Blue Planet 1501xi permanently connected system ratings as follows Maximum System Voltage 400 Vdc Range of Operating DC Voltage 125 300 Vdc Maximum Operating Current DC 14 A The and US indicators adjacent to the CSA Mark signify thot the product has been evaluated to the applicable CSA and ANSI UL Stand
3. General Use Power Supplies UL Std No 1741 First Edition Static Inverters and Charge Controllers for Use in Photovoltaic Power Systems Including Revisions through and including January 17 2001 DOD S07 Rev 2004 06 30 KACO Solar Inc 19 Installation Instructions US d CSA INTERNATIONAL Certificate of Compliance Certificate 1779571 Master Contract 228346 Project 177957 Date Issued 2006 7 2 2 Is amp ued to KACO Geratetechnik GmbH Gottfried Leibniz Str 1 Neckarsulm 74172 Germans Attention Mr Mattias Hang The products listed below are eligible to bear the CSA Mark shown with adjacent indicators C and US Issued by Ernesto Lopez AScT US Authorized by Lindsay Clark Product Group Manager PRODUCTS CLASS 831109 POWER SUPPLIES Distributed Generation Power Svstems Equipment CLASS 8311 89 POWER SUPPLIES Dhstributed Generation Power Systems Equipment Certified to US Standards Utility Interactive Inverter Models Bluc Planet 2901 x1 and SUNstring 4000 permancnily connected swstem ratings as follows Maximum System Voltage 400 Vide Range of Operating DC Voltage 125 300 Vde The X7 UF andieseors adjacent bo the CSA Moark stenafy that the product has been evaluated to the applicable CEA and ASSET Stemddards fer usg in Canada and the US The UF indicate meludia predicts bo hear the RTL indicstar HAT
4. Installer s Manual for skilled and authorized electricians blue planet 3601xi blueplanet KACO green power r For skilled and authorized electricians Installation Instructions Blue Planet 1501xi 2901xi 3601xi About this document Attachment and Maintenance of documents Symbols used in this document UL Certification Labeling Type label no Important Safety information and instructions Save these Instructions 2 Notes concerning installation and operation3 Factory warranty and liability Service Intended normal use Device description Dimensioning of the PV generator Protective concepts Mechanical dimensions Installation and startup Selecting the appropriate place of installation Installing the inverter Electrical connections co0050 AoA Aa ARAO Connecting the fault signal relay Connection of the So output Connection of the RS485 interface Startup of the inverter Ground fault indication Jumper Position Applications Acceptance by Your Utility Company T 8 9 9 1 Switching off the inverter Troubleshooting Technical Data Peak efficiency curves of blueplanet inverter series 10 Certificates of Compliance 10 1 UL Certificates of Compliance for all blueplanet inverters 10 2 Supplement to Certificates of Compliance 12 12 12 15 About this document The following information will guide you through the entire documentation Further documents will be v
5. Technical rules The assembly must be in compliance with the local regulations and technical rules Regulations concerning the prevention of accidents The inverter must be installed by an approved skilled electrician who is responsible for the adherence to existing standards and regulations The proper and safe operation of the device instrument requires proper transportation storage erection and assembly as well as careful operation and maintenance Only personnel who have read and fully understood all safety information contained in these operating and installation instructions as well as the assembly operating and maintenance instructions shall be authorized to operate the inverter Installation Instructions US During the operation of this device certain parts of the device inevitably carry hazardous live voltages which may lead to severe personal injury or even death The following precautions should be followed to minimize the risk of lethal hazards or personal injuries The installation of the device must be in compliance with the relevant safety regulations e g NEC 690 or other applicable national or local provisions Proper grounding conductor dimensioning and an appropriate short circuit protection must be provided to ensure operational safety All instrument covers must remain closed during operation Prior to performing any visual checks and maintenance work the device must be disconnected from all power so
6. The electrically isolated blue planet xi series devices are currently available for two different power classes The appropriate inverter type should be selected in accordance with the power rating of the selected photovoltaic module array The max power values are indicated in the data sheet Section 9 The inverter designation is shown on the front side above the display and on the type label 4 1 Dimensioning of the PV generator The selection of the PV generator is of crucial importance when dimensioning a PV installation It must be observed by all means that the solar generator is the right match for the KACO Solar Inc inverter Please observe the data given in the Technical Data Sheet Section 9 for dimensioning the solar generator The design and dimensioning KACOCalc pro is available for easy selection of PV modules please obtain your free download at http www kacosolar com Dimensioning of the PV generator The number of PV modules connected in series must be selected in such a way that the output voltage of the PV generator is maintained within the admissible input voltage range of the inverter even in the event of extreme external temperatures The U S module temperatures significantly vary and you should be sure to consult your solar installation specialist about the effect on final voltage calculation It is important that the temperature coefficient of the solar modules is observed The followi
7. max PV generator power of the inverter for a short time particularly due to clouds and relatively low module temperatures it is possible that the inverter switches off for safety reasons and automatically switches on again after approx 10 seconds The overload status is shown on the display in plain text Under normal circumstances however the dynamic control of the inverter ensures that this condition is recognized and the inverter operation is continued without any interruption The solar generator still represents the most substantial cost factor of a solar installation Therefore it is very Installation Instructions US important to obtain maximum energy yields To achieve this goal solar generators located in the US should be orientated towards the South at an angle of inclination of 30 and shading of whatever kind should be prevented under all circumstances In many cases the recommended angle of inclination cannot be implemented for technical reasons To achieve the highest energy yield of a solar generator with optimal orientation South inclination angle of 30 the efficiency of the solar generator can be increased For roofs that are orientated towards the East West we recommend two string PV installations To ensure optimum yield of the installation the first string should be installed on the East side of the roof whereas the second string should be installed on the West side of the roof Please consult you
8. power relay is switched on after approx 5 minutes audible acoustic noise and power delivery is started This is also signaled by the green Grid feeding LED The display now shows the delivered power The Display key can be used to indicate the various measurement values see Operator s Manual It may be necessary to reset the date and hour please refer to the Operator s Manual 5 8 Ground fault indication The Inverter is equipped with a ground fault detection and interruption GFDI as required by UL 1741 If a ground fault occurs on the DC side the inverter disconnects from the grid and a message is displayed In this case the inverter blocked until the following actions are done Switch off the AC and DC disconnect Remove the ground fault on the DC side Replace the GFDI fuse with a Littletuse KLKD 1 600V fuse Switch on the AC and DC disconnect KACO Solar Inc 5 9 Jumper position 7 Lt Soe Fi eeeceonn Figure 5 8 Jumper Position in normal feed in operation power delivery shipping status FACTORY USE ONLY DO NOT ATTEMPT TO ALTER SETTINGS DOING SO WILL VOID WARRANTY AND COULD POTENTIALLY BE HARMFUL TO USER Danger Installation Instructions US 6 Applications Acceptance by Your Utility Company Your PV installation must meet all applicable utility NEC and local electrical codes regarding PV installation requirements The documents you will need to apply
9. the blue planet inverter indicated on the type label meets the fundamental requirements according to the following IEC directives Directive concerning Electromagnetic Compatibility with Class B Council Directive 89 336 EWG Low Voltage Directive Council Directive 73 23 EWG For more information on UL certification please see section 10 1 4 Type label The type label indicating the exact device description is located on the support panel at the underside of the enclosure 2 Important Safety information and instructions Save these Instructions Danger Danger due to lethal voltages Hazardous live voltages are present inside the device instrument and power lines Danger Therefore the device instrument must only be installed and opened by a skilled electrician Even when the device instrument is switched off dangerous live voltages may still be present inside the instrument Standards and Regulations Electrical conformity according to U S Canadian and international safety operating standards and code requirements UL 1741 Standard for Inverters Converters and Controllers for Use in Independent Power Systems CSA C222 No 107 1 01 General Use Power Supplies EEE Recommended Practice on Surge Voltages in Low Voltage AC Power Circuits NEC Sections 690 ANSI NFPA 70 The blue planet inverter has complete on board over current over temperature and anti islanding protection
10. CO Solar Inc 21 Installation Instructions US ee CSA INTERNATIONAL Certificate of Compliance Certificate 1807010 Master Contract 228346 Project 1807016 Date Issued 2006 2 2 Issued to KACO Geratetechnik GmbH Gottfried Leibniz Str 1 Neckarsulm 74172 Germans Attention Mr Mattias Hang The products listed below are eligible to bear the CSA Mark shown with adjacent indicators C and US Issued by Ernesto Lopez AScT Authorized by Lindsay Clark Product Group Manager pr CLASS 831109 POWER SUPPLIES Distributed Generation Power Svstems Equipment CLASS 8311 89 POWER SUPPLIES Dhstributed Generation Power Systems Equipment Certified to US Standards Utility Interactive Inverter Models Bluc Planet 360 x1 and SU Nstring 5000 permancntly connected svstcm ratings as follows Maximum 5ystem Voltage 400 Vde Range of Operating DC Voltage 125 300 Vde The Y UF indicators adjacent bo the CSA Hark stgnafy that the prodest has been evaluated i the applicable CRA and ANSD UL Stemdards for usg in Cansda and the US The UF inidicatir melide predicts b hear the RTL ndier NR TL ce Istum Tsing Laloralery is granted I the 1 5 Safety and Health Adia ran OSA AD Do Blaaie which have heen le Do 17 5 Sandre 5177 Fass ML a KACO Solar Inc 22 Installation Instruct
11. age Max operating current DC Max array short circuit current DC Polarity safeguard Overvoltage protection Rated output 25 C AC Rated output 40 C AC Max output power AC Nominal voltage AC Grid voltage AC Max utility backfeed current AC Max continuous current AC Overcurrent protection Frequency Distortion factor Fault signal relay So output Max degree of efficiency CEC efficiency Internal consumption Min grid feeding power Circuit design Clock frequency Principle Grid monitoring Optical displays Operating elements Connections Ambient temperature Temperature monitoring Cooling Protection Class Noise emission Housing enclosure Dimensions W x D x H Weight KACO Solar Inc Input Electrical data 1501xi 2901xi 3601xi 1580 W 3250 W 4100 W 1700 W 3400 W 4400 W 125 300 Vpc Up to 400 Vpc Stand by from Ue 125Vpc Night shutdown from Ue lt 100Vpc 14 Apc 30 Apc 43 Apc 15 Apc 33 Apc 48 Apc Short circuit diode Varistors Output Electrical data 1500 W 3100 W 3900 W 1500 W 2900 W 3600 W 1650 W 3400 W 4400 W 240 V 211 264 V 0 Aac 0 Aac 0 Aac 7 8 Aac 15 0 Aac 24 0 Aac 15 Aac 20 Aac 30 Aac 59 3 60 5 Hz lt 3 at rated power lt 5 over the entire range Potential free NO contact make contact max 30V 1A Open Collector output max 30V 50mA Inverter Electrical data 95 0 94 0 96 95 0 93 5 95 0 96 94 0 96 Night shutdown OW Oper
12. alid in conjunction with these operating installation instructions We shall not be liable for any damage caused by non adherence to the instructions given in this manual Pertaining documents During the inverter installation please observe all assembly and installation instructions for components and other parts of the system These instructions are shipped together with the respective installation components or supplementary equipment 1 1 Attachment and Maintenance of documents Please keep these operating and installation instructions in a safe place to ensure that they are available if needed 1 2 Symbols used in this document Please observe the safety information provided in this manual when operating your inverter Warning Lethal Hazard Danger Lethal Hazard by Electric Shock Danger Caution Potential hazard for the product and environment gt Caution Note Useful information and remarks Important Non adherence to these instruc tions may adversely affect the operating convenience or func tionality of the device S l This symTo connect the inverter the AC and DC side must be disconnected from all voltaae Caution PoTo reduce the risk of fire connect only to a circuit provided with branch circuit over current protection in accordance with the KACO Solar Inc 1 3 UL Certification Labeling UL labeling is used to document that
13. ards for use in Canada and the U S respectively This US indicator includes products eligible to bear the indicator NRTL i e National Recognized Testing Laboratory is a desipnation granted by the U S Occupational Safety and Health Administration OSHA to laboratories which have been recognized to perform cenification to U S Standards non EI Rev _ Solar Inc 18 Installation Instructions US tt m ms fT WEYY rm E L mum ki in CSA INTERNATIONAL a Certificate 1624128 Master Contract 228346 Project 1790852 Date Issued 2006 06 01 Maximum Array Short Circuit Current 15 Maximum Utility Backfeed Current AC 0 A Operating Voltage Range AC 211 264 Vac 240 Vac nominal Operating Frequency Range HZ 59 3 60 5 Hz Nominal Output Voltage AC 240 Vac Normal Output Frequency 60 Hz Maximum Continuous Output Current 40 7 8 Maximum Continuous Output Power 40 C AC 1500 W Maximum Output Fault Current 18 A Maximum Output Overcurrent Protection 15 Enclosure Rating Type 3R Notes 1 Inverter Model Blue Planet PVI1501xi has been evaluated for use in utility interactive applications 2 Utility interactive evaluation were conducted with firmware version 1 2 APPLICABLE REQUIREMENTS CAN CSA C22 2 No 0 M91 General Requirements Canadian Electrical Code Part 11 CAN CSA C22 2 No 04 04 Bonding of Electrical Equipment CSA C22 2 No 107 1 01
14. ation 5 W 10W Grid tied electrically isolated RF transformer 18 kHz 1 Potential free DC DC converter 2 IGBT full bridge as part of the inverter UL 1741 Inverter Mechanical and technical data DC Power In green AC Power Out green Error red LC display 2 x 16 characters 2 keys for display operation PCB terminals inside the device Cable routing via PG fittings 4 104 gt 167 F temperature dependent power gt 167 F temperature dependent power gt 158 F temperature dependent power adjustment adjustment adjustment gt 176 F disconnection from gt 185 F disconnection from gt 185 F disconnection from the grid the grid the grid True convection no fan or blower NEMA 3R IP54 according to EN 60529 lt 35dB soundless Aluminum wall mounted enclosure 13 1 4 x 23 3 4 x 8 3 4 in 52 7 los 13 1 4 x 25 3 4 x 8 3 4 in 65 7 los 13 3 8 x 7 7 8 x 17 3 4 in 30 8 lbs 15 Installation Instructions US 9 1 Peak efficiency curve blueplanet 1501xi 75 4 70 4 0 000 0 500 1 000 Pac KW peak efficiency curve Blue Planet 1501xi blueplanet 2901xi 1 500 2 000 125 V 100 90 85 80 TS 70 e 125 0 10 20 30 40 50 60 70 of Rated Output Power 80 90 100 peak efficiency curve Blue Planet 2901xi KACO Solar Inc 16 Installation Instructions US H
15. cess for assembly or service work Maintain a minimum clearance of 19 11 16 in around the device and between the device and other objects such as cabinets ceiling or similar The device has been designed for vertical wall installation Please ensure free air circulation around the device and through the heat sink at the rear side f the inverter is installed in a switch cabinet or similar please provide forced ventilation to ensure that heat is dissipated adequately Ensure that the wall has an adequate load bearing Figure 5 1a Wall installation of blue planet capacity and only use the appropriate installation material n areas with a special risk of flooding always make sure to install the inverter in a sufficiently elevated place Installation at eye level makes it easier to read the display Temperature Ensure that the GT Inverter is mounted in a location where the ambient temperature range is 4 to 104 33 Important L Due to the high system voltage less current may flow on the DC v voltage side than on the AC voltage side Given the same cable cross sections losses are there fore higher on the AC voltage side than on the DC voltage side The inverter will ideally be located in close proximity to the local utility s electric meter tase for Pen Irg MS pereg Figure 5 1b Wall installation of blue planet KACO Solar Inc 6 Installation Instruct
16. conditions the generator voltage or respectively generator power fed from the roof may be insufficient for grid feeding After an interruption of the grid feeding process due to a disturbance grid power failure overtemperature overload etc the inverter always waits for approx 5 minutes before resuming its grid feeding operation Grid failures may cause interruptions during the day If more than 10 interruptions per day should occur over several weeks you should contact your solar installation provider Although there is enough solar irradiation the inverter delivers power for a few seconds only and switches off again During this short time a grid feeding value between 0 5 W is displayed If insufficient generator power can be ruled out in this case the grid isolation relay is presumably defective and prevents the inverter from being activated 13 Installation Instructions US Error Possible causes Remedy Explanation Inverter causes noise Special environmental Under special environmental conditions the devices may cause conditions audible noise This may be due to the following causes Grid effects and or grid disturbances caused by special consumers motors machines etc which are connected to the same grid point or which may be installed in the vicinity of the inverter Dynamic weather conditions frequent changes between sun and clouds may cause slight line hum due to high energy Certain grid conditions ma
17. ction 5 8 Figure 5 5 Sg Connection 5 6 Connection of the RS485 interface On the control board at the rear side of the door of the blue planet inverter there are four terminals marked RS485 A and B see Figure 5 6 To connect several blue planet inverters terminal A of the first blue planet must be connected to terminal A of the second blue planet terminals B are connected in the same way You need a twisted and shielded data cable for connection such as an ISDN cable The connection to proLOG is established analogously The wiring plan is shown in Figure KACO Solar Inc 10 KACO 5 7 The total length of the RS485 wiring should not exceed 250 m max 32 Pirmicir Figure 5 7 Wiring plan for RS485 Interface Figure 5 7 shows a terminator which is connected to the left inverter Ra 3300 This terminator resistor is needed on the last device in the chain to ensure correct signal transfer The terminator is supplied together with the blue planet inverters Within a bus system such as the RS485 each device taking part in this system must have a unique address regardless of whether this is an inverter or current sensor For inverters the address range can be selected between 0 and 31 The address of each inverter can be determined via the Set menu see Operator s Manual I5 Important Please ensure correct connection of the A and B wires If these wires are improperly connected no correct comm
18. display reads Start from 125 V Measurement xxx V Inverter is active but does not deliver power the display reads Start from 125 V Measurement xxx V measured voltage is higher than 125V The inverter terminates grid feeding shortly after starting up although there is enough solar irradiation KACO Solar Inc measuring elements sensors Grid voltage failure Insufficient grid fuse rating Inverter hardware is damaged Device is in the night shut down mode No grid voltage is present Solar generator voltage is less than 100V Device is in the night shut down mode No grid voltage is present The solar generator voltage is less than 100 V Insufficient generator voltage Voltage measured 125V The inverter has interrupted grid feeding due to a malfunction disturbance Defective grid isolation relay in the inverter values are given in the Operator s Instructions The daily yield value may deviate from the value shown on the power meter by up to 15 Even if an incorrect daily peak value is displayed the inverter continues to work properly and without any yield losses Values are reset overnight If you wish to reset the display immediately disconnect the inverter and the DC grid voltage supply and switch on the inverter again At times of high solar irradiation the inverter may exceed its rated current for a short time depending on the type of solar generator Therefore the grid fuse sh
19. ects You have purchased a product that has left our factory in proper operating condition Each individual device has successfully passed extensive inspection tests for proper operation and functioning of protective devices as well as a long duration test at our factory Should your PV installation not work properly despite all these measures we recommend the following procedure for remediation Check the solar generator and grid connections leading to the PVI observing all the safety instructions given in this manual Please observe the inverter carefully and take note of the display messages and LED displays Below is a summary of possible error and recommended remedies Warning These servicing instructions are for use by qualified personnel only To reduce the risk of electric shock do not perform any servicing other than that specified in the operation instructions Warning Installation Instructions US Table 8 1 Troubleshooting Guide Possible Cause Remedy Explanation Daily yield values do not Tolerances of the Measuring errors are caused by tolerances of the measuring correspond to the values inverter s internal elements sensors The tolerances of the individual measuring shown on the power meter of the Utility company Inverter shows an unrealistic daily peak value Grid fuse triggers No display shown Inverter does not start Inverter is active but does not deliver power the
20. for acceptance of your PV system can be provided by your solar system installer If you are licensed electrical contractor you may be eligible to install the PV system yourself In this case you may then request all necessary documents directly from your local utility 7 Switching off the inverter The inverter must be switched off for adjusting maintenance and repair work Please proceed as follows To shutdown the inverter follow the directions exactly or arcing might occur when disconnecting the DC connector under load This will destroy the connectors Disconnect the deactivate the breakers Disconnect the photovoltaic module via the DC disconnect Check that the grid terminals of the inverter are disconnected from all voltage sources grid external voltage safety Danger Lethal hazard by electric shock Hazardous live voltages can be present in the inverter even if the electrical connections have been switched off or disconnected Please wait for five minutes before accessing the inverter If you have to work on the solar generator you must additionally disconnect all connections of the DC main switch on the generator connection box or DC connector It is not sufficient to switch off the grid voltage Danger KACO Solar Inc 12 8 Troubleshooting Within the scope of our continuously expanding Quality Assurance System our goal is to rule out and eliminate any faults and def
21. g the serial number and the type of inverter The warranty belongs to the unique serial number of the inverter and not any particular person therefore KACO inverters are sold with a 10 year transferable warranty The inverter must be returned to KACO Solar Inc in the original packaging materials or packaging providing equal protection during shipment KACO Solar Inc is not responsible for damage occurring during shipment To satisfy the claims of our easy swap warranty KACO Solar Inc will ship any replacement inverter within 24 hours after a claim has been issued and approved If the inverter fails out of the box or within a 6 month period of operation a new inverter shall be issued After 6 months of installation a factory reconditioned unit of newer or similar age shall be issued Exclusion of Liability KACO Solar Inc disclaims any liability for direct or indirect damages due to 1 improper installation or commissioning 2 modifications alterations or repair attempts 3 inappropriate use or operation 4 insufficient ventilation of the device 5 non compliance with relevant safety standards or regulations 6 flood lightning overvoltage storm fire acts of nature We do not guarantee that the software is completely free of faults In most cases technical alerts will be posted on the KACO Solar website describing how to avoid the effects of the fault If the concern is greater written explanation will be mailed to reg
22. in the first one year of commissioning Thereafter KACO customers will still enjoy the protection of the standard 10 years replacement guarantee and compensation for service performed to repair an inverter will be awarded on a case by case basis Technical support is available by telephone at 1 866 522 6765 Monday through Friday 8 AM 5PM PST 3 3 Intended normal use Blue planet inverters are built according to state of the art and approved safety requirements However improper use may cause lethal hazards for operators or third parties and or damage of instruments devices or other property The device is intended to convert the direct voltage generated in the photovoltaic PV modules into alternating voltage AC and feed this voltage into the grid The inverter is intended to convert direct current dc energy generated by the photovoltaic PV modules into alternating current ac energy that is then fed into the utility grid Any use other than the specified intended use is not deemed intended or normal use the manufacturer supplier shall not be liable for any damage caused by such unintended use Damage caused by unintended use is at the sole risk of the operator The term intended use shall also include the adherence to the operating and installation instructions Some of the documents which are needed for these applications and acceptance are attached to these installation instructions 4 Device description
23. ions US KACO p CSA INTERNATIONAL Certificate 1807016 Master Contract 223346 Project 807016 Date Issued 2006 1 2 2 Maximum Operating Current DC 43 A Maximum Array Short Circuit Current 48 A Maximum Utility Backfeed Current AC U Operating Voltage Range AC 211 264 Vac 240 Vac nominal Operating Frequency Range HZ y 393 605 Hz Nominal Output Voltage 240 Vac Normal Output Frequency 60 Hz Maximum Continuous Output Current ACh 24 A Maximum Continuous Output Power AC 4000 W i 25 C 3900 W ig HPE Maximum Output Fault Current 54 A Maximum Output Overcurrent Protection 30 Enclosure Rating Type for Model Bloc Planet 3601 xi 1 for Model SUNstring 5001 Notes 1 Inverter Models Blue Planet 36011 and SUNstring 3000 have been evaluated for use in wtility interactive applications CAN UCSA C22 2 No 0 M9 General Requirements Canadian Electrical Code Part I 4 04 Bonding of Electrical Equipment 107 1 01 General Use Power Supplices UL Std Mo 1741 First Edition Static Inverters and Charge Controllers for Use in Photovoltaic Power Svstems Including Revisions through and including January 17 2001 DEO 507 Rey 2003 06 30 KACO Solar Inc 23 Installation Instructions US 10 2 Supplement to Certificate of Compliance Supplement to Certificate of Compliance Certificate 1624128 Master Contract 228346 The products listed i
24. ions US The inverter is shipped together with an installation kit consisting of four dowel pins and four 2 34 in screws Prior to installation the condition of the mounting wall has to be checked If necessary use a kit other than the one shipped with your inverter Drill the holes for the dowel pins according to the positions indicated on the mounting plate Place the dowel pins into the holes Do not just hang the dowel pins on holes in drywall wall board Ensure that the screws and preferably the dowel pins are fastened to a solid wood support such as a wall stud 2x4 lumber Using the screws fasten the mounting plate to the wall Make sure that the arrow shown on the mounting plate is directed upwards Suspend the inverter in the suspension fixture Ensure that the bars rest on the appropriate lugs noses in the heat sink Lock the safety catch To do this slide the upper end of the catch towards the wall until the groove is parallel to the wall see Figure 5 2 Safety catch is open left and closed right KACO Solar Inc T Installation Instructions US 5 3 Electrical connections General Information The electrical connections can be established after the inverter has been installed in its fixed location Caution The electrical installation of the blue planet must only be performed by a qualified electrician Caution Caution To connect the inverter the AC and DC
25. istered installers The solar system installer is responsible for the correct selection proper use supervision and consequences of the use of software We reserve the right to make alterations that will improve the functioning of the device KACO Solar Inc will not be liable for any direct indirect or consequential damages losses costs or expenses however arising in contract or tort including without restriction any economic losses of any kind any loss or damage to property any personal injury any damage or injury arising from or as a result of misuse or abuse or the incorrect installation integration or operation of the product Installation Instructions US 3 2 Service From the initial stages of product development high quality and longevity for our inverters is of central importance to us This philosophy is the result of our experience of over 60 years in the field of power conditioning and current inverters Despite these quality assuring measures in some rare cases errors may occur KACO Solar Inc will offer a maximum of assistance if one of these cases should arise KACO Solar Inc will take every effort to remedy any defects fast and without unnecessary bureaucracy Please contact our service department directly for fast and efficient support Service Reimbursement KACO Solar will pay 100 00 for each inverter replacement and 25 per additional inverter at the site when there is a true inverter failure with
26. ncluding the latest revision described below are eligible to be marked in accordance with the referenced Certificate Product Certification History Project Date Description 1790852 2006 06 01 Update to Report 1624128 to Include Alternative Construction and Firmware Revision 1672417 2005 11 25 Update to Report 1624128 Inverter Model Blue Planet 1501 xi 1624128 2005 02 14 Original certification KACO Solar Inc 24 Installation Instructions US S KACO KACO Solar Inc 1002 B OReilly Ave San Francisco CA 94129 T 1 415 931 2046 F 1 415 931 1688 info kacosolar com www kacosolar com
27. ng criteria must be met for calculating the voltage of the PV generator Uo 13 F lt max input voltage 400 VDC Even at very low external temperatures 13 F the no load voltage of the connected string must remain within the admissible input voltage range For example if the temperature falls from 77 F to 13 F the no load voltage of 12 V modules will increase by approx 2 8 V per module 5 6V for 24V modules The no load voltage of the entire string must be less than 400 volts Umpp 140 F gt min input voltage 125VDC Caution Using the device for any purpose other than intended normal use is prohibited Caution Even at very high external temperatures 140 F the MPP voltage of the connected string should remain within the admissible input voltage range If the temperature rises from 77 F to 140 the MPP voltage of 12V modules will decrease by approx 3 6 V per module 7 2 V for 24V modules The MPP voltage of the entire string should be gt 125 V Even if the MPP voltage is beyond the admissible input range the installation nevertheless will continue to work properly However the delivered power is slightly less than the maximum yield Provided that the input voltage is within the admissible input voltage range the inverter will not be damaged if a connected PV generator should supply current above the max usable input current If the PV generator should supply more than the
28. ould have a higher rating than the max grid feeding current The grid fuse acts immediately if the inverter changes over to grid feeding i e on termination of the start up period In this case the inverter hardware is damaged and the device has to be returned to KACO for repair The inverter shuts down over night If the display should not be illuminated during a normal time of the day you should check on the power meter whether or not the device delivers power If power is delivered the display module is defective and the inverter has to be returned to KACO for repair If no power is delivered you should check that grid voltage is present and that the solar generator voltage is higher than 125 V If this is the case but the inverter still fails to deliver power the device will have to be returned to KACO for repair The inverter shuts down over night If the display should not be illuminated during a normal time of the day you should check on the power meter whether or not the device delivers power If power is delivered the display module is defective and the inverter has to be returned to KACO for repair If no power is delivered you should check that grid voltage is present and that the solar generator voltage is higher than 125 V If this is the case but the inverter still fails to deliver power the device has to be returned to KACO for repair After sunrise at sunset and during times of low solar irradiation due to bad weather
29. r specialist dealer or notify us if you should require any further assistance KACO Solar Inc 4 2 Protective concepts The following monitoring and protective functions are integrated in blue planet inverters BiSI grid monitoring to protect against personal injuries and avoid islanding effects according to UL 1741 Overvoltage varistors protect the power semiconductors against high energy transients on the grid side Temperature monitoring of the heat sink EMC filters to protect the inverter against high frequency grid interference Grid side varistors to earth ground to protect the inverter against burst and surge pulses Ground Fault Detector Interrupter GFDI according to NEC 690 5 4 3 Mechanical dimensions Figure 4 1 Dimensions of Blue Planet Type Height Width Depth 1501xi 17 3 4 18 3 8 2901xi 19 5 8 13 3 8 8 3 8 3601xi 25 5 8 13 3 8 8 3 8 Installation Instructions US 5 2 Installing the inverter 5 Installation and startup 5 1 Selecting the appropriate place of installation 35 Blue planet inverter housings meet the requirements of NEMA 3R The inverter is outdoor rated In addition the installation environment should be well ventilated so as to protect against overheating and ensure long inverter life The following rules should be observed when selecting the place of installation of your inverter Ensure good ac
30. ross sections for cable lengths up to 60 feet Blue Planet 1501xi Blue Planet 2901 xi Blue Planet 3601xi AWG 12 15A Breaker AWG 12 20A Breaker AWG 10 30A Breaker Larger cross sections should be used for longer cable lengths Please make sure to use Wires with sufficient cross section width to avoid excessive line impedance internal resistance of the electrical grid between the domestic distribution and the respective blue planet inverter NEC ANSI NFPA 70 wiring methods must be used At a high line impedance i e long AC side leads the voltage at the grid terminals will increase during power delivery This voltage is measured by the inverter If the voltage across the grid terminals exceeds a defined limit the inverter will switch off due to grid overvoltage This condition must be taken into consideration when sizing the AC lead Danger Hazard due to electric shock from contact with terminals carrying high voltages The external AC and DC disconnects should be opened before any connections are made Danger Installation Instructions US Route the wire through the conduit fitting Connect the wire according to the mark shown on the sticker on the right side of the PCB Determine the DC voltage between protective earth PE and the positive lead or respectively between ground and the negative lead of the PV generator If stabilized voltages can Caution be measured this indica
31. side must be disconnected from all voltage sources and protected against Caution inadvertent switching on Caution To reduce the risk of fire connect only to a circuit provided with branch circuit over current protection in accordance with the Caution National Electrical Code ANSI NFPA70 All applicable safety instructions and technical connections stipulated by local utility and the relevant NEC codes along with any other local or regional stipulations must be followed The connection of the PV Generator and the grid are established via terminal blocks on the printed circuit board See Figure 5 3 Openings for conduit fittings are located on the bottom plate of the unit Open the door of the housing enclosure The door is secured against opening by means of two recessed head screws on the right upper side d The max connecting wire cross section for the AC and DC connection terminals is 13 3 AWG 6 for flexible lines and 16 mm for rigid non flexible lines The stripping length is 10 mm The terminal is to be tightened with a torque of 1 2 to 1 5 Nm KACO Solar Inc DC Input Wiring AC Output Wiring Negative Positive L1 GND L2 Figure 5 3 Connection box of blue planet Grid connections 3 lead connections are used L1 GRD L2 To insert the wires use watertight conduits at the underside of the housing We recommend the following wire c
32. tes a ground Please check all leads for proper fault in the PV generator or generator connection wiring The ratio between the measured voltages indicates the location of this fault Make sure to remedy this fault prior to performing any further actions Caution Once again check if all connected leads are securely fastened Fasten Determine the electrical resistance the wire connection of the cable between the ground and the negative fitting minus lead of the PV generator A low resistance value lt 2 MQ indicates a high resistance ground fault of the PV generator which must A disconnect switch shall be provided be remedied prior to further install by others for the dc input and ac ation output circuit Caution Prior to connecting the DC leads 5 3 1 PV array connections to the inverter terminals the The PV array connections are established on the right side Cauti voltage of the solar generator of the connection box must be measured The DC voltage must not exceed max 400 VDC Connecting to Caution higher voltages will result in the Do not connect the ground to the destruction of the device DC negative at any point This is Caution already done within the inverter Connect the DC leads as described in the following Insert the DC leads through a watertight conduit at the Caution underside of the housing Risk of damage Connect the positive lead on
33. the DC terminal and Ensure correct polarity the negative lead on the DC terminal Caution Connect the ground wire to one of the marked ground terminals Ensure all connections are correctly wired and properly torqued with 17 in lb 1 2Nm Danger To ensure maximum protection against hazardous live voltages Danger during the assembly of the The input and output circuits are isolated from the enclosure System grounding is the responsi T x bility of the installer as required by dig e sections 690 41 and 690 49 of the plus and minus leads must be NEC ANSI NFPA 70 strictly isolated from earth potential GRD KACO Solar Inc 9 Installation Instructions US 5 4 Connecting the fault signal relay The inverter is equipped with a potential isolated relay contact to signal faults If a fault occurs this contact will be closed Max contact load 30V 1A qe Important In the event of a power failure in the public grid the relay will not trigger In this case all LEDs and the display will be extinguished and the inverter will be shut down completely A fault signal will not be possible in this case E wore tio pee Figure 5 4 Fault signal relay 5 5 Connection of the So output The inverter is equipped with an So pulse output for connection of e g a large display The pulse rate is adjustable see page 11 Se
34. transport to our customers Nevertheless transport damage may not be ruled out completely In this case the forwarding agent carrier will be responsible Please check the inverter carefully on arrival Should you discover any visible signs of damage on the packaging which may imply that the inverter may be damaged or should you find any visible signs of damage on the inverter please notify your responsible forwarding agent carrier immediately If necessary your solar installation provider or KACO solar service specialist will assist you However written damage KACO Solar Inc reports must be received by the forwarding agent within six days after receipt of the goods Use exclusively the original packaging for returning the inverter only this material will ensure safe transportation 3 Notes concerning installation and operation 3 1 Factory warranty and liability Terms and conditions Customers shall contact KACO Solar Inc to obtain a Return Merchandise Authorization RMA number before returning products KACO Solar Inc accepts no responsibility or liability for products returned without prior authorization KACO Solar Inc at its sole determination will repair or replace inverters returned by customers Inverters must be returned with a copy of the original dealer invoice or written proof of installation if the inverter has not been already registered by fax or mail Inverters must include a legible data label showin
35. unication will be possible Installation Instructions US 5 7 Startup of the inverter After completing the mechanical and electrical installation you may now put the inverter into operation as follows NOTE The inverter can only be put into operation under daylight conditions i e at a solar generator voltage of 100 V If no daylight or solar generator voltage is present the inverter can be activated by pressing the Start key see Section 4 4 of the Operating Instructions but normal operation will not be possible in this condition Only the values can be read off the display Switch on the grid voltage via the external automatic safety breakers Switch on the solar generator via the DC circuit breaker or DC plug type connector The green LED PV generator will now be illuminated if the generator voltage is greater than 125V The display now shows the current generator voltage Start from 125V measurement xxx V If the measured voltage is greater than 125V the device will start power delivery after approx 5 minutes This starting up period of 5 minutes is necessary to ensure that the generator voltage is permanently above the power delivery limit of 125V A quick start routine is provided for test purposes this routine circumvents the start up period This quick start is menu controlled and obtained from the set up mode see Operator s Manual During the normal startup procedure the line
36. urces and protected against accidental activation If measurements must be conducted while the device is connected to power NEVER touch live terminals Remove all jewelry from your wrists and fingers Ensure that the equipment is in proper condition When working on an energized inverter use appropriate tools and do not come into contact with grounded surfaces including the earth Exactly follow the instructions given in these operating and installation instructions especially observe information concerning possible hazards warnings and precautions Should any specific problems occur which are specifically in this or the operators manual please contact your specialist dealer Modifications Changes Performing any modifications or changes on the inverter is generally prohibited Performing any changes or modifications in the environment of the inverter is only permitted if they comply with national standards Transportation Caution Hazard of damage due to unauthorized modifications manipulation means manipulate the inverter Caution modify or change the inverter or any other part of the installation The blue planet inverter is subjected to extensive testing and inspection in our test field so as to ensure the superb quality of our products Our inverters leave our factory in proper electrical and mechanical condition Special packaging ensures that nothing can happen during the
37. y result in grid resonance between the input filter of the device and the grid which may continue to be audible even after the inverter is switched off Persons with very sensitive ears children in particular may perceive high frequency hum of the inverter caused by the operating frequency of 18 kHz This noise does not affect the operation of the inverter or inverter performance and will not result in any failure damage or shorter useful life of the devices If the defects found should not be able to be remedied through utilization of the measures described above please contact your solar installation provider or our Service Department Please have the following information ready to enable the KACO Solar Inc Service Department to respond quickly and properly Inverter Data Serial number of the device Inverter type Short description of errors the fault or error reproducible If so please provide a short description Does the fault or error occur sporadically Describe the solar irradiation conditions when the error occurred Hour of the day when the hour occurred Photovoltaic module data Module type manufacturer if available send data sheet Number of modules connected in series Number of strings Generator power KACO Solar Inc 14 Installation Instructions US 9 Technical Data Model DC rated power Max PV generator power MPP range No load voltage Monitoring input volt
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