110318_XPUser and Installation Manual
Contents
1. KACO RN new energy XP100U H2 XP100U H4 XP83U H6 XP90U H6 XP100U H6 CANADA CERTIFICATION ONLY USER AND INSTALLATION MANUAL Note The H6 models are certified for use in Canada only IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the Inverter that shall be followed during installation operation and maintenance of the inverter Warning These service instructions are for use by qualified personnel only To reduce the risk of electric shock do not perform work other than that specified in the operating instructions unless you are qualified to do so Caution To reduce the risk of fire connect only to a circuit provided with 150 H4 models 400 H2 models and 125 H6 models amperes maximum branch circuit over current protection in accordance with the National Electrical Code ANSI NFPA 70 NOTE THE H6 models are certified for use in Canada only Warnings A warning describes a hazard to equipment or personnel It calls attention to a procedure or practice which if not correctly performed could result in damage to or destruction of part or all of the Inverter equipment and or other equipment connected to the Inverter equipment or personal injury N DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury N WARNING WARNING indicates a hazardous situation which if2. 660 lt Vac lt 720 120 lt Vac Grid Maximum Voltage 249 lt Vac 576 lt Vac 720 lt Vac 10 cycles Page 72 new energy Grid Frequency Range Every voltage and frequency range is adjustable and password protected XP100U H2 XP100U H4 Frequency Range System Condition XP83U H6 XP90U H6 XP100U H6 Trip Time f lt rated 3 0 Grid Minimum Frequency f lt 57 0 10 cycles f lt rated 0 7 Grid Under Frequency f lt 59 3 10 cycles rated 0 7 lt f lt rated 0 5 Normal Operation 59 3 lt f lt 60 5 f gt rated 0 5 Grid Over Frequency f gt 60 5 10 cycles Page 73 new energy 17 CONFIGURATION The Inverter Block Diagram 10 Kao MC21 CB20 ene 0 F4 DC PV Modules 300 600 VDC E So Input OY mi Se Outpetta Ch mi Cel Temo E Digital ingutti Ch Ambient Temp mi Digital Ovtpwtis Ch Ml Weed Speed Cammunk son E Digita n States Mono eng Block Diagram of the Inverter 18 CERTIFICATIONS Intertek KACO new energy AUTHORIZATION TO MARK This authorizes the application of the Certification Mark s shown below to the models described in the Product s Covered section when made in accordance with the conditions set forth in the Certification Agreement and Listing Report This authorization also applies to multiple listee model s identified on the correlation page of the Listing Report This document is the property of Intertek Testing Services and is not transferable T
3. 2 Protocol for the PVI go Page 53 KACO new ergy RS485 ID 0 999 ID for communication with RS485 Do ne CAN ID 0 999 ID for communication with CAN ANALOG INTERFACE PARAMETERS Parameters Units Ranges Descriptions Default ona a san aaa ee NES ECHO IR fe ae Talaan maana e Cao Jalan maa 0 Cao lalan mma Lo NETWORK PARAMETERS Parameters Units Ranges Descriptions Default IP address in the form of xxx XxxX XXX XXX Address for the router in the form of XXX XXX XXX XXX OKT KI C KO e Du Netmask used for the Network Its form is EJ XXX XXX XXX XXX H n Page 54 KACO new energy RECORDING PARAMETERS Parameters Units Ranges Descriptions Default Recording Interval ER period for recording parameters 1 Grid Power On 1 If off the Grid power isn t recorded 0 0 Off 0 On 1 If off the PV Power isn t recorded Off 0 PV Voltage On 1 If off the PV Voltage isn t recorded Off 0 O n ff ff ff On 1 If off the PV current isn t recorded ff 0 On ff ff PV Temp Delete All Statistics If off the PV Temperature isn t recorded Off 0 On 1 If off the Irradiation isn t recorded Off 0 N A Delete all statistics data N A Page 55 KACO new energy 13 FAULTS amp WARNINGS When a problem occurs in the system the Inverter will beep and inform the user on the GUI The Inverter displays two ba
4. are present in the live components of the low voltage grid Death may result from burns and electric shock Do not touch the live components of the Inverter or low voltage grid Pay close attention to all safety precaution measures regarding the low voltage grid Page 8 N DANGER During operation high voltages are present in the Inverter Death may result from burns and electric shock Before commencing work on the Inverter disconnect completely and ensure that the device will not be accidentally energized Ensure that no voltage is present Ground and short circuit Cover any nearby live parts N DANGER Normally grounded conductors may be ungrounded and energized when a ground fault is indicated Risk of electric shock Test before touching Contact customer support for information at KACO new energy Inc 1 415 931 2046 WARNING Failure to follow the manual the operating instructions and the safety precautions may lead to severe injury from electrocution All work on the Inverter may only be done as described in this manual and must be performed by qualified personnel Pay attention to all safety instructions Follow all operating instructions If problems occur when performing the work described here contact the customer support department at KACO new energy Inc 1 415 931 2046 Page 9 KACO N WARNING Operating the Inverter if its damaged may cause severe injury from electroc
5. energy Intertek AUTHORIZATION TO MARK This authorizes the application of the Certification Mark s shown below to the models described in the Product s Covered section when made in accordance with the conditions set forth in the Certification Agreement and Listing Report This authorization also applies to multiple listee model s identified on the correlation page of the Listing Report This document is the property of Intertek Testing Services and is not transferable The certification mark s may be applied only at the location of the Party Authorized To Apply Mark Applicant KACO new energy Inc Manufacturer KACO new energy Inc 1st Floor Dongbang Rental Bidg 333 1st Floor Dongbang Rental Bldg 333 1 1 Sangdaewon dong Jungwon gu Sangdaewon dong Jungwon gu Seongnam si Gyeonggi do Korea 462 Seongnam si Gyeonggi do Korea 462 807 807 Country Korea Country Korea Contact Jake Shin Contact Jake Shin Phone 82 31 732 7300 Phone 82 31 732 7300 FAX 82 31 732 7380 FAX 82 31 732 7380 Email jake shin kaco newenergy kr Email jake shin kaco newenergy kr Party Authorized To Apply Mark Same as Manufacturer Report Issuing Office Taiwan Control Number 3189197 Authorized by C 4 Intertek This document supersedes all previous Authorizations to Mark for the noted Report Number This Authorizzagon to Mark is for the exriuzive use of intertek s Client and is provided pursuart to the Cert
6. in the front and back 1 Check the ventilation air flow by placing a sheet of paper near the vents to ensure air is flowing 2 Ifthe Inverter does not suck air in or does not blow it out contact the technical support dept at KACO new energy Inc 1 415 931 2046 Page 46 KACO new ergy 10 OPENING THE INVERTER Electric shock is possible from improper startup of the Inverter Death may result from burns and electric shock All procedures described in this section may only be conducted by qualified personnel If problems occur when performing the work described here contact the technical support dept at KACO new energy Inc 1 415 931 2046 Opening the Inverter cabinet 1 Insert the key into the GUI lock and open the GUI cover 2 Press the OFF button on screen for the Inverter to turn off and wait 1 minute fa 4 Fault Ng History statistics nf Setup Page 47 KACO amp 3 Turn off the DC and AC switches DC Switch 4 Put the key into the cabinet s locks and open it The handle flips up then turns the handle Page 48 KACO new esergy 11 OPERATING Startup Instructions N TM TT LULLETALDI me conte cb kay amn gt A ca ag mm a rm me H Hm PoE UU UU ERS Ie 8 II ee l Let a N Inside of the Inverter After installation and elect
7. introduction describes the features of Inverter and details the components in the Inverter 2 The installation amp operation section details how to install and operate the Inverter and how to use the Graphic User Interface GUI 3 The fault amp warning section contains a list of error codes of the Inverter and their descriptions 4 The maintenance section contains directions on how to clean and replace fans and periodically check the parts of the Inverter 5 The parameters section contains parameter settings for the Inverter A The specification section details the Inverter specifications B The user Interface section will provide information about the digital interface analog interface Ethernet and RS485 serial connection of the Inverter C The configuration section shows the configuration of the Inverter Contact Information KACO new energy Inc USA Tel 1 415 931 2046 Fax 1 415 931 1688 E mail kacoinfo kaco newenergy com Page 6 new esergy 2 SAFETY Appropriate Usage Any other application of the Inverter or installation of components and modifications which are not explicitly allowed endanger the safety and void the warranty as well as the operation permit A PV Modules B String Combiner Box C Inverter D AC overcurrent protection E Grid Basic Solar Power System with the Inverter Page 7 KACO O new energy Safety Instructions N DANGER High voltages
8. n ertek and Rs Clent intertex s responsibiiy and lability are Imited to the terms and conditions of the agreement imertek assumes no lability any party other than to the Cilent in accordance wih the agreement for any loos expemse or damage occasioned by the use of Mis Authorization to Mart Only the Clert is authorized to permit copying or distribution of fis Authorization to Mark and then only in ts entrety Use of intertek s Certification mark is restricted to the conditions laid cut in the agreement and in this Auforzstion to Mark Any further use of he interte name for the sale or sdvertsemert of the tested material product or service must frst be approved in wrting by Intertek inital Factory Assessments and Follow up Services are for the purpose of assuring appropriate usage of the Certification mark in accordance with the agreement they are not for Me purposes of production quality control and do not relieve the Clent of her obligations in this respect Intertek Testing Services NA Inc 165 Main Street Cortland NY 13045 Telephone 800 345 3851 or 607 753 6711 Fax 607 756 6699 Standards for General Use Power Supplies CAN CSA C22 2 No 107 1 01 Dated September 2001 Reaffirmed 2006 Product PY inverter Brand Name KACO new energy Models XP100U H6 XP90U H6 and XP83U H6 Standard s ATM for Report TP10090145 CT Page 2 of 2 ATM Issued 24 Jan 2011 ED 16 3 15 8 Jan 10 Mandatory Page 78
9. 485 chain Page 39 KACO new energy UAI terminal blocks User Analog Inputs The Inverter provides 4 user analog input interface connections and 4 extra terminal blocks are provided as well for further uses The User analog inputs are connected to an Irradiation sensor a PV cell temperature sensor and a PT1000 temperature sensor and a Wind Speed sensor The user analog input interface voltage range is 0 10V The terminal block diagrams depicted below are representative of inverters with the optional 24VDC power supply If the inverter does not have the optional power supply the wire numbers should be used to identify the proper connections for the sensors Note On some inverters the exact location of the wires in the terminal blocks may vary Please verify the wire number in the given charts Irradiance and Cell temperature Sensor Si 12TC Si 12TC figure Wire description Wire Color Specification Red VCC 12 24Vdo eee Black GND _ mm E Irradiation value 0 10V Cell Temperature 0 10V Frame GND Connect the wires Port num Port name Wire Specification Wire size IVP Yellow C311 IVN Black C310 18 24 AWG OV 10Vdc Page 40 new meetgy PT1000 external temperature sensor PT1000 figure Wire description Brown Ambient Temperature 0 10V Target port figure Port num Port name Wire Specification Wire size PTP Bro
10. 94 F 90 C copper wire 40 Ibs ft UKG tightening torque Return All 194 F 90 C copper wire 40 Ibs ft tightening torque 194 F 90 C copper wire 40 Ibs ft PE 1 tightening torque 1 0AWG Page 4 new etergy CONTENTS IMPORTANT SAFETY INSTRUCTIONS Ere 2 1 ADOUL T AIS MAMA AANGAT AA NANA ala AASA 6 2 SO E i AA i lei 7 3 The blueplanet Inverter Overview 13 4 UNDACKIO AA n A ee 17 5 Installation amp TTANSDONMALION ends d cerne E eue 18 6 Connecting the Gela AA 23 T IC CHIC AM COMING CUO ironici AA 26 8 Connecting User Interfaces iii 34 9 COMMISSIONING ote ne a 0 en E 45 10 Opening Bia AJA AA 47 11 Oppa Aa AA n 49 12 FCE a EEA 53 13 FAUS e NLA AA AA 56 14 VUE SIN NGS aaa ne 60 15 EO CON a nn 65 16 SEEN 872 0 NG a AA AA AA AA 69 17 CONIOUdIOl nai 74 18 COCOON AA AA 15 1 ABOUT THIS MANUAL This manual provides information about the Inverter This manual contains instructions to install operate maintain and troubleshoot the KACO Inverter The user must keep this manual available at all times This manual contains 5 sections and 3 appendixes Safety is important The Inverter operates with high voltages Improper use or control of the inverter can cause an accident and damage to the inverter or the user The user must understand directions thoroughly in each section in order to properly install operate and maintain the Inverter 1 The
11. Check the MC21 Problem e The grid frequency is outside the permitted range Solution s e Check the grid frequency Problem e The grid frequency is outside the permitted range Solution s e Check the grid frequenc Problem e Short circuit in the IGBT e Short circuit in the Grid Solution s e Check the grid connection e Check the inverter connection Page 66 MC21 Failure Inv Phase Order Inductor or TR Over Temp PEBB Over Temp Analog PEBB Over Temp Digital Grid Over Voltage Grid Under Voltage Grid Over Voltage Grid Under Voltage Grid Over Frequency Inverter AC side contactor failure Phase order failure on the inverter side Inductor or transformer temperature is above 150 C PEBB 1 IGBT PEBB IGBT U failure Fault PEBB 2 IGBT PEBB IGBT V failure Fault PEBB 3 IGBT PEBB IGBT W failure Fault The temperature of the heat sink exceeds operational parameters The heat sink over temperature generated by the thermal trip device Over voltage on the grid side Under voltage on the grid side Over voltage on the grid side Under voltage on the grid side Over frequency on the grid side KACO Problem e MC21 contactor is open e Auxiliary switch is inoperable Solution s e Check the wiring connection e Change the MC21 Problem e Phase order failure on the inverter e Wrong phase rotation Solution s e Check the wiring connection Reverse two phases Probl
12. If it is necessary to return the Inverter please use the original packing material If you need assistance with damaged inverter contact your dealer or KACO new energy Inc Contents A Inverter B User and Installation Manual C Test Report D Keys for GUI cover and front door Storage ATTENTION The inverter should be properly stored to ensure optimal performance gt The inverter should be closed when stored to protect from dust and moisture If the storage period is longer the inverter should be kept in a dry place Page 17 KACO new energy 5 INSTALLATION amp TRANSPORTATION Selecting an appropriate place of installation If possible the inverter should be installed in an area that is as dry as possible This is to ensure maximum product longevity Additionally if the ambient temperature at the installation site is above or below the specifications designated by the manufacturer the inverter should then be mounted indoors where the ambient temperature can be controlled within the specifications Again this is in order to ensure maximum product longevity The following rules should be observed while choosing the site for the installation of your inverter 1 Ensure good access for assembly or service work 2 Please ensure free air circulation at the sides of the housing 3 The place of installation must ensure proper heat dissipation If necessary provide forced ventilation of the room to ens
13. SOC S90 9 TOC OO 1 4D CIE 6909 JOC oo SD LI 909 JOC DIO evol e90 9 DODO LED OI Gord f JOO DC Port num Port name Wire KACO Connect the wires TOUT como TIC ICT PEO como IC MI Lede com MG MG AE corre oc oC Toto oo bol Specification Wire size 18 24 AWG MAX 27Vdc 27mA 0 82 0 20mm Connect the wires LEvo GO 9 II DO ey Goto OC DC 1 Go CU SOM TOC oT e90 e90 8 JOC DC LED Ci Gord F JOC WOO Specification Wire size 18 24 AWG MAX 27Vdc 27mA 0 82 0 20mm Page 36 KACO new energy UDIO User digital output relay contacts Target port figure Connect the wires COM COL 5 DOE Goce Sareea 2970 20 II COL O SEE Ces LOIRE Normally Open Normally Closed Port num Port name Wire Specification Wire size UDO1A C305 External output N O Y TESOL COU dI TD GONO 3D Ol GOL 0 1 4D CE 690 OOTOOI ULI 6009 JOC Jot evo 290 IOC 10 LED OIL Gots 8 ID QT UDO1C C306 External output common CAANG UDO1B C307 External output N C 0 82 0 20mm _ Doo External output common Page 37 KACO new esergy RS 485 terminal blocks The Inverter provides two RS485 interfaces RS485 1 communicates with the control board XCU and is reserved for future use RS485 2 communicates with the GUI and is used for standard datalogger monitoring The connection method for each RS 485 port is de
14. U main control board FPGA failure in XCU main control board F2000 DSP failure in XCU main control board ADC block failure in XCU main control board The door is open KACO Problem e The grid frequency is outside the operation range Solution s e Check the grid frequenc Problem Short circuit in the grid Solution s Check the wiring connections Problem Different version between the NVSRAM parameter table and the program parameter table Solution s e Initialize the parameter menu setting in the GUI and reset faulted parameter e Change the PCB module Problem Internal C6000 error Solution s Change the PCB module Problem e Internal FPGA error Solution s e Change the PCB module Problem e Internal F2000 error Solution s e Change the PCB module Problem e Internal A to D converter error Solution s Change the PCB module Problem e Front door is open e Broken or out of alignment door switch Solution s e Close the door e Align or replace door switch Page 68 new etergy KACO new energy 16 SPECIFICATIONS The Inverter Specifications 1 DC XP100U H2 XP100U H4 XP83U H6 XP9OU H6 XP100U H6 Maximum PV Power 105kW 87 5kW 95kW 105kW Range of input operating voltage 300 600V Specification Maximum input voltage 600V Maximum input current 350A 292A 317A 350A Maximum input short circuit current 410A 380A 380A 476A Maximum input source backfe
15. by qualified personnel Page 11 KACO nem e ergy Inverter shutdown WARNING Hazardous live voltages can be present in the inverter even if the electrical connections are switched off or disconnected Please wait for 1 minute before accessing the inverter The inverter must be switched off for adjusting maintenance and repair work Please proceed as follows ma Turn the inverter off by pushing the off button in the GUI Turn the AC and DC switches to the OFF position N a The off position is green and the on position is color coded red Disconnect the inverter from the PV array Disconnect the inverter from the grid Check that the inverter is disconnected from all voltage sources O a A O If possible Install lockout devices on the utility connection circuit breaker AC and DC disconnect switches N Wait 1 minute for all capacitors inside inverter to discharge 8 When reactivating the XP inverter expect a five minute commission window Page 12 3 THE BLUEPLANET INVERTER OVERVIEW Full digital control using digital signal processing DSP The KACO XP uses two DSPs to control the inverter and an ARM processor for user and external interface These full digital control schemes offer enhanced reliability accuracy efficiency flexibility and convenience High reliability The KACO Inverter features built in reliability with redundant power supplies highly efficient cooling o
16. e Check the input current e Check module wiring e Change the FUSE Problem SP1 PV SP Failure e PEBB Fan Failure PEBB Over Temp The temperature of the heat sink of Solution s Warning the PEBB exceeds 75 C 167 F e Clean the filters or PEBB heat sink fins e Change the PEBB Fan Problem PEBB Fan Failure Solution s e Change the PEBB Fan Problem e Lightning strike on or near the grid Failure of the grid side surge system wiring protector SP2 Solution s e Visual inspection e Change the SPD Problem e The system is working in test mode Solution s e Change the parameters in the GUI Problem e Cabinet Fan Failure Solution s e Clean the air filters e Change the cabinet fan Cabinet Under The temperature of the cabinet falls Ion en i e Ambient temperature is too low for Temp Warning below operational parameters operation Possible causes Control SMPS Failure of the control SMPS e Failure of the control SMPS PEBB Fan Failure PEBB heat sink fan failure SP2 Grid SP Failure Test Mode The system is working in test mode Cabinet Over The temperature of the cabinet Temp Warning exceeds operational parameters Failure Solution s e Change the control SMPS Page 65 Fault Code Message PV Over Voltage PV Over Current CB10 PV CB Trip PV Polarity Failure Ground Fault Inv Over Voltage Inv Under Voltage Inv Over Frequency Inv Under Frequency Inv Over Curren
17. e Code Description a ice KIO PV Contactor Faure FO4 PV side contactor K10 failure PV Polarity Failure Polarity of PV side is reversed S10 PV Switch Trip a S10 PV Disconnect Switch tripped during operation Page 57 KACO Inv Over Voltage F10 Over voltage on the inverter side TI HIN lt Inv Under Voltage Under voltage on the inverter side Inv Over Frequency F12 Over frequency on the inverter side Inv Under Frequency F13 Under frequency on the inverter side Inv Over Current F 14 Over current on the inverter side MC21 Inv MC Failure F15 Inverter side contactor MC21 failure Inv Phase Order F16 Phase order failure on the inverter side wrong phase rotation Inductor or TR Over Temp F18 Inductor or Transformer temperature is above 150 C PEBB 1 IGBT Fault F20 PEBB 1 IGBT failure PEBB 2 IGBT Fault F21 PEBB 2 IGBT failure PEBB 3 IGBT Fault F22 PEBB 3 IGBT failure PEBB Over Temp Analog F24 The temperature of the heat sink exceeds 90 C 194 F PEBB Over Temp Digital F25 The heat sink temperature generated by the thermal trip device has exceeded operational parameters Thermal Switch Grid Over Voltage F30 Over voltage on the grid side Grid Under Voltage F31 Under voltage on the grid side Grid Over Frequency F32 Over frequency on the grid side Page 58 KACO Grid Under Frequency F33 Under frequency on the grid side CB20 AC Disconnect Grid circuit breake
18. e electronic printed circuit board components in the inverter can be damaged by static electricity When handling the printed circuit boards please follow ESD safety regulations mp To prevent the damage from static electricity touch the enclosure of the grounded inverter Please go to the next step when you are sure it is safe Page 26 KACO Connection Area Left side Bottom A AC Connection B DC Hot Connection C DC Return Connection D Ground Connection Right side new energy Page 27 PE Connection PE Protective Earth or Ground rails are located on both sides of the field wiring enclosure Please ensure the Ground rails are connected with cables Any of these connection points can be used for the Grounding Electrode Conductor GEC and bonding conductors N CAUTION Before connection please check that all external cabling is connected properly and not able to be energized accidentally Page 28 Grid Connection The inverter is connected to the grid through AC bus bars which are located on the left bottom of the field wiring area of the inverter which are labeled A B C and N The minimum cable size is 1 AWG for both H4 and H6 and 300kcmil for the H2 model The torque value for AC terminal connections is 40 lb ft The maximum AC overcurrent protection is 125A for the H6 model 150A for the H4 model and 400A for the H2 model NOTE The AC service must be a three phase wye co
19. ed current Specification XP100U H2 XP100U H4 XP83U H6 XP90U H6 XP100U H6 Rated power 100kW 83kW 90kW 100kW Output Power gt 0 factor 0 99 at rated power Nominal output 3 phase 3 phase 3 Phase 600V voltage 208V 480V 528 to 660V 10 to 12 acceptable range 184 to 228V 422 to 528V Canada certification Only Nominal output 60Hz frequency acceptable range 59 3 to 60 5Hz Maximum continuous output current Page 69 KACO new energy Maximum continuous output 100kW 83kW 90kW 100kW power MAXIM GULDU 277A 121A 80A 87A 96A fault current Maximum output over current 400A 150A 125A protection Synchronization 20A in rush current AC current lt O distortion 3 at rated power Voltage trip limit 1 fan Trip limit and trip Voltage trip time 1 time accuracy Frequency trip limit 0 1 Frequency trip time 0 1 3 Efficiency Specification XP100U H2 XP100U H4 XP83U H6 XP90U H6 XP100U H6 CEC efficiency o H2 and H4 models only 96 Maximum efficiency 96 5 Page 70 KACO new energy 4 Power Consumption Specification XP100U H2 XP100U H4 XP83U H6 XP90U H6 XP100U H6 Stand by and Night tare loss lt 65W 5 Environmental Parameters XP100U H4 XP100U H2 Specification XP83U H6 XP90U H6 XP100U H6 Storage temperature range 5 F 20 C 158 F 70 C Normal Operating temperature range 5 F 20 C 122 F 50 C Fu
20. em e Cabinet fan failure Solution s e Cleaning the filters e Change the cabinet Fan Problem e Short circuit in the IGBT Solution s Visual inspection e Change the PEBB Problem PEBB fan failure Solution s e Clean the filters e Inspect and if necessary clean the heat sink fins e Change the PEBB Fan Problem PEBB Fan Failure Solution s e Inspect and if necessary clean the heat sink fins Change the PEBB Fan Problem e The grid voltage is too high Solution s e Check the grid voltage e Check the grid parameter Problem e The grid voltage is too low Solution s e Check the grid voltage e Check the grid parameter e Check the MCB24 Problem e The grid voltage is too high Solution s e Check the grid voltage e Check the grid parameter Problem e The grid voltage is too low Solution s e Check the grid voltage e Check the grid parameter e Check the MCB24 Problem e The grid frequency is outside the permitted rang Solution s e Check the grid frequency Page 67 new etergy Grid Under Frequency CB20 Grid SW Trip Parameters Version Error Flash Memory Failure FPGA Failure DSP28x Failure ADC Failure Emergency Stop Under frequency on the grid side CB20 AC disconnect grid circuit breaker was tripped during operation Different version between the NVSRAM parameter table and the program parameter table C6000 DSP program flash memory failure in XC
21. f critical components and intelligent cooling fans The fans are monitored and controlled according to load and environmental temperature conditions All components used in the KACO XP are designed for industrial use The IGBT stack was designed based on the IEEE WG PEBB TF2 standards These standards mandate the use of laminated DC bus bars that provide for very low stray inductance and gate drive interfacing with differential signaling This feature enhances reliability and ease of maintenance Full digital control technology of the XP also enhances reliability by reducing component count compared to traditional analog electronics Powerful human interface and networking The Inverter features a powerful and friendly Graphic User Interface GUI The all in one design for the GUI provides for more convenient operation and monitoring The GUI is a big easy to use display with color TFT LCD 480 x 272 dots and provides detailed operating information in different languages RS232 RS485 and Ethernet interfaces for networking are standard in the Inverter System flexibility The Inverter provides 4 analog inputs an SO input 1 programmable dry contact output A type Normally open and B type Normally closed and 1 digital input The analog inputs are preconfigured for the user and allow easy connection of temperature sensors and a reference cell The SO input is preconfigured for smart metering Page 13 KACO Shape amp Com
22. ge 77 new energy Intertek AUTHORIZATION TO MARK This authorizes the application of the Certification Mark s shown below to the models described in the Product s Covered section when made in accordance with the conditions set forth in the Certification Agreement and Listing Report This authorization also applies to multiple listee model s identified on the correlation page of the Listing Report This document is the property of Intertek Testing Services and is not transferable The certification mark s may be applied only at the location of the Party Authorized To Apply Mark Applicant KACO new energy Inc Manufacturer KACO new energy CANADA Inc 1st Floor Dongbang Rental Bldg 333 1 Sangdaewon dong Jungwon gu Address 5 m i Gyeonggi do Korea 462 Address 15835 Robins Hill Road London Ontario 807 Country Korea Country Canada Contact Jake Shin Contact George Matuvi Phone 82 31 732 7300 Phone 905 517 8462 FAX 82 31 732 7380 FAX NA Email jake shin kaco newenergy_kr Email matuvig gmail com Party Authorized To Apply Mark Same as Manufacturer Report Issuing Office Taiwan Control Number 4001956 Authorized by William T Starr Certification Manager c t Intertek This document supersedes all previous Authorizations to Mark for the noted Report Number This Authorizz on to Mark is for the exriuzive use of intertet s Clent and is provided pursuart to the Certification agreement between
23. he certification mark s may be applied only at the location of the Party Authorized To Apply Mark Applicant KACO new energy Inc Manufacturer KACO new energy Inc 1st Floor Dongbang Rental Bldg 333 1st Floor Dongbang Rental Bldg 333 1 Address 1 Sangdaewon dong Jungwon gu Address Sangdaewon dong Jungwon gu Seongnam si Gyeonggi do Korea 462 Seongnam si Gyeonggi do Korea 462 807 807 Country Korea Country Korea Contact Arnold Park Contact Arnold Park Phone 82 31 732 7300 Phone 82 31 732 7300 FAX 82 31 732 7380 FAX 82 31 732 7380 Email arnold park kaco newenergy kr Email arnold park kaco newenergy kr Party Authorized To Apply Mark Report Issuing Office Same as Manufacturer Taiwan Authorized by I Liaveo Intertek Control Number 3189197 William T Starr Certification M amp nager This document supersedes all previous Authorizations to Mark for the noted Report Number This Authorization to Mark is for the exclusive use of Intertek s Client and is provided pursuant to the Certification agreement between Intertek and its Client Intertek s responsibility and liability are limited to the terins and conditions of the agreement Intertek assumes no liability to any party other than to the Client in accordance with the agreement for any loss expense or damage occasioned by the use of this Authorizalion to Mark Only the Client is authorized to permit copying or distribution of this Authoriza
24. ification agreement between intertet and its Client intertex s responsibilty and lability are Imitec to the terms and conditions of the agreement Intertek assumes no lability to any party other than to the Cilent in accordance wih the agreement for any loos expemse or damage occasioned by the use of Mis Authorization to Mart Only the Client is authorized to permit copying or distribution of fis Authorization to Mark and then only in ts entirety Use of intertertz Certification mark ts restricted to the conditions laid cut in the agreement and in this Auforzation to Mark Any further use of he intertek mame for the sale or sdvertsemert of the tested material product or service must frst be approved in wrting by Intertes inital Factory Assessments and Follow up Services are for the purpose of assuring appropriate usage of the Certification mark in accordance with the agreemert they are not for Me purposes of production quality control and do not relieve the Client of her cbligatons in this respect Intertek Testing Services NA Inc 165 Main Street Cortland NY 13045 Telephone 800 345 3851 or 607 753 6711 Fax 607 756 6699 Standards for General Use Power Supplies CAN CSA C22 2 No 107 1 01 Dated September 2001 Reaffirmed 2006 Product PV inverter Brand Name KACO new energy Models XP100U H6 XP90U H6 and XP83U H6 Standard s Page 1 of 2 ATM Issued 26 Nov 2010 ED 16 3 15 8 Jan 10 Mandatory ATM for Report TP10090145 CT Pa
25. is present the inverter will begin operation Today 102 kWh The inverter will start operating and GUI Total 633 kWh icons will be green Page 50 KACO new etergy GUI during proper operation IMPORTANT The inverter can t be started when a fault is present Use the fault reset procedure and retry the start operation Refer to the Fault amp Warning section for a description of the fault mp reset procedure If the GUI gives a Code F16 or Inv Phase Order failure message the phase rotation is reversed Shut down the system power off all AC and DC voltage to the inverter and reverse the phase A and B connections on the AC field wiring terminals N CAUTION If the fault isn t resolved after fault reset procedure is complete contact the KACO technical dept at 1 415 931 2046 Operating State The Inverter has eight 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 Disconnect state the Inverter On button on the GUI is selected and the PV voltage is kept above 200V for 5 seconds the system turns on the PV Array side contactor PV_MC In this state if the PV voltage falls below 100V the inverter returns to the Disco
26. ity of the DC input N DANGER Ensure protection against hazardous live voltages during the assembly of the PV installation Both positive and negative leads must be correctly isolated N CAUTION Page 31 KACO new energy Each cable is related to certain polarity During cable connection make sure that the cable is connected to the proper location Negative Positive Positive Negative DC Port for Negative ground system DC Port for Positive ground system IMPORTANT Please check if all cables are securely fastened and torqued mp Use copper conductors only Check that all conduit fittings are installed correctly Check that all fittings are sealed correctly if installed outdoors XP100U H2 XP100U H4 XP100U H6 XP83U H6 XP90U H6 Number of strings 1 2 3 or 4 1 fuse is standard and 2 3 or 4 fuses are optional DC input voltage 300V 600V Maximum DC current 350A 290A 317A XP100U H2 XP100U H4 XP83U H6 XP90U H6 XP100U H6 Number of PV strings Cable Size Torque gi LAGI SUL All 194 F 90 C copper wire 40 Ib ft Page 32 KACO new etetgy All 194 F 90 C copper wire 40 Ib ft tightening torque 300kcmil All 194 F 90 C copper wire 40 Ib ft W HANG tightening torque 194 F 90 C copper wire 40 Ib ft tightening torque Fuse CB10 pa Hot Return GFDi Negative Ground Hot Positive Return Negative Hot Return Positive G
27. lations are exact Page 43 KACO O new energy Ethernet Target port figure iti erat Connect the wires Connector Type Cable Type yy Rea Direct 1 1 NOTE If using a direct cable connection to a computer please use a crossover cable Page 44 9 COMMISSIONING DANGER Electric shock is possible from improper startup of the Inverter Death may result from burns and electric shock All procedures described in this section may only be conducted by qualified personnel If problems occur when performing the work described here contact the technical support dept at KACO new energy Inc 1 415 931 2046 Visual Inspection Inspect all large power cables and bus connections throughout the inverter to verify that they are tight Verify that all PV wires are connected with the proper polarity and tightened to the proper torque specification Check the AC connections for proper phase rotation and that they are tightened to the proper torque specification Verify that the AC and DC ground wires are connected correctly and tightened to the proper torque specification Inspect the interior of the Inverter to insure that it is clear of tools foreign objects water debris or documents Page 45 KACO new energy How to check the Ventilation The Inverter is cooled by top quality variable speed fans In the Inverter air flow is from the top front and expelled at the bottom
28. ll power operating ambient 5 F 20 C 122 F 50 C Relative humidity 0 95 non condensing internal dehumidifier standard Audible noise lt 65dB 6 Standard XP100U H2 XP83U H6 XP90U H6 Specification XP100U H4 XP100U H6 UL1741 Rev 2005 IEEE1547 IEEE1547 IEEE1547 1 General Standard IEEE 1547 1 CAN CSA C22 2 No 107 1 CAN CSA C22 2 No 107 1 Canada certification Only Emitted Interference FCC Class LY Page 71 new energy 7 Interface XP100U H2 XP100U H4 XP83U H6 XP90U H6 XP100U H6 1 Digital input 1 Digital output Digital Analog I O Ports 1 SO input 1 SO output 4 Analog inputs 2 RS485 1 CAN 1 Ethernet SD Card up to 8GB Specification 8 Enclosure XP83U H6 Specification XP100U H2 XP100U H4 XP90U H6 XP100U H6 Height Width 73 x 68 x 36in eben 1840 x 1724 x 930mm H W D Weight kg 3086lbs 1400kg 3086lbs 1400kg 2425lbs 1100kg Protection Class NEMA 3R 9 Overvoltage under voltage and Frequency ranges XP83U H6 System Condition XP100U H2 XP100U H4 XP90U H6 Trip Time XP100U H6 Vac lt 50 Grid Minimum Voltage Vac lt 104 Vac lt 240 Vac lt 300 10 cycles 50 lt Vac lt 88 Grid Under Voltage 104 lt Vac lt 184 240 lt Vac lt 423 300 lt Vac lt 528 Voltage Range of Nominal 88 lt Vacs110 Normal Operation 184 lt Vacs228 422 lt Vac lt 528 528 lt Vac lt 660 po 110 lt Vacs120 Grid Over Voltage 228 lt Vacs249 528 lt Vac lt 576
29. nnect state Connecting to Grid When the inverter is in the Connecting to PV Array state and the PV voltage 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 measurement of PV voltage and the parameter MPP Factor After 5 seconds the inverter system enters into the MPP start state MPP start In this state the inverter controls the PV voltage Reference of the PV voltage Vac reference parameter the inverter changes from open circuit voltage to the value of the MPPT V start parameter Page 51 KACO new energy 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 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
30. nnection and the neutral conductor must be used N DANGER Electric shock can result from handling the components with high voltage present Please be sure that all voltage sources are disconnected and cannot be accidentally energized N CAUTION The inverter AC connections must have the proper phase rotation in order to connect to the grid and operate Proper rotation is A B C Please check with a phase rotation meter If the phase rotation is incorrect an error will be displayed on the user interface and the inverter will not connect to the grid if this happens reverse any two phases to correct the rotation Page 29 KACO new energy IMPORTANT mp Please check that the cables are connected and torqued properly Use 90 C copper conductors only XP100U H2 XP100U H4 XP83U H6 XP90U H6 XP100U H6 A B C N and PE XP100U H4 XP83U H6 XP90U H6 XP100U H6 A B C N 4 1AWG All 194 F 90 C copper wire 40 Ib ft tightening torque PE 7 AAWG 194 F 90 C copper wire 40 lb ft tightening torque Page 30 KACO new emergy XP100U H2 A B C N 4 300kcmil All 194 F 90 C copper wire 40 Ib ft tightening torque PE 1 AAWG 194 F 90 C copper wire 40 Ib Ft tightening torque PV Connection PV Array is connected to the inverter through the DC input bus bars which are located on the bottom right of the field wiring area of the inverter N CAUTION Risk of damage Make sure NOT to reverse polar
31. not avoided could result in death or serious injury Hereinafter referred to as all five Models XP100U H2 XP100U H4 XP100U H6 XP83U H6 and XP90U H6 unless specific model names are indicated Page 2 KACO new energy N CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury BURNHAZARD Do not touch The Inverter contains components that become hot during normal operation li INFORMATION This symbol accompanies notes that you should know and use to ensure optimal operation of the system Wiring Requirements All wiring methods and materials shall be in accordance with the National Electrical Code ANSI NFPA 70 as well as all state and local code requirements Cable sizes in the chart below are the minimum Because the field connections are bus bars for accepting crimp lugs larger cables can be used if needed Grid Connection XP100U H4 XP83U H6 HP90U H6 XP100U H6 1AWG All 194 F 90 C copper wire 40 Ibs ft tightening torque i PE 1 AAWG 194 F 90 C copper wire 40 Ibs ft tightening torque Page 3 new meetgy XP100U H2 A B C N 4 300kcmil All 194 F 90 C copper wire 40 Ibs ft tightening torque 194 F 90 C copper wire 40 Ibs ft tightening torque PV Connection XP100U H2 XP100U H4 XP83U H6 XP90U H6 XP100U H6 All 194 F 90 C copper wire 40 Ibs ft an tightening torque Hot All 1
32. ns set forth in the Certification Agreement and Listing Report This authorization also applies to multiple listee model s identified on the correlation page of the Listing Report This document is the property of Intertek Testing Services and is not transferable The certification mark s may be applied only at the location of the Party Authorized To Apply Mark Applicant KACO new energy Inc Manufacturer KACO new energy Inc 1st Floor Dongbang Rental Bldg 333 1 1st Floor Dongbang Rental Bldg 333 1 Sangdaewon dong Jungwon gu Sangdaewon dong Jungwon gu do Seongnam si Gyeonggi do Korea 462 naaa Seongnam si Gyeonggi do Korea 462 807 807 Country Korea Country Korea Contact Jake Shin Contact Jake Shin Phone 82 31 732 7300 Phone 82 31 732 7300 FAX 82 3 1 732 7380 FAX 82 31 732 7380 Email jake shin kaco newenergy kr Email Jake shin kaco newenergy kr Party Authorized To Apply Mark Same as Manufacturer Report Issuing Office Tawian A Control Number 3189197 Authorized by William T Starr Certification Manager nf ER Tey lb This document supersedes all previous Authorizations to Mark for the noted Report Number This Authorization to Mark is for the exclusive use of Intertek s Client and is provided pursuant to the Certification agreement between Intertek and its Client Intertek s responsibility and liability are limited to the terms and conditions of the agreement Intertek assumes no liability to an
33. nting L bracket to the inverter L bracket for mounting Transport Instructions Please note the weight of the inverter and follow the instructions below The mode of transportation must support the weight the inverter During transport be certain to center the weight of the inverter as the center is closer to the left side Do NOT tilt the inverter while transporting The pictures below are examples for transportation Page 21 KACO new energy Fork lift from front or rear Crane fork from front or rear Eye nuts with crane rack Slope angle 0 in any direction Page 22 KACO new esetgy 6 CONNECTING THE CONDUIT In this section see how to insert the cables in the inverter and where to punch the holes for the conduit fittings NOTICE When installing please be cautious that water is not able to enter into the inside of the cabinet Only recognized NEC compliant watertight conduit and fittings must be used for outdoor mp applications Moisture can affect the performance of the inverter through improper conduit or hubs How to install the cables There are two ways of connecting cables shown in the following figures The field wiring area is designed for DC cable AC cable and data cables The conduit entry points can be used for any cables Example Left side for DC conduit and bottom for AC conduit Using the left side panel for cables 1 Remove the bolts which secure the plate to
34. of MPPT P stop parameter during time of MPPT T stop parameter connection to the grid is terminated In addition If PV voltage is below 100V the inverter stops 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 allows three auto fault resets within 30 minutes After three attempts the system will log an error and the system will not try to restart Operating start Inverter On 200 lt Vpv lt 630 Fault Reset amp amp T gt 5 sec Vpv lt 200 amp amp T gt 120 sec Inverter Off Vpv gt Vpy start amp amp T gt Tstart Heavy Fault Ppv lt Pstop amp amp T gt Tstop Out of range T gt Tbuildup 3 5 sec Vpv MPP Ref Vpv gt Vmpp_ min amp amp T gt 5sec Page 52 KACO new energy Operating states chart of the Inverter 12 PARAMETERS DATE TIME PARAMETERS Parameters Units Ranges Descriptions Default Current month Current hour Current minute Current second DIGITAL INTERFACE PARAMETERS 1731 0 23 0 59 0 59 Parameters Units Ranges Descriptions Default DO1 Select Selection for digital output1 DO2 Select Selection for digital output2 RS485 Protocol KI n 0 999 0 ACI protocol 1 Protocol for the prolog
35. ponents External shape Front Page 14 Left Right and Back Page 15 Location of the Safety Notices The figure to the right shows the location of the safety notice on the Inverter A Front door handle Caution risk of electric shock hot surface B PEBB cover Caution risk of electric shock C Switch panel cover Caution risk of electric shock D Fuse panel cover Caution risk of electric shock E Control system panel Caution risk of electric shock Refer to the operating instructions F Filter capacitor cover Caution risk of electric shock The Inverter identification You can identify the Inverter using the type plate The inverter type identification plate can be found inside on the doors of the cabinet Firmware The Inverter firmware is shown on the display of the GUI The Inverter operator manual describes how to obtain the firmware version Page 16 4 UNPACKING This section describes unpacking and inspection of the inverter Unpacking and inspection All KACO inverters are thoroughly inspected before packing Although they are shipped in sturdy packaging damage can still occur during shipping and delivery It is important to carefully inspect the shipping container and contents prior to installation When you detect any external damage before or after unpacking report the damage immediately to your KACO dealer and the shipping company that delivered the unit
36. propriate short circuit protection must be provided to ensure operational safety All instrument covers must remain closed during operation Prior to performing some visual checks and maintenance work the inverter must be disconnected from all power sources and protected against inadvertent activation If measurements have to be conducted while the inverter is connected to power NEVER touch live terminals Remove all jewelry from your wrists and fingers Ensure that the test equipment is in a proper and safe operating condition When working on the inverter while energized make sure to stand on an insulated surface and ensure that there is no connection to ground Follow the instructions exactly as given in these operating and installation instructions and especially observe all information concerning possible hazards warnings and precautions This manual may not cover all possible scenarios Should a specific problem occur that is not sufficiently explained please contact your dealer or KACO new energy Modifications Changes N CAUTION Hazard of damage due to unauthorized modifications manipulation By no means manipulate the inverter or modify or change the inverter or any other parts of the installation Performing any modifications or changes on the inverter is generally prohibited Performing any changes or modifications to the installation of the inverter is only permitted if in compliance with national standards and performed
37. r was tripped during operation Different version between the NVSRAM parameter table and the program parameter table Flash Memory Failure C6000 DSP program flash memory failure in XCU main control board FPGA Failure FPGA failure in XCU main control board DSP28x Failure F2000 DSP failure in XCU main control board ADC Failure ADC block failure in XCU main control board Cabinet Over Temp Temperature of cabinet is too high Inverter has stopped operation Page 59 KACO 14 MAINTENANCE Insulating gloves must be used during maintenance The Inverter needs to be periodically maintained IMPORTANT All service MUST be done by authorized personnel only A DANGER DC terminals may be energized Allow ten minutes for all capacitors within the main Enclosure to disch arge after disconnecting the Inverter from AC and DC sources Before touching any electrical connectio ns make certain that no hazardous live voltage is present Page 60 KACO new energy De Energize Isolation Procedure The following procedure should be followed to de energize the Inverter for maintenance To isolate the Inverter 1 Turn the main ON OFF switch in the GUI to the OFF position 2 Open the utility connection circuit breaker 3 Open the AC Disconnect 4 Open the DC Disconnect Switch 5 Install lockout devices on the utility connection circuit breaker AC and DC disconnect switches 6 Before touching an
38. rical connection the Inverter will be ready for operation Follow these instructions e Check that the switches in the part1 are turned on If not turn on the switches e Check that the switches in the part2 are turned on If not turn on the switches Turn on the switch in the part3 e Close the cabinet doors e Turn on the AC and DC and disconnect switches on the left cabinet door N DANGER High voltage may be present inside inverter When turning off or on the switches be careful not to touch conductors Page 49 KACO new energy Switch on the grid voltage via the external breaker or switch Switch on the solar generator via the DC disconnecting switch or DC plug type connectors fe Fault CT History statistics nf Setup 17 9k 0 0kW mn en el Jul 17 2008 10 22 09 Once the inverter is connected the GUI turns on After about two minutes the GUI will ask if you would like to change the country settings Select NO Note If the GUI gives the warning Current settings don t match and countries Wrong country setting may result in damage this is a bug select Ok and disregard If the dialog Current country settings are set to USA CANADA MEXICO displays select OK and disregard See GUI screen A History Statistics Touch the ON button on GUI screen Today 0 0 kWh Total 0 0 kWh Crore n a 1 LI kal History PA statistics If no fault
39. round Hot Negative Return Positive Connection Diagram XP100U H2 Negative Ground Hot Return PV GND XP 100U H4 XP83U H6 XP90U H6 XP100U H6 Positive Ground Return Hot PV GND DC Terminal Polarity Page 33 KACO new energy 8 CONNECTING USER INTERFACES Left side Right side Bottom User Interface of the Inverter Page 34 new energy UDIO User digital input output terminal blocks UO CL I il DO VO JOC oC N JOLIS DC OLI QO JOC DC Om a OSLID D IDC UAI User analog input output terminal blocks mike TOTO Om a One foO mot ee de ce ce ce LO OC Note On some inverters the exact location of the wires in the terminal blocks may vary Please verify the wire numbers using the given charts UDIO User digital input Target port figure Connect the wires 1 DDL GO OC DC TUE 69019 OO DO Jev GO 91 JOC Wo Len CO 9 TOC LG M GO 9 OO oO EDO Gold 9 OC oO 4D CO 6009 OC oC GD TIL e90 9 TOC DC 1 nO 2909 OC DC LED ON e00 9 JOC WoO Port num Port name Wire Specification Wire size VIGILE a Dry contact input 18 24 AWG mon a PAVe 10ma 0 82 0 20 Page 35 UDIO S0 input Target port figure q wo c00 00 IOC IC Geo ENDO HOO UC I Toto foc oct Leno con Ff foO loc Port num Port name Wire UDIO S0 output Target port figure I
40. sic 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 WARNING AND FAULT TABLES Warning Message Code Description SP1 PV SP Failure Failure of the PV side surge protector SP1 PV Fuse Failure PV side Fuse failure option Ground Fault Warning The insulation resistance of the PV falls short of the limit set in the ground fault monitoring for Alert1 option PEBB Over Temp The temperature of the PEBB Power Electronics Building Block Warning heatsink exceeds 75 C 167 F PEBB Fan Failure ER Failure of a PEBB Power Electronics Building Block fan SP2 Grid SP Failure Failure of the grid side surge protector SP2 Test Mode The system is working in test mode Page 56 KACO new energy Cabinet Over Temp The temperature of the cabinet exceeds the operational parameter Warning Cabinet Temperature Maximum Cabinet Under Temp The temperature of the cabinet falls below the operational Warning parameter Cabinet Temperature Minimum Control SMPS Failure Failure of the control SMPS Switching Mode Power Supply Fan SMPS Failure Failure of the fan SMPS Switching Mode Power Supply Cabinet Fan Failure Failure of a cabinet fan Fault Messag
41. struction section 2 Open the front doors You can find the fans on the top of the cabinet as below pictures 3 Clean or replace fans Left cabinet fan A When assembling a new fan ensure that the air flow direction is correct Caution Page 63 KACO PEBB fan assembly 1 Switch off the inverter according to inverter shutdown direction in safety instruction section 2 Open the PCB module doors Find the PEBB fans under the IGBT stack as shown in the pictures below 3 Clean or replace fans A When assembling a new fan ensure that the air flow direction is correct Caution Page 64 KACO new ergy 15 ERROR CODES The 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 Warnings Code Message Warning description Possible causes Diagnosis Problem e Lightning strike on or near the PV Failure of the PV side surge protector system wiring SP1 Solution s e Visual inspection e Change the SPD Problem PV system wiring short e Short circuit in the IGBT PV Fuse Failure PV side Fuse failure option Solution s
42. t Warning Description PV voltage exceeds the parameter PV current exceeds the parameter PV side circuit breaker CB10 tripped Polarity of PV side is reversed PV side ground fault Over voltage on the inverter side Under voltage on the inverter side Over frequency on the inverter side Under frequency on the inverter side Over current on the inverter side KACO nem esetgy Possible problem and solution s Problem e The voltage of the solar generator is too high Solution s e Check the input voltage e Check module wiring and system Problem e The current of the solar generator is too high PV system wiring short Solution s e Check the input current e Check module wiring and system Problem e CB10 disconnect switch is open e Auxiliary switch is inoperable K10 contactor failed closed Solution s e Check the wiring connection e Change the CB10 replace K10 contactor Problem e Polarity of PV side is reversed Solution s e Check the wiring connection and change if necessary Problem e DC amp ground are shorted causing the GFDI fuse to open Solution s e Check the solar generator for a ground fault and Replace the GFDI Fuse Problem e The inverter voltage is too high Solution s e Check the inverter voltage e Check the inverter parameter Problem e The inverter voltage is too low Solution s e Check the inverter voltage e Check the inverter parameter e
43. tailed below Note Not all RS485 systems use the A and B signals in the same way thereby reversing the polarity On some applications if there is no communication reversing the polarity will allow communication Note On some inverters the exact location of the wires in the terminal blocks may vary Please verify the wire number in the given charts RS485 1 Future Use connections Target port figure Connect the wires IE SET repo Gens OO oO edo eons oc oC Apo do occ gt To add termination resistance a jumper should be connected between 1D and 2C Port num Port name Wire Specification Wire size RS485A1 C322 RS485 signal A1 RS485B1 C323 RS485 signal B1 ere RS485C1 C324 Termination resistance setup port 0 82 0 20mm nana C325 RS485 communication GND1 Note Termination resistance should only be used at the beginning and the end ofthe RS485 chain Page 38 KACO new energy RS485 2 Data logging Target port figure Connect the wires Signal Transmitter gt To add termination resistance a jumper should be connected between 3D and 4C Port num Port name Wire Specification Wire size EN RS485A2 C326 RS485 signal A2 RS485B2 C327 RS485 signal B2 18 24 AWG RS485C2 C328 Termination resistance setup 0 82 0 20m port RS485G2 C329 RS485 communication GND2 Note Termination resistance should only be used at the beginning and the end ofthe RS
44. the inverter 2 Remove the plate 3 Mark all the holes for the conduit You need conduit for the AC DC and data cables 4 Punch holes for the conduit 5 Attach the plate to the Inverter 6 Attach the bolts and tighten 7 Attach the conduit with the appropriate conduit fittings a Ensure that proper conduit duct sealant is used to prevent rodent and insect infestation b The bottom plate must be secured in place during operation If conduit is used the proper conduit fittings must be used Page 23 Left panel dimensions for conduit Page 24 Using the bottom panel for conduit 1 26 in 32mm 26 6 in 676mm 1 26 in 32mm 1 22 in 31mm 1 22 in 31mm 5 3 in 134mm Bottom access panel for conduit Page 25 KACO new etergy 7 ELECTRICAL CONNECTION The electrical connections should only be made after the inverter has been installed in its final location To complete the electrical connections the AC and DC terminal connections must not be connected to any source of voltage This will protect the installer from harm and ensure that the inverter is not accidentally activated N CAUTION After the inverter has been installed in the fixed location the electrical connection can be established Please be sure that both AC and DC side are disconnected from all voltage sources Please be sure that the switches are locked out and switching on unintentionally is not possible NOTICE Th
45. tion to Mark and then only in its enurety Use of Intertek s Certification mark 18 restricted to the conditions laid out in the agreement and in this Authorization to Mark Any further use of the Intertek name for the sale or advertisement of the tested material product or service must first be approved in writing by Intertek Initial Factory Assessments and Follow up Services are for the purpose of assuring appropriate usage of the Certification mark in accordance with the agreement they are not foi the purposes of production quality control and do not relieve the Client of their obligations in this respect Intertek Testing Services NA Inc 165 Main Street Cortland NY 13045 Telephone 800 345 3851 or 607 753 6711 Fax 607 756 6699 Standards for Inverters Converters Contollers and Interconnection System Equipment for Use With Distributed Energy Resources UL 1741 1st Ed Dated May 7 1999 Revision Dated November 7 2005 and General Use Power Supplies CAN CSA C22 2 No 107 1 01 Dated September 2001 Reaffirmed 2006 Standard s Product PV inverter Brand Name KACO new energy Models XP100U H2 ATM Issued 31 Dec 2009 ED 16 3 15 3 12 08 Informative ATM for Report TP09110128 CT Page 1 of 1 Page 75 KACO new energy Intertek AUTHORIZATION TO MARK This authorizes the application of the Certification Mark s shown below to the models described in the Product s Covered section when made in accordance with the conditio
46. ure that heat is dissipated adequately 4 Ensure that the supporting area has an adequate load bearing capacity Weights and Dimensions XP100U H2 Weight 1400Kg XP100U H4 Weight 1400Kg XP83 90 100U H6 Weight 1100kg The installation site must be easily accessible for installation or service work and should preferably not expose the inverter to direct sunlight or enclose the inverter in an unventilated space Page 18 KACO new ergy Minimum Workspace Requirements The minimum clearance space shown below should be maintained for ventilation and access ite 39in D If you use a left side conduit plate the minimum clearance is 4 inches on the left side for installation but actual clearance will be dictated by the requirements of conduit fitting installation and maintenance accessibility Installation Site Requirements The foundation must guarantee a solid and safe surface to bear the weight of the inverter Page 19 Preparation of the mounting surface Prepare the mounting surface structure appropriately based on the chosen site Secure the Inverter to the chosen site with the pre installed L brackets 6 6 in 167 5 mm su 72 4 in 1840 mm 3 2 in 80 mm 24 8 in 630 mm Position of the mounting holes bottom view Page 20 2 inj 50mm 4 7 in 120mm 12 9201 Foundation L bracket surface mount 3 9 in 100mm 3 60 5x0 7 in SLOT 3 613x18mm SLOT Mou
47. ution The Inverter may only be used when it is functioning correctly Regularly check the XP Inverter for visible damage and operate only if there is no visible damage Ensure that all safety features are accessible at any time and that their correct operation is tested regularly ATTENTION The printed circuit board PCB components in the Inverter can be damaged by electrostatic discharge When working on the Inverter and when handling the PCB components observe all ESD safety regulations Discharge electrostatic charge by touching the grounded Inverter enclosure Only then is it safe to touch any electronic components Technical rules The installation must be in compliance with the local regulations and technical rules in particular with regard to electrical connections National Electric Code NEC The installer is responsible for knowing and understanding local standards and regulations as well as utility interconnection requirements Page 10 Regulations concerning the prevention of accidents During the operation of the inverter certain parts of the device carry high 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 or other applicable national or local provisions Proper ground conductor dimensioning and an ap
48. wn 0314 z 18 24 AWG 0 82 OV 10Vdc 0 20 mn 5D PTN Black C315 Page 41 new meeigy Wind Speed sensor Wind Speed Sensor figure Wire description Specification VCC 5 24Vdc Target port figure 8D OL 800 9 JOC DC JUDO VOL 9 JU DC ERO 6009 OVVIO LT SPO 600 OO TOO Lapo 400 JOC DC SDLILI GOD Gf 10 DC EE ce ee e m O Port num Port name Wire Specification Wire size Wind Speed signal E mm OHz 125Hz 18 24 AWG 0 82 0 20mm 7D WSN Brown C317 Page 42 To get the most accurate data from the analog interface the user must calculate gain and offset Then the user must change the parameters of the Inverter The symbols for gain and offset are listed here M lower limit of analog input by sensor Mu upper limit of analog input by sensor D lower limit of displayed value Du upper limit of displayed value M input value in range of M and M D displayed value in range of D and D Gain G D D My M3 Offset O D G x M3 Displayed value D G x M O After calculating gain and offset the user must change the values through the GUI or use the CMT change the settings in the analog tab located in parameter panel N CAUTION Voltages gt 10Vdc or reversed polarity may lead to damage of the sensor input circuits IMPORTANT mp System will show unexpected values if gain and offset are not properly set Ensure that calcu
49. y electrical connections make certain that no hazardous live voltage is present Maintenance includes A Inspection of parts which may become worn and repairing or exchanging them B Functional testing of components C Inspection of connections D If needed cleaning of the cabinet exterior interior NOTE Maintenance frequency is dependent on the location and environmental conditions The Inverter can function in dusty environments but must be maintained more frequently than is recommended in the following table Page 61 KACO new energy Time intervals for maintenance work maintenance interval Maintenance work recommended Inspection of a cabinet for strong dust sedimentation pollution moisture and water penetration from the outside Visual inspection of redundant auxiliary power supplies 12 month Function test of the door contacts 12 month Inspection of the run and fault indicators 12 month If the installation site is especially dirty maintenance intervals will be reduced Visual inspection of fuses breakers and surge protection 12 month Page 62 KACO Cleaning and replacing fans The fans should be cleaned periodically to ensure optimum performance They should be replaced and or serviced if an air flow issues arises The Inverter includes two cabinet fans and one PEBB fan assembly Cabinet fan 1 Switch off the inverter according to the inverter shutdown directions in the safety in
50. y party other than to the Client in accordance with the agreement for any loss expense or damage occasioned by the use of this Authorization to Mark Only the Client is authorized to permit copying or distribution of this Authorizalion to Mark and then only in its entirety Use of Intertek s Certification mark is restricted to the conditions laid out in the agreement and in this Authorization to Mark Any further use of the Intertek name for the sale or advertisement of the tested material product or service must first be approved in wriling by Intertek Initial Factory Assessments and Follow up Services are for the purpose of assuring appropriate usage of the Certification mark in accordance with the agreement they are not for the purposes of production quality control and do not relieve the Client of their obligations in this respect Intertek Testing Services NA Inc 165 Main Street Cortland NY 13045 Telephone 800 345 3851 or 607 753 6711 Fax 607 756 6699 Standards for Inverters Converters Contollers and Interconnection System Equipment for Use With Distributed Energy Resources UL 1741 1st Ed Dated May 7 1999 Revision Dated November 7 2005 and Standard s General Use Power Supplies CSA C22 2 No 107 1 01 Dated September 2001 Reaffirmed 2006 Product PV inverter Brand Name KACO new energy Models XP100U H4 ATM for Report TP09070225 CT Page 1 of 1 ATM Issued 10 Sep 2009 ED 16 3 15 3 12 08 Informative Page 6 new
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