M a n u a l.

- For the Operator

- For skilled and authorized electricians

P o w a d o r.
The next generation of transormerless solar inverters .

f u l l o f e n e r g y.
For the operator

Operator’s Instructions
Powador 2500xi / 3500xi / 4000xi / 4500xi / 5000xi

1 About this document 2 4 Operation 4

1.1 Attachment and Maintenance of documents 2 4.1 Overview of operating elements and displays 4
1.2 Symbols used in this document 2 4.2 LED displays 4
1.3 CE Certification 2 4.3 ”Display” and „Adjustment“ button 5
1.4 Type label 2 4.4 Set Mode 6
4.5 Start key 6
2 Safety information and instructions 2 4.6 The serial RS232 interface 7
3 Notes concerning installation and operation 3 4.7 The RSS485 interface 9
3.1 Factory guarantee and liability 3 4.8 Display 9
3.2 Service 3 5 Accessories 13
3.3 Intended use 3
6 Troubleshooting 14
7 Recycling and disposal 15
1 About this Manual

General information
With an inverter manufactured by KACO Gerätetechnik Note!
GmbH you have purchased a device that excels by Useful information and remarks!
highly reliable and powerful technology. You will benefit
from our long-standing experience in the field of current
inverter technology and power electronics.
Important!
Powador 2500xi, 3500xi, 4000xi, 4000xi and 4500xi and
Non-adherence to these
5000 xi inverters are electrically isolated, robust
instructions may adversely affect
inverters, which are operated without any blowers and
the operating convenience or
offer a high degree of efficiency. An illuminated display
functionality of the device.
and intuitive menu guidance enables you to display the
most important grid feeding data of the inverter. A
mounting panel is provided (included in the scope of
delivery) for easy and optimized wall installation. This symbol designates a required
Inverter data can be transmitted to a PC for action.
visualization.

Protection class IP 54 makes the inverters ready for use

in any kind of environment – our inverters are even
1.3 CE Certification
suitable for use in agricultural and industrial
applications.
CE labeling is used to document that the Powador
inverter indicated on the type label meets the
1 About this document fundamental requirements according to the following
The following information will guide you through the directives:
entire operator’s manual. Further documents will be - Directive concerning Electromagnetic Compatibility
valid in conjunction with these operating and installation with Class B (Council Directive 89/336/EWG)
instructions.
We shall not be liable for any damage caused by 1.4 Type label
non-adherence to the instructions given in this The type label indicating the exact device description is
manual. located on the support plate at the underside of the
enclosure.
Pertaining documents
During the inverter installation please observe all 2 Safety information and
assembly and installation instructions for components
and other parts of the system. These instructions are
instructions
shipped together with the respective installation
components or supplementary equipment. Danger!
Danger due to lethal voltages!
Hazardous live voltages are present
1.1 Attachment and Maintenance of documents inside the device/instrument and power
Please keep these operating and installation Danger ! lines. Therefore, the device/instrument
instructions in a safe place to ensure that they are must only be installed and opened by a
available if needed. skilled electrician.
Even when the device/instrument is
switched off, dangerous live voltages
1.2 Symbols used in this document may still be present inside the
Please observe the safety information provided in this instrument.
manual when operating your inverter!

Regulations concerning the prevention of accidents

Danger! The inverter must be installed by an approved skilled
Lethal Hazard by Electric electrician who is responsible for the adherence to
Shock! existing standards and regulations.
Danger ! The proper and safe operation of the device/instrument
requires proper transportation, storage, erection and
assembly, as well as careful operation and
Warning! maintenance.
Lethal Hazard!
Only personnel who have read and fully understood
Warning these operating instructions shall be authorized to
operate the inverter.

Caution!
Potential hazard for the product
and environment!
Caution !

KACO Gerätetechnik GmbH 2 Operator’s Instructions Powador 00-xi-Series

3 Notes concerning installation and operation

Modifications/Manipulation - Improper use and installation that does not comply

Manipulating the inverter is generally prohibited. Before with the required standards
performing any modification on or in the environment of - Improper operation
the inverter, a skilled electrician must be consulted by - Operation of the devices with defective protective
all means, as this electrician will assume responsibility. equipment
- Manipulation of the device or makeshift repairs by the
Caution! customer
Hazard of damage due to - Influence of foreign objects or Act of God (lightning,
unauthorized overvoltage, tempest, fire)
modifications/manipulation! By no - Inadequate ventilation of the device
means manipulate the inverter or - Non-adherence to the relevant safety instructions
Caution ! (VDE (Association of German Engineers), a.o.
modify or change the inverter or any
other parts of the installation! - Transport damage

All guarantee claims shall be handled at the premises of

KACO Gerätetechnik GmbH. To this end, return
Transport transport shall be effected, as far as possible, in the
The Powador inverter is subjected to extensive testing original or equivalent packaging. The costs for these
and inspection in our test field, so as to ensure the services cannot be borne by KACO Gerätetechnik
superb quality of our products. Our inverters leave our GmbH.
factory in a proper electrical and mechanical condition.
Special packaging ensures that nothing can happen Guarantee claims shall only be compensated by KACO
during the transport to our customers. Nevertheless, if the damaged device is returned to KACO together
transport damage may not be ruled out completely. In with a copy of the invoice issued to the consumer by the
this case, the forwarding agent/carrier will be specialist dealer. The type label on the device must be
responsible. fully legible. In the event of noncompliance KACO
reserves the right to deny guarantee services.
Please check the inverter carefully on arrival. Should
you discover any visible signs of damage on the The warranty period for rework or replacement
packaging, indicating that the inverter may be shipments shall be six months after shipment. However,
damaged, or should you find any visible signs of it shall continue at least until expiration of the original
damage on the inverter please notify your responsible warranty period granted for the shipped object.
forwarding agent/carrier immediately.
3.2 Service
If necessary, your solar installation provider or KACO High quality and longevity of our inverters always have
Gerätetechnik GmbH will assist you. However, written been of central importance for us - already at the time
damage reports must be received by the forwarding of product development. Our more than 60 years of
agent within six days after receipt of the goods at the experience in the field of current inverters are backing
latest. up this philosophy.

Use exclusively the original packaging for returning the Despite all these quality-assuring measures, however,
inverter – only this material will ensure safe disturbances may occur in very rare cases. KACO
transportation. GERÄTETECHNIK GmbH will offer a maximum of
assistance if one of these cases should arise. KACO
3 Notes concerning installation and GERÄTETECHNIK GmbH will take every effort to
remedy any defects fast and without unnecessary
operation bureaucracy. Please contact our service department
directly – and you will be aided and supported very
3.1 Factory guarantee and liability quickly.
KACO Gerätetechnik GmbH grants a guarantee of six
years on Powador inverters, starting from the date of 3.3 Intended use
installation and max. 78 months after shipment by Powador inverters are built according to state-of-the-art
KACO. and approved safety requirements. However, improper
use may cause lethal hazards for operators or third
During this time, KACO Gerätetechnik GmbH parties and/or damage of instruments/devices or other
guarantees the proper function of the devices and free property.
repair in the event that a defect should occur which we The device is intended to convert the direct voltage
are accountable for. generated in the photovoltaic (PV) modules into
alternating voltage (AC) and feed this voltage into the
Should your device show a defect or malfunction during grid.
the guarantee period, please contact your specialist The inverter must only be operated in connection with a
dealer or, respectively, your installation expert. fixed/stationary connection to the public grid. Inverters
Guarantee claims shall be excluded in the following are not intended for mobile use.
cases: Any use other than the specified intended use shall not
- Use of the device for other than the intended use be deemed intended or normal use, and the
(normal use) manufacturer/supplier shall not be liable for any
damage caused by such unintended use. Damage

Kaco Gerätetechnik GmbH 3 Operator’s instructions Powador 00-xi-series

4 Operation

caused by unintended use is at the sole risk of the 5. Start key

operator. This key is used to activate the display messages at the
end of the day when it is getting dark.
The term „intended use“ shall also include the 6. RS232 interface
adherence to the operating and installation instructions. 7. Cable duct for RS485 interface
Your skilled and authorized electrician will obtain the 8. Cable duct for DC connection
necessary applications and acceptance for your
photovoltaic installation from your Utility Company. 4.2 LED displays
Some of the documents which are needed for these Under normal operating conditions the photovoltaic
applications and acceptance are attached to these modules will start to generate voltage as soon as
installation instructions. enough daylight or sunlight is available. If a certain
. amount of voltage is applied to the inverter for a certain
period of time, the inverter will start the grid-feeding
process. The inverter is equipped with three LEDs,
Caution! which provide information about the different modes of
Using the device for any purposes operation as follows:
other than intended/normal use is
prohibited!
Caution ! Figure 4.2: LED displays

4 Operation
The grid-feeding process starts in the morning when
there is enough daylight and, consequently, a certain
minimum voltage is applied to the inverter. After a
startup period of 3 minutes the inverter enables the grid
feeding process. If this minimum voltage is fallen below
at the end of day, the grid feeding process will be
terminated and the inverter will be switched off.
LED DC Power In (1) (green):
4.1 Overview of operating elements and displays The LED is illuminated from a generator voltage of
approx. 300 V onward and extinguishes as soon as the
module voltage falls below 250 V. The DC Power In
LED signals that the inverter is in its active state and
the inverter controls are enabled. If this LED is not lit up
the inverter will not be able to start grid feeding. Under
normal operating conditions the LED is illuminated in
the morning when there is enough daylight, and
extinguishes again when it gets dark.

LED AC Power Out (2) (green):

This LED is illuminated during the grid feeding process.
To this effect, the generator voltage must first exceed a
value of 410 V (factory setting) for 3 minutes, ensuring
that the PV generator provides enough power. This
means that the “AC Power Out“ LED is not lit up unless
the PV generator LED is illuminated.
Figure 4.1: Overview of Powador Under normal operating conditions the inverter starts
grid feeding in the morning and terminates this process
Captions as it becomes dark. On cloudy days or during the winter
1. Display months the grid feeding process can be interrupted at
Display of measured values and parameter settings certain times, depending on the PV generator and the
2. LED displays actual grid feeding capacity, and can be resumed later
Display of operating status on. This process might be repeated for several times,
3. Operating keys especially in the morning and evening. This is not a sign
Toggle function between measured values and of faulty operation but is normal operating behavior.
parameter settings
4. Screwed cable gland for AC connection
LED Failure (3) (red):
This LED indicates that the grid-feeding process has
been terminated as a result of a
malfunction/disturbance.

Kaco Gerätetechnik GmbH 4 Operator’s instructions Powador 00-xi-series

4 Operation

The “Failure” LED is activated in the following cases:

Keep this key pressed for approx. 1
- Grid overvoltage or low voltage across one of the
second to select which measured value
three phases
is to be displayed.
- Failure of one of the phase L2 or L3
- Excessive generator voltage
- Excessive generator power The menus are continuous, i.e. after reaching the last
- High-temperature shutdown entry of the menu and pressing the “Display” key (1) the
- Device defect first entry is displayed again (see Figure 4.4).
Please wait for approx. 10 minutes to verify if the
malfunction only occurs temporarily. If not, please Display of inverter type
contact your authorized electrician. On elimination of
the disturbance the grid-feeding process is re-started
after approx. 10 seconds. Generator voltage and current

Grid voltage, current and power

Important!
During feeding power failure (power
failure in the public grid) the “Failure” Daily peak capacity
LED is not lit up. In this case all LEDs
and the display are deactivated and Temperature inside device
the inverter is completely shut down.
Only after the feeding power has
returned can the inverter resume its Status display
normal operation.
Date and hour

Yield today
Please check whether the cause of your disturbance is
a general power failure or if the fuse between the power
meter and inverter has blown. In the event of a fuse Yield during the current year
failure please contact your authorized electrician. In
case of a general power failure please wait until the
problem has been resolved. The installation will restart Total yield
automatically.
Operating hours today
4.3 ”Display” and „Adjustment“ button

Operating hours per year

Total operating hours

Figure 4.4: Display Mode Menu

If the “Display” key on the inverter is not operated for a
longer period of time, the display will automatically
show the currently fed-in power.

Figure 4.3: Operating keys of the Powador

The “Display” key (1) is used to toggle between the
various read values and data. Using the „Adjustment“
key (2) you may change the setting parameters, such
as date and hour. The menu guidance is subdivided
into two levels. Level 1 (display mode) is used to
display the measured values, e.g. solar generator
voltage. Only the “Display” key (1) is active at this level.

Kaco Gerätetechnik GmbH 5 Operator’s instructions Powador 00-xi-series

4 Operation

Select interface and set address

4.4 Set Mode Using the menu item “Select interface”, you may
change between the RS232 and RS485 interface by
means of the „Adjustment“ key (2). If the RS485
To go to level 2 (Set Mode), keep the interface is enabled, you can set the address by means
“Display” key (1) pressed and of the “Display” key (1). Using the „Adjustment“ key (2)
simultaneously press the “Set” (2) key you may set addresses consecutively from 1 to 32.
for approx. 1 second. Thereafter, the address will be reset to 1.
By pressing the “Display“ key you may
change between the different setting Immediate start
parameters. For acceptance by your local utility company, or for test
purposes, the inverter can also be started immediately,
Using the “Set” key (2) you may now i.e. without the wait time of 3 minutes.
change the selected parameter.
Depending on the parameter the value Keep the ”Adjustment“ key pressed
will change after pressing the “Set” key until the inverter connects with an
(2). The various setting parameters are audible „click“ of the relays and the
shown in Figure 4.5. green AC Power Out LED is
illuminated. If there should not be
enough solar generator power, the
inverter will switch off again after a
Set time - hour short time.

Set time - minutes

4.5 Start key
Set date - year

Set date - month

Set date - day

Display of software version

Clear grid-feeding meter

Select interface and set RS485

address Figure 4.6: Underside of Powador
The device will be switched off in the evening with the
Immediate start break of dusk, and the display messages will be
deactivated. If you wish to retrieve the values of the
current day, press the start key (see graph of underside
Figure 4.5: Set Mode Menu of inverter) to enable the device at nighttime.
Set hour and date
Set hour and date. The set values are consecutive, i.e. Press the start key (1) at the
as soon as you have reached the max. value the underside of the device for approx. 5
display will be reset to the min. value after pressing the seconds, until a message appears
„Display (1) button once again. The display for setting on the display and the LEDs “AC
the date covers a range up to 2050. After that, the value Power In“ and “Failure “ are no
will be reset. longer lit up.
You may now scroll through the menu and retrieve the
Clear grid-feeding meter values of the current day. If no key is pressed for longer
All yield and hours will be reseted to 0. The required than one minute the device will be switched off again
parameter is “2” – please enter it by means of the automatically.
„Adjustment“ key (2). The inverter will only store the latest values of a day.
The values of “Operating hours per year”, “Total
operating hours”, “Annual fed-in power” and “Total grid
The grid-feeding meter can only be
feeding power” will be stored and added up. These
cleared – it is not possible to make
values will not be lost even if the device is not operated
any other adjustments!
for a longer period of time. The date and hour may have
to be reset if the device has not been used for several
days.

Kaco Gerätetechnik GmbH 6 Operator’s instructions Powador 00-xi-series

4 Operation

4.6 The serial RS232 interface

By means of an electrically isolated serial interface (2)
the operating data can be transmitted to a computer
(e.g. notebook) and processed individually with any
commercial spreadsheet program. To connect the
inverter to the PC you only need a commercially
available interface cable. The cable length should not
exceed 20 meters.

Using the optional accessories (see

page 12) you can also establish a
wireless data connection between the
inverter and your PC over a long
distance.

Inverter data is transmitted via the serial interface as

text only; there is not error check.

Powador Sub- Meaning of PC Sub-D

D male message on PC female 9-pole
9-pole
2 TXD 2
3 RXD 3
4 RTS 4
5 GND 5
Table 4-1: Pin allocation of RS232 interface
The RS232 interface has the following parameters:
- Baud rate: 9600 Baud
- Data bits: 8
- Parity: None
- Stop bits: 1
- Protocol: None

Figure 4.7 shows an example of a transmission via

RS232 interface.

Data can be transmitted by means of any terminal

emulation supplied together with all commercially
available operating systems, or by means of the
KACOViso visualization tool.

The KACOViso visualization tool is

available for download under:
http://www.kaco-geraetetechnik.de

In connection with the Powador inverter, KACOViso

assumes the function of a data logger. It stores the
inverter data and displays it in different diagram types,
such as daily or monthly displays.

The PC has to remain switched on permanently in this

case. Therefore, this type of monitoring should be
limited to a certain period of time (e.g. troubleshooting)
due to energy reasons. For continuous system
monitoring we recommend the optional Powador-
Display, Powador easyLOG or Powador-proLOG
accessories (see page 12).

Kaco Gerätetechnik GmbH 7 Operator’s instructions Powador 00-xi-series

4 Operation

Column 1 2 3 4 5 6 7 8 9 10
04.06.2005 16:55:30 4 363.8 0.37 134 226.1 0.53 103 23
04.06.2005 16:55:40 4 366.0 0.39 142 226.1 0.53 112 23
04.06.2005 16:55:50 4 359.5 0.41 147 226.1 0.53 116 23
04.06.2005 16:56:00 4 369.8 0.42 155 226.1 0.58 118 23
04.06.2005 16:56:10 4 377.0 0.43 162 226.1 0.63 131 23
04.06.2005 16:56:20 4 373.6 0.45 168 226.1 0.63 133 23
04.06.2005 16:56:30 4 364.0 0.48 174 226.1 0.68 146 23
04.06.2005 16:56:40 4 364.3 0.49 178 226.1 0.68 146 23

Figure 4.7: Excerpt of communication protocol via RS232 interface

Column Explanation Column Explanation
1 Date 6 Generator power in W
2 Hour 7 Grid voltage in VAC
3 Operating mode (see below) 8 Grid current, delivered current in AAC
4 Generator voltage in V 9 Grid-feeding power in W
5 Generator current in ADC 10 Device temperature in °C
Table 4-2: Explanation of individual columns
Status Explanation Comments
0 Inverter has just switched on Only after the fist startup in the morning
1 Waiting for start Self-test is completed
2 Waiting for shut-down Insufficient generator voltage and generator power.
Condition that precedes the night shutdown.
3 Constant voltage regulator Short-term grid-feeding at constant generator voltages at
the start of the grid-feeding process (80% of the
measured no-load voltage)
4 MPP- tracker, permanent search/tracking At times of low insolation the MPP tracker is used for
movement grid feeding (search/tracking movements)
5 MPP- tracker, without search/tracking At times of high insolation the patented MPP tracker is
movement used to ensure maximum grid-feeding capacity
6 Wait mode before grid feeding. Test grid and The inverter waits until generator voltage is higher than
solar voltage switching on threshold (410V) and the grid-feeding
process can be started after 3 minutes.
Test of grid voltage
7 Wait mode before self test. Test grid and solar The inverter waits until generator voltage is higher than
voltage switching on threshold (410V) and the self test of grid
relay can be started after 3 Minutes.
Test of grid voltage
8 Self-test relays Test of grid relays prior to the start of the grid-feeding
process
10 Overtemperature shut-off If the inverter is overheated (heat sink temperature
>80°C) due to continuous overload and lacking air
circulation, the inverter will shut-off. Possible causes: too
large solar generator dimensions, excessive ambient
temperature, defective inverter.
11 Power limitation Protective function of the inverter, e.g. if excessive
generator power is delivered or the heat sink of the
device exceeds 75°C
12 Overload shut-off Protective function of the inverter, e.g. if excessive
generator power is delivered
13 Overvoltage shut-off Protective function of the inverter, e.g. if the grid voltage
is too high
14 Grid failure (3-phase monitoring) Protective function of the inverter, e.g. if one of the three
grid phases has failed or the voltage is out of tolerance.
15 Transition to night shut-down Inverter goes to sleep
18 RCD shut-down Excessive fault current
19 Insufficient insulation resistance Insufficient insulation resistance from PV-/PV+ to PE
30 Measuring error Current and voltage measurements in the solar inverter
are not plausible
31 RCD module error An error occurred in the universal AC/DC circuit breaker.
32 Self-test error An error occurred when testing the grid isolation relay
33 DC grid-feeding error Excessive amount of DC grid-feeding power
34 Communication error An error occurred during internal data transmission.

KACO Gerätetechnik GmbH 8 Operator’s Instructions Powador 00-xi-Series

4 Operation

The interface of the connected PC or laptop must 4.8 Display

comply with the standard for RS232 interfaces. Some The inverters of the Powador xi-series are equipped
computer manufacturers are not 100 % compliant with with an illuminated LCD display (see Fig. 4-1 – (1)).
this standard. In these cases there may be problems This display shows all measured values and data. In the
during the data transfer. normal mode of operation the background illumination
is deactivated. As soon as you press one of the keys
the background illumination will be activated. If 10
The read data for current and voltage seconds elapse without a key being pressed, the
are subject to the indicated tolerances background illumination will be switched off again.
and not suitable for measuring the During normal operation the current grid-feeding power
degrees of efficiency or yield data. will be shown on the display, if no key is pressed for a
longer period of time.
These readings are merely used to
check the installation for its general
function and proper operation. Important!
Due to measuring tolerances the
measured values may not always
correspond to the actual values. The
4.7 The RSS485 interface measuring sensors of the inverter
To enable remote monitoring of your photovoltaic have been selected in a way to ensure
installation, Powador inverters are additionally equipped maximum solar yields.
with an RS485 interface (see Figure 4.1 – (7)). Figure
4.1 – (7). This interface enables monitoring several Due to the tolerances the daily yields
inverters at the same time. By means of the Powador- displayed on the inverter may deviate
proLOG series you can receive your yield and from the values of your Utility
operating data or error messages by SMS or e-mail. Company’s grid-feeding meter by up
This monitoring option is especially recommended in to 15 % (admissible meter tolerance
cases where you are unable to check the functionality approved by your Utility Company:
of your installation on-site at regular intervals, i.e. if your ± 2 %).
domicile is too far away from the installation site. In
addition, you can use the Powador-link in your
installation, so as to bridge long distances between
several inverters or between an inverter and proLOG
Using the operating keys (see Section 0 ) the values
by means of a wireless RF connection. Please contact
and data listed in Table 4-3 can be shown.
your installer if you wish to integrate remote monitoring
in your system.

No. Display Explanation

1 Display shown during the starting-up period (in the morning),
Start from 410 V after a malfunction or prior to night shutdown. No grid
Measurement xxx.x V feeding in this mode of operation. The inverter waits until the
voltage has exceeded a value of 410 V. If this value is
exceeded for longer than 3 minutes the grid feeding will be
started. An audible sound is generated when the grid
isolation relay is enabled
2 Existing voltage and current of the solar generator connected
Solar generator to the inverter. Shown in volts and amps; voltage tolerance ±
xxx.x V xx.xx A 3 %; current tolerance ± 5% at rated power. Greater
tolerances are possible when smaller generator currents are
displayed.
3 Existing grid voltage, grid current and power (measurement
Grid xxxx W of the phase into which power is delivered); displayed in
xxx.x V xx.xx A volts, amps and watts; voltage tolerance: ± 3%; current
tolerance: ± 3 %.

4 Short-term peak grid feeding capacity of the day,

Daily peak displayed in W. According to the regulations stipulated by the
capacity xxxx W Power companies, this peak capacity must not exceed 10 %
of the rated power of the inverter. However, the generator
may be dimensioned for higher capacities.
5
Temperature Display of the current heat sink temperature, in °C. The
inside device xx ° inverter will limit grid feeding if the temperature exceeds
75°C. If the device temperature exceeds 85°C it will switch
off automatically.

Kaco Gerätetechnik GmbH 9 Operator’s instructions Powador 00-xi-series

4 Operation

No. Display Explanation

6
Status: Display of the various operating statuses
Device feeds to grid Normal grid-feeding operation. Power is fed into the grid.

Status: Wait Waiting for sufficient solar generator power. The generator
for startup voltage is not sufficiently high for grid feeding, or the grid
feeding process was stopped and the system is re-started
after a failure.
Waiting for night shutdown. The generator capacity is no
Status: Wait longer sufficient for grid feeding, and the device waits for the
for shutdown night shutdown.
The connected solar generator has fed-in more power than
the inverter was able to adjust (short-term). As a result, a
safety shutdown was initiated.
Status:
Overload
The connected solar generator has supplied excessive
voltage.
Status:
Overvoltage

The device changes over to night shutdown.

Status: Device
switches off

Kaco Gerätetechnik GmbH 10 Operator’s instructions Powador 00-xi-series

4 Operation

No. Display Explanation

7 Error message:

Grid disturbance The grid voltage is not correct, i.e. grid-feeding is not
Low voltage Lx possible. The display shows which phase is disturbed (low
voltage).

Grid disturbance The grid voltage is not correct, i.e. grid-feeding is not
Overvoltage Lx possible. The display shows which phase is disturbed (over-
voltage).

Grid disturbance The phase-to-phase voltage is not correct – no proper three-

Phase-to-phase voltage phase grid is connected.

Grid error Overvoltage shut-down due to increased voltage resulting

from an increased line resistance of the grid connection.

Grid disturbance The grid frequency is too low, thus inhibiting the grid-feeding
Low frequency process.

Grid disturbance
High frequency The grid frequency is too high, thus inhibiting the grid-feeding
process.

Error DC grid feeding above the admissible limit value.

DC grid feeding The inverter has been disconnected from the grid.

Fault current Non-permissible fault current on the AC or DC side.

Shut-down The inverter has been disconnected from the grid.

Error
AFI module A failure of the universal AC/DC circuit breaker has occurred.
The inverter has been disconnected from the grid.

Error The test of the internal grid isolation relay has failed.
Self-test The grid-feeding process cannot be started.

Error
Communication An internal data communication error has occurred.
The grid-feeding process cannot be started.

Error
Measuring error Current and voltage measurements in the inverter are not
plausible. The inverter has been disconnected from the grid.

Insulation fault The insulation resistance on the DC side is < 1.2MOhm.

Generator The grid-feeding process cannot be started.

Kaco Gerätetechnik GmbH 11 Operator’s instructions Powador 00-xi-series

4 Operation

No. Display Explanation

8
Self test
runing Function test of the grid isolation relays

9
Date xx.xx.200x
Hour xx:xx:xx Indicates date and hour

10
Yield today Power delivered since sunrise. Display in watt hours
xxxxx kWh (not kWH!)

11
Yield per year
xxxxx kWh Power delivered in the actual year. Display in kWh.

12
Total yield Power delivered since the start-up of the inverter
xxxxx kWh

13
Operating hours Power delivered since sunrise today, indicated in hours and
today xxxxx:xx minutes.

14
Operating hours Operating hours throughout this calendar year (since 1
Year xxxxx:xx January) until the present day.

15
Total Operating Operating hours since the startup of the inverter.
hours xxxxx:xx

Table 4-3: Possible display messages

Caution!
If the values for date and hour are
set incorrectly, this will also affect
the display of operating hours and
Caution !
yields!

Kaco Gerätetechnik GmbH 12 Operator’s instructions Powador 00-xi-series

5 Accessories

5 Accessories
KACO Gerätetechnik GmbH offers its customers a wide Powador-easyLOG
range of useful accessories. The product range Powador-easyLOG is used to transmit the operating
includes devices of superb quality for monitoring, data of your inverter via a wireless connection and
display, data transfer and visualization. display such data either on the Powador-Display or on a
PC.
Powador-Display
You wish to see what your installation is doing and
whether everything is the way it should be? Then
Powador-Display is the right choice for you. Via an RF
module, the inverter transmits its data to the display,
where you can observe the daily curve or read the
current output or daily yield. You will be able to
recognize any problems in your installation very quickly.
The attractive display is suitable for use in home or
office surroundings.

Figure 5.3: Powador -easyLOG

Powador -go
If you simply wish to know if your installation is working
properly, Powador-go is the right choice for you. If your
PV installation or your modules stop producing current,
Powador-go-Set will provide an acoustic warning signal
after 24 hours. The entire process is independent of the
inverter, so just lean back and relax – your installation
will tell you if there is a problem.
Figure 5.1: Powador -Display

Powador-proLOG
You wish professional monitoring and data recording of
your installation? Powador-proLOG is the high-end
solution to provide error messages by SMS, fax or e-
mail, remote access to installation data, display of your
PV installation on the web or many other things – it’s
just no problem for Powador-proLOG. Up to 32 devices
can be connected to Powador- proLOG by means of
the RS485 interface.

Figure 5.4: Powador -go

Figure 5.2: Powador -proLOG

Kaco Gerätetechnik GmbH 13 Operator’s instructions Powador 00-xi-series

6 Troubleshooting

6 Troubleshooting Should your PV installation not work properly despite all

these measures, we recommend the following
Within the scope of our continuously expanding Quality procedure for remediation:
Assurance System, our goal is to rule out and eliminate
any faults and defects. You have purchased a product Check the solar generator and grid connections leading
that has left our factory in a proper condition. Each to the Powador, observing all the safety instructions
individual device has successfully passed extensive given in this manual. Please observe the inverter
inspection tests for proper operation and functioning of carefully and take note of the display messages and
protective devices, as well as a long-duration test at our LED displays.
factory.
Below is a summary of possible error and
recommended remedies.

Error Cause Remedy/Explanation

Inverter shows an Grid voltage failure Even if an incorrect daily peak value is displayed the inverter
unrealistic daily peak continues to work properly and without any yield losses. Values
value 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.

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. The tolerances of the individual measuring values are
shown on the power measuring elements shown in Table 4-3. The daily yield value may deviate from the
meter of the Utility value shown on the power meter by up to 15%.
company.
No display shown Device is in the night shut- The inverter shuts down over night.
down mode If the display should not be illuminated during a normal time of
No grid voltage is present the day you should check on the power meter whether or not
Solar generator voltage is the device delivers power. If power is delivered the display
less than 300 V 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
410V. If this is the case but the inverter still fails to deliver
power the device has to be returned to KACO for repair.

Inverter does not start Device is in its night shut- The inverter shuts down over night.
down mode If the display should not be illuminated during a normal time of
No grid voltage is present the day you should check on the power meter whether or not
The solar generator the device delivers power. If power is delivered the display
voltage is less than 410 V 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 410 V.
If this is the case but the inverter still fails to deliver power the
device has to be returned to KACO for repair.
Inverter is active but Insufficient generator After sunrise, at sunset, and during times of low insolation due
does not deliver power – voltage. Voltage to bad weather conditions the generator voltage or,
the display reads: Start measured < 410 respectively, generator power fed from the roof may be
from 410 V insufficient for grid feeding.
Measurement:
xxx V
Inverter is active but The inverter has After an interruption of grid feeding due to a malfunction (grid
does not deliver power – interrupted grid feeding power failure, overtemperature, overload, etc.) the inverter
the display reads: due to a always waits for approx. 3 minutes before resuming its grid
Start from 410 V malfunction/disturbance. feeding operation. Grid failures may cause interruptions during
Measurement: the day. If more than 10 interruptions should occur over several
xxx V (measured voltage weeks you should contact your solar installation provider.
is higher than 410)

Kaco Gerätetechnik GmbH 14 Operator’s instructions Powador 00-xi-series

7 Recycling and disposal

Error Cause Remedy/Explanation

The inverter terminates Defective grid isolation Although there is enough insolation, the inverter delivers power
grid feeding shortly after relay in the inverter. for a few seconds only and switches off again. During this short
starting-up although time a grid feeding value between 0 – 5 W is displayed. If
there is enough insufficient generator power can be ruled out in this case the
insolation. grid isolation relay is presumably defective and prevents the
inverter from being activated.

Grid fuse triggers Insufficient grid fuse At times of high insolation the inverter may exceed its rated
rating current for a short time, depending on the type of solar
generator. Therefore, the grid fuse should have a higher rating
Inverter hardware is than the max. grid feeding current.
damaged 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.
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 a slight um due to high energy
- Certain grid conditions may 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.
- People 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 failure, damage or
shorter useful life of the devices.

If any defect found should not be able to be remedied 7 Recycling and disposal
by means of the measures described above please
contact your solar installation provider or our Service Both the inverter and associated transport packaging
Department. mainly consist of recyclable raw materials.

Please have the following information ready to enable Device

our Service Department to respond quickly and Defective inverters and accessories do not belong in
properly: your household garbage. Please ensure that the old
device and any accessories are disposed of according
Inverter Data to the applicable regulations.
- Serial number of the device
- Inverter type Packaging
- Short description of error Please ensure that the transport packaging is disposed
- Is the fault or error reproducible? If so, please of properly.
provide a short description.
- Does the fault or error occur sporadically?
- Describe the insolation conditions prevailing when the
error occurred.
- Hour of the day

Photovoltaic module data:

- Module type, manufacturer (please send data sheet,
if available).
- Number of modules connected in series
- Number of strings
- Generator power

Kaco Gerätetechnik GmbH 15 Operator’s instructions Powador 00-xi-series

For skilled and authorized electricians

Installation instructions
Powador 2500xi / 3500xi / 4000xi / 4500xi / 5000xi

5.6 Connection of the RS485 interface 10

1 About this document 2 5.7 Startup of the solar inverter 11
1.1 Attachment and maintenance of documents 2 5.8 Programming the parameters 11
1.2 Symbols used in this document 2
1.3 CE Certification/Labeling 2 6 Application/Acceptance by your Electricity
1.4 Type label 2 Board 13
2 Safety information and instructions 2 7 Switching off the inverter 14
3 Notes concerning installation and 8 Troubleshooting 14
operation 3
3.1 Factory guarantee and liability 3 9 Technical Data 17
3.2 Service 4 10 The Powador as a part of a PV plant 18
3.3 Intended use (normal use) 4 10.1 Setup of a PV plant/installation 18
4 Device description 4 10.2 Multi-inverter installations 20
4.1 Dimensioning of the PV generator 4 10.3 Special conditions for Powador 5000xi: 21
4.2 Protective concepts 5 11 Appendix 22
4.3 Mechanical dimensions 5 11.1 EU Declaration of Conformity 22
5 Installation and startup 6 11.2 Declaration of conformity concerning the rated
5.1 Selecting an appropriate place of installation 6 power and max. output of photovoltaic
5.2 Installing the inverter 6 inverters 23
5.3 Electrical connections 7 11.3 Declaration of Conformity/Non-Objection 24
5.4 Connection of the fault-signal relay 10
5.5 Connection of the S0 output 10
1 About this document

fundamental requirements according to the following

1 About this document directives:
The following information will guide you through the • Directive concerning Electromagnetic Compatibility
entire documentation. Further documents will be valid with Class B (Council Directive 89/336/EWG)
in conjunction with these operating and installation • Low Voltage Directive (Council Directive 23/EWG
instructions.
1.4 Type label
We shall not be liable for any damage caused by The type label indicating the exact device description is
non-adherence to the instructions given in this located on the support panel at the underside of the
manual. enclosure.

Pertaining documents
During the inverter installation please observe all 2 Safety information and
assembly and installation instructions for components instructions
and other parts of the system. These instructions are
shipped together with the respective installation
components or supplementary equipment. Danger!
Danger due to lethal voltages!
1.1 Attachment and maintenance of documents Hazardous live voltages are present
Please forward these operating and installation inside the device/instrument and
instructions to the Plant Operator for maintenance. The power lines. Therefore, the
Plant Operator will ensure that these instructions are device/instrument must only be
made available as needed. installed and opened by a skilled
1.2 Symbols used in this document electrician.
Please observe the safety information provided in this
manual when operating your inverter! Even when the device/instrument is
switched off, dangerous live voltages
may still be present inside the
instrument.
Danger!
Lethal Hazard by electric shock! Standards and regulations
- VDEW conformity according to the regulations of the
Association of German Utility companies
- “Independent power generating plants on low-voltage
grids”, Directive concerning the connection and
Warning! parallel operation of independent power generating
Direct hazard of personal injury plants on the low-voltage grid, 4th Edition 2001
and death! - IEC 60364-7-712 Electrical installations of buildings -
Part 7-712
- DIN EN 60891 Process of converting measured
current-voltage characteristic curves of photovoltaic
Caution! components
Potential hazard for the product - DIN EN 60904 Photovoltaic Installations – Part 1 to 8
and environment! - EMC Test Methods according to EN50081-1:1992,
EN50082-1:1997
- Emitted interference: EN 55014-1: 1993
- Interference immunity: EN 55014-2: 1997
Note! - Harmonic (upper) waves: EN61000-3-2: 1995
Useful information and remarks! - Voltage fluctuations + Flicker: EN61000-3-3: 1995
- Semiconductor inverters: EN 60146-1-1: 1994,
EN60146-1-3: 1994

Technical rules
Important! The assembly must be in compliance with the local
regulations and technical rules, in particular with regard
to:
- Electrical connections
This symbol indicates that a - VDE 0100 Setting-up of power installations with rated
certain action is required. voltages of up to 1000 volts
- VDE 0105 Part 100 Operation of electrical
plants/installations
- VDE 0185 General information concerning the setup
1.3 CE Certification/Labeling of lightning protection installations
CE labeling is used to document that the Powador - VDE 0190 Main potential isolation of electrical
inverter indicated on the type label meets the plants/installations

KACO Gerätetechnik GmbH 2 Operating Instructions Powador 00-xi-Series for skilled electricians only
3 Notes concerning installation and operation

- VDE 0298 Part 4 Rubber-insulated leads carrying Modifications/Manipulation

rated voltages of up to 450/750 volts Performing any modifications or changes on the inverter
- DIN 18382 electrical cable and routing installation in is generally prohibited. Performing any changes or
buildings modifications in the environment of the inverter is only
permitted if in compliance with national standards.
Regulations concerning the prevention of accidents
The inverter must be installed by an approved skilled Caution!
electrician who is responsible for the adherence to Hazard of damage due to unauthorized
existing standards and regulations. modifications/manipulation! By no means
The proper and safe operation of the device/instrument manipulate the inverter or modify or
requires proper transportation, storage, erection and change the inverter or any other part of
assembly, as well as careful operation and the installation!
maintenance.
Only skilled and trained personnel who have read and
fully understood all safety information contained in Transport
these operating and installation instructions, as well as The Powador inverter is subjected to extensive testing
the assembly, operating and maintenance instructions, and inspection in our test field, so as to ensure its
shall be authorized to operate the inverter superb quality. Our inverters leave our factory in a
proper electrical and mechanical condition. Special
During the operation of this device, certain parts of the packaging ensures that nothing can happen during the
device inevitably carry hazardous live voltages, which transport to our customers. Nevertheless, transport
may lead to severe personal injury or even death. The damage may not be ruled out completely. In this case,
following precautions should be followed to minimize the forwarding agent/carrier will be responsible.
the risk of lethal hazards or personal injuries.
Please check the inverter carefully on arrival. Should
you discover any visible signs of damage on the
1. The installation of the device must be in compliance packaging, which imply that the inverter may be
with the relevant safety regulations (e.g. DIN, VDE) damaged, or should you find any visible signs of
or other applicable national or local provisions. damage on the inverter please notify your responsible
Proper earthing, conductor dimensioning and an forwarding agent/carrier immediately.
appropriate short-circuit protection must be provided
to ensure operational safety. If necessary, your solar installation provider or KACO
2. All instrument covers must remain closed during Gerätetechnik GmbH will assist you. However, written
operation. damage reports must be received by the forwarding
3. Prior to performing any visual checks and agent within six days after receipt of the goods at the
maintenance work the device must be disconnected latest.
from all power sources and protected against Use exclusively the original packaging for returning the
inadvertent switching on. inverter – only this material will ensure safe
If measurements have to be conducted while the transportation.
device is connected to power, NEVER touch live
terminals. Remove all jewellery from your wrists and
fingers. Ensure that the test equipment is in a good 3 Notes concerning installation and
and safe operating condition. operation
4. When working on the switched-on device, make sure 3.1 Factory guarantee and liability
to stand on an insulated surface and ensure that
there is no connection to ground. KACO Gerätetechnik GmbH grants a guarantee of six
years on Powador inverters, starting from the date of
5. Exactly follow the instructions given in these installation and max. 78 months after shipment by
operating and installation instructions and especially KACO.
observe all information concerning possible hazards, During this time, KACO Gerätetechnik GmbH
warnings and precautions. guarantees the proper function of the devices and free
repair in the event that a defect should occur which we
6. This list does not constitute a complete list of all are accountable for.
required measures. Should any specific problems
occur, which are not covered sufficiently for the Should your device show a defect or malfunction during
purposes of the buyer, please contact your specialist the guarantee period, please contact your specialist
dealer. dealer or, respectively, your installation expert.
Guarantee claims shall be excluded in the following
cases:
- Use of the device for other than the intended use
(normal use)
- Improper use and installation that does not comply
with the required standards
- Improper operation

KACO Gerätetechnik GmbH 3 Operating Instructions Powador 00-xi-Series for skilled electricians only
4 Device description

- Operation of the devices with defective protective caused by unintended use is at the sole risk of the
equipment operator.
- Manipulation of the device or makeshift repairs
- Influence of foreign objects or Act of God (lightning, The term ”intended use“ shall also include the
overvoltage, tempest, fire) adherence to the operating and installation instructions.
- Inadequate ventilation of the device Some of the documents which are needed for these
- Non-adherence to the relevant safety instructions applications and acceptance are attached to these
(VDE (Association of German Engineers), a.o. installation instructions.
- Transport damage

All guarantee claims shall be handled at the premises of

KACO Gerätetechnik GmbH. To this end, return
transport shall be effected, as far as possible, in the
Caution!
original or equivalent packaging. The costs for these
Using the device for any purpose
services cannot be borne by KACO Gerätetechnik
other than intended/normal use is
GmbH.
prohibited!
Guarantee claims shall only be compensated by KACO
if the damaged device is returned to KACO together
with a copy of the invoice issued to the consumer by the
specialist dealer. The type label on the device must be 4 Device description
fully legible. In the event of noncompliance KACO
reserves the right to deny guarantee services. The transformerless Powador xi-series devices are
The warranty period for rework or replacement currently available for five different power ratings. The
shipments shall be six months after shipment. However, appropriate inverter type is selected in accordance
it shall continue at least until expiration of the original with the selected and mounted photovoltaic modules.
warranty period granted for the shipped object. The max. power values are indicated in the data sheet
(Section 9).

3.2 Service The inverter designation is shown on the front side

above the display, and on the type label.
High quality and longevity of our inverters always have
been of central importance for us - already at the time 4.1 Dimensioning of the PV generator
of product development. Our more than 60 years of
experience in the field of current inverters are backing The selection of the PV generator is of crucial
up this philosophy. importance when dimensioning a PV installation.
Despite all these quality-assuring measures, however, It must be observed by all means that the solar
disturbances may occur in very rare cases. KACO generator is the right match for the inverter. Please
GERÄTETECHNIK GmbH will offer a maximum of observe the data given in the Technical Data Sheet
assistance if one of these cases should arise. KACO (Section 9) for dimensioning the solar generator.
GERÄTETECHNIK GmbH will take every effort to
remedy any defects fast and without any unnecessary The design and dimensioning program,
bureaucracy. Please contact our service department Kacocalc, is available for free download
directly – and you will be aided and supported very under
quickly. http://www.kaco-geraetetechnik.de

Dimensioning of the PV generator:

3.3 Intended use (normal use) The number of PV modules connected in series must
Powador inverters are built according to state-of-the-art be selected in such a way that the output voltage of the
and approved safety requirements. However, improper PV generator is maintained within the admissible input
use may cause lethal hazards for operators or third voltage range of the inverter – even in the event of
parties and/or damage of instruments/devices or other extreme external temperatures. In Central Europe,
property. module temperatures between –10°C and +70°C
The device is intended to convert the direct voltage should be assumed. Depending on the type of module
generated in the photovoltaic (PV) modules into assembly and geographical conditions, +60°C or +70°C
alternating voltage (AC) and feed this voltage into the should be used for calculating the voltage. The
grid. temperature coefficient of the solar modules should be
observed. The following criteria must be met for
The inverter must only be operated in connection with a calculating the voltage of the PV generator:
fixed/stationary connection to the public grid. Inverters
are not intended for mobile use.
Any use other than the specified intended use is not
deemed intended or normal use, and the
manufacturer/supplier shall not be liable for any
damage caused by such unintended use. Damage

KACO Gerätetechnik GmbH 4 Operating Instructions Powador 00-xi-Series for skilled electricians only
4 Device description

- Uo (-10°C) < max. input voltage (800VDC) 4.2 Protective concepts

Even at very low external temperatures (-10°C), the The following monitoring and protective functions are
no-load voltage of the connected string must remain integrated in Powador inverters:
within the admissible input voltage range. For
example, if the temperature falls from 25°C to –10 °C, - Redundant 3-phase grid monitoring to protect against
the no-load voltage of 12-V modules will increase by personal injuries and avoid islanding effects
approx. 2.8 V per module (5.6 V for 24V modules). according to VDE0126-1-1.
The no-load voltage of the entire string must be less - Overvoltage varistors to protect the power
than 800 volts. semiconductors against high-energy transients on the
grid side.
- UMpp (+60°C) > min. input voltage (350VDC) - Temperature monitoring of the heat sink
- EMC filters to protect the inverter against high-
Even at very high external temperatures (+60°C) the frequency grid interference
MPP voltage of the connected string should remain - Grid-side varistors to earth/ground, to protect the
within the admissible input voltage range. If the inverter against burst and surge pulses
temperature rises from 25°C to 60 °C, the MPP voltage - AC/DC-sensitive circuit breakers (AFI circuit
of 12V modules will decrease by approx. 3.6 V per breakers) to monitor the deduced current from the
module (7.2 V for 24V modules). The MPP voltage of Powador grid connection through to the PV generator
the entire string should be 350 V. and disconnect the circuit at a difference current
value of greater than 30 mA. The AFI circuit breaker
Even if the MPP voltage is beyond the admissible input will trigger in the event of an insulation fault, ground
range, the installation nevertheless will continue to work fault, or body contact of a conductor.
properly. However, the delivered power will be slightly
less than the maximum yield. 4.3 Mechanical dimensions

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 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 red and as 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 Figure 4.1: Powador dimensions
cost factor of a solar installation. Therefore, it is very
important to obtain maximum energy yields. To achieve
this goal, solar generators located in Central Europe Type Height Width Depth
should be orientated towards the South at an angle of 2500xi 500mm 340mm 200mm
inclination of 30°, and shading of whatever kind should 3500xi 500mm 340mm 200mm
be prevented under all circumstances. 4000xi 550mm 340mm 220mm
In many cases, the recommended angle of inclination 4500xi 600mm 340mm 220mm
cannot be implemented for technical reasons. To 5000xi 600mm 340mm 220mm
achieve the high 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.
In exposed mountain areas or in Southern regions it is
recommended to reduce the efficiency ranges. Please
consult your specialist dealer or notify us if you should
require any further assistance.

KACO Gerätetechnik GmbH 5 Operating Instructions Powador 00-xi-Series for skilled electricians only
5 Installation and startup

5.2 Installing the inverter

5 Installation and startup
5.1 Selecting an appropriate place of installation

Powador inverters will meet the

requirements of protection class IP54,
if all cable connections are allocated
or closed accordingly.

Nevertheless the place of installation should be as dry

as possible in order to ensure long lifetimes. In addition,
the installation environment should be well air-
conditioned so as to protect against overheating and
prolongate the useful life.
The following rules should be observed when selecting
the place of installation of your inverter:
- Ensure good access for assembly or service work.
- Maintain the following minimum clearances around
the device: 200 mm side clearance to other devices;
700 mm clearance on the top surface 500 mm
clearance to cabinets, walls, or similar
- The device has been designed for vertical wall
installation.
Figure 5.1: Wall installation of Powador
- Please ensure free air circulation around the device
and through the heat sink at the rear side. The inverters are shipped together with an installation
- If the inverter is installed in a switch cabinet or similar, kit consisting of four dowel pins and four 70 mm screws.
please provide forced ventilation to ensure that heat Prior to installation the condition of the mounting wall
is dissipated adequately. has to be checked. If necessary, use a kit other than the
- The heat sink may reach a temperature of max. 90°C. one shipped with your inverter.
Therefore, only mount the inverter on walls that are
made from a heat-resistant material.
- Ensure that the wall has an adequate load-bearing - Drill the holes for the dowel pins
capacity and only use the appropriate installation according to the positions indicated
material. on the mounting plate.
- In areas with a special risk of flooding, always make - Place the dowel pins into the holes.
sure to install the inverter in a sufficiently elevated - Using the Philips-type screws, fasten
place. the mounting plate to the wall. Make
- Installation at eye level makes it easier to read the sure that the arrow shown on the
display. 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).

KACO Gerätetechnik GmbH 6 Operating Instructions Powador 00-xi-Series for skilled electricians only
5 Installation and startup

Figure 5.2: Catch is open (left) and closed (right)

5.3 Electrical connections Figure 5.3: Connection box of Powador

General information Grid connection

The electrical connections can be established after the 5-lead connections are used (L3, L2, L1, N, PE). To
inverter has been installed in its fixed location. insert the wires an appropriate screwed cable gland is
provided at the underside of the housing.
Caution! We recommend the following wire cross sections for
The electrical installation of Powador cable lengths up to 20 m:
must only be performed by skilled
personnel and by an electrician who - Powador 2500xi/3500xi: 2.5 mm2
2
has been approved by the - Powador 400 xi:: 4.0 mm
-
responsible Electricity Board. Powador 4500xi/5000xi: 6 mm2
Larger cross sections should be used for longer cable
lengths. According to VDE 0100 Part 430 “Protection of
cables and lines in the event of overcurrent”, NYM
All applicable safety instructions, technical connections leads should be protected as follows (fixed wiring,
stipulated by the responsible Electrical Supply ambient temperature 25 °C and installation type B2
Company/Electricity Board, and the relevant VDE (multi-wire lead in a tube or channel on or inside walls
regulations must be adhered to. or buried):
To connect the inverter the AC and DC side must be - 2.5 mm2 ⇒ 20A
disconnected from all voltage sources and protected 2
- 4 mm ⇒ 25A
against inadvertent switching-on. 2
- 6 mm ⇒ 35A
The connection of the PV generator and the grid
connection are established via PCB terminals in the
NEOZED cutout fuses of the type gL should be used as
connection box of the inverter (see Figure 5-3).
fuses.

Please make sure to use sufficiently

wide wire cross-sections to avoid
Open the door of the excessive line impedance (internal
housing/enclosure. The door is resistance of the electrical grid)
secured against opening by between the domestic distribution and
means of two recessed-head the respective Powador inverter.
screws at the upper right side.
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
The max. cross section of the AC and grid terminals exceeds a defined limit,
DC terminals is 10 mm². the inverter will switch off due to grid
overvoltage. This condition must by all
means be taken into consideration for
dimensioning the AC lead.

KACO Gerätetechnik GmbH 7 Operating Instructions Powador 00-xi-Series for skilled electricians only
5 Installation and startup

AC/DC (Universal) ground fault circuit breaker (AFI)

Danger!
The solar inverter is equipped with a universal ground- To ensure maximum protection
fault circuit breaker according to VDE 0126-1-1. In the against hazardous live voltages
event of a non-permissible fault current the inverter is during the assembly of the
disconnected from the grid. photovoltaic installation, both the
plus and minus leads must be
Therefore, any further external ground fault circuit strictly isolated from earth
breakers are not required. potential (PE).

Danger!
Hazard of electric shock due to Please check that the PV generator is
contact with terminals carrying ground-free before connecting it to the
high voltages! Check that the Powador inverter. Determine the DC
power cord is disconnected voltage between protective earth (PE)
before inserting and routing it and the positive lead or, respectively,
inside the device! between the protective earth (PE) and
the negative lead of the PV generator. If
stabilized voltages can be measured,
this indicates a ground fault in the PV
Route the shielded and stripped lead generator or generator wiring. The ratio
through the cable fitting. Connect the between the measured voltages
shielded and stripped lead according to indicates the location of this fault. Make
the mark shown on the left side of the sure to remedy this fault prior to
PCB terminal. performing any further measurements!

Determine the electrical resistance with

a meter according to DIN VDE 0100
between the protective earth (PE) and
Caution! the positive (plus) lead or, respectively,
Please check the leads for proper between the protective earth (PE) and
connection. Reversing L and N will the negative (minus) lead of the PV
result in the destruction of the generator. A low resistance value (< 2
inverter. MΩ) indicates a high-resistance ground
fault of the PV generator, which must
by all means be remedied prior to
further installation!
Once again check that all connected
cables and leads are securely
tightened. Tighten the terminal seal
of the cable fitting.

Caution!
Prior to connecting the DC leads
PV generator connections to the inverter terminals the
The PV generator connections are established on the voltage of the solar generator
right side of the connection box. must be measured.
The DC voltage must not exceed
max. 800VDC. Connecting to
Caution! higher voltages will result in the
Risk of damage! destruction of the device.
By all means make sure not to
reverse poles when connecting the
device.
The PV generator can be connected in different ways:
- Via PG fittings
- Via Tyco connectors
- Via MC plug-type connectors

PG fittings are provided as a standard. Tyco and MC

plug-type connectors may be provided as options.

KACO Gerätetechnik GmbH 8 Operating Instructions Powador 00-xi-Series for skilled electricians only
5 Installation and startup

PV generator connection by means of cable fittings

To do this, open the cable fittings until you

can insert the cables. Route the cables
through the ferrite core and fasten the cable
ends in the terminals marked “PV+“ and
“PV-“.

Make sure not to reverse the poles.

Tighten the cap of the cable fittings.

Figure 5.5: Assembly of Tyco receptacles

For easier installation the ferrite core may

be removed from the heat sink. The assembly of the Tyco and MC-type connectors is
However, always make sure to route all depicted in Figure 5.6 and Figure 5.7.
DC leads through the ferrite core!

Caution!

To ensure Protection Class IP54 any

unused cable fittings must be closed by Figure 5.6: Assembly of Tyco plug-type connectors
means of the enclosed blind caps!

Figure 5.7: Assembly of MC connectors

Figure 5.4: Connection of three PV strings

Caution!
PV generator connections by means of multi-
contact or Tyco plug-type connectors The PV generator should not be
MC or Tyco plug-type connectors may be enclosed to disconnected from the Powador
the inverter as options. These connectors may be used inverter (i.e. by pulling the connector)
instead of the PG-type fittings mounted on the device under load except in absolute
(shipping condition). In this case, please remove the emergency cases. It should by all
PG-type fittings and assemble the appropriate means be avoided during the normal
connectors instead. grid feeding operation.
Prior to disconnecting, always
disconnect grid voltage by
Remove the PG-type connectors from deactivating the grid fuses.
the provided apertures in the baseplate
of the inverter. Insert the Tyco- or MC If this is not observed, arcing may
receptacle (female connector) from occur and damage the connectors –
outside into the apertures and fasten both parts of the connector will have to
inside by means of the black plastic be replaced.
nuts (see Figure 5.5).

KACO Gerätetechnik GmbH 9 Operating Instructions Powador 00-xi-Series for skilled electricians only
5 Installation and startup

5.4 Connection of the fault-signal relay

The solar 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.

Important!

In the event of a power failure on the

public grid the relay will not trigger.
Figure 5.9: Connection terminals for the RS485-
In this case, all LEDs and the display
interface
will be extinguished and the inverter
will be shut down completely.
A fault signal will not be possible in Powa- Powa- Powa- Pro Phone
this case! dor dor dor log Connect.
AB AB AB AB AB AB AB
230VAc
Ra
max. 32 Powador

Figure 5.10: Wiring plan for the RS485 interface

Figure 5.10 shows a terminator resistor, which is

connected to the left inverter (Ra,330Ω). This terminator
resistor is needed on the last device in the chain to
ensure correct signal transfer. The terminator is
supplied together with the Powador inverters.
Within a bus system, such as the RS485, each device
Figure 5.8 Fault-signal relay and S0 connection 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
5.5 Connection of the S0 output inverter can be determined via the Set menu, (see
Operator’s Manual
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, Section 5.8, “Parameter Important!
Programming”). Please ensure correct connection of the
A and B wires. If these wires are
confused, no communication will be
5.6 Connection of the RS485 interface possible.

On the control board (at the rear side of the door of the
Powador inverter), there are four terminals marked
RS485 A and B (see Figure 5.9). To connect several
Powador inverters, terminal A of the first Powador must
be connected to terminal A of the second Powador;
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. A wiring plan is
shown in Figure 5.10. The total length of the RS485
wiring should not exceed 250 m.

KACO Gerätetechnik GmbH 10 Operating Instructions Powador 00-xi-Series for skilled electricians only
5 Installation and startup

Immediate start
5.7 Startup of the solar inverter For acceptance by your local Electricity Board, or for
After completing the mechanical and electrical test purposes, the inverter may also be started without
installation you may now put the inverter into operation the wait time of 3 minutes (immediate start).
as follows
Change to the Set mode. Using the
“Display“ (1) key, scroll through the
NOTE!
menu until you have reached the sub-
The inverter can only be put into
item „“Start immediately with key 2
operation under daylight conditions
Vxxx“.
(i.e. at a solar generator voltage of
Keep the “Set“ key pressed until you
> 300 V). If no daylight or solar
hear an audible “click“ indicating that
generator voltage is present, the
the inverter switches on. The green
inverter can be activated by pressing
grid-feeding LED is illuminated. If there
the Start key (see Section 4.4 of the
should be no sufficient solar generator
Operating Instructions), but normal
voltage, the inverter will switch off
operation will not be possible in this
again.
condition. (Only the values can be
read off the display).
.

5.8 Programming the parameters

The programming mode offers several options to
change or program the parameters of your Powador
- Switch on the grid voltage (via the inverter.
external automatic safety breakers).
- Switch on the solar generator via the
DC circuit breaker (or DC plug-type Caution!
connector). Incorrect parameter settings will
lead to a loss of functions. In
addition, incorrect parameter
settings will render your Declaration
of Conformity invalid, and all the
The green LED “DC Power in“ will now be illuminated (if safety function will be lost.
the generator voltage is greater than 300V). The display Parameter changes are only
now shows the current generator voltage: “Start from permitted in exceptional cases and
410V; measurement xxx V.“ If the measured voltage is in consultation with the manu-
greater than 410V, the device will start power delivery facturer and Electricity Board.
after approx. 3 minutes. This starting-up period of 3
minutes is necessary to ensure that the generator
voltage is permanently above the power delivery limit of
410V. A quick-start routine is provided for test purposes The following parameters can be adjusted:
– this routine circumvents the start-up period. This Break threshold of low voltage protection
quick-start is menu-controlled and obtained from the Break threshold of overvoltage protection
set-up mode (see Operator’s Manual ). Generator starting voltage (i.e. start of inverter grid-
feeding operation)
7. During the normal startup procedure the line power Adjust generator voltage
relay is switched on after approx. 3 minutes (audible Adjust generator current
“click“), and power delivery is started. This is also Adjust grid voltage
signaled by the green “AC Power out“ LED. The Adjust grid current
display now shows the delivered power. The
“Display“ key can be used to indicate the various
Danger!
measurement values (see Operator’s Manual).
Always disconnect the inverter from all
voltage sources before opening the
8. It may be necessary to reset the date and hour
inverter housing!
(please refer to the Operator’s Manual).

To change to the programming mode

please change the jumper position as
shown in Figure 5-11.Change the
jumper position as shown in Figure
5.13, so as to get to the Display and
Programming Mode.

KACO Gerätetechnik GmbH 11 Operating Instructions Powador 00-xi-Series for skilled electricians only
5 Installation and startup

To save the changed parameters, Close the device again.

confirm “save parameters” in the menu To change to the programming mode,
with “yes”. keep the “Display” key pressed and
simultaneously press the “Set” button.
After approx. 2 seconds, the first setting
parameter will appear on the display.

Use the ”Display“ key to scroll through

the menu. This menu is continuous, i.e.
if you have reached the end it will
automatically return to the first menu
item

Break threshold – grid undervoltage

Grid threshold – grid overvoltag

Grid break threshold EN50160

Voltage drop - AC side

Min. grid frequency

Figure 5.11: Jumper position to change between
programming mode and power delivery (grid-feeding
operation). Max. grid frequency

Start at solar voltage

Scaling of solar voltage +

Scaling of solar voltage -

Scaling of solar current +

Scaling of solar current -

Scaling of grid voltage +

Figure 5.12: Jumper-Position in normal grid-feeding
operation (shipping status)
Scaling of grid voltage -

Scaling of grid current +

Figure 5.13: Jumper position in the programming mode
Scaling of grid current -

S0 interface

Save parameters

Figure 5.14: Set Parameters Menu

KACO Gerätetechnik GmbH 12 Operating Instructions Powador 00-xi-Series for skilled electricians only
6 Application/Acceptance by your Electricity Board

- Scaling of grid voltages and grid current:

Prior to shipment all the displayed values are
The “Set” key is used to change the checked and adjusted in our factory. If the grid
respective parameter. Depending on the voltage shown on the display should not correspond
parameter, the value increases or to the grid voltage actually measured the value can
decreases. The values are continuous, be adjusted. If the grid voltage shown on the display
i.e. if you have reached the max. value, is too low you can use the menu item "SCALING xxx
they will be reset to the min. value. +” to increase the value. If the grid voltage shown on
the display should be too high you can use
"SCALING xxx -" to reduce this value. This scaling is
available for adjusting the solar voltage, generator
Explanation of individual parameters: current, grid voltage and grid current.
- Undervoltage break threshold: The solar inverter is
equipped with a redundant 3-phase monitoring - S0 interface: The S0 interface is used to control a
according to VDE 0126-1-1 and VDEW Directive. If large display. Use this parameter to adjust how many
the grid voltage falls below a defined value the pulses per kWh are to be transmitted. The possible
inverter must terminate its power delivery operation settings are 500, 1000 and 2000 pulses per kWh.
and disconnect from the grid. According to the
Directive the defined value can be 1.0 to 0.7 of the After changing these parameters the inverter must be
grid voltage value (161V …230V). Under standard reset to its original condition.
operating conditions the inverter shuts down at 190V
and is thus within the permissible range. Under
special circumstances your Electricity Board can To do this, disconnect the inverter from
request that the inverter shuts down at a different all voltage sources and reset the
voltage - in this case you can use the menu item jumper to its original position.
"Minimum grid voltage" to set the new break
threshold. The min. grid voltage can be adjusted in
the range between 190 V and 230 V in increments of The inverter can now assume “normal” operation and
2 volts. By all means ensure that the standard VDE be left unattended.
0126-1 is observed.

- Grid break threshold EN50160: The average grid 6 Application/Acceptance by your

voltage is calculated over a period of 10 minutes. If Electricity Board
the adjusted value is exceeded, the inverter will be The practices of the responsible Utility Company must
disconnected from the grid. This break threshold can be observed for all applications and acceptances of
be adjusted via “Grid break threshold EN50160” in your PV installation. Some of the documents you will
increments of 2V and within a range between 244 V need for application and acceptance are enclosed to
and 253V (factory setting: 253 V). these installation instructions.
- Grid frequency: The grid frequency is also monitored. The usual setting-up procedure is as follows:
If it should fall below a defined value the inverter must
terminate its power delivery operation and disconnect - Submittal of documents to the Electricity Board
from the grid. Both thresholds can be adjusted in - Installation
increments of 0.1 Hz. The min. grid frequency range - Installation of power meter by the Electricity Board
is between 47.5 – 50 Hz, the max. frequency range is - Acceptance of your installation by the Electricity Board
between 50 Hz and 50.2 Hz (factory setting if 47.5 –
50.2 Hz). You will require the following documents:

- Start at solar voltage: The inverter starts its grid- Application / Completion notice by the registered
feeding process in the morning, after reaching a installation company
voltage of 410V (display: Start from 410V). This Location plan showing the estate borders and place of
setting enables safe operation in any solar generator installation
configuration. In exceptional cases it may be Complete circuit diagram of installation and utilities
necessary (and advisable) to adjust this starting (unipolar view);
voltage threshold. At a low generator voltage (few Data sheet for independent power generating plants
modules connected in series), the starting voltage (VDEW form)
may be reduced to ensure safe start even under Description of the protection devices indicating the type,
unfavorable weather conditions. At a high generator circuit, make and function
voltage (many modules connected in series) the Description of the inverter / declaration of conformity of
starting voltage may be increased to prevent the the manufacturer;
inverter from switching on and off again too frequently Information on the short-circuit resistance of circuit
(which is the case during low-power starts). The components.
starting voltage may be adjusted within a range of
370V and 600V in increments of 10V. The factory
setting is 410V.

KACO Gerätetechnik GmbH 13 Operating Instructions Powador 00-xi-Series for skilled electricians only
7 Switching off the inverter

8 Troubleshooting
7 Switching off the inverter Within the scope of our continuously expanding Quality
The inverter must be switched off for adjusting, Assurance System, our goal is to rule out and eliminate
maintenance and repair work. Please proceed as any faults and defects. You have purchased a product
follows. that has left our factory in a proper condition. Each
individual device has successfully passed extensive
inspection tests for proper operation and functioning of
The sequence of work, especially when protective devices, as well as a long-duration test at our
using DC connectors as DC circuit factory.
breakers, must be observed by all
means. Should your PV installation not work properly despite all
Otherwise, arcing might occur when these measures, we recommend the following
disconnecting the DC connector under procedure for remediation:
load. This will destroy the connectors. Check the solar generator and grid connections leading
to the Powador, observing all the safety instructions
given in this manual. Please observe the inverter
- Disconnect the grid voltage carefully and take note of the display messages and
(deactivate the external safety LED displays.
breakers). Below is a summary of possible error and
- Disconnect the photovoltaic module recommended remedies.
via the generator box or DC plug-type
connector.
- Check that the grid terminals of the
inverter are disconnected from all
voltage sources.

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
carry out any 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 in this case.

KACO Gerätetechnik GmbH 14 Operating Instructions Powador 00-xi-Series for skilled electricians only
8 Troubleshooting

Error Cause Remedy/Explanation

Inverter shows an Grid voltage failure Even if an incorrect daily peak value is displayed the inverter
unrealistic daily peak continues to work properly and without any yield losses. Values
value 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.

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 measuring values are given in the Operator’s Instructions. The daily yield
meter of the Electricity elements/sensors value may deviate from the value shown on the power meter by
Board up to 15%.
Grid fuse triggers - Insufficient grid fuse At times of high insolation/irradiation the inverter may exceed its
rating rated current for a short time, depending on the type of solar
- Inverter hardware is generator. Therefore, the grid fuse should have a higher rating
damaged 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.
No display shown - Device is in the night The inverter shuts down over night.
shut-down mode If the display should not be illuminated during a normal time of
- No grid voltage is the day you should check on the power meter whether or not
present the device delivers power. If power is delivered the display
- Solar generator voltage module is defective, and the inverter has to be returned to
is less than 300V KACO for repair. If no power is delivered you should check that
grid voltage is present and that the solar generator voltage is
greater than 410 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.

Inverter does not start - Device is in its night The inverter shuts down over night.
shut-down mode If the display should not be illuminated during a normal time of
- No grid voltage is the day you should check on the power meter whether or not
present the device delivers power. If power is delivered the display
- The solar generator module is defective and the inverter has to be returned to
voltage is less than 410 V KACO for repair. If no power is delivered you should check that
grid voltage is present and that the solar generator voltage is
greater than 410 V.
If this is the case but the inverter still fails to deliver power the
device has to be returned to KACO for repair.
Inverter is active but Insufficient generator After sunrise, at sunset, and during times of low insolation due
does not deliver power – voltage. Voltage to bad weather conditions the generator voltage or,
the display reads: Start measured < 410V respectively, generator power fed from the roof may be
from 410 V insufficient for grid feeding.
Measurement:
xxx V
Inverter is active but The inverter has After an interruption of the grid feeding process due to a
does not deliver power – interrupted grid feeding disturbance (grid power failure, overtemperature, overload, etc.)
the display reads: due to a the inverter always waits for approx. 3-4 minutes before
Start from 410 V malfunction/disturbance. resuming its grid feeding operation. Grid failures may cause
Measurement: interruptions during the day. If more than 10 interruptions per
xxx V (measured voltage day should occur over several weeks you should contact your
is greater than 410V) solar installation provider.

The inverter terminates Defective grid isolation Although there is enough insolation/irradiation, the inverter
grid feeding shortly after relay in the inverter. delivers power for a few seconds only and switches off again.
starting-up although During this short time a grid feeding value between 0 – 5 W is
there is enough displayed. If insufficient generator power can be ruled out in this
insolation/irradiation case the grid isolation relay is presumably defective and
prevents the inverter from being activated.

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

KACO Gerätetechnik GmbH 15 Operating Instructions Powador 00-xi-Series for skilled electricians only
8 Troubleshooting

consumers (motors, machines, etc.), which are connected to

the same grid node 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 may 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

by means of the measures described above, please
contact your solar installation provider or our Service
Department.
Please have the following information ready to enable
our Service Department to respond quickly and
properly:
Inverter Data:
- Serial number of the device
- Inverter type
- Short description of errorIs the fault or error
reproducible? (If so, please provide a short
description).
- Does the fault or error occur sporadically?
- Describe the insolation conditions prevailing when the
error occurred.
- Hour of the day

Photovoltaic module data:

- Module type, manufacturer (if available, send data
sheet)
- Number of modules connected in series
- Number of strings
- Generator power

KACO Gerätetechnik GmbH 16 Operating Instructions Powador 00-xi-Series for skilled electricians only
9 Technical Data

9 Technical Data

Input – Electrical data

Type 2500xi 3500xi 4000xi 4500xi 5000xi
DC rated power 2710W 3600W 4590W 4800W 5730W
Max. PV generator power 3200W 4200W 5250W 6000W 6800W
MPP range 350 – 600 VDC
No-load voltage Up to 800VDC
Monitoring – input voltage Stand- by from Ue>300VDC
Night shut-down from Ue<250VDC
DC voltage ripple < 3% rms
Max. DC input current 8.6 A 11.5 A 14.5 A 15.2 A 18 A
Polarity safeguard Short-circuit diode
Overvoltage protection Varistors

Output – Electrical data

Rated power 2600W 3450W 4400W 4600W 5500W
Max. power 2850W 3800W 4800W 5060W 6000W
Grid voltage 190 ... 253V (according to EN50160)
Safety shut-down: 190 – 264V within 0.2s
Rated current 11.3A 15A 19.1A 20A 23.9A
Max. current 12.4 16.5 A 20.9A 22A 26A
Power factor ≈1
Frequency 47.5 – 50.2 Hz
Distortion factor according to <3% at rated power
VDE0838 Part 2 (EN61000-3- <5% over the entire range
2)
Fault-signal relay Potential-free NO-contact (make contact) max. 30V / 1A
S0 output Open-Collector – output max. 30V / 50mA

Inverter – Electrical data

Max. degree of efficiency 95.6% 95.7% 96.3% 96.3% 96.3%
European efficiency 94.3% 94.8% 94.4% 94.5% 94.5%
Internal consumption Night shutdown: 0W
Operation: 11W
Min. grid-feeding power 15W 20W 30W 40W 40W
Circuit design Grid-tied, transformerless
Clock frequency 18 kHz
Principle Single-phase full bridge in IGBT technology
Grid monitoring Redundant 3-phase monitoring according to VDE 0126-1-1

Inverter – Mechanical and technical data

Type 2500xi 3500xi 4000xi 4500xi 5000xi
Optical displays DC Power in (green)
AC Power out (green)
Failure (red)
LC-Display (2 x 16 characters)
Operating elements 2 keys for display operation
Connections PC terminals inside the device
Cable routing via screwed cable gland
Ambient temperature -20 ... +40°C
Temperature monitoring >75°C temperature-dependent power adjustment
>85°C disconnection from grid
Cooling Free convection (no fan or blower)
Protection Class IP54 according to EN 60529
Noise emission < 35dB (noiseless)
Enclosure Aluminum wall-mounted enclosure
Dimensions W x D x H 340 x 200 x 340 x 200 x 340 x 220 x 340 x 220 x 340 x 220 x
500 mm 500 mm 550 mm 600 mm 600 mm
Weight 20kg 20kg 23kg 28kg 28kg

KACO Gerätetechnik GmbH 17 Operating Instructions Powador 00-xi-Series for skilled electricians only
10 The Powador as a part of a PV plant

10 The Powador as a part of a PV plant

10.1 Setup of a PV plant/installation

The overall circuit diagrams (single-pole) shown below illustrate an example setup of a grid-tied PV installation with a
Powador photovoltaic inverter.

Figure 10.1 single pin diagram for a plant with one inverter

KACO Gerätetechnik GmbH 18 Operating Instructions Powador 00-xi-Series for skilled electricians only
10 The Powador as a part of a PV plant

Figure 10.2 single pin diagram for a plant with two inverters
Overview of components:

1.) Solar generator:

2.) DC-terminal:
Parallel wiring of two generator strings is effected either at a DC terminal between the solar generator and inverter
or, if DC connectors are used, directly on the inverter (the inverter is provided with terminals for two strings). Of
course you may also connect the strings directly to the solar generator and lead only a plus and minus cable to the
inverter.

3.) DC main switch:

To disconnect the inverter from voltage on the generator side, a DC main switch must be provided between the
inverter and solar generator. The current and voltage ratings of the solar generator must be observed when
selecting the switch. Instead of a DC main switch you may also use multi-contact or Tyco connectors for
disconnection on the DC lead of the inverter. In this case please deactivate the grid fuses of the inverter before
pulling the DC connectors. This is necessary to ensure that the connectors are no longer live when the connection is
interrupted, and to prevent arcing which would destroy the plug-type connection.

4.) Grid fuses:

The inverter cable should be provided with NEOZED fuse protection. Depending on the cable cross-section being
used, a 25A fuse link is used for 4 mm2, and a 35A fuse link is used for 6 mm2 cable cross section.

5.) Grid-feeding meter:

The required grid-feeding meter is specified and installed by the responsible Electricity Board. (Grid-feeding meters
have a tolerance of ± 2%). Some Electricity Boards permit installation of own calibrated meters. In this case no
rental fees will be charged for the meter, but the Electricity Board may request calibration of the meter at periodic
intervals.

6.) Selective circuit breaker:

According to TAB 2000 (Technical requirements for the connection of power installations), the main switch must be
a selective main circuit breaker according to E DIN VDE 0643: 2000-08 or, respectively, E DIN VDE 0645: 2000-8. If
you should have any queries concerning the required main switch, please contact your responsible Electricity Board.

KACO Gerätetechnik GmbH 19 Operating Instructions Powador 00-xi-Series for skilled electricians only
10 The Powador as a part of a PV plant

10.2 Multi-inverter installations

Please note the following information for multi-inverter plants/installations:

1. Asymmetric grid-feeding:
Wherever possible the grid-feeding power should be distributed evenly over the three phases. Pursuant to the VDEW
guideline (= guideline published by the Association of German power-generating plants) for the connection and parallel
operation of independent power generating plants on the low-voltage grid, 4th Edition 2001, asymmetry between phases
must be restricted to max. 4.6 KW.

2. Electrical connection:
Although the photovoltaic inverter is equipped with 3-phase monitoring, grid-feeding takes place on one phase only
(single-phase). To avoid asymmetries on the grid the inverters of multi-inverter plants should feed-in on different
phases. (The inverter feeds into the phase designated L1 on the inverter terminals).
Therefore, if your installation has several inverters, connect phase L1 to terminal L1 of the first device. For the
second device, connect phase L2 to terminal L1. For the third device, connect phase L3 to terminal L1 – this
ensures optimum distribution of grid-feeding power over these phases.

Terminal L1 is Terminals L2
used for grid- and L3 are
feeding. monitored
only.

KACO Gerätetechnik GmbH 20 Operating Instructions Powador 00-xi-Series for skilled electricians only
10 The Powador as a part of a PV plant

10.3 Special conditions for Powador 5000xi:

Powador 5000xi has been designed for multi-inverter plants/installations and with
its 5.2 kW, is above the limits for single-phase grid-feeding. Therefore,
it must only be operated in combination with at least two other inverters to restrict asymmetry
to 4.6 kW. The inverter power is distributed over three phases.

Configuration example:

L1: Powador 5000i L2: Powador 5000xi L3: Powador 1501i Asymmetry: 3.7 kW
L1: Powador 5000i L2: Powador 5000xi L3: Powador 2500i Asymmetry: 2.7 kW
L1: Powador 5000i L2: Powador 5000xi L3: Powador 3500i Asymmetry: 1.9 kW
L1: Powador 5000i L2: Powador 4000xi L3: Powador 4000i Asymmetry: 0.8 kW
L1: Powador 5000i L2: Powador 5000xi L3: Powador 4500i Asymmetry: 0.6 kW

KACO Gerätetechnik GmbH 21 Operating Instructions Powador 00-xi-Series for skilled electricians only
10 The Powador as a part of a PV plant

Appendix
10.4 EU Declaration of Conformity

Name and address of manufacturer: KACO GERÄTETECHNIK GmbH

Gottfried-Leibniz-Str. 1
D-74172 Neckarsulm

Product description: Photovoltaic grid-tied inverter

Powador

Type description: Powador 2500xi

Powador 3500xi
Powador 4000xi
Powador 4500xi
Powador 5000xi

This is to confirm that the devices stated above are compliant with the protection requirements set forth in
the EU Council Directive as of May 3 1998 for the Harmonization of Legal Stipulations of the Member States concerning
Electromagnetic Compatibility (89/336/EWG) and the Low Voltage Regulations (72/23 EWG).

The devices are compliant with the following standards:

73/23/EWG DIN EN 60950-1

“Directive concerning electrical DIN EN 50178
equipment for use within defined
voltage thresholds”

89/336/EWG DIN EN 61000-6-3

“Directive concerning electromagnetic DIN EN 61000-6-1
compatibility DIN EN 61000-3-2
DIN EN 61000-3-3

Therefore, the types stated above are designated with the CE label.

Any manipulation or modifications on the supplied devices and/or any use for other than for the intended purposes shall
render this Certificate of Conformity null and void.

st
Neckarsulm, 21 June 2005
KACO GERÄTETECHNIK GmbH

p.p. Matthias Haag

Head of Photovoltaics Division

KACO Gerätetechnik GmbH 22 Operating Instructions Powador 00-xi-Series for skilled electricians only
10 The Powador as a part of a PV plant

10.5 Declaration of conformity concerning the rated power and max. output of photovoltaic inverters

Inverter type AC rated power AC peak power * Ratio

(ACNENN) in W (ACPEAK) in W ACPEAK / ACNENN
Powador 2500xi 2600 W 2850 W 1,10
Powador 3500xi 3450 W 3800 W 1,09
Powador 4000xi 4400 W 4800 W 1,09
Powador 4500xi 4600 W 5060 W 1,10
Powador 5000xi 5500 W 6000 W 1,09

* The AC peak power has been indicated as an average value measured over a period of 10 minutes.

The cosφ of the inverters is 0.999 at rated load. Therefore, the AC power in W is equivalent to the apparent power in VA.

This declaration of conformity has been given by

KACO GERÄTETECHNIK GmbH
Gottfried-Leibniz-Str. 1
D-74172 Neckarsulm

and authorized by its responsible representative,

Matthias Haag
Head of Photovoltaics Division

Neckarsulm, 08 July 2004

KACO GERÄTETECHNIK GmbH

p.p.
Matthias Haag

KACO Gerätetechnik GmbH 23 Operating Instructions Powador 00-xi-Series for skilled electricians only
10 The Powador as a part of a PV plant

10.6 Declaration of Conformity/Non-Objection

KACO Gerätetechnik GmbH 24 Operating Instructions Powador 00-xi-Series for skilled electricians only
Your solar installation provider.

KACO GERÄTETECHNIK GmbH

Gottfried-Leibniz-Straße 1
D-74172 Neckarsulm

KACO GERÄTETECHNIK GmbH

Entwicklungs- und Logistik-Zentrum
Werner-Heisenberg-Straße 1
D-74235 Erlenbach

Phone +49 (0) 7132 / 38 18 - 0

Fax +49 (0) 7132 / 38 18 - 22
e-Mail: info@kaco-geraetetechnik.de
www.kaco-geraetetechnik.de

31000150-02-060328