M a n u a l.

P o w a d o r.
The new DC-isolated xi-series.

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

Operator’s Instructions
Powador 1501xi / 3501xi / 4501xi

4.4 Set Mode 6

1 About this document 2 4.5 Start key 6
1.1 Attachment and Maintenance of documents 2 4.6 The Serial RS232-Interface 7
1.2 Symbols used in this document 2 4.7 The RS485 Interface 9
1.3 CE Certification 2 4.8 Display 9
1.4 Type Label 2
5 Accessories 12
2 Safety information and instructions 2
6 Troubleshooting 13
3 Notes concerning installation and operation 3
3.1 Factory guarantee and liability 3 7 Recycling and disposal 14
3.2 Service 3
3.3 Intended use (normal use) 3
4 Operation 4
4.1 Overview of operating elements and displays 4
4.2 LED displays 4
4.3 “Display” and “Set” buttons 5
1 Operation

General Remarks
With the 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 01xi inverters are electrically isolated, robust Non-adherence to these
inverters, which are operated without any blowers and instructions may adversely affect
offer a high degree of efficiency. An illuminated display the operating convenience or
and intuitive menu guidance enables you to display the functionality of the device.
most important grid feeding data of the inverter. The
inverter data can be transmitted to a PC for
visualization.
This symbol designates a required
Protection class IP 54 makes the inverters ready for use action
in any kind of environment – our inverters are even
suitable for use in agricultural and industrial
applications. 1.3 CE Certification
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. - Low Voltage Directive (Council Directive 73/23/EWG)
We shall not be liable for any damage caused by
non-adherence to the instructions given in this 1.4 Type Label
manual. The type label indicating the exact device description is
located on the support plate at the underside of the
Pertaining documents enclosure.
During the inverter installation please observe all
assembly and installation instructions for components 2 Safety information and
and other parts of the system. These instructions are
shipped together with the respective installation instructions
components or supplementary equipment.
Danger!
1.1 Attachment and Maintenance of documents Danger due to lethal voltages!
Please keep these operating and installation Hazardous live voltages are present
instructions in a safe place to ensure that they are inside the device/instrument and power
available if needed. Danger lines. Therefore, the device/instrument
must only be installed and opened by a
1.2 Symbols used in this document skilled electrician.
Please observe the safety information provided in this Even when the device/instrument is
manual when operating your inverter! switched off, dangerous live voltages
may still be present inside the
instrument.
Warning!
Lethal Hazard!
Regulations concerning the prevention of accidents
Warning The inverter must be installed by an approved skilled
electrician who is responsible for the adherence to
existing standards and regulations.
Danger! The proper and safe operation of the device/instrument
Lethal Hazard by Electric requires proper transportation, storage, erection and
Shock! assembly, as well as careful operation and
Danger maintenance.

Only personnel who have read and fully understood

Caution! these operating instructions shall be authorized to
Potential hazard for the product and operate the inverter.
environment!
Caution

KACO Gerätetechnik GmbH 2 Operator’s Instructions Powador

3 Operation

Modifications/Manipulation - Improper operation

Manipulating the inverter is generally prohibited. Before - Operation of the devices with defective protective
performing any modifications on or in the environment equipment
of the inverter, a skilled electrician must be consulted by - Manipulation of the device or makeshift repairs by the
all means, as this electrician will assume responsibility. customer
- Influence of foreign objects or Act of God (lightning,
overvoltage, tempest, fire)
Caution!
- Inadequate ventilation of the device
Hazard of damage due to
- Non-adherence to the relevant safety instructions
unauthorized
(VDE (Association of German Engineers), a.o.
modifications/manipulation! By no
Caution - Transport damage
means manipulate the inverter or
modify or change the inverter or any
All guarantee claims shall be handled at the premises of
other parts of the installation!
KACO Gerätetechnik GmbH. To this end, return
Transportation 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 3.3 Intended use (normal use)
years on Powador inverters, starting from the date of Powador inverters are built according to state-of-the-art
installation and max. 78 months after shipment by and approved safety requirements. However, improper
KACO. use may cause lethal hazards for operators or third
parties and/or damage of instruments/devices or other
During this time, KACO Gerätetechnik GmbH property.
guarantees the proper function of the devices and free The device is intended to convert the direct voltage
repair in the event that a defect should occur which we generated in the photovoltaic (PV) modules into
are accountable for. alternating voltage (AC) and feed this voltage into the
grid.
Should your device show a defect or malfunction during The inverter must only be operated in connection with a
the guarantee period, please contact your specialist fixed/stationary connection to the public grid. Inverters
dealer or, respectively, your installation expert. are not intended for mobile use.
Guarantee claims shall be excluded in the following Any use other than the specified intended use shall not
cases: be deemed intended or normal use, and the
- Use of the device for other than the intended use manufacturer/supplier shall not be liable for any
(normal use) damage caused by such unintended use. Damage
- Improper use and installation that does not comply caused by unintended use is at the sole risk of the
with the required standards operator.

Kaco Gerätetechnik GmbH 3 Operator’s Instructions Powador

4 Operation

4.2 LED displays

The term „intended use“ shall also include the Under normal operating conditions the photovoltaic
adherence to the operating and installation instructions. modules will start to generate voltage as soon as
Your skilled and authorized electrician will obtain the enough daylight or sunlight is available. If a certain
necessary applications and acceptance for your amount of voltage is applied to the inverter for a certain
photovoltaic installation from your Utility Company. period of time, the inverter will start the grid-feeding
Some of the documents which are needed for these process. The inverter is equipped with three LEDs,
applications and acceptance are attached to these which provide information about the different modes of
installation instructions. operation as follows:

Caution!
Using the device for any purposes
other than intended/normal use is
prohibited!
Caution

4 Operation Figure 4.2: LED displays

The grid-feeding process starts in the morning when
there is enough daylight and, consequently, a certain LED DC Power In (1) (green):
minimum voltage is applied to the inverter. After a This LED is illuminated from a generator voltage of
startup period of 3 minutes the inverter enables the grid approx. 100 V onward and extinguishes as soon as the
feeding process. If this minimum voltage is fallen below generator voltage falls below 80 V. The DC Power In
at the end of day, the grid feeding process will be LED signals that the inverter is in its active state and
terminated and the inverter will be switched off. 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
4.1 Overview of operating elements and displays 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 125 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.
Under normal operating conditions the inverter starts
grid feeding in the morning and terminates this process
as it becomes dark. On cloudy days or during the winter
months the grid feeding process can be interrupted at
certain times, depending on the PV generator and the
actual grid feeding capacity, and can be resumed later
on. This process might be repeated for several times,
Figure 4.1: Overview of Powador
especially in the morning and evening. This is not a sign
of faulty operation but is normal operating behavior.
Captions
1 Display
Display of measured values and parameter settings
2 LED displays
Failure LED (3) (red):
Display of operating mode
This LED indicates that the grid-feeding process has
3 Operating keys
been terminated as a result of a malfunction / failure.
Toggle function between measured values and
The “failure” LED is activated in the following cases:
parameter settings
- Grid overvoltage or low voltage
4 Cable fitting for AC connection
- Grid frequency error
5 Start key
- Excessive generator voltage
This key is used to activate the display messages at the
- Excessive generator power
end of the day when it is getting dark.
- High-temperature shutdown
6 RS232 interface
- Defective device
7 Cable duct for RS485 interface cable
Please wait for approx. 10 minutes to verify if the
8 Cable duct for DC connection
malfunction only occurs temporarily. If not, please
contact your authorized electrician. On elimination of
the disturbance the grid-feeding process is re-started
after approx. 10 seconds.

KACO Gerätetechnik GmbH 4 Operator’s Instructions Powador

4 Operation

Display of inverter type

Important!
During feeding power failure (power
failure in the public grid) the “Failure” Generator voltage and current
LED is not lit up. In this case all LEDs
and the display are deactivated and Grid voltage, current and power
the inverter is completely shut down.
Only after the feeding power has
returned can the inverter resume its Daily peak capacity
normal operation.
Temperature inside device
Please check whether the cause of your disturbance is
a general power failure or if the fuse between the power Status display
meter and inverter has blown. In the event of a fuse
failure please contact your authorized electrician. In
Date and hour
case of a general power failure please wait until the
problem has been resolved. The installation will restart
automatically. Yield today

4.3 “Display” and “Set” buttons

Yield during the current year

Total yield

Operating hours today

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
Figure 4.3: Operating keys of the Powador show the currently fed-in power.
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.

Keep this key pressed for approx. 1

second to select which measured value
is to be displayed.

The menus are continuous, i.e. after reaching the last

entry of the menu and pressing the “Display” key (1)
the first entry is displayed again (s. Figure 4.4).

Kaco Gerätetechnik GmbH 5 Operator’s Instructions Powador

4 Operation

4.4 Set Mode Selection of interface and address

Using the menu item “Select interface”, you may
change between the RS232 and RS485 interface by
To go to level 2 (Set Mode), keep the means of the “Adjustment” key (2). If the RS485
“Display” key“ (1) pressed and interface is enabled, you can set the address by means
simultaneously press the “Adjustment” of the “Display” key (1). Using the “Adjustment” key (2)
(2) key for approx. 1 second. you may set addresses consecutively from 1 to 32.
Using the “Adjustment” key (2) you may Thereafter, the address will be reset to 1.
now change the selected parameter.
Depending on the parameter the value
will change after pressing the
“Adjustment” key (2). The various 4.5 Start key
setting parameters are shown in Figure
4.5.

Set time - hour

Set time - minutes

Set date - year

Set date - month Figure 4.6: Underside of Powador

The device will be switched off in the evening with the
Set date – day 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 Figure underside
Display of software version of inverter) to enable the device at nighttime.

Clear grid-feeding
Display yield meter Press the start key (1) at the
underside of the device for approx. 5
seconds, until a message appears
Clear grid-feeding meter on the display and the LEDS “Grid
feeding“ and “Disturbance“ are no
longer lit up.
Select and set RS485 interface
address You may now scroll through the menu and retrieve the
values of the current day. If no key is pressed for longer
than one minute the device will be switched off again
automatically.
The inverter will only store the latest values of a day.
Figure 4.5: Set Mode Menu The values of “operating hours per year”, “Total
operating hours”, “Annual fed-in power” and “Total grid
Set hour and date
feeding power” will be stored and added up. These
The set values are consecutive, i.e. as soon as you
values will not be lost even if the device is not operated
have reached the max. value the display will be reset to
for a longer period of time. The date and hour may have
the min. value after pressing the „display (1) button
to be reset if the device has not been used for several
once again. The display for setting the date covers a
days.
range up to 2050. After that, the value will be reset.

Clear grid-feeding meter

When clearing the grid-feeding meter, the values for
“total yield” and “total operating hours” will be reset. The
required parameter is “2” – please enter it by means of
the “Adjustment” key (2).

The grid-feeding meter can only be

cleared – it is not possible to make
any other adjustments!

KACO Gerätetechnik GmbH 6 Operator’s Instructions Powador

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

The inverter data is transmitted via the serial interface

as text only; there is no error check.

Powador Sub-D Meaning of PC Sub-D

male 9-pole message on female 9-pole
PC
2 TXD 2
3 RXD 3
4 RTS 4
5 GND 5
Table 4-1: Pin allocation of the 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 software 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

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: Extract from a communication protocol via RS 232 interface

Column Explanation Column Explanation
1 Date 6 Generator power in W
2 Hour 7 Grid voltage in VAC
3 Operating mode/status (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 the individual columns
Status Explanation Comment
0 Inverter has just switched on Only after the first start-up in the morning.
1 Waiting for start Grid parameters and generator voltage are checked.
2 Waiting for shut-down Insufficient generator voltage and generator power.
Condition that precedes the night shutdown.
5 Grid feeding operation The inverter starts feeding into the grid.
15 Transition to night cut-off Inverter “goes to sleep”
16 Inhibited operation 3 errors during self test – operation will be resumed after
complete shutdown
24 DSP error error
- Communication error
- Grid shutdown frequency
- Offset (grid feeding is to high)
- High-temperature cut-off
- Transducer (Plausibility error – measuring technique)
- Impedance cut off
- Overload cut off
25 Self test of power electronics The shutdown behavior of the power electronics is
checked before the start of the grid-feeding process
26 Self test of grid isolation relay The grid isolation relay is checked before the start of the
grid-feeding process.
28 Hardware error Self test was unsuccessful, a defect has occurred.

KACO Gerätetechnik GmbH 8 Operator’s Instructions Powador

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).
this standard. In these cases there may be problems
during the data transfer.

The read data for current and voltage

are subject to the indicated tolerances
and not suitable to measured degrees
of efficiency or yield data.

These readings are merely used to

check the installation for its general
function and proper operation.

4.7 The RS485 Interface

To enable remote monitoring of your photovoltaic Figure 4.1 – (1). This display shows all measured
installation, Powador inverters are additionally equipped values and data. In normal operation the background
with an RS 485 interface see Figure 4.1 illumination is de-activated. As soon as you press one
of the keys the background illumination will be
activated. If 10 seconds elapse without a key being
pressed, the background illumination will be switched
off again.
During normal operation the current grid-feeding power
is shown on the display, if no key is pressed for a longer
period of time.

Important!
Due to measuring tolerances the
measured values may not always
correspond to the actual values. The
measuring sensors of the inverter
have been selected in a way to ensure
maximum solar yields.
Figure 4.1 Due to the tolerances the daily yields
displayed on the inverter may deviate
This interface enables monitoring several inverters at from the values of your Utility
the same time. By means of the Powador-proLOG Company’s grid-feeding meter by up
series you can receive your yield and operating data or to 15% (admissible meter tolerance
error messages by SMS or e-mail. This monitoring approved by your Utility Company:
option is especially recommended in cases where you
± 2%).
are unable to check the functionality of your installation
on-site at regular intervals, i.e. if your 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 Using the operating keys (see Section 4.3 ) the values
inverter and proLOG by means of a wireless RF and data listed in Table 4-3 can be shown.
connection. Please contact your installer if you wish to
integrate remote monitoring in your system.

Kaco Gerätetechnik GmbH 9 Operator’s Instructions Powador

4 Operation

No. Display Message Explanation

1 Start from 125 V Display shown during the starting-up period (in the morning), after
Measurement xxx.x V a malfunction or prior to night shutdown. No grid feeding in this
mode of operation. The inverter waits until the voltage has
exceeded a value of 125 V. If this value is exceeded for longer
than 4 minutes the grid feeding will be started. An audible sound
is generated when the grid isolation relay is enabled

2 Solar generator Existing voltage and current of the solar generator connected to
xxx.x V xx.xx A the inverter. Shown in volts and amps; voltage tolerance ± 3 %;
current tolerance ± 5% at rated power. Greater tolerances are
possible when smaller generator currents are displayed.
3 Grid xxxx W Actual grid voltage, grid current and power (measurement of the
xxx.x V xx.xx A phase into which power is delivered); displayed in volts, amps
and watts; voltage tolerance: ± 3%; current tolerance: ± 3 %.

4 Daily peak
Capacity xxxx W Short-team peak grid feeding capacity of the day,
displayed in W. According to the regulations stipulated by the
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 inside
the device xx ° Display of the actual heat sink temperature, in °C. The inverter
will limit grid feeding if the temperature exceeds 65°C. If the
device temperature exceeds 80°C it will switch off automatically.

6 Status: Grid feeding operation Display of the various operating statuses

Normal grid-feeding operation. Power is fed into the grid.

Status: Waiting for

startup Waiting for sufficient solar generator power. The generator
voltage is not sufficiently high for grid feeding, or the grid feeding
process was stopped and the system is re-started after a failure.

Status: Waiting for Waiting for night shutdown. The generator capacity is no longer
shutdown sufficient for grid feeding, and the device waits for the night
shutdown.

Status: Device
The device changes over to night shutdown.
switches off

Kaco Gerätetechnik GmbH 10 Operator’s Instructions Powador

4 Operation

7 Error Error Message

Grid voltage
Grid voltage is not correct (overvoltage or undervoltage), thus
inhibiting the grid-feeding process.

Error
Grid frequency The grid frequency is not correct (excessive or low frequency),
making the grid-feeding process impossible.

Error There is an impedance jump in the AC network. This can be

Grid impedance caused by e.g. bridging high capacity.

Safety A grid voltage error, grid current problem, grid frequency or grid
shutdown impedance problem has occurred. The inverter has switched off
to protect against damage.

8 Internal failure
xxx xxx xxx xxx An internal failure occurred. It will clear itself and the unit starts
again.

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

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

11 Total yield
xxxxx kWh Power delivered during the current calendar year (January 1 to-
date)

12 Operating hours
Today xxxxx:xx Power delivered since the time of inverter startup.

13 Operating hours Today’s operating hours since sunrise. Displayed in hours and
Year xxxxx:xx minutes.

14 Operating hours
Total xxxxx:xx Operating hours during the past calendar year (January 1 to-
date).

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 11 Operator’s Instructions Powador

5 Operation

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 processes are 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 12 Operator’s Instructions Powador

6 Operation

Should your PV installation not work properly despite all

6 Troubleshooting these measures, we recommend the following
procedure for remediation:
Within the scope of our continuously expanding Quality
Assurance System, our goal is to rule out and eliminate Check the solar generator and grid connections leading
any faults and defects. You have purchased a product to the Powador, observing all the safety instructions
that has left our factory in a proper condition. Each given in this manual. Please observe the inverter
individual device has successfully passed extensive carefully and take note of the display messages and
inspection tests for proper operation and functioning of LED displays.
protective devices, as well as a long-duration test at our
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, Display Operation and Settings. The daily
meter of the Utility yield value may deviate from the value shown on the power
company. meter by up to 15%.
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 110V module is defective, and the inverter has to be returned to
KACO for repair.
If no power is delivered you should check that grid voltage is
present and that the solar generator voltage is higher than 125
V.
If this is the case but the inverter still fails to deliver power the
device has to be returned to KACO for repair.

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 125 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 125
V.
If this is the case but the inverter still fails to deliver power the
device has to be returned to KACO for repair.
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 < 125V respectively, generator power fed from the roof may be
from 125 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 125 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 125V)

Kaco Gerätetechnik GmbH 13 Operator’s Instructions Powador

7 Operation

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 rating At times of high insolation the inverter may exceed its rated
Inverter hardware is current for a short time, depending on the type of solar
damaged generator. Therefore, the grid fuse should have a higher rating
than the max. grid feeding current.
The grid fuse acts immediately if the inverter changes over to
grid feeding (i.e. on termination of the start-up period). In this
case, the inverter hardware is damaged and the device has to
be returned to KACO for repair.
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

by means of the measures described above please
7 Recycling and disposal
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

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

Solar generator data:

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

Kaco Gerätetechnik GmbH 14 Operator’s Instructions Powador

For skilled and authorized electricians

Installation Instructions
Powador 1501xi / 3501xi / 4501xi

5.7 Startup of the inverter 10

1. About this document 2 5.8 Programming the parameters 11
1.1 Attachment and Maintenance of documents 2
1.2 Symbols used in this document 2 6. Applications/Acceptance by Your Utility
1.3 CE Certification/Labeling 2 Company 13
1.4 Type label 2
7. Switching off the inverter 14
2. Safety information and instructions 2
8. Troubleshooting 14
3. Notes concerning installation and operation 3
3.1 Factory guarantee and liability 3 9. Technical Data 17
3.2 Service 4 10. Appendix 18
3.3 Intended use (normal use) 4 10.1 EU Declaration of Conformity 18
4. Device description 4 10.2 Declaration of Conformity concerning the rated
4.1 Dimensioning of the PV generator 4 power and max. output of photovoltaic
4.2 Protective concepts 5 inverters 19
4.3 Mechanical dimensions 5 10.3 Certificate of Conformity/Non-Objection 20

5. Installation and startup 6

5.1 Selecting the appropriate place of installation 6
5.2 Installing the inverter 6
5.3 Electrical connections 7
5.4 Connecting the fault-signal relay 10
5.5 Connection of the S0 output 10
5.6 Connection of the RS485 interface 10
1 About this document

1. About this document 1.3 CE Certification/Labeling

The following information will guide you through the CE labeling is used to document that the Powador
entire documentation. Further documents will be valid inverter indicated on the type label meets the
in conjunction with these operating and installation fundamental requirements according to the following
instructions. directives:
We shall not be liable for any damage caused by non- - Directive concerning Electromagnetic Compatibility
adherence to the instructions given in this manual. with Class B (Council Directive 89/336/EWG)
-Low Voltage Directive (Council Directive 73/23/EWG
Pertaining documents 1.4 Type label
During the inverter installation please observe all The type label indicating the exact device description is
assembly and installation instructions for components located on the support panel at the underside of the
and other parts of the system. These instructions are enclosure.
shipped together with the respective installation
components or supplementary equipment.
2. Safety information and instruct-
1.1 Attachment and Maintenance of documents
Please keep these operating and installation ions
instructions in a safe place to ensure that they are
available if needed. Danger!
1.2 Symbols used in this document Danger due to lethal voltages!
Please observe the safety information provided in this Hazardous live voltages are present inside
manualw hen operating your inverter! the device/instrument and power lines.
Danger Therefore, the device/instrument must only
be installed and opened by a skilled
electrician.
Warning!
Even when the device/instrument is
Lethal Hazard!
switched off, dangerous live voltages may
still be present inside the instrument.
Warning

Danger! Standards and Regulations

Lethal Hazard by Electric Shock! - VDEW conformity according to the regulations of the
Association of German Utility companies
Danger - “Independent power generating plants on low-voltage
grids”, Directive concerning the connection and
parallel operation of independent power generating
Caution! plants on the low-voltage grid, 4th Edition 2001
Potential hazard for the product - IEC 60364-7-712 Electrical installations of buildings -
and environment! Part 7-712
Caution - DIN EN 60891 Process of converting measured
current-voltage characteristic curves of photovoltaic
components
Note! - DIN EN 60904 Photovoltaic Installations – Part 1 to 8
Useful information and remarks - EMC Test Methods according to EN50081-1:1992,
EN50082-1:1997
- Emitted interference: EN 55014-1: 1993
- Interference immunity: EN 55014-2: 1997
- Harmonic (upper) waves: EN61000-3-2: 1995
Important! - Voltage fluctuations + Flicker: EN61000-3-3: 1995
Non-adherence to these - Semiconductor inverters: EN 60146-1-1: 1994,
instructions may adversely affect EN60146-1-3: 1994
the operating convenience or
functionality of the device. Technical rules
The assembly must be in compliance with the local
regulations and technical rules, in particular with regard
to:
This symbol indicates that a
certain action is required. - Electrical connections
- VDE 0100 Setting-up of power installations with rated
voltages of up to 1000 volts
- VDE 0105 Part 100 Operation of electrical
plants/installations
- VDE 0185 General information concerning the setup
of lightning protection installations

KACO Gerätetechnik GmbH 2 Installation Instructions Powador 01xi

3 Notes concerning installation and operation

- VDE 0190 Main potential isolation of electrical Modifications/Changes

plants/installations Performing any modifications or changes on the inverter
- VDE 0298 Part 4 Rubber-insulated leads carrying is generally prohibited. Performing any changes or
rated voltages of up to 450/750 volts modifications in the environment of the inverter is only
- DIN 18382 electrical cable and routing installation in permitted if they comply with national standards.
buildings Transportation

Regulations concerning the prevention of accidents Caution!

The inverter must be installed by an approved skilled Hazard of damage due to
electrician who is responsible fort he adherence to unauthorized
existing standards and regulations. modifications/manipulation! By no
The proper and safe operation of the device/instrument means manipulate the inverter or
Caution
requires proper transportation, storage, erection and modify or change the inverter or any
assembly, as well as careful operation and other part of the installation!
maintenance.
Only personnel who have read and fully understood all The Powador inverter is subjected to extensive testing
safety information contained in these operating and and inspection in our test field, so as to ensure the
installation instructions, as well as the assembly, superb quality of our products. Our inverters leave our
operating and maintenance instructions, shall be factory in a proper electrical and mechanical condition.
authorized to operate the inverter Special packaging ensures that nothing can happen
During the operation of this device, certain parts of the during the transport to our customers. Nevertheless,
device inevitably carry hazardous live voltages, which transport damage may not be ruled out completely. In
may lead to severe personal injury or even death. The this case, the forwarding agent/carrier will be
following precautions should be followed to minimize responsible.
the risk of lethal hazards or personal injuries. Please check the inverter carefully on arrival. Should
The installation of the device must be in compliance you discover any visible signs of damage on the
with the relevant safety regulations (e.g. DIN, VDE) or packaging, which imply that the inverter may be
other applicable national or local provisions. Proper damaged, or should you find any visible signs of
earthing, conductor dimensioning and an appropriate damage on the inverter please notify your responsible
short-circuit protection must be provided to ensure forwarding agent/carrier immediately.
operational safety. If necessary, your solar installation provider or KACO
All instrument covers must remain closed during Gerätetechnik GmbH will assist you. However, written
operation. damage reports must be received by the forwarding
Prior to performing any visual checks and maintenance agent within six days after receipt of the goods at the
work the device must be disconnected from all power latest.
sources and protected against inadvertent switching on. Use exclusively the original packaging for returning the
If measurements have to be conducted while the device inverter – only this material will ensure safe
is connected to power, NEVER touch live terminals. transportation.
Remove all jewellery from your wrists and fingers.
Ensure that the test equipment is in a good and safe 3. Notes concerning installation and
operating condition.
operation
When working on the switched-on device, make sure to 3.1 Factory guarantee and liability
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
Exactly follow the instructions given in these operating installation and max. 78 months after shipment by
and installation instructions and especially observe all KACO.
information concerning possible hazards, warnings and
precautions. During this time, KACO Gerätetechnik GmbH
guarantees the proper function of the devices and free
This list does not constitute a complete list of all repair in the event that a defect should occur which we
required measures. Should any specific problems are accountable for.
occur, which are not covered sufficiently for the
purposes of the buyer, please contact your specialist Should your device show a defect or malfunction during
dealer. the guarantee period, please contact your
specialist 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 Installation Instructions Powador 01xi

4 Device description

- Operation of the devices with defective protective Some of the documents which are needed for these
equipment applications and acceptance are attached to these
- Manipulation of the device or makeshift repairs installation instructions.
- Influence of foreign objects or Act of God
(lightning, overvoltage, tempest, fire)
- Inadequate ventilation of the device Caution!
- Non-adherence to the relevant safety instructions Using the device for any purpose
(VDE (Association of German Engineers), a.o. other than intended/normal use is
- Transport damage prohibited!
Caution

All guarantee claims shall be handled at the premises of

KACO Gerätetechnik GmbH. To this end, return 4. Device description
transport shall be effected, as far as possible, in the
original or equivalent packaging. The costs for these
services cannot be borne by KACO Gerätetechnik The electrically isolated Powador xi-series devices are
GmbH. currently available for three different power classes.
The appropriate inverter type is selected in accordance
Guarantee claims shall only be compensated by KACO with the selected and mounted photovoltaic modules.
if the damaged device is returned to KACO together The max. power values are indicated in the data sheet
with a copy of the invoice issued to the consumer by the (Section 9).
specialist dealer. The type label on the device must be The inverter designation is shown on the front side
fully legible. In the event of noncompliance KACO above the display and on the type label.
reserves the right to deny guarantee services. 4.1 Dimensioning of the PV generator
The selection of the PV generator is of crucial
The warranty period for rework or replacement importance when dimensioning a PV installation. It must
shipments shall be six months after shipment. However, be observed by all means that the solar generator is the
it shall continue at least until expiration of the original right match for the inverter. Please observe the data
warranty period granted for the shipped object. given in the Technical Data Sheet (Section 9) for
3.2 Service dimensioning the solar generator.
High quality and longevity of our inverters always have
been of central importance for us - already at the time The design and dimensioning Kacocalc
of product development. Our more than 60 years of pro is available for easy selection of PV
experience in the field of current inverters are backing modules – please obtain your free
up this philosophy. download at
http://www.kaco-geraetetechnik.de
Despite all these quality-assuring measures, however,
failures may occur in very rare cases. KACO
Dimensioning of the PV generator:
GERÄTETECHNIK GmbH will offer a maximum of
assistance if one of these cases should arise. KACO The number of PV modules connected in series must
be selected in such a way that the output voltage of the
GERÄTETECHNIK GmbH will take every effort to
PV generator is maintained within the admissible input
remedy any defects fast and without any unnecessary
voltage range of the inverter – even in the event of
bureaucracy. Please contact our service department
extreme external temperatures. In Central Europe,
directly – and you will be aided and supported very
module temperatures between –10°C and +70°C
quickly.
should be assumed. Depending on the type of module
3.3 Intended use (normal use) assembly and geographical conditions, +60°C or +70°C
Powador inverters are built according to state-of-the-art should be used for calculating the voltage. The
and approved safety requirements. However, improper temperature coefficient of the solar modules should be
use may cause lethal hazards for operators or third observed. The following criteria must be met for
parties and/or damage of instruments/devices or other calculating the voltage of the PV generator:
property. The device is intended to convert the direct
voltage generated in the photovoltaic (PV) modules into Uo (-10°C) < max. input voltage (500VDC)
alternating voltage (AC) and feed this voltage into the Even at very low external temperatures (-10°C), the no-
grid. load voltage of the connected string must remain within
The inverter must only be operated in connection with a the admissible input voltage range. For example, if the
fixed/stationary connection to the public grid. Inverters temperature falls from 25°C to –10 °C, the no-load
are not intended for mobile use. voltage of 12-V modules will increase by approx. 2.8 V
per module (5.6 V for 24V modules). The no-load
Any use other than the specified intended use is not voltage of the entire string must be less than 500 volts.
deemed intended or normal use, and the
manufacturer/supplier shall not be liable for any
damage caused by such unintended use. Damage
caused by unintended use is at the sole risk of the
operator.
The term ”intended use“ shall also include the
adherence to the operating and installation instructions.

KACO Gerätetechnik GmbH 4 Installation Instructions Powador 01xi

4 Device description

UMpp (+60°C) > min. input voltage (125VDC) 4.3 Mechanical dimensions
Even at very high external temperatures (+60°C) the
MPP voltage of the connected string should remain
within the admissible input voltage range. If the
temperature rises from 25°C to 60 °C, the MPP voltage
of 12V modules will decrease by approx. 3.6 V per
module (7.2 V for 24V modules). The MPP voltage of
the entire string should be > 125 V.
Even if the MPP voltage is beyond the admissible input
range, the installation nevertheless will continue to work
properly. However, the delivered power is slightly less
than the maximum yield.
Provided that the input voltage is within the admissible
input voltage range, the inverter will not be damaged if
a connected PV generator should supply current above
the max. usable input current.
If the PV generator should supply more than the 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 Figure 4.1: Dimensions of Powador
for safety reasons and automatically switches on again Type Height Width Depth
after approx. 10 seconds. The overload status is shown 1501xi 450mm 340mm 200mm
on the display in plain text. Under normal 3501xi 500mm 340mm 200mm
circumstances, however, the dynamic control of the 4501xi 650mm 340mm 220mm
inverter ensures that this condition is recognized and
the inverter operation is continued without any
interruption.

The solar generator still represents the most substantial

cost factor of a solar installation. Therefore, it is very
important to obtain maximum energy yields. To achieve
this goal, solar generators located in Central Europe
should be orientated towards the South at an angle of
inclination of 30°, and shading of whatever kind should
be prevented under all circumstances.
In many cases, the recommended angle of inclination
cannot be implemented for technical reasons. To
achieve the 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.

4.2 Protective concepts

The following monitoring and protective functions are

integrated in Powador inverters:
- BISI grid monitoring to protect against personal
injuries and avoid islanding effects according to
VDE0126.
- Overvoltage varistors to protect the power
semiconductors against high-energy transients on the
grid side.
- Temperature monitoring of the heat sink
- EMC filters to protect the inverter against high-
frequency grid interference
- Grid-side varistors to earth/ground, to protect the
inverter against burst and surge pulses.

KACO Gerätetechnik GmbH 5 Installation Instructions Powador 01xi

5 Installation and startup

5.2 Installing the inverter

5. Installation and startup
5.1 Selecting the 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 a minimum clearance of 500 mm around the
device and between the device and other objects, such
as cabinets, ceiling, or similar
The device has been designed for vertical wall
installation.
Please ensure free air circulation around the device and
through the heat sink at the rear side. Figure 5.1: Wall installation of Powador
If the inverter is installed in a switch cabinet or similar,
please provide forced ventilation to ensure that heat is The inverter is shipped together with an installation kit
dissipated adequately. consisting of four dowel pins and four 70 mm Philips-
The heat sink may reach a temperature of max. 90°C. type screws. Prior to installation the condition of the
Therefore, only mount the inverter on walls that are mounting wall has to be checked. If necessary, use a kit
made from a heat-resistant material. other than the one shipped with your inverter.
Ensure that the wall has an adequate load-bearing
capacity and only use the appropriate installation
material. - Drill the holes for the dowel pins
In areas with a special risk of flooding, always make according to the positions indicated
sure to install the inverter in a sufficiently elevated on the mounting plate.
place. - Place the dowel pins into the holes.
Installation at eye level makes it easier to read the - Using the Philips-type screws, fasten
display. the mounting plate to the wall. Make
sure that the arrow shown on the
mounting plate is directed upwards.
- Suspend the inverter in the
suspension fixture. Ensure that the
Important! bars rest on the appropriate
Due to the high system voltage, lugs/noses in the heat sink.
less current may flow on the DC - Lock the safety catch. To do, this,
voltage side than on the AC slide the upper end of the catch
voltage side. Given the same cable towards the wall until the groove is
cross-sections, losses are parallel to the wall (see Figure 5.2)
therefore higher on the AC voltage
side than on the DC voltage side.
For this reason and for thermal
reasons, the inverter should
therefore be placed in the vicinity
of a metering station.

KACO Gerätetechnik GmbH 6 Installation Instructions Powador 01xi

5 Installation and startup

Figure 5.2: Safety catch is open (left) and closed (right)

5.3 Electrical connections

General Information Figure 5.3: Connection box of Powador

The electrical connections can be established after the

inverter has been installed in its fixed location. Grid connections
3-lead connections are used (L1, N, PE). To insert the
wires use watertight conduits at the underside of the
housing.
Caution!
We recommend the following wire cross sections for
The electrical installation of
cable lengths up to 20 m:
Powador must only be performed
Powador 1501xi: 1.5 mm2
by skilled personnel and by an
Caution Powador 3501xi: 2.5 mm
electrician who has been approved
Powador 4501xi: 6 mm2
by the responsible Electrical Utility
Larger cross sections should be used for longer cable
Company.
lengths. According to VDE 0100 Part 430 “Protection of
cables and lines in the event of overcurrent”, NYM
leads should be protected as follows (fixed wiring,
All applicable safety instructions, technical connections
ambient temperature 25 °C and installation type B2
stipulated by the responsible Electrical Supply
(multi-wire lead in a tube or channel on or inside walls
Company, and the relevant VDE regulations must be
or buried):
adhered to.
1.5 mm2 16A
To connect the inverter the AC and DC side must be 2.5 mm2 20A
disconnected from all voltage sources and 4 mm2 25A
protected against inadvertent switching-on. 6 mm2 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 housing/enclosure. excessive line impedance (internal
The door is secured against opening by resistance of the electrical grid)
means of two recessed-head screws on between the domestic distribution and
the right upper side. the respective Powador inverter.
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 Installation Instructions Powador 01xi

5 Installation and startup

Danger! Please check that the PV generator

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

Caution! Determine the electrical resistance

Please check all leads for proper between the protective earth (PE)
connection. and the positive (plus) lead or,
respectively, between the protective
Caution earth (PE) and the negative (minus)
lead of the PV generator.

A low resistance value (< 2 MΩ)

Once again check if all connected indicates a high-resistance ground
leads are securely fastened. Fasten fault of the PV generator, which must
the wire connection of the cable by all means be remedied prior to
fitting. further installation!

5.3.1 PV Generator connections Caution!

The PV generator connections are established on the Prior to connecting the DC leads
right side of the connection box. to the inverter terminals the
Caution
voltage of the solar generator
must be measured.
The DC voltage must not exceed
Caution! max. 500VDC. Connecting to
Risk of damage! higher voltages will result in the
By all means ensure the correct destruction of the device.
Caution polarity!

Danger! The PV generator can be connected in different ways:

To ensure maximum protection - Via screwed cable gland fittings
against hazardous live voltages - Via Tyco connectors
Danger during the assembly of the - Via MC plug-type connectors
photovoltaic installation, both the
plus and minus leads must be Screwed cable gland fittings are provided as a
strictly isolated from earth standard. Tyco and MC plug-type connectors may be
potential (PE). provided as options.

KACO Gerätetechnik GmbH 8 Installation Instructions Powador 01xi

5 Installation and startup

PV generator connection by means of screwed The assembly of the Tyco and MC-type connectors is
cable gland fittings depicted in Figure 5.6 and. Figure 5.7.

Open the screwed cable gland fittings

until you can insert the cables.
Fasten the cable ends in the terminals
marked “PV+” and “PV-“. Observe the
correct polarity.
Fasten the cap of the screwed cable
gland fittings. Figure 5.6: Assembly of Tyco connectors

Connecting three or four strings to the inverter requires

double allocation of one or, respectively two terminals
(see Figure 5.4).

Figure 5.7: Assembly of MC connectors

Caution!
Figure 5.4: Connection of three PV strings The PV generator should not be
PV generator connection by means of multi-contact disconnected from the Powador
or Tyco plug-type connectors Caution inverter (i.e. by pulling the
MC or Tyco plug-type connectors may be enclosed to connector) under load except in
the inverter as options. These connectors may be used absolute emergency cases. It
instead of the screwed cable gland fittings-type fittings should by all means be avoided
mounted on the device (shipping condition). In this during the normal grid feeding
case, please remove the screwed cable gland fittings- operation.
type fittings and assemble the appropriate connectors Prior to disconnecting, always
instead. disconnect grid voltage by
deactivating the grid fuses.

Remove the screwed cable gland -type If this is not observed, arcing may
connectors from the provided apertures occur and damage the connectors
in the baseplate of the inverter. Insert – both parts of the connector will
the Tyco- or MC connector from outside have to be replaced.
into the apertures and fasten them
inside by means of the black plastic
nuts (see Figure 5.5).

Figure 5.5: Assembly of Tyco connectors.

KACO Gerätetechnik GmbH 9 Installation Instructions Powador 01xi

5 Installation and startup

5.4 Connecting the fault-signal relay 5.6 Connection of the RS485 interface

The inverter is equipped with a potential-isolated relay On the control board (at the rear side of the door of the
contact to signal faults. If a fault occurs, this contact will Powador inverter), there are four terminals marked
be closed. RS485 A and B (see Figure 5.10). To connect several
Max. contact load: 30V / 1A. 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.
Important! You need a twisted and shielded data cable for
In the event of a power failure in the connection, such as an ISDN cable. The connection to
public grid the relay will not trigger. proLOG is established analogously. The wiring plan is
In this case, all LEDs and the display shown in Figure 5.11. The total length of the RS485
will be extinguished and the inverter wiring should not exceed 250 m.
will be shut down completely.
A fault signal will not be possible in
this case!

Figure 5.10: Connection terminals for RS485-Interface

Figure 5.8 Fault-signal relay

Phone
230VA
5.5 Connection of the S0 output

The inverter is equipped with an SO pulse output for

connection of, e.g. a large display. The pulse rate is Figure 5.11: Wiring plan for RS485 Interface
adjustable (see page 11, Section 5.8)
The figure above shows a terminator 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
taking part in this system must have a unique address
(regardless of whether this is an inverter or current
sensor). For inverters, the address range can be
selected between 0 and 31. The address of each
inverter can be determined via the Set menu, (see
Operator’s Manual).

Figure 5.9 S0-Connection Important!

Please ensure correct connection of
the A and B wires. If these wires are
confused, no correct communication
will be possible!

5.7 Startup of the inverter

After completing the mechanical and electrical
installation you may now put the inverter into operation
as follows:

KACO Gerätetechnik GmbH 10 Installation Instructions Powador 01xi

5 Installation and startup

5.8 Programming the parameters

NOTE! The programming mode offers several options to
The inverter can only be put into change or program the parameters of your Powador
operation under daylight conditions inverter.
(i.e. at a solar generator voltage of >
100 V). Caution!
If no daylight or solar generator Incorrect parameter settings may
voltage is present, the inverter can be lead to a loss of functions!
activated by pressing the Start key
(see Section 4.4 of the Operating Caution
Instructions), but normal operation
will not be possible in this condition.
(Only the values can be read off the
display). The following parameters can be adjusted:
- Break threshold of undervoltage protection
- Break threshold of overvoltage protection
- Adjust grid voltage
- Adjust grid current
- Switch on the grid voltage (via the
external automatic safety breakers).
- Switch on the solar generator via the Danger!
DC circuit breaker (or DC plug-type Always disconnect the inverter from all
connector). voltage sources before opening the
inverter housing!
Danger

The green LED “PV generator“ will now be illuminated

To change to the programming mode
(if the generator voltage is greater than 125V). The
please change the jumper position as
display now shows the current generator voltage: “Start
shown in Figure 5.11).
from 125V; measurement xxx V“ If the measured
voltage is greater than 125V, the device will start power Change the jumper position as
delivery after approx.3 minutes. This starting-up period shown in Figure 5.13, so as to get to
of 3 minutes is necessary to ensure that the generator the Display and Programming Mode.
voltage is permanently above the power delivery limit of
125V.
A quick-start routine is provided for test purposes – this
routine circumvents the start-up period. This quick-start
is menu-controlled and obtained from the set-up mode
(see Operator’s Manual ).

During the normal startup procedure the line power

relay is switched on after approx. 3 minutes (audible
acoustic noise), and power delivery is started. This is
also signaled by the green “Grid-feeding“ LED. The
display now shows the delivered power. The “Display“
key can be used to indicate the various measurement
values (see Operator’s Manual).
It may be necessary to reset the date and hour (please
refer to the Operator’s Manual).

KACO Gerätetechnik GmbH 11 Installation Instructions Powador 01xi

5 Installation and startup

Close the device again.

To change to the programming mode,
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.

Figure 5.11: Jumper position to change between

programming mode and power delivery (feed-in
operation)

Break threshold – grid undervoltage

Break threshold – grid overvoltage

Min. grid frequency

Max. grid frequency

Max. grid frequency

Max. Impedance jump

Figure 5.12: Jumper Position in normal feed-in Scaling of grid voltage -

operation (power delivery) – (shipping status)
Scaling of grid current +

Scaling of grid current -

Scaling of intermediate circuit +

Scaling of intermediate circuit -

S0 Interface

Set parameters

Delete parameters
Figure 5.13: Jumper position in the programming mode

Display setings

Figure 5.14: Set Parameters Menu

KACO Gerätetechnik GmbH 12 Installation Instructions Powador 01xi

6 Applications/Acceptance by Your Utility Company

- SO interface:
The “Set” key is used to change the The SO interface is used to control a large display. Use
respective parameter. Depending on the this parameter to adjust how many pulses per kWh are
parameter, the value increases or to be transmitted. The possible settings are 500, 2000
decreases. The values are continuous, and 1500 pulses per kWh.
i.e. if you have reached the max. value,
they will be reset to the min. value. After changing these parameters the inverter must be
reset to its original condition.

Explanation of individual parameters:

To do this, disconnect the inverter from
- Undervoltage break threshold: all voltage sources and reset the
If the grid voltage falls below a defined value the jumper to its original position.
inverter must terminate its power delivery operation and
disconnect from the grid. According to the applicable
Directive the defined value can be 1.0 to 0.8 of the grid The inverter can now assume “normal” operation and
voltage value (184V …230V). Under standard operating be left unattended. Application/Acceptance of Utility
conditions the inverter shuts down at 190V and is thus Company
within the permissible range. Under special
circumstances your Electrical Supply Company can 6. Applications/Acceptance by Your
request that the inverter shuts down at a different Utility Company
voltage - in this case you can use the menu item
"Minimum grid voltage" to set the new break threshold. The practices of the responsible Utility Company must
The min. grid voltage can be adjusted in the range be observed for all applications and acceptances of
between 190 V and 230 V in increments of 2 volts. your PV installation. Some of the documents you will
By all means ensure that the standard VDE 0126-1 is need for application and acceptance are enclosed to
observed. these installation instructions.
The usual setting-up procedure is as follows:
- Overvoltage break threshold
If the grid voltage should exceed a defined value the - Submittal of documents to the Utility Company
inverter must terminate its input operation and (responsibility of your solar installer)
disconnect from the mains. According to the directive, - Installation
this value can be 1.0 to 1.15 of the rated voltage (230V - Installation of power meter by the Utility Company
.... 264V). Under standard operating conditions the - Acceptance of your installation by the Utility Company
inverter shuts down at 264V and is thus within the
permissible range. Under special circumstances your You will require the following documents:
Utility Company may request that the inverter shuts
down at a different voltage - in this case you can use - Application / Completion notice by the registered
the menu item "Maximum grid voltage" to set the new installation company
break threshold. - Location plan showing the estate borders and place
of installation
- Grid frequency: - Complete circuit diagram of installation and utilities
The grid frequency is also monitored. If it should fall (unipolar view);
below a defined value the inverter must terminate its - Data sheet for independent power generating plants
power delivery operation and disconnect from the grid. (VDEW form) (responsibility of your solar installation
Both thresholds can be adjusted in increments of 0.1 company);
Hz. The min. grid frequency range is between 49,8, – - Description of the protection devices indicating the
60,0Hz, the max. frequency range is between 60,0 Hz type, circuit, make and function (responsibility of your
and 50,2,0 Hz (factory setting if 49,8, –50,2, Hz). solar installation company);
- Description of the inverter / declaration of conformity
of the manufacturer;
- Scaling Grid Voltages and Grid current: - Information on the short-circuit resistance of circuit
Prior to shipment all the displayed values are checked components
and adjusted in our factory. If the grid voltage shown on
the display should not correspond to the grid voltage
actually measured the value can be adjusted. If the grid
voltage shown on the display is too low you can use the
menu item "SCALING xxx +” 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 current, grid voltage and grid current.

- Scaling of intermediate circuit voltage:

This parameter must only be changed by a service
technician!

KACO Gerätetechnik GmbH 13 Installation Instructions Powador 01xi

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
protective devices, as well as a long-duration test at our
factory.
The sequence of work, especially when
Should your PV installation not work properly despite all
using DC connectors as DC circuit
these measures, we recommend the following
breakers, must be observed by all
procedure for remediation:
means.
Check the solar generator and grid connections leading
Otherwise, arcing might occur when
to the PVI, observing all the safety instructions given in
disconnecting the DC connector under
this manual. Please observe the inverter carefully and
load. This will destroy the connectors.
take note of the display messages and LED displays.
Below is a summary of possible error and
recommended remedies:

- Disconnect the grid voltage

(deactivate the external safety
breakers).
Disconnect the photovoltaic module
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
Danger 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 Installation Instructions Powador 01xi

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 Utility elements/sensors value may deviate from the value shown on the power meter by
company. up to 15%.
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
- 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 100 KACO for repair.
If no power is delivered you should check that grid voltage is
present and that the solar generator voltage is higher than 125
V.
If this is the case but the inverter still fails to deliver power the
device will have to be returned to KACO for repair.

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 100 KACO for repair.
V If no power is delivered you should check that grid voltage is
present and that the solar generator voltage is higher than 125
V.
If this is the case but the inverter still fails to deliver power the
device has to be returned to KACO for repair.
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 < 125V respectively, generator power fed from the roof may be
from 125 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 failure
does not deliver power – interrupted grid feeding (grid power failure, overtemperature, overload, etc.) the inverter
the display reads: due to a always waits for approx. 3-4 minutes before resuming its grid
Start from 125 V malfunction/failure. feeding operation. Grid failures may cause interruptions during
Measurement: the day. If more than 10 interruptions per day should occur over
xxx V (measured voltage several weeks you should contact your solar installation
is higher than 125V) provider.

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.

KACO Gerätetechnik GmbH 15 Installation Instructions Powador 01xi

8 Troubleshooting

Error Cause of error Remedy / Explanation

Inverter causes noise Special environmental - Under special environmental conditions the devices may
conditions cause audible noise. This may be due to the following
causes:
- Grid effects and/or grid failures caused by special consumers
(motors, machines, etc.), which are connected to the same
grid point or which may be installed in the vicinity of the
inverter.
- Dynamic weather conditions (frequent changes between sun
and clouds) may cause slight line hum due to high energy.
- Certain grid conditions 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 errors 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 Installation Instructions Powador 01xi

9. Technical Data

Input – Electrical data

Type 1501xi 3501xi 4501xi
DC rated power 1580 W 3490 W 4880 W
Max. PV generator power 2000 W 4000 W 6000 W
MPP range 125 – 400 VDC
No-load voltage Up to 500 VDC
Monitoring - input voltage Stand-by from Ue>125VDC
Night shutdown from Ue<100VDC
Max. DC input current 14 A 30.5 A 43 A
Polarity safeguard Short-circuit diode
Overvoltage protection Varistors

Output – Electrical data

Rated power 1500 W 3300 W 4600 W
Max. power 1650 W 3600 W 5060 W
Grid voltage 190– 264V
Rated current 6.5 A 14.5 A 20.0 A
Max. current 7.2 A 15.7 A 22.0 A
Frequency 49,8 – 50,2 Hz
Distortion factor according to <3% at rated power
VDE 0838 part 2 (EN61000- <5% over the entire range
3-2)
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 95.0 % 94.5 % 94.4 %
European efficiency 94.2 % 93.3 % 93.2 %
Internal consumption Night shutdown: 0W
Operation: < 5 W
Min. grid-feeding power 10W
Circuit design Grid-tied, electrically isolated, RF transformer
Clock frequency 18 kHz
Principle 1.) galvanically isolated DC/DC converter
2.) IGBT full bridge as part of the inverter
Grid monitoring BISI according to E DIN VDE 0126, compliant with VDEW

Inverter – Mechanical and technical data

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 PCB terminals inside the device
Cable routing via screwed cable gland fittings
Ambient temperature -20 ... +40°C
Temperature monitoring >70°C temperature- >75°C temperature- >75°C temperature-
dependent power dependent power dependent power
adjustment adjustment adjustment
>80°C disconnection >85°C disconnection >85°C disconnection
from the grid from the grid from the grid
Cooling Free convection (no fan or blower)
Protection Class IP54 according to EN 60529
Noise emission < 35dB (noiseless)
Housing/enclosure Aluminum wall-mounted enclosure
Dimensions W x D x H 340 x 200 x 450 mm 340 x 220 x 500 mm 340 x 220 x 650 mm
Weight 10 kg 19 kg 28 kg
10 Appendix

10. Appendix
10.1 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 descriptions: Powador 1501xi

Powador 3501xi
Powador 4501xi

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 the Photovoltaics Division

KACO Gerätetechnik GmbH 18 Installation Instructions Powador 01xi

10 Appendix

10.2 Declaration of Conformity concerning the rated power and max. output of photovoltaic inverters

Inverter type AC rated power AC peak power * (ACPEAK) in Ratio

(ACNENN) in W W ACPEAK / ACNENN
Powador 1501xi 1500 W 1650 W 1.10
Powador 3501xi 3300 W 3600 W 1.09
Powador 4501xi 4600 W 5060 W 1.10

The AC peak power has been indicated as a mean 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 the Photovoltaics division
th
Neckarsulm, 8 July 2005
KACO GERÄTETECHNIK GmbH

p.p.
Matthias Haag

KACO Gerätetechnik GmbH 19 Installation Instructions Powador 01xi

10 Appendix

10.3 Certificate of Conformity/Non-Objection

KACO Gerätetechnik GmbH 20 Installation Instructions Powador 01xi

Your solar installation provider.

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