Improper handling of the inverter can be dangerous
› You must read and understand the operating instructions before you can install and
use the inverter safely.
1.1.1 Other applicable documents
During installation, observe all assembly and installation instructions for components and other parts of the
system. These instructions are delivered together with the respective components and other parts of the system.
Some of the documents which are required to register your photovoltaic system and have it approved are
included with the operating instructions.
1.1.2 Retention of documents
These instructions and other documents must be stored near the system and be available whenever they are
needed.
The inverter converts the DC voltage generated by the photovoltaic (PV) modules into AC voltage and feeds this
into the power grid. The inverter is built according to the state of the art and recognized safety rules. Nevertheless, improper use may cause lethal hazards for the operator or third parties, or may result in damage to the
unit and other property. The inverter may be operated only with a permanent connection to the public power
grid.
1.4 Safety instructions
DANGER
Lethal voltages are still present in the terminals and lines of the inverter even after
the inverter has been switched off and disconnected!
Coming into contact with the lines and terminals in the inverter will cause serious
injury or death.
Only authorised electricians who are approved by the supply grid operator are allowed
to open, install and maintain the inverter.
› Keep all doors and covers closed when the unit is in operation.
› Do not touch the lines and terminals when switching the unit on and off!
The electrician is responsible for observing all existing standards and regulations.
• Above all, be sure to observe standard IEC 60364-7-712:2002, “Requirements for Special Installations or
Locations – Solar Photovoltaic (PV) Power Supply Systems”.
• Ensure operational safety by providing for proper earthing, conductor dimensioning and appropriate
protection against short circuiting.
• Observe the safety instructions located on the inner sides of the doors.
• Switch off all voltage sources and secure them against being inadvertently switched back on before per-
forming visual inspections and maintenance.
• When taking measurements while the inverter is live:
– Do not touch the electrical connections.
– Remove jewelry from your wrists and fi ngers.
– Make sure that the testing equipment is in good and safe operating condition.
• Stand on an insulated surface when working on the inverter.
• Generally, the inverter may not be modifi ed.
• Modifi cations to the surroundings of the inverter must comply with national and local standards.
If you need help solving a technical problem with one of our KACO products, please contact our service
hotline. Please have the following information ready so that we can help you quickly and efficiently:
• Inverter type / serial number
• Fault message shown on the display / Description of the fault / Did you notice anything unusual? / What has
You can find our warranty conditions on our website:
http://kaco-newenergy.de/de/site/service/garantie
From there, you can easily navigate to our international websites by clicking on the appropriate flag. Please
use our website to register your unit within 24 months:
http://kaco-newenergy.de/en/site/service/registrieren
You can also select the appropriate flag on this page to access the website for your own country.
In this manner, you can assist us in providing you with the quickest service possible. In return, you receive two
additional years of warranty coverage for your unit.
Note: The maximum length of the warranty is based on the currently applicable national warranty conditions.
We have prepared a template for complaints. It is located at
http://www.kaco-newenergy.de/en/site/service/kundendienst/index.xml.
The inverters leave our factory in proper electrical and mechanical condition. Special packaging ensures that
they are transported safely. The shipping company is responsible for any damage that occurs during transportation.
4.1.1 Scope of delivery
• XP500/550-OD-TL
• Documentation
Check your delivery
Inspect the inverter thoroughly.
Notify the shipping company immediately if you discover any damage to the packaging which indicates
that the inverter may have been damaged or if you discover any visible damage to the inverter.
Send the damage report to the shipping company right away. It must be received by them within six days
following receipt of the inverter. We will be glad to help you, if necessary.
4.2 Transportation
The inverter should be shipped using the original packaging to ensure that it is transported safely.
The inverter cabinets is delivered on a pallet.
The centre of gravity of the inverter is not in the middle of the XP500/550-OD-TL. Take this into
consideration when transporting the XP500/550-OD-TL.
The centre of gravity of the inverter is marked with the centre of gravity symbol on the packaging and the enclo-
When inverters are in storage, the following conditions are required. If not, this may cause failures. The company will not be responsible for the problems if following condition is not observed.
• The unit should be stored indoor in its original packaging when it’s being stored more than 6 months. If its
original packaging is removed, it should be stored indoor in a cool, dry place.
• When the unit is stored outdoor, please keep the remained original packaging and do not leave the unit out-
side for long term period.
• Storage temperature: -20°C ~ +70°C
• When inverter is stored under high humidity condition for long term period, it has to be dried out suffi ciently
more than 1 day before connecting to the power.
CAUTION
Inverter Storage Caution
Inverters need to be sotred at the correct temperature and correct humidity. If not,
this may cause failures.
5.2 Transporting the unit to the installation location
Once it has arrived at the installation location, the inverter may be transported using the designated eyebolts
or fork-lift. These are located on the top of the inverter housing.
CAUTION
Impact hazard, risk of breakage to the inverter
The centre of gravity is located in the upper part of the inverter.
› Transport the inverter in an upright position.
Transporting the inverter
Transporting the inverter using eyebolts
Transport the inverter in an upright position.
Connection the rope to the two eyebolts on the left.
Connection the rope to the two eyebolts on the right.
Attach both ropes to a hook, making sure that the ropes do not cross each other.
Lethal voltages are still present in the terminals and lines of the inverter even after
the inverter has been switched off and disconnected!
Coming into contact with the lines and terminals in the inverter will cause serious
injury or death.
Only authorised electricians who are approved by the supply grid operator may open,
install and maintain the inverter.
› Use extreme caution when working on the unit.
› Disconnect the AC and DC sides.
› Secure them against being inadvertently switched back on.
› Connect the inverter only after the aforementioned steps have been taken.
5.4.1 Protective earth connection
Connect the PE bus bars
The PE (protective earth) bus bars are located on the left and right sides of the inverter cabinets.
Connect the wires for “both” PE bus bars.
Earth the inverter
Determine the lay-out of the permanent wiring.
Secure the protective earths (tightening torque for PE terminals: 43Nm). Do not use plug connections.
Check whether all connected cables are securely attached and protected from mechanical forces.
5.4.2 Connecting to the external transformer (AC connection)
The inverter is connected to the power grid using a 3-phase connection. The connection for the power grid is
located in the left side of the housing, at the bottom.
Use the screws that are supplied to screw down the bus bars on both sides.
Connection data
Number of AC Cables (A,B,C)12
Max. Cable diameter for each phase240mm2 x 4
Tightening torque for AC terminal connections43Nm
Cable lug hole size12mm ~ 14mm
Connect the cables
Each cable corresponds to one phase.
Guide the cables through the opening. Be sure to connect each of the cables to the correct terminal.
Screw down the cables.
Check to make sure that all of the cables are securely attached.
Before starting the inverter, if components are condensed inside the inverter or have been stored in a highly
humid air for a long time, it has to be dried out enough for more than a day, otherwise it will cause failure. After
that the circuit breakers must be switched ON to start the inverter, which also switches on the control circuits.
DANGER
Lethal voltages are still present in the terminals and lines of the inverter even after
the inverter has been switched off and disconnected!
Coming into contact with the lines and terminals in the inverter will cause serious
injury or death.
Only authorised electricians who are approved by the supply grid operator may open,
install and maintain the inverter.
› Keep all doors and covers closed when the unit is in operation.
› Do not touch the lines and terminals when switching the unit on and off!
Switch on the circuit breakers or Fuse
StepCheckAction
1Fuse F30, 31, 34, 35, 36, 38, 39
Circuit breakers CB32, 40
2Circuit breakers MCB20, 21
Circuit breakers CB20
3Circuit breaker CB37 Switch on
4Key switchON Inverter ON
ON Proceed to Step 2
OFF Switch on,
Then proceed to Step 2
ON Proceed to Step 3
OFF Switch on,
Then proceed to Step 3
Then proceed to Step 4
OFF Inverter OFF
NOTE
For NG and PG type Inverter, please do not operate MCB20 arbitrarily.
It may cause failure of the unit.
When voltage is present at the inverter, it can be started up. Use the HMI interface to start up the inverter.
The inverter begins operation in a specifi ed sequence. For more information, see section 5.2 (“Transporting
the unit to the installation location”).
If a fault occurs, the inverter cannot begin operation. For more information on faults, see section 6 (“Faults
and Warnings”).
NOTE
If the fault cannot be reset using “Fault reset”, please contact our service department.
Since CB20 cannot be switched ON/OFF by Key switch, it must be operated manually.
CB20 is a MCCB which can be ON after charged and then OFF without further charging. (one cycle)
When operating, the process below showing how to turn on and off CB20 must be followed.
12
34
Figure 19: On/off operation of CB20
Key
1The default appearance of CB20, with black-on-white phrase “DISCHARGED SPRING”.
2After pulling out the handle, move it back and forth continuously until the CB20 gets charged.
3When charged, the black-on-white phrase “DISCHARGED SPRING” turns to be “CHARGED SPRING”
in black-on-yellow.
4Push “Push ON” button to switch ON CB20, then the state of CB20 will go back to the state of
‘Key 1’. To switch it OFF, press the “Push OFF” button.
Lethal voltages are still present in the terminals and lines of the inverter even after
the inverter has been switched off and disconnected!
Coming into contact with the lines and terminals in the inverter will cause serious
injury or death.
Only authorised electricians who are approved by the supply grid operator may open,
install and maintain the inverter.
› Keep all doors and covers closed when the unit is in operation.
› Do not touch the lines and terminals when switching the unit on and off!
5.6.1 Operating states
The Inverter has eight operating states. The explanations about each state are below.
Disconnected (default)Before operation has commenced the inverter is in the disconnected state. In
this state, the inverter is totally isolated from the PV array and the utility grid.
Connecting to the PV arrayWhen the inverter is in the “Disconnected” state, the ‘Key Switch On’ com-
mand is operated and the PV voltage is kept above 400V for 5 seconds, the
system turns on the PV Array side contactor (PV_MC).
Connecting to GridWhen the inverter is in the “Connecting to PV Array” state and the PV volt-
age is kept above the value of “MPPT V Start” parameter during the time set
by “MPPT T start” parameter, the contactor on the grid side is turned on. The
inverter keeps this state for 8 seconds.
Initializing MPPThe inverter calculates the MPPT start voltage which is product of measure-
ment of PV voltage and the parameter “MPP Factor”. After 5 seconds, the
inverter system enters into the “MPP start” state.
MPP startIn this state, the inverter controls the PV voltage. Reference of the PV voltage
is determined by MPPT start voltage which is calculated at “Initializing MPP”
state.
MPPTIf the PV voltage approximates the MPP start voltage (value of “MPPT V Start”
parameter), the MPPT will start. The inverter follows the MPP target value
automatically, which is varied by irradiance values. If the MPP target value is
out of the allowable MPPT range ([MPP start voltage – MPP Range lower] ~
[MPP start voltage + MPP range upper]), the system will return to the “Initializing MPP” state and will recalculate the MPPT start voltage.
System stopWhen the key switch is off, the PV Array side contactor and the Grid side
contactor are turned off and the system stops. If the output power of inverter
is kept below value of “MPPT P stop” parameter during time of “MPPT T
stop” parameter, connection to the grid is terminated.
Fault If a fault occurs during operation, the system stops. The system resets the
fault and tries to remove the fault. In the case that system removes a fault
successfully, system restarts all by itself. The system tries to remove the fault
at intervals of “MPPT Start” parameter since the last try until trial count
reaches to the number set in an “Auto Fault Reset Count” parameter. After
the number reaches to the “Auto Fault Reset Count” parameter, the system
will log an error and the system will not try to restart. In this case, XP500/550OD-TL inverter will try to remove the fault again using key Switch On command (after turning off by key Switch).
Table 4: Operating states
NOTE
If The System doesn’t try to remove the fault, please contact our service hotline.